E-Z-GO 625619 2012 Technician's Repair And Service Manual
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E-Z-GO 625619 2012 Technician's Repair And Service Manual

Gasoline powered utility vehicle
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625610
TECHNICIAN'S REPAIR AND SERVICE MANUAL
GASOLINE POWERED UTILITY VEHICLE
625619
ISSUED JUNE 2012
REVISED AUGUST 2012

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Summary of Contents for E-Z-GO 625619 2012

  • Page 1 625610 TECHNICIAN’S REPAIR AND SERVICE MANUAL GASOLINE POWERED UTILITY VEHICLE 625619 ISSUED JUNE 2012 REVISED AUGUST 2012...

  • Page 2: Safety

    SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 TERRAIN 1500 STARTING MODEL YEAR 2012 E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.

  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ........................Inside Covers GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C BRAKES............................D CONTINUOUSLY VARIABLE TRANSMISSION (CVT)..............E DIRECTION SELECTOR ......................... F ELECTRICAL ..........................G ENGINE............................H FRONT SUSPENSION AND STEERING ..................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z- GO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has rea- son to believe may be operated in personal transportation applications.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specification.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated. •...
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page viii...

  • Page 11: General Information & Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY........ A - 1 SERVICING THE VEHICLE ..................A - 1 FUEL ......................... A - 2 TOWING........................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-ii...

  • Page 13: Serial Number Location

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LOCATION Observe all instructions provided by the manufacturer of the charger. Three serial number and manufacture date code labels are on the vehicle.

  • Page 14: Fuel

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. any components that are not operating properly, con- sider the safety of yourself and those around you, should the component move unexpectedly.

  • Page 15: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. differential case. When in this position, the rear axle (2) Ball Joint remains locked in the neutral position. To make the Idler Arm King Pin King Pin...

  • Page 16: Brakes

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKES Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber After the vehicle has been put into service, it is recom- cleaner.

  • Page 17: Sun Top And Windshield

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP AND WINDSHIELD water heater, or other appliance that uses a pilot light or has a device that can create a spark.

  • Page 18: Hardware

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE marks on the hexagonal head. Unmarked hardware is Grade 2 (Ref. Fig. 6). Periodically the vehicle should be inspected for loose fasteners.

  • Page 19: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • Page 20 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REMARKS Steering Assembly - excessive play, loose or missing hardware Tie Rods - excessive play, bent rods, loose or missing hardware Rear Axle - fluid level, oil leakage, noise, loose or missing hardware...
  • Page 21 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-9...
  • Page 22 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-10...
  • Page 23 SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTICES, CAUTIONS WARNINGS AND DANGERS ..........B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE................B - 1 GENERAL MAINTENANCE..................B - 1 BEFORE SERVICING THE VEHICLE............... B - 1 Battery Removal and Installation..............
  • Page 24 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-ii...
  • Page 25 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICES, CAUTIONS WARNINGS hands, face, feet or body in a location that could expose them to injury should an unforeseen situation occur. AND DANGERS Always use the appropriate tools listed in the tool list Throughout this manual, the following NOTICES,...
  • Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always turn the key switch to ‘OFF’ and an explosion and severe personal injury or remove the key before disconnecting a live death.

  • Page 27: Safety

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Removal and Installation Some servicing operations may require the front, rear or the entire vehicle to be raised. Tool List Qty.
  • Page 28 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Center of Front Axle Flat Portion of Frame Outside End of Rear Axle View from Underside of Vehicle Fig.
  • Page 29 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-5...
  • Page 30 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-6...
  • Page 31 BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. GENERAL ......................... C - 1 BODY COMPONENT REPLACEMENT ..............C - 1 Instrument Panel Replacement ................ C - 2 Cowl Replacement ................... C - 3 Front Bumper Replacement ................C - 3 Rocker Panel Replacement................
  • Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-ii...

  • Page 33: Body Component Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Drill Out Rivet Head Onl Pop Rivet In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original positions unless otherwise specified.

  • Page 34: Instrument Panel Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 4 Body Components (Front) Instrument Panel Replacement Tool List Qty. instrument panel is to be replaced, the serial number Insulated wrench, 1/2”..........

  • Page 35: Cowl Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To prevent the possibility of injury due to lack To prevent personal injury, disconnect the of vehicle information, the correct safety label negative (-) battery cables before servicing must be on the instrument panel at all times.

