Cushman Shuttle 2 Service Manual
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Cushman Shuttle 2 Service Manual

Electric powered utility vehicle
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625610
TECHNICIAN'S REPAIR AND SERVICE MANUAL
ELECTRIC POWERED UTILITY VEHICLE
625614
ISSUED MAY 2011
REVISED AUGUST 2012

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Questions and answers

matt
February 20, 2025

I **** doping a lithium swap on a 2016 shuttle 4E and after i have swapped i **** getting a speed sensor fault code and the cazrt wont move. I have swapped sensors and same thing. Any thoughts?

0
1 comments:
Mr. Anderson
May 14, 2025

A speed sensor fault code on a 2016 Cushman Shuttle 4E after a lithium battery swap could be caused by:

1. Incorrect or loose sensor harness connections.
2. Faulty speed sensor.
3. Improper grounding at J2-4 (should be 0 volts).
4. Incorrect voltage at J2-5 (should be between 0–6.5 volts).

Verify the sensor harness, connections, and sensor operation using a digital voltmeter as described.

This answer is automatically generated

0
Bradley
May 2, 2025

Is there a electrical diagram using all 12 v batteries in series and parallel on cushman 2 shuttle

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Summary of Contents for Cushman Shuttle 2

  • Page 1 625610 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED UTILITY VEHICLE 625614 ISSUED MAY 2011 REVISED AUGUST 2012...

  • Page 2: Transporting Vehicle

    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 prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 SERVICE AND REPAIR MANUAL ELECTRIC POWERED UTILITY VEHICLES Shuttle 2 Shuttle 4 Shuttle 6 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.
  • Page 4 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 TITLE PAGE SAFETY ........................Inside Covers GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D FRONT SUSPENSION AND STEERING ..................E ELECTRONIC SPEED CONTROL ....................F BRAKES - FRONT DISC.........................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...
  • Page 7 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.

  • Page 8: General Operation

    SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL OPERATION ALWAYS: use the vehicle in a responsible manner and maintain the vehicle in safe operating condition. read and observe all warnings and operation instruction labels affixed to the vehicle.
  • 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. ALWAYS: test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.
  • 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: Page viii Repair and Service Manual...

  • Page 11: Table Of Contents

    GENERAL INFORMATION & ROUTINE MAINTANENCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 TRANSPORTING VEHICLE ..................A - 1 Towing ......................A - 1 Hauling......................A - 1 SERVICING THE ELECTRIC VEHICLE..............A - 1 ROUTINE MAINTENANCE ..................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page A-ii Repair and Service Manual...

  • Page 13: Hauling

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LABEL SERVICING THE ELECTRIC LOCATION VEHICLE Two serial number and manufacture date code label are on the vehicle.

  • Page 14: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE ITEM SERVICE OPERATION The only maintenance required for the first five years is Batteries Charge batteries the periodic inspection of the lubricant level.

  • Page 15: Vehicle Care Products

    GENERAL INFORMATION & ROUTINE MAINTANENCE 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 cause damage to seals, plastics, the electrical system, body finish or seat material. Do not use pressure in excess of 700 psi (4826 kPa) to wash vehicle.

  • Page 16: Hardware

    GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HARDWARE Generally, two grades of hardware are used in the vehicle. Periodically the vehicle should be inspected for loose •...

  • Page 17: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTANENCE 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 18 GENERAL INFORMATION & ROUTINE MAINTANENCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page A-6 Repair and Service Manual...

  • Page 19: Table Of Contents

    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 Additional Warnings..................B - 2 BATTERY REMOVAL &...
  • Page 20 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page B-ii Repair and Service Manual...

  • Page 21: Notices, Cautions Warnings And Dangers

    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 Always use the appropriate tools listed in the tool list and wear approved safety equipment. AND DANGERS MODIFICATIONS TO VEHICLE Throughout this manual, the following NOTICES,...

  • Page 22: Additional Warnings

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. become caught in the moving parts of the collect in the ceiling of buildings powertrain. necessitating proper ventilation. Five air exchanges per hour is considered the Use care not to contact hot objects.

  • Page 23: Battery Removal & Installation

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. should be present. If any corrosion is found, it should be immediately removed with a putty knife and wire brush. The area should be washed with a solution of sodium bicarbonate (baking soda) and water and thoroughly Overfilling batteries may result in electrolyte being...

