Body Component Replacement; Drill Out Metal Rivet; General - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
BODY
NOTICE
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. Non-specified torques are as
shown in the table in Section A.

General

To prevent possible injury or death from battery
explosion. Batteries should always be removed
before any servicing that will generate sparks. It
is important to use a sharp drill bit when remov-
ing the rivets on the side of the vehicle. Extreme
care must be used when drilling out the rivets
located in the front of the body and the bottom
side of the body. Excessive pressure could
result in the drill bit being forced through the
body panel and penetrating a component. As
extra protection, it is recommended that a pro-
tective piece of sheet metal be placed between
the battery and the rivet. Use of a drill depth
stop will provide additional protection.
In general, body component replacement can be accom-
plished with a minimum of specialized tools. Most body
components are held in place with conventional remov-
able hardware (nuts, bolts, washers and screws). Some
components are mounted with 'pop' rivets which require
that the rivet head be removed in order to push out the
shank of the rivet. The rivet head is easily removed by
drilling into the head with a sharp drill bit that is slightly
larger than the shank of the rivet (Ref. Fig. 1). Care must
be exercised when drilling to prevent the drill from being
forced through and damaging components where it could
damage components located immediately behind the
rivet. The best way to prevent this from occurring is to use
a sharp drill bit that requires very little pressure to cut suc-
cessfully and to place a piece of protective sheet metal
between the surface being drilled and components
directly behind it.

BODY COMPONENT REPLACEMENT

The body components can be replaced by removing the
securing hardware, replacing the component and secur-
ing with hardware in the same orientation as removed.
The illustrations on the following pages indicate the
assembly methods for the various components.
Repair and Service Manual
Drill Out Rivet
Pop Rivet
Head Only
Fig. 1 Drill Out Metal Rivet
BODY
B
B
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