  • Page 36: Rocker Panel Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. per and spacer tube (or front strut) only. Insert spacer console and off hinge pins. (20) and push bolt through cowl and threading it into To remove passenger seat bottom (30), remove four frame.

  • Page 37: Fig. 7 Body Components (Rear)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 7 Body Components (Rear) Repair and Service Manual Page C-5...

  • Page 38: Seat Support Panel Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Support Panel Replacement Seat Filler Panel Replacement Tool List Qty. Tool List Qty. Electric/air drill ............. 1 Electric/air drill .............1 Drill bit, 7/32"...

  • Page 39: Rear Fender Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Fender Replacement Raise bed using electric lift toggle switch. Tool List Qty. With a person on each side of bed, remove cotter pin (66), spacers (67) and clevis pin (68) that connect elec- Socket, 7/16"...

  • Page 40: Fig. 10 Plastic Truck Bed Components (Manual Lift)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Plastic Bed Latch Handle Rubber Bumper Latch Plate Fig. 10 Plastic Truck Bed Components (manual Lift) Repair and Service Manual Page C-8...

  • Page 41: Fig. 11 Plastic Truck Bed Components (Power Actuator)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Plastic Bed Electric Actuator Actuator may be rotated 90° on some models Front of Vehicle ELECTRIC DUMP DOWN WHT from Actuator BLK from Battery RED from Battery...

  • Page 42: Fig. 12 Metal Truck Bed Components (Manual Lift)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Metal Bed Latch Handle Latch Plate Fig. 12 Metal Truck Bed Components (Manual Lift) Repair and Service Manual Page C-10...

  • Page 43: Fig. 13 Metal Truck Bed Components (Power Actuator)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Metal Bed Electric Actuator Actuator may be rotated 90° on some models ELECTRIC DUMP Fig. 13 Metal Truck Bed Components (Power Actuator) Repair and Service Manual Page C-11...

  • Page 44: Minor Scratches

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING up paint. III. Apply spray touch up paint in light even overlapping Follow the paint manufacturer's recommendations for strokes.
  • Page 45 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-13...
  • Page 46 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-14...

  • Page 47: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. GENERAL ......................... D - 2 How the Hydraulic System Works ..............D - 2 Wheel Brake ....................D - 2 MAINTENANCE ......................D - 2 Daily Brake Performance Test ................. D - 2 Brake System Inspection..................
  • Page 48 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page D-ii...
  • Page 49 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Pedal Part of Part of Part of Frame Frame Frame Bellcrank Master Shaft Bushing Cylinder Plug Torsion Flexible Bushing Spring...

  • Page 50: General

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL MAINTENANCE How The Hydraulic System Works Daily Brake Performance Test A hydraulic system actuates the rear brakes. The sys- tem transmits the power required to activate the friction surfaces (brake shoes) of the braking system from the pedal to the individual brake units at each wheel.

  • Page 51: Master Cylinder

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wrench, 5/8” ..............1 Needle nose pliers ............1 Wrench, 9/16” ..............2 Do not allow brake fluid to contact surfaces. Wipe off Wrench, 1"...

  • Page 52: Brake Linkage

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Install brake light switch into branch tee using teflon tape Push Rod and tighten to 70 - 80 in. lbs. (8 - 9 Nm) torque. Rubber Clevis Yoke Boot...

  • Page 53: Brake Drum Removal And Installation

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE DRUM REMOVAL AND Bumper INSTALLATION Mounting Plate Lock Tool List Qty. Slip joint pliers..............1 Needle nose pliers ............1 Socket, 1 1/8”...............1 7/8 - 1"...
  • Page 54 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. axle splines. If not, remove drum and install one addi- cotter pin can be installed through the castellated nut tional inner brake drum washer (total of 2) to obtain and the hole in the axle.

  • Page 55: Wheel Brake Service

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL BRAKE SERVICE Remove any accumulated brake dust from the wheel brake assembly with a brush. Tool List Qty.

  • Page 56: Replacing An Adjuster

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. than .06" (1.5 mm) at any point on the shoe. It is normal Place upper end of shoe webs against wheel cylinder, for the shoes to show more wear at the leading and trail- and install upper shoe-to-shoe spring.