  • Page 24: Lifting The Vehicle

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Center of Tool List Qty. Front Axle Floor jack ..............1 Jack stands..............4 Chocks................. 4 Some servicing operations may require the vehicle to be raised.
  • Page 25 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 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page B-6 Repair and Service Manual...
  • Page 27 Fig. 3 Body Components (Seats and Rear)..................C - 3 Fig. 4 Body Components (Cargo Box, Seat, Foot Rest)..............C - 4 Fig. 5 Shuttle 2, Rear Body ......................C - 9 Fig. 6 Seat Support Removal ......................C - 10 Fig.
  • Page 28 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 29 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill Out Rivet Pop Rivet Head Only NOTICE In the following text, there are references to removing/installing bolts etc.
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...
  • Page 31 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SHUTTLE 4 MODEL ONLY Fig. 3 Body Components (Seats and Rear) Repair and Service Manual Page C-3...
  • Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Back Support or Seat Bed Frame Fig. 4 Body Components (Cargo Box, Seat, Foot Rest) Repair and Service Manual Page C-4...
  • Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Instrument Panel Replacement Wrench, 5/16" ..............1 Phillips Screwdriver .............1 Tool List Qty. Rivet Gun..............1 Electric/air Drill ............1 Duct Tape..............1 Drill Bit, 7/32"...............
  • Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Seat Pod Replacement Ratchet, 3/8" Drive............1 Wrench, 3/8" ..............1 Tool List Qty. Wrench, 1/2" ..............1 Wrench, 7/16" .............. 2 Wrench, 9/16"...
  • Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the screws (37) that secure seat back support to Remove the screws (37) that secure the seat back sup- the vehicle frame.
  • Page 36 To replace the front facing rear seat, install in the reverse order of removal. The following text is sequenced to remove the rear body struc- ture of the Shuttle 2. Each successive step requires that the Rear Facing Rear Seat previous be accomplished.
  • Page 37 Mid Support Load Bed Battery Rack Bed Frame Side Panel Rear Valance Rear Fender Fig. 5 Shuttle 2 Rear Body Seat Support Removal Phillips Screwdriver .............1 Open End Wrench, 7/16" ..........1 Tool List Qty. Open End Wrench, 7/8" ..........1 3/8" Drill ............... 1 3/16"...
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. result in severe injury or death, remove the neg- Rear Fender Removal ative (-) battery cable before proceeding. Tool List Qty.
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Drill out the two rivets (1) securing the fuse block (2) to two washers (3) (Ref. Fig. 9). the fender (3) (Ref.
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Nuts (3) securing the bulkhead (4) to the bed frame (5) are to be tightened to 8.5 - 9.0 ft. lbs. (11.5 - 12.2 Nm) torque.
  • Page 41 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bed Frame Removal The bed frame (4) may now be lifted vertically and removed. Tool List Qty. Reassembly is the reverse of disassembly. Torque Wrench, ft.
  • Page 42 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The front seat frame (2) may now be lifted vertically and Remove the two horizontal bolts, washers and lock nuts removed.
  • Page 43 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. 3. Apply spray touch up paint in light even overlapping Follow the paint manufacturer’s recommendations for strokes.
  • Page 44 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-16...
  • Page 45 WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ................... D - 1 Tire Repair ....................... D - 1 Wheel Installation..................... D - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tire Installation .................D - 2 Repair and Service Manual Page D-i...
  • Page 46 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 D-ii...
  • Page 47 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL AND TIRE SERVICE Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section Tools List Qty.

  • Page 48: Wheel Installation

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten lug nuts as shown. Then, tighten lug nuts to 50 - 85 ft.
  • Page 49 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 D-3...
  • Page 50 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 D-4...

  • Page 51: Fig. 2 Lubrication Points

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ......................E - 2 Lubrication ..........................E - 2 Wheel Bearing and King Pin Bushing Inspection ..............E - 2 Wheel Bearing Packing ......................E - 2 Wheel Bearing Adjustment ....................E - 3 Wheel Alignment ........................E - 3 FRONT SUSPENSION ....................
  • Page 52 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 E-ii...
  • Page 53 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 Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...
  • Page 54 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. MAINTENANCE NOTICE Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause In the following text, there are references to removing/installing grease seals to fail or grease migration into areas that bolts etc.
  • Page 55 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 hub from spindle and disassemble. See Illus- lated nut must be loosened to align with the closest tration “Seal Installation”...
  • Page 56 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. Measure the distance between the chalk lines at both the front and rear of the tires (Ref Fig. 4). The measure- ment taken at the front of the tires should be 0"...

