Ezgo EXPRESS L4 Technician's Repair And Service Manual
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Ezgo EXPRESS L4 Technician's Repair And Service Manual

Gasoline powered utility vehicle
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See also: Service Manual , Owner's Manual
625610
TECHNICIAN'S REPAIR AND SERVICE MANUAL
GASOLINE POWERED UTILITY VEHICLE
625617
ISSUED MAY 2012
REVISED AUGUST 2012

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  • Page 1 625610 TECHNICIAN’S REPAIR AND SERVICE MANUAL GASOLINE POWERED UTILITY VEHICLE 625617 ISSUED MAY 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 SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual. TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124 SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 INTERNATIONAL: PHONE: 001-706-798-4311, FAX: 001-706-771-4609 Repair and Service Manual Page i...

  • 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 WHEELS AND TIRES ........................D FRONT SUSPENSION AND STEERING ..................E SPEED CONTROL...........................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    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 in maintaining the vehicle in accordance with procedures developed by the manufacturer.
  • 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 .........................
  • 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 SERVICING THE VEHICLE 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. sider the safety of yourself and those around you, should the component move unexpectedly. Some components are heavy, spring loaded, highly cor- FUEL Leave 1”...

  • 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. Use extra caution when towing vehicle. Do not tow a sin- odic Service Schedule for appropriate service intervals gle vehicle at speeds in excess of 12 mph (19 kph).

  • 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 TOP AND WINDSHIELD After the vehicle has been put into service, it is recom- mended that the brakes be checked by periodically con- ducting a brake performance test.

  • Page 17: Care And Cleaning Of The Vehicle

    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. • Properly inflate the tires to recommended pres- Occasional cleaning and waxing with non-abrasive sure (psi) stated on sidewall of tires.

  • Page 18: Torque Specifications

    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. TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.

  • 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 battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders AND DANGERS if not treated with utmost caution.

  • Page 26: Safety

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. injury. In particular, use care when working Wrap wrenches with vinyl with or around batteries, compressed air tape to prevent the possi- or solvents.
  • Page 27 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 Fig. 1 Drill Out Metal Rivet ......................C - 1 Fig. 2 Front Body Components ....................... C - 2 Fig. 3 Body Components Continued (Express L4 & Express S4) ........... C - 3 Fig. 4 Body Components Continued (Terrian 250, 500 & 1000) ............. C - 4 Fig.
  • 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

    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 34: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Splash Panel Glove Box Door Fender Flare Instrumental Panel Front Fascia Front Basket Splash Panel Floorpan Brush Guard Fig.
  • Page 35 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Splash Panel Floor Mat Seat Support Battery Tray Frame Fender Liner Box Cooler Box Cooler and Bracket Fig. 3 Body Components Continued (Express L4 & Express S4) Repair and Service Manual Page C-3...
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Floor Mat Splash Panel Seat Wrap W/Louvers (For TERRIAN 250) Battery Tray Rocker Panel Side Panel Seat Frame (For TERRIAN 500 AND 1000) Ashtray Floor Mount Gun Holder Fig.
  • Page 37 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Access Panel Seat Hinge Plate Notched Rear Bumber EXPRESS L4 & EXPRESS S4 Seat Hinge Plate Rear Fender Rear Panel TERRIAN 250, 500 &...
  • Page 38 Seat Back Support Handrail Seat Frame Weldment Footrest Handle Front of Vehicle Footrest Weldment Seat Back Support Seat Back Assembly Seat Back Support Seat Bottom Assembly Hip Restraint Fig. 6 Seating (Express L4 & Express S4) Repair and Service Manual Page C-6...
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Seat Back Assembly Seat Bottom Assembly Hip Restraint Seat Back Support Bracket Seat Back Support Bracket Seat Back Support Access Cover TERRAIN 1000 TERRAIN 250 &...
  • Page 40 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 Heat Shield Latch Plate Rubber Bumper Fig. 6 Plastic Bed Components (Manual Lift) Repair and Service Manual Page C-8...
  • Page 41 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: 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. 3. Apply spray touch up paint in light even overlapping Follow the paint manufacturer’s recommendations for strokes.
  • Page 43 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-11...
  • 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-12...
  • 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