  • Page 57: Adjustment

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjustment 177 in. lbs. (14 - 20 Nm) torque. Tighten allen head bolts and lock nuts to 23 - 27 ft. lbs. (31 - 37 Nm) torque. After the brake system has been bled, make 3 to 10 for- ward and reverse stops by applying firm pressure to the BLEEDING AND FLUSHING...

  • Page 58: Flushing

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. An assistant will be necessary to perform this procedure. Do not force brake pedal to floor. The operating rod jam nut could be forced into master cylinder where it could Use a clean cloth to wipe off the master cylinder reser- damage internal components.
  • Page 59 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. parking brake. See Section A - Periodic Service Sched- ule for recommended lubrication schedule. Adjustment Brake The parking brake adjustment is made at the clevis yoke Pedal on the end of the parking brake lever cable located Part of...
  • Page 60 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Boot (If equipped) Center Console Park Brake Lever Pulley Support Bracket Jam Nut Clevis Yoke Park Brake Lever Cable Equalizer Parking Brake Cable Part of Frame...
  • Page 61 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-13...
  • Page 62 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-14...

  • Page 63: Continuously Variable Transmission (Cvt)

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL ......................... E - 1 CLUTCHES ....................... E - 1 Drive Clutch ..................... E - 1 Driven Clutch ....................E - 1 Increased Load ....................E - 2 Equilibrium .......................
  • Page 64 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-ii...
  • Page 65 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driven Clutch Drive Clutch Starter/Generator Belt Fig. 1 Continuously Variable Transmission System (CVT) GENERAL moveable sheave which is forced outwards against the cams by a compression spring.
  • Page 66 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Increased Load Equilibrium The CVT functions because the drive and driven When a vehicle traveling at governed speed begins to clutches maintain equilibrium.
  • Page 67 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Apply thread locking adhesive to the threads of the clutch bolt and install and tighten to 40 ft. lbs. (55 Nm) torque.
  • Page 68 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STORAGE adhesive to the threads of the clutch bolt. Install the bolt and tighten to 14 - 17 ft. lbs. (19 - 23 Nm) torque. If the vehicle is to be out of service for an extended period of time, the clutches should not be coated with DRIVE BELT...
  • Page 69 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-5...
  • Page 70 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-6...

  • Page 71: Direction Selector

    DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ..................F - 1 Removing Direction Selector ................F - 1 Replacing the Reverse Warning Buzzer............F - 2 Replacing a Micro Switch ................. F - 2 Shift Cable Adjustment..................
  • Page 72 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page F-ii...
  • Page 73 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Knob Front of Vehicle Phillips Screws Center Console Handle Direction Selector Bracket Micro Switch Spacer 6" RED Wire Reverse Warning Buzzer Fig.
  • Page 74 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Replacing a Micro Switch replacing. It is not necessary to remove the direction selector assembly to replace the reverse buzzer or Tools List Qty.
  • Page 75 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-3...
  • Page 76 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-4...

  • Page 77: Electrical

    ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS ..................G - 2 STARTER/GENERATOR ..................G - 3 Starter Mode ....................G - 3 Generator Mode ....................G - 3 DIGITAL VOLT OHM METER ...................G - 3 TESTING IGNITION CIRCUIT ..................G - 3 TESTING CHARGING CIRCUIT ...................G - 4 STARTER/GENERATOR....................G - 6 Starter/Generator Removal ..................G - 6...
  • Page 78 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page G-ii...

  • Page 79: Engine

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cover Negative (-) Post Battery Electrical Plate Assembly Positive (+) Post To Ground Terminal on Engine Electronic Ignition Chassis Control Harness...
  • Page 80 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BLACK Voltage Regulator Solenoid BLACK To Battery (+) To F2 On Starter/ Generator Fig. 2 Electrical Plate Assembly CIRCUITS AND CONTROLS (see Section “B”) or the neutral lock engaged (see Section “A”).

  • Page 81: Starter Mode

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR visual signal. If an analog meter is used it will read ∞ infinity ( Starter Mode When starting the engine, the field coils are in series with the armature and the starter/generator operates as a motor (Ref Fig.

  • Page 82: Testing Charging Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 3.Check for loose wires at all terminal connections. The charging circuit consists of a starter/generator, voltage regulator and battery (Ref Fig. 4 on page G-5). 4.Check the complete electrical system for correct cir- The solenoid must be functional in order to start the cuitry.