  • Page 57: 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 SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
  • Page 58 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. Installation of shock absorber is reverse of disassembly. Remove the three 1 3/4" long bolts (18), two 1 1/2" long Mounting nuts should be tightened until rubber bushings bolts (28), spring plate (24) and five lock nuts (19) secur- (4) expand to diameter of shock absorber washers (5).
  • Page 59 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. (23). Then pull long bolt and spring plate (24) from axle and spring. Retain above items (20 - 24) for assembly at their original locations.
  • Page 60 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. Install outer wheel bearing (4) and secure hub loosely with castellated nut. Place wheel onto hub and hand View from Underside tighten lug nuts.
  • Page 61 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. of the rollers requires replacement of the bearing. If the roller portion of the bearing is to be replaced, the race must also be replaced.
  • Page 62 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 Front of Vehicle Flat Section Fig. 12 Steering Components Rack Ball Joint Replacement To remove rack ball joint (1), loosen passenger side front wheel and lift and support front of vehicle per Tool List Qty.
  • Page 63 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. To install new rack ball joint close to its correct position, Tie Rod Inspection/Replacement measure amount of threads exposed from jam nut (Ref Tool List Qty.
  • Page 64 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. hammer to release tie rod from spindle arm. Remove nut large end loose until rack extension-to-rack and pinion to drop tie rod from spindle arm.
  • Page 65 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. To access the pinion seal, remove rack and pinion unit from vehicle. “Rack and Pinion Unit Replacement” on page E - 15 Anchor in vice by clamping on the mounting ears of the rack and pinion unit.
  • Page 66 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. Wire Tie, 10" Long ............1 Torque Wrench, in. lbs..........1 Front of Vehicle NOTICE The rack and pinion gears are not serviceable items. If they are found to be damaged or excessively worn, a new rack and pinion unit must be installed.
  • Page 67 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. If rack and pinion pass inspection, clean them, tensioner Remove cotter pin (2) and loosen castellated nut (3) and housing thoroughly and lubricate for assembly.
  • Page 68 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. Check for proper rack extension-to-rack and pinion unit torque. Secure bellows to rack and pinion unit with new clearance by first turning steering wheel fully to the right.
  • Page 69 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. Loosen the steering wheel retaining nut (6) two to three Ratchet ................1 turns (Ref Fig. 23). DO NOT REMOVE NUT AT THIS Socket, 3/4"...
  • Page 70 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 small retaining ring (11) and press bearing from steering shaft. To assemble steering shaft, first press new bearing onto shaft until it stops against shoulder.
  • Page 71 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 E-19...
  • Page 72 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 E-20...
  • Page 73 ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. PERFORMANCE ...................... F - 1 Speed Control ....................F - 1 Pedal-Up Features ................... F - 1 Walk Away Feature ..................F - 1 Anti Roll Back Feature ..................F - 1 Anti Stall Feature .....................
  • Page 74 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 F-ii...
  • Page 75 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERFORMANCE Pedal-Up Feature The pedal-up feature slows the vehicle when the accel- erator pedal is released while the vehicle is moving NOTICE between 8 mph (13 kph) and the vehicle’s top speed.
  • Page 76 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. backwards slightly before again stopping in the stalled • the controller is activated condition. This process will repeat itself periodically until •...
  • Page 77 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the operator attempts to override the electronic brak- Controller ing feature by moving the direction selector or key switch to another position, the warning beeper will The controller is a solid state unit that activates a sole- sound and the vehicle will brake rapidly until it reaches...
  • Page 78 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL TROUBLESHOOTING To assure accurate readings, be sure to set the meter to the closest voltage reading above the expected voltage. Tool List Qty.