    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 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: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. FRONT SUSPENSION AND STEERING ..............E - 1 FRONT SUSPENSION....................E - 1 Front Shock Absorber Replacement .................E - 1 Shock Boot Removal and Replacement ................E - 1 Front Axle Replacement ....................E - 1 Front spring Replacement ....................E - 2 Tie Rod, Wheel Bearing and King Pin Inspection .............E - 3...
  • Page 52 FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ (CONT.) SECTION TITLE PAGE NO. Axle Linkage Rod Replacement ..................E - 16 Front Spring Replacement....................E - 17 Hub Replacement ....................... E - 18 Wheel Bearing and Race Replacement................E - 18 STEERING........................
  • 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. NOTES: Repair and Service Manual Page E-iii...
  • 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. NOTES: Repair and Service Manual Page E-iv...
  • 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. FRONT SUSPENSION Front Axle Replacement NOTICE Tool List Qty. In the following text, there are references to removing/installing Wheel chocks ..............4 bolts etc.
  • 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. Tighten the shock absorber mounting hardware until the rubber bushings expand to the diameter of the shock ITEM TORQUE SPECIFICATION absorber washer.
  • Page 57 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. Jack stands..............2 NOTICE Pliers................1 Impact wrench .............1 Failure of a single spring will result in overstressing the other Impact socket, 3/4"...
  • 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. Ball peen hammer ............1 When steering wheel is loosened, remove retaining nut Torque wrench ............. 1 and remove steering wheel.
  • 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. nuts (10) from the coupling (11) and remove shaft (12) Bolts (6) must be replaced with new bolts. Tighten bolts from the steering assembly.
  • 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. To remove the tensioner, remove the bolts (31), the cover plate (32) and gasket (33) that secures the rack ITEM TORQUE SPECIFICATION tensioner in the steering housing.
  • 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. MAINTENANCE and removing the ball joint (21) from the rack (Ref Fig. Good routine maintenance of the front suspension and Rack Ball Joint Installation steering consists of routine lubrication (See Lubrication Chart and the Periodic Service Schedule in Section ‘A’).
  • 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. Remove the dust cap (14), cotter pin (15) castellated nut and washer (16), outer roller bearing (18) and hub assembly (17) from the spindle (Ref Fig.
  • 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. Sizing reamer, .875" ............ 1 five feet in order to allow the tires to take their normal Socket, 15/16"...
  • 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. INDICATES AREAS OF EXCESSIVE TIRE WEAR NOTES: ILLUSTRATIONS ARE DISTORTED FOR CLARITY. DUE TO LOW WEIGHT OF VEHICLE &...
  • Page 65 FRONT SUSPENSION AND AXLE MOUNTED 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...
  • Page 66 FRONT SUSPENSION AND AXLE MOUNTED 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.
  • Page 67 FRONT SUSPENSION AND AXLE MOUNTED 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- slight resistance is felt. If the cotter pin hole in the spin- tration “Seal Installation”...
  • Page 68 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. tern. Lower vehicle and, with tires in the straight ahead Fig. 18). Reconnect intermediate shaft and tighten bolt position, roll it forward approximately five feet in order to to 155 - 215 in.
  • Page 69 FRONT SUSPENSION AND AXLE MOUNTED 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 70 FRONT SUSPENSION AND AXLE MOUNTED 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. rack and pinion unit back to rest on top of front springs Mounting nuts should be tightened until rubber bushings (17).
  • Page 71 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hold nut (21) with wrench and loosen long bolt (20). Note location of washer (22) and thread long bolt out as far as possible to remove the washer, nut and spacer (23).
  • Page 72 FRONT SUSPENSION AND AXLE MOUNTED 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 73 FRONT SUSPENSION AND AXLE MOUNTED 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 74 FRONT SUSPENSION AND AXLE MOUNTED 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. 25 Steering Components Rack Ball Joint Replacement Remove passenger side front wheel and turn steering wheel fully to the left.
  • Page 75 FRONT SUSPENSION AND AXLE MOUNTED 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, Wrench, 9/16" ..............1 measure amount of threads exposed from jam nut (Ref Needle Nose Pliers ............1 Fig.
  • Page 76 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. large end loose until rack extension-to-rack and pinion unit clearance is checked or adjusted. NOTICE The distance to center of tie rod ball joint from jam nut on both ends of threaded tube should be the same.
  • Page 77 FRONT SUSPENSION AND AXLE MOUNTED 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 - 25 Anchor in vice by clamping on the mounting ears of the rack and pinion unit.
  • Page 78 FRONT SUSPENSION AND AXLE MOUNTED 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.
  • Page 79 FRONT SUSPENSION AND AXLE MOUNTED 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 80 FRONT SUSPENSION AND AXLE MOUNTED 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 81 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bearing Separator............1 Gear Puller..............1 Arbor Press..............1 Bearing Driver Set ............1 Torque Wrench, ft. lbs..........1 Torque Wrench, in.
  • Page 82 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. as far as possible using snap ring pliers (Ref Fig. 38). Use fingers to push retaining ring fully into groove. Slide wave washer into base of steering column.
  • Page 83 FRONT SUSPENSION AND AXLE MOUNTED 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-29...
  • Page 84 FRONT SUSPENSION AND AXLE MOUNTED 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-30...
  • Page 85 SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. SYSTEM OPERATION ..................F - 1 Pedal Box Operation ..................F - 1 Governor Operation ..................F - 2 TROUBLESHOOTING ....................F - 2 SPEED CONTROL....................F - 2 Accelerator Cable Removal at Governor ............
  • Page 86 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 87: Speed Control