  • Page 83: Starter/Generator

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Reverse Solenoid Warning Fuse Buzzer 7.5 AMP RED/WHT Accelerator Pedal Box Switch Ignition Shutoff Module Switch Voltage Regulator Magneto Engine...

  • Page 84: Starter/Generator Removal

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR Fig. 5 Starter/Generator Starter/Generator Removal See ENGINE section. In general, starter/generator service is best performed by trained motor technicians who have the knowledge and equip- Starter/Generator Disassembly ment to overhaul the unit.

  • Page 85: Starter/Generator Inspection

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. to the line marked on the brush. Brush Spring 3. Test the insulation between the core and the commu- tator segments and shaft with a circuit tester.

  • Page 86: Storage Of Battery

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STORAGE OF BATTERY negative (-) probe on a wire terminal at the beginning of the circuit and work towards the device that is not A battery that is removed from service for storage must working with the positive (+) probe.

  • Page 87: Accessory Wiring

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIGHT BULB REPLACEMENT To replace the headlight bulb, locate the two screws in back of the headlight underneath the cowl that secure Use of incorrect fuse rating can damage electrical compo- the front part of the light (bulb) to the rear housing.
  • Page 88 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Passenger Side Driver Side Headlight Turn Signal Turn Signal Headlight BLU/ BLU/ BLU/WHT Low Oil Key Switch Fuel Pressure Gauge Light...
  • Page 89 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BLU/WHT RED/YEL Seatwrap Support RED/WHT ORN/WHT Floorboard NOTE: Truck Bed and Driver Seat Not Shown For Clarity Fig. 9 Horn and Fuse Block Repair and Service Manual Page G-11...
  • Page 90 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Console Plate Power Outlet Wire Harness (Chassis) Ignition Switch Fuel Gauge Light Indicator Ignition Key Fig. 10 Ignition Switch and 12 Volt Power Outlet Repair and Service Manual Page G-12...
  • Page 91 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Turn Signal Steering Wheel Head Light Turn Signal Flasher Turn Signal Switch Rear Fender Tail Light Fig. 11 Headlight, Turn Signal and Taillight Repair and Service Manual Page G-13...
  • Page 92 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hour Meter Hour Meter BLACK YELLOW (+) (-) Solenoid Fig. 12 Hour Meter Repair and Service Manual Page G-14...
  • Page 93 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page G-15...
  • Page 94 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page G-16...
  • Page 95 ENGINE TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE ................H - 2 Removing Debris ..................... H - 2 Oil Capacity ..................... H - 2 Oil Recommendations ..................H - 2 Checking the Oil Level..................H - 2 Changing the Oil ....................
  • Page 96 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page H-ii...
  • Page 97 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Oil Fill Dipstick Air Cleaner Remote Air Hose Starter/Generator Starter/Generator Belt Oil Pressure Switch Oil Filter Oil Drain Valve Spark Arrestor Fig.

  • Page 98: Powertrain Maintenance

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This section describes procedures for performing regular mUlti-viscosity oil (Ref Fig. 3 on page H-2). Synthetic oil maintenance, preparing vehicle to test engine condition meeting ILSAC GF-2, API certification mark and API and replacing engine.

  • Page 99: Changing The Oil

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Changing the Oil Tool List Qty. Oil Fill ................1 Pliers Oil drain pan ..............1 Clean cloth..............2 For maximum performance and longevity, the engine oil Dipstick should be replaced after the first five (5) to eight (8) hours of operation.

  • Page 100: Changing The Oil Filter

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Changing the Oil Filter fitter paper deterioration. Clean cartridge by gently tap- ping on a flat surface. Tool List Qty.

  • Page 101: Adjusting The Belt Tension

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPARK PLUGS NOTICE Tool List Qty. A loose belt can cause audible vibration and squeal. Spark plug socket, 5/8” ..........1 Tighten a new starter/generator belt to 115 - 125 lbs.

  • Page 102: Engine Description

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the piston rises forcing burned gases from the combus- NOTICE tion chamber in what is known as the exhaust stroke. As the piston moves through TDC and starts down, the Do not sand blast spark plugs.

  • Page 103: Engine Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (located on fan cover at side of engine) to the Wrench, 10mm ............1 ground cable bolted to the frame. Wrench, 3/4”...
  • Page 104 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove truck bed per BODY AND TRUCK BED section. Differential Lock Cable If engine is to be repaired, not replaced, wash engine Loosen This Jam Nut and chassis to remove dirt build-up.