  • Page 79 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. removing the BL- connection to the battery. Always use insulated wrenches when working on batteries. To check for continuity, set the DVOM to the KW setting Battery and select ‘Continuity’.
  • Page 80 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the continuity test indicates that contacts are not TROUBLESHOOTING DIAGRAMS “welded” and the wiring to the solenoid coil is good, the The following diagrams will assist in servicing the vehi- coil has failed and the solenoid must be replaced.
  • Page 81 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Fault Vehicle Operation Corrective Action Code Change - - - Direction Selector Fault Vehicle Operates in •...
  • Page 82 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4 - 3 M- fault Vehicle will not run • Check M- wiring and repair; Replace controller 4 - 4 Auxiliary contact did not Vehicle will not run...
  • Page 83 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ground To Hand Speed Input Held MAIN Sensor Diagnostic +15V RUN/ STORE SWITCH (20 A) Charger Interlock Throttle Switch (Optional) Pot High...
  • Page 84 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Charger Interlock Switch (Optional) Pot High Logic Enable Pot Low Fuse Sense Pot Wiper Logic Power Ground Main Contactor Brake Light Relay...
  • Page 85 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 86 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ground SPARE Speed Input SPARE Sensor +15V SPARE All tests are to be performed with the negative lead of the DVOM connected to the negative side of battery pack voltage.
  • Page 87 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAIN This test will verify secondary circuit voltage. Please reference the chart for probe connections. If not/ Then Probe Connection Voltage Positive prove on BL+ and...
  • Page 88 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INDUCTIVE THROTTLE SENSOR (ITS) ‘ITS’. Carefully remove the two wires that attach to the ITS TESTING AND REPLACEMENT and carefully remove the nuts securing the ITS to the plastic pedal box studs.
  • Page 89 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PEDAL PRE-TRAVEL PEDAL UP Pedal bracket rest against front of pedal frame opening Lock Nut Use 7/32" drill to measure gap between plunger Micro switch...
  • Page 90 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2.7 ± 0.5 volts 1.0 ± 0.3 volts Fig. 17 ITS Adjustment (Sheet 2 of 2) Repair and Service Manual Page F-16...
  • Page 91 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTROLLER REPLACEMENT Reconnect the BL- battery cable and replace the seat. Tool List Qty. SOLENOID REPLACEMENT Socket, 10mm .............
  • Page 92 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Mount new solenoid and reconnect wiring. Tighten the solenoid mounting nuts to 67 - 82 in. lbs. (8 - 9 Nm) torque, the #10 terminal nuts to 13 - 17 in.
  • Page 93 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 F-19...
  • Page 94 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 F-20...
  • Page 95 BRAKES - FRONT DISC TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. SYSTEM DESCRIPTION ........................ G - 1 MASTER CYLINDER REPLACEMENT ..................G - 1 BRAKE MASTER CYLINDER FLUID .................... G - 2 Check Brake Fluid ........................ G - 2 ROUTINE MAINTENANCE......................
  • Page 96 BRAKES - FRONT DISC 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 97 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SYSTEM DESCRIPTION Remove the braided brake line from the master cylinder and allow brake fluid to drain into a container. Do not reuse old brake fluid.
  • Page 98 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE MASTER CYLINDER FLUID REPLACEMENT OF WEAR ITEMS Brake Pad Replacement NOTICE Brake pads should always be replaced as a full set of Hydraulic brake systems must be totally flushed if the fluid four pads.
  • Page 99 BRAKES - FRONT DISC Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. bushing may be installed (flange down) to the lower Clean each fitting before opening to prevent contaminat- actuator pivot and the actuator linkage reinstalled using ing the system.
  • Page 100 BRAKES - FRONT DISC 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-4...
  • Page 101 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW .................. K - 1 General Description ..................K - 1 How the Service Brake Works................K - 1 Equalizer Link ....................K - 2 Automatic Adjuster Mechanism ................ K - 2 How the Parking Brake Works .................
  • Page 102 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO Fig. 15 Brake Shoe Wear ..................K - 13 Fig. 16 Orientation of Brake Shoe Springs ............K - 14 Fig. 17 Free Travel Adjustment ................K - 15 Fig.
  • Page 103 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Hinge Pin Identification Hole* Service Brake Pedal Pedal Latch Spacer Kick Off Catch Bracket Cap Screw...
