E-Z-GO FLEET 1999 Technician's Repair And Service Manual page 49

BODY
Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
BODY
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In the following text, there are references to
NOTE
removing/installing bolts etc. Additional hard­
ware (nuts, washers etc.) that are removed must always be
installed in their original positions unless otherwise specified.
Non-specified torques are as shown in the table in Section A.
General
AwARNINGA
could generate sparks or repairs that require welding
or cutting. The fuel tank must always be protected to
prevent it being punctured by a drill bit.
In general, body component replacement can be accom­
plished with a minimum of specialized tools. Most body
components are held in place with conventional remov­
able hardware (nuts, bolts, washers and screws). Some
components are mounted with 'pop' rivets which require
that the rivet head be removed in order to push out the
shank of the rivet. The rivet head is easily removed by
drilling into the head with a sharp drill bit that is slightly
larger than shank of the rivet (Ref Fig. 1 on page C-1 ).
Care must be exercised when drilling to prevent the drill
from being forced through the plastic body components
where it could damage components located immediately
behind the rivet. The best way to prevent this from occur­
ring is to use a sharp drill bit that requires very little pres­
sure to cut successfully and to place a piece of protective
sheet metal between the surface being drilled and com­
ponents directly behind it.
T h e b a t t e r y s h o u l d
a l w a y s b e r em o v e d
before any servicing that
Repair and Service Manual
Pop Rivet
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Fig. 1 Drill Out Metal Rivet
BODY COMPONENT REPLACEMENT
The body components can be replaced by removing the
securing hardware, replacing the component and secur­
ing with hardware in the same orientation as removed.
The illustrations on the following pages indicate the
assembly methods for the various components.
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"the instrument panel is to be replaced, the
NOTE
�- serial number plate and CE plate must be
- - - � -
removed and reinstalled on the new instrument panel.
C
Drill Out Rivet
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Head Only
Page C-1