  • Page 105: Engine Installation

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE The engine will be lifted out between differential and wide crossmember of frame. Pump The following step involves lifting substantial weight.

  • Page 106: Starter/Generator Replacement

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR REPLACEMENT The following step involves lifting substantial Starter/Generator Removal weight. Two people are recommended. Use of a personal back support brace and proper lift- Tool List Qty.
  • Page 107 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR VIEW FROM Ground F1 (On Starter/Generator) A2 (On Starter/Generator) A on Solenoid Green from Voltage Regulator Fig. 18 Starter/Generator Wiring Spacer Rear Pivot Bolt Adjusting Bolt...
  • Page 108 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-12...

  • Page 109: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. FRONT SUSPENSION ....................J - 1 Front Shock Absorber Replacement ..................J - 1 Shock Boot Removal and Replacement................J - 1 Front Axle Replacement ......................J - 1 Front Spring Replacement.....................
  • Page 110 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-ii...

  • Page 111: Front Suspension

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Axle Replacement FRONT SUSPENSION Tool List Qty. NOTICE Wheel chocks .............. 4 Floor jack..............1 In the following text, there are references to removing/installing Jack stands ..............

  • Page 112: Front Spring Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Part of Frame Fig. 1 Suspension Components Replace front wheels per WHEELS AND TIRES section and lower vehicle.

  • Page 113: Tie Rod, Wheel Bearing And King Pin Inspection

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Torque wrench, ft. Ibs..........1 NOTICE Pliers................1 Wrench, 3/4” ..............1 A worn tie rod is likely to be out of adjustment. The vehicle will Ball joint separator ............

  • Page 114: Steering Shaft Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. white stress lines. If stress lines are present, replace hub NOTICE cover. Install by carefully pressing, first the top two, then the bottom two retaining tabs into the matching slots in To maintain correct orientation when replacing.steering wheel, steering wheel.

  • Page 115: Steering Housing Assembly Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 6 Steering Components driver side front wheel, remove the steering wheel (3), Steering Housing Assembly Replacement and remove the steering shaft (12) as instructed above.

  • Page 116: Idler Arm Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Idler Arm Replacement The rack can be removed by loosening the tensioner bolts (31), removing cotter pin and backing off nut (20) on Tool List Qty.

  • Page 117: Steering Pinion And Bearing Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Pinion and Bearing Replacement Wheel Bearing Inspection/Packing Tool List Qty. Tool List Qty. Floor jack..............1 Retaining ring pliers .............1 Jack stands ..............

  • Page 118: Seal Installation

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the inner bearing seal (20), inner roller bearing (2) aligns with a slot in the castellated nut (1), insert a new (18) and bearing races (19) by tapping lightly around the cotter pin (3).

  • Page 119: Wheel Alignment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. mm) or greater, the bushings should be replaced. Press Rear out the old bushings and press new ones into the spindle Idler until flush with the spindle housing.
  • Page 120 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-10...

  • Page 121: Fuel System

    FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. GENERAL ......................... K - 1 CARB CANISTER ..................... K - 2 FUEL ......................... K - 2 FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT......K - 2 Fuel Lines and Filters ..................K - 3 Fuel Pump......................
  • Page 122 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page K-ii...
  • Page 123 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fuel Cap Fuel Level Sender To EVAP Hose on Engine Fuel Line Fuel Pump From Tank Fuel Filter Fuel Hose...
  • Page 124 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Engine Manual (PIN 272144) for Vanguard™ VTwin The fuel tank cap is located under the passenger seat Overhead Valve engines.
  • Page 125 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. has become clogged. The filter should be replaced peri- section. odically. See 'Periodic Service Schedule' in Section A . Disconnect fuel hose and gauge wires from tank.
  • Page 126 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Carburetor Choke Pivot Leve Set Screw Center Console Tool List Qty. Ball Stud Pliers................1 Insulated wrench, 1/2 ” ..........1 Wire lead with alligator clips ........1 To properly prepare for carburetor service: a) Disconnect fuel hose at fuel filter and plug ends to...
  • Page 127 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page K-5...
  • Page 128 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page K-6...