  • Page 104 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. system. Continued motion of the brake pedal pulls both the left and right brake cables. Each brake cable pulls a Brake brake lever which pushes the rear brake shoe against Shoe...
  • Page 105 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly Older Models The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.
  • Page 106 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of: Includes...
  • Page 107 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • Page 108 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING TABLE Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Test (PBPT), and Aggressive Stop Test is performed (Ref.
  • Page 109 MECHANICAL BRAKES 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 Unequal braking (one wheel locks Wheel not locking is not adjusting. Check brake operation of wheel that is not locking.
  • Page 110 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPECTION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this 1/4"...
  • Page 111 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Either condition can prevent the brakes from adjusting loose, but brake pedal free travel is correctly adjusted properly.
  • Page 112 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. soon as the accelerator pedal is depressed. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0"...
  • Page 113 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cles, several vehicles should be tested when new and the range of stopping locations or distances recorded. NOTICE Over time, a subtle loss of performance may take place;...
  • Page 114 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To perform an Aggressive Stop Test, equally load both sides of the vehicle (Ref. Fig. 13) and apply maximum force and travel to the service brake pedal while moving.
  • Page 115 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. brake adjusters be replaced when installing new brake shoes. Wheel Brake Lever 10. Inspect the brake shoe springs. Be sure that they are not broken or damaged and are correctly installed.
  • Page 116 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pliers ................1 Vernier/Dial Calipers ............1 Heavy Shoe Spring Plastic Tipped Hammer..........1 Puller (P/N 15947-G1) ..........1 Light Pry Bar .................1 Shoe Spring Dust Mask ..............1...
  • Page 117 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. latches. The parking brake should latch between 65 and 7/8" - 1 1/8" (2.2 - 2.9 cm) 75 lbs.
  • Page 118 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. until a new cotter pin can be installed through the castel- lated nut and the hole in the axle. Maximum torque is 140 ft.
  • Page 119 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lubricate the backing plate friction points of the shoes Backing Plate/Entire Wheel Brake Assembly and moving anchor with Multi Purpose Grease (MPG) Removal and Installation lubricant (Ref.
  • Page 120 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always replace both brake shoes on both wheels as a Heavy Shoe Spring set. Install the shoes as indicated and install the shoe Shoe Clamp clamp (5) over the shoe clamp pin (4) and rotate 90°...
  • Page 121 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. replace if needed. Remove the brake cable and equalizer the bracket. Move the hook back and to the side to assembly and discard.
  • Page 122 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Catch Bracket Removal and hardened part. Do not grind or file it as doing so will cause the part to lose its hardness char- Installation acteristics.
  • Page 123 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Inspect the bushings (9,10) and spacer. If they are worn, replace them with new ones. Accelerator Pedal Fig.
  • Page 124 MECHANICAL 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 K-22...
  • Page 125 ELECTRICAL SYSTEM TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. DIGITAL VOLT OHM METER ..................J - 1 TROUBLESHOOTING ....................J - 1 POWER SUPPLY.......................J - 3 Check For Loose Or Bare Wires ...............J - 3 Check battery Condition ..................J - 3 Check Green Power Wire..................J - 3 Check Fuse .......................J - 3 ACCESSORY WIRING....................J - 3...
  • Page 126 ELECTRICAL 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 J-ii...
  • Page 127 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIGITAL VOLT OHM METER TROUBLESHOOTING A typical digital volt ohm meter (DVOM) is shown (Ref. In order to effectively troubleshoot the circuits that Fig.
  • Page 128 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driver Side Passenger Side Marker Headlight Headlight Marker Turn Turn BLU/WHT Horn + 12V ORN /WHT 15 AMP Fuse 15 AMP Brake...

