Controls And Wiring; Removing The Engine From The Vehicle; Engine Installation; Drive Clutch Removal - Cushman HAULER 800X Technician's Repair And Service Manual

ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
11. Disconnect the pulse line from the fuel pump using pli-
ers.
12. Disconnect the fuel line from the carburetor inlet, use
drip pan to catch any fuel leakage.
13. Remove throttle rod cover using a 6" extension and a
12 mm socket. Remove the throttle rod at the carbure-
tor butterfly using a flat blade screwdriver to pop the
retaining tab from the throttle rod and lift throttle rod
out of hole. Remove throttle rod at rear by rotating 45
degrees from the bracket and lift through the bracket
slot and remove rod from vehicle.
14. Loosen nuts on the choke cable using a 10 mm
wrench. Close choke butterfly and remove cable from
slot.
15. Remove both bolts from starter/generator bracket
using a 15 mm wrench. Move throttle bracket away
from engine.
16. Remove muffler bolts from muffler stack using a 10
mm and a 13 mm wrench.
17. Remove the passenger side hub cap if equipped and
using a 3/4" lug wrench, remove the wheel and tire
assembly.
18. Set Park Brake and place direction selector in For-
ward to place tension on the clutches.
19. Access the driven clutch from the passenger side of
the vehicle and using a 19mm combo wrench, remove
the bolt from the driven clutch.
20. Install the clutch puller bolt in clockwise position until it
bottoms out.
21. Using a impact tool and an impact socket on the clutch
puller bolt, remove the clutch then remove the clutch
puller bolt.
22. To remove the drive clutch, use a 19mm impact socket
with an impact tool remove the 19 mm bolt from the
center of the drive clutch.
23. Raise the powertrain with the floor jack so that the
clutch puller bolt clears the spring hanger. Remove the
front eyebolt from the spring hanger using a 15 mm
socket and a 15 mm wrench. Install the clutch puller
bolt in a clockwise position and using the impact tool
remove the drive clutch from the shaft. Remove the
clutch puller bolt.
24. Remove the four 15 mm bolts from the engine support
bracket connecting the engine to the differential and
the engine to the inner frame.
25. Remove the 15 mm bolts from the bottom of the skid
plate. Access the forward two nuts through the oil
drain access hole.
Page G-10

Controls and Wiring

Unplug the wiring harness from the engine and cut the
wire tie securing the accelerator cable to the engine.

Removing the Engine from the Vehicle

Place suitable blocks under the engine frame for support.
Although the blocks are not required for engine removal, they
will help maintain the alignment of the frames and simplify

engine installation.

It is not necessary to remove the muffler as part of the engine
removal.
Engine Installation
When installing the fuel and pulse lines, pay particular
attention to assure that the lines are not confused.
It is important to follow the assembly sequence recom-
mended for mounting hardware.
With the assistance of a hoist or another person, lower
the engine into position over the engine support cast-
ings.
Install one rear horizontal and one front bottom engine
bolt through the casting and engine and lightly snug in
place.
Install the remaining horizontal engine bolts and finger
tighten. Remove the front bottom bolt and reinstall the
skid plate finger tight.
Tighten the bottom and horizontal mounting bolts to 45
ft. lbs. (60 Nm) torque.
The remaining installation is in the reverse order of dis-
assembly using standard torque specifications.

DRIVE CLUTCH REMOVAL

To prevent the possibility of personal injury,
use only impact sockets when using an impact
wrench.
Insert a clutch puller bolt (p/n 608429) into the clutch
and hand tighten for several turns. Remove the clutch by
Repair and Service Manual
NOTICE
NOTICE