  • Page 129: Rear Axle And Suspension

    REAR AXLE AND SUSPENSION TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. REAR AXLE ............................L - 1 Maintenance........................L - 1 Checking the Lubricant Level ..................... L - 1 Differential Lock Cable Adjustment ..................L - 2 Rear Axle Removal ......................L - 2 Rear Axle Installation ......................
  • Page 130 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page L-ii...
  • Page 131 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Frame Shock Absorber Shock/Stop Mount Rear Axle Rear Axle Link Spring Subframe Rear Axle and Suspension Components Fig.
  • Page 132 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Axle Removal Fill / Check Plug Tool List Qty. Lug wrench, 3/4”............1 Wheel chocks .............. 1 Jack stands ..............
  • Page 133 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cable bracket and remove cable (Ref Fig. 6 on page L- 4). To reduce the possibility of personal injury, fol- Remove governor cable from ball stud on lower end of low the lifting procedure in SAFETY section of governor bellcrank located between engine and differen-...
  • Page 134 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Shaft The differential makes the rear axle assembly top heavy and may tend to rotate when sepa- rated from springs.

  • Page 135: General

    REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Center end of exhaust pipe between driven clutch and Shock Absorber Installation subframe and tighten clamp till no loose play is present. Shock absorber installation is in the reverse order of dis- Tighten banjo bolts to 124 - 177 in.
  • Page 136 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Shock Absorber Nut Front of Vehicle Shock Absorber Shock/Stop Mount Bushing Washer Shock Absorber Nut Front Spring Hardware Spring Rear Spring...
  • Page 137 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-7...
  • Page 138 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-8...

  • Page 139: Electronic Speed Control

    ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. ACCELERATOR, GOVERNOR AND CARBURATOR LINKAGE......M - 1 System Operation ....................M - 1 Governor Operation ..................M - 1 TROUBLESHOOTING ....................M - 2 GENERAL CABLE ADJUSTMENT PROCEDURE ...........M - 2 ACCELERATOR/GOVERNOR CABLE ADJUSTMENT ...........M - 2 PEDAL BOX ADJUSTMENTS ..................M - 3 Accelerator Pedal Arm Adjustment..............M - 3...
  • Page 140 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page M-ii...
  • Page 141 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Pedal Micro Switch Control Arm Link Accelerator Rod Control Arm Clevis Accelerator Micro Switch Cam Return Spring Accelerator Cable Rear Bellcrank at Rear Axle...
  • Page 142 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the ground speed governor in the rear axle assembly To decrease amount of available cable, loosen the nuts operates against the governor spring and closes the car- on either side of the bracket and move the cable away buretor until the correct governed speed is achieved (Ref...
  • Page 143 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Loosen the adjustment nuts on the accelerator cable NOTICE bracket. Tighten front adjustment nut till governor bell crank begins to pivot.
  • Page 144 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. and tighten set screw to 45 - 55 in. Ibs. (5 - 6 Nm) Be sure accelerator pedal moves smoothly and acceler- torque.
  • Page 145 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GOVERNOR COMPRESSION SPRING Test drive the vehicle and confirm that the compression spring adjustment results in the maximum governed ADJUSTMENT speed specified in the GENERAL SPECIFICATIONS section.
  • Page 146 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page M-6...

  • Page 147: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. ENGINE ........................N - 1 GASOLINE VEHICLE PERFORMANCE..............N - 1 Starter Does Not Turn ..................N - 1 Starter Turns Slowly ..................N - 1 Starter Rotates but Vehicle Doesn’t Start or Hard to Start........ N - 2 Poor Low Speed Performance .................
  • Page 148 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page N-ii...

  • Page 149: Gasoline Vehicle Performance

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE For engine troubleshooting, diagnostic and repair proce- & dures, refer to Briggs Stratton® Repair Manual (PIN 272144) for Vanguard™ V-Twin Overhead Valve Engine GASOLINE VEHICLE PERFORMANCE Condition Possible Cause...
  • Page 150 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction STARTER ROTATES BUT VEHICLE Weak Battery Recharge or replace as necessary WILL NOT START OR HARD TO Corroded or loose battery connections Clean and tighten battery connections.

  • Page 151: Poor Low Speed Performance

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR LOW SPEED Plugged gas tank vent Clean or repair PERFORMANCE Choke on Push choke in Carburetor float level incorrect Check/Replace float Clutches not shifting out...