  • Page 129: Light Bulb Replacement

    ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. POWER SUPPLY NOTICE Tool List The green wire supplies power to the entire fuse block. DVOM ................. 1 4.
  • Page 130 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. unlock and pull out bulb. Insert new bulb and rotate socket a quarter turn clockwise to secure. Turn Signal Light Headlights...
  • Page 131 ELECTRICAL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STATE OF CHARGE METER AND KEY SWITCH FUSE BLOCK BLU/WHT (Light Switch) ORN/WHT (Horn Switch) (Brake Light Switch) Battery BL+ Fig.
  • Page 132 ELECTRICAL 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 Floormat Floorboard Fig. 6 Horn TURN SIGNAL HOUR METER Solenoid Fig. 7 Turn Signal & Hour Meter Repair and Service Manual Page J-6...
  • Page 133 ELECTRICAL 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 J-7...
  • Page 134 ELECTRICAL 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 J-8...
  • Page 135 MOTOR TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. GENERAL ......................... K - 1 Motor Removal....................K - 1 Motor Disassembly ..................K - 1 Bearing Replacement..................K - 2 Field Coil Replacement ..................K - 3 Brush Replacement..................K - 3 Motor Assembly ....................
  • Page 136 MOTOR 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 137 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Mark both the axle and motor housings to permit realign- ment during reassembly of motor to rear axle (Ref. Fig. Do not hold vehicle on hill by using accelerator and motor.
  • Page 138 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Motor Components Bearing Replacement cover as possible, and press the armature out of the bearing. Tool List Qty.
  • Page 139 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brushes should be measured as shown and replaced when the minimum dimension of .62" (16 mm) is NOTICE reached (Ref.
  • Page 140 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Align the commutator end cover with the holes in the quantity of molybdenum grease to the male portion of motor housing and assemble (Ref.
  • Page 141 MOTOR 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 142 MOTOR 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 143 BATTERIES AND CHARGING TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. SAFETY ........................L - 1 BATTERY ......................... L - 1 BATTERY MAINTENANCE ..................L - 1 At Each Charging Cycle ..................L - 2 Monthly ......................L - 2 Electrolyte Level and Water ................L - 2 Cleaning Batteries.....................L - 3 Battery Replacement..................L - 4...
  • Page 144 BATTERIES AND CHARGING 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 145 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY cause damage to the vehicle and storage facility. Always observe the following warnings when working on Aerosol containers of battery terminal pro- or near batteries: tectant must be used with extreme care.
  • Page 146 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. At Each Charging Cycle Do not overfill batteries. The charging cycle will expel electrolyte and result in component damage. To reduce the possibility of fire, never attach a A battery being charged will ‘gas’...
  • Page 147 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. These watering devices are fast and accurate to use and maintain the correct electrolyte level within the bat- tery cells.
  • Page 148 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Replacement and battery wire terminals with a commercially available protective coating. Front of Vehicle BL+ to Charger BL- to B- Solenoid...
  • Page 149 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. deposits neutralized and removed from the battery case • The charger connector is fully inserted into the to prevent self discharge.
  • Page 150 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A cost effective way to identify a poorly performing bat- Specific gravity is the measurement of a liquid that is tery is to use a hydrometer to identify a battery in a set compared to a baseline.
  • Page 151 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY CHARGER problem with the low reading cell(s). As a battery ages the specific gravity of the electrolyte Description will decrease at full charge.
  • Page 152 BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. wait a few seconds and observe ammeter on charger to make sure it moves indicating that charger is charging. Polarized Receptacle Fig.
  • Page 153 REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................M - 1 General ......................M - 1 Shock Absorber Removal.................M - 1 Shock Absorber Installation................M - 1 Rear Spring Removal ..................M - 1 Rear Spring Installation ..................M - 1 REAR AXLE REMOVAL ...................M - 3 Rear Axle Installation ..................M - 3 LIST OF ILLUSTRATIONS...
  • Page 154 REAR 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 M-ii...
  • Page 155 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of dis- assembly except that the shock absorber nuts (1,3) NOTICE must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer...
  • Page 156 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual Page M-2...
  • Page 157 REAR 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 the governor and remove the cable. See SPEED CON- TROL section. Remove the linkage rod off of the gover- Tool List nor.
  • Page 158 REAR 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 M-4...
  • Page 159 REAR AXLE TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. REAR AXLE ........................... N - 1 Checking the Lubricant Level .................... N - 1 REAR AXLE DISASSEMBLY ......................N - 2 Axle Shaft Removal and Disassembly ................N - 2 Axle Shaft Seal Removal and Replacement ..............
  • Page 160 REAR AXLE 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 161: Rear Axle

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further axle information, see Electric Rear Axle NOTICE Manual P/N 28148-G01. Refer to REAR SUSPENSION section for axle removal. It is recommended that whenever a bearing, seal or ‘O’...
  • Page 162 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Removing/Installing Axle Shaft Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pressure to the threaded end of the axle shaft (Ref.
  • Page 163 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Replacement NOTICE Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with Tighten the castellated axle nut to 70 ft.
  • Page 164 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page N-4 Repair and Service Manual...
  • Page 165 WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD ................... P - 1 Trailering ......................P - 1 SHUTTLE 4 AND SHUTTLE 6 SUN TOP ..............P - 1 Rear Support Installation.................. P - 1 Front Struts ......................
  • 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. NOTES: Repair and Service Manual Page P-ii...
  • 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. TOP AND WINDSHIELD Straight blade screwdriver ...........1 Rear Support Installation Using a plastic faced hammer, tap end caps (5) into the top of the rear struts (3, 4) (Ref.
  • 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. Front Of Vehicle Rear of Vehicle (Driver Side Shown) Front Strut Front of Vehicle Fig. 1 Shuttle 4 and Shuttle 6 Sun Top Repair and Service Manual Page P-2...
  • Page 169 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPILT WINDSHIELD Insert bolt (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
  • Page 170 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD Install sash (3) on each side of the windshield. Using a plastic faced mallet, gently tap sash to ensure wind- Tool List Qty.
  • Page 171 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 172 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 173 TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. ELECTRICAL SYSTEM ....................Q - 1 Basic Electrical Power System Troubleshooting ..........Q - 2 Basic Electrical Troubleshooting for Accessories ..........Q - 2 SUSPENSION AND STEERING ................Q - 3 Repair and Service Manual Page Q-i...
  • Page 174 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 Q-ii...

  • Page 175: Electrical System

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL SYSTEM For non-PDS vehicles, see Electronic Speed Control Section. For PDS vehicles, see Electronic Speed Control (PDS) Section. For PDS vehicles, also use Diagnostic Mode, PDS Fault Codes and Troubleshooting Diagrams.
  • Page 176 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 Vehicle/charger connector damaged Replace connector Battery case damage Replace battery Low electrolyte level Maintain correct electrolyte level Battery capacity deficient Perform hydrometer/load test and replace battery if required...

  • Page 177: Suspension And Steering

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUSPENSION AND STEERING Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires STIFF STEERING Bent rack...
  • Page 178 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 Q-4...
  • Page 179 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. Grounding Requirements ....................... R - 1 Ground Systems ..........................R - 1 Lightning Protection Requirements ....................R - 1 Equipment Fault and Personal Safety System ................R - 1 Ground Network Requirements ......................
  • Page 180 LIGHTNING PROTECTION AND GROUNDING 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 181 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 1.
  • Page 182 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 6.
  • Page 183 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 from penetrating or structurally damaging the building.
  • Page 184 LIGHTNING PROTECTION AND GROUNDING 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 185 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions (SHUTTLE 4 & SHUTTLE 6) ..........S - 4 Fig. 2 Vehicle Dimensions (SHUTTLE 2) ..............S - 5 Fig. 3 Incline Specifications ..................S - 6 Fig. 4 Turning Clearance Diameter ................S - 7...
  • Page 186 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 T-ii...
  • Page 187 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE™ 2 TYPE: GASOLINE POWERED CARGO CARRIER MODEL YEAR: 2012 Part No:. 618849 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki Valve Train:...
  • Page 188 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE™ 4 TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 618851 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki Valve Train:...
  • Page 189 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE™ 6 TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 618853 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki Valve Train:...
  • Page 190 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lowest Clearance At Di erential 4.3 in. (11.0 cm) (All Models) SHUTTLE 4 SHUTTLE 6 93.5 in. (237.0 cm) 122.0 in.
  • Page 191 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SHUTTLE 2 93.5 in. (237.0 cm) 122 in. (310.0 cm) 138 in. (351.0 cm) 46.5 in. (119.0 cm)
  • Page 192 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 72.0 in. (183.0 cm) 48.6 in. (123.0 cm) RECOMMENDED MAX SIDE TILT Front Wheel Track 25% or 14° MAX 34.2 in.
  • Page 193 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED RECOMMENDED MAX SIDE TILT MAX RAMP GRADE 25% or 14˚ MAX 25% or 14° MAX TURNING CLEARANCE DIAMETER 22.0 ft.
  • Page 194 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 S-8...
  • Page 196 E-Z-GO Division of Textron Inc., 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...

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