  • Page 152: Repeated Spark Plug Fouling

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction REPEATED SPARK PLUG Wrong spark plug type Replace with correct spark plug FOULING Wrong spark plug gap Check and adjust if required Faulty ignition system Check and replace if required...

  • Page 153: Erratic, Surging, Or Sudden Change In Governed Speed

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction ERRATIC, SURGING, OR SUDDEN Governor bracket spring dragging Replace CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm...

  • Page 154: Operation And Application

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction OPERATION AND APPLICATION Engine not reaching full temperature Increase run time intervals to build higher cylinder temperature Continuous use at 1/4 throttle or less at low Instruct operator...

  • Page 155: Poor High Speed Operation

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR HIGH SPEED OPERATION Fuel pump faulty Replace fuel pump Loose main jet Tighten main jet Incorrect fuel level in float bowl Adjust float Dirt in fuel tank or hoses...

  • Page 156: Rectification Is Imperfect

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction RECTIFICATION IS IMPERFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough...

  • Page 157: Steering Pulls To One Side

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure Dragging wheel brakes Service brake system Suspension component failure Repair...

  • Page 158: Neither Wheel Locks When Park Brake Is Latched

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction NEITHER WHEEL LOCKS WHEN Incorrect cable adjustment Return to factory specification PARK BRAKE IS LATCHED. (NOTE: Excessive brake pedal free travel Adjust per manual AT FULL SPEED THE WHEELS MAY...
  • Page 159 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page N-11...
  • Page 160 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page N-12...

  • Page 161: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. SUN TOP AND WINDSHIELD .................. P - 1 Trailering ......................P - 1 SUN TOP ........................P - 1 Rear Support Installation.................. P - 1 Front Struts ...................... P - 1 Sun Top ......................
  • Page 162 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page P-ii...
  • Page 163 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP AND WINDSHIELD Rear Support Installation At driver side of vehicle, align the holes in the rear strut (5) with the holes in the seat back support bracket, being sure that the open end of the strut faces the front of the The top does not provide protection from roll...
  • Page 164 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Front of Vehicle CANOPY STRUT KIT includes item 3 - 8 HARDWARE KIT includes item 9 - 16 seat back support Bumper Front of...
  • Page 165 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
  • Page 166 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Install sash (3) on each side of the windshield. Using a strut so that it snaps into place (See Details B and C). plastic faced mallet, gently tap sash to ensure wind- Repeat for opposite side of windshield.
  • Page 167 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page P-5...
  • Page 168 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page P-6...

  • Page 169: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ...................Q - 1 Tire Repair .......................Q - 1 Wheel Installation.....................Q - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tires ..................Q - 2 Repair and Service Manual Page Q-i...
  • Page 170 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page Q-ii...
  • Page 171 Wear OSHA Do not use low inflation pressure tires on any approved safety equipment when E-Z-GO vehicle. Do not use any tire which has mounting/demounting tires. a recommended inflation pressure less than the inflation pressure recommended in Own-...
  • Page 172 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Follow all instructions and safety warnings provided by Ibs. (30 Nm) increments following the same 'cross the mounting/demounting machine manufacturer.
  • Page 173 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page Q-3...
  • Page 174 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page Q-4...

  • Page 175: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. TERRAIN 1500 ......................R - 1 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions ..................R - 2 Fig. 2 Incline Specifications and Turning Clearance Diameter ........R - 3 Repair and Service Manual Page R-i...
  • Page 176 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page R-ii...
  • Page 177 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: TERRAIN 1500 TYPE: GASOLINE POWERED TRUCK MODEL YEAR: 2012 Part No:. 618860 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS 16 hp (11.9 kW) rated, 4 cycle, 29.2 ci (480 cc) V-Twin, air-cooled Vanguard Engine: Overhead valve...
  • Page 178 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 110.5 in. (281.0 cm) 18 in. (46.0 cm) 49.0 in. (125.0 cm) 10.5 in. (27.0 cm) 34 in. 15 in.
  • Page 179 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING CLEARANCE DIAMETER Approx. 23.5 ft (7.2 m) Fig. 2 Incline Specifications and Turning Clearance Diameter Repair and Service Manual Page R-3...
  • Page 180 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page R-4...
  • Page 182 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.

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