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Governor Lever - Upper Governor Lever - Lower Governor Spring Accelerator Compression Spring Fig. 1 Accelerator and Speed Control System SYSTEM OPERATION Pedal Box Operation NOTICE...
  • Page 88 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Governor Operation Torque Wrench, in. lbs ..........1 Torque Wrench, ft. lbs ..........1 Until the vehicle reaches its governed speed, the vehicle will continue to accelerate in relation to the accelerator Drill, 1/4"...
  • Page 89 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Installation To install the accelerator cable, proceed in reverse order (Ref Fig. 3)(Ref Fig. 4)(Ref Fig. 5). ITEM TORQUE SPECIFICATION 30 - 33 ft.
  • Page 90 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE Note that the factory applies a thread sealant to the accelera- tor rod threads before threading the rod into the clevis. Fig.
  • Page 91 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 setscrew (9) in cam (10) using an 1/8" Allen wrench. Loosen the jam nut (12) and move the cam to adjust as needed (Ref Fig.
  • Page 92 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-6...
  • Page 93 ENGINE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE ................G - 1 Checking the Oil Level ..................G - 1 Changing the Oil ....................G - 1 AIR FILTER INSPECTION/REPLACEMENT ............G - 3 Cleaning the Air Filter Element................. G - 4 STARTER/GENERATOR BELT TENSION ...............G - 4 Adjusting the Belt .....................
  • Page 94 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 G-ii...
  • Page 95 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further engine information, see Engine Shop Rebuild Maximum Oil Level Fill Cold Engine and Service Parts Manual. For Hot Engine To This Point Do Not Overfill...

  • Page 96: Engine

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HEAVY DUTY WORK 10W-30 10W-40 Be careful of hot oil when drained. It may be hot enough to burn you severely LIGHT DUTY WORK Place the oil drain pan under the oil drain plug (1) found 10W-30...
  • Page 97 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. from the engine and allow the oil to drain into the oil drain pan (Ref. Fig. 6). The ‘O’ ring (5) may remain on engine (6) or filter (7) (Ref.
  • Page 98 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE The air filter assembly on the vehicle is a dry unit. Do not use oil on the filter element or any part of the unit. The air cleaner may be accessed by raising the seat.
  • Page 99 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR REPLACE- MENT (Ref. Fig. 12) Tool List Qty. Wrench, 8 mm ............. 1 Wrench, 10 mm ............1 Wrench, 13 mm ............
  • Page 100 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 16 Cleaning Cooling System with Air SPARK PLUG Fig. 14 Starter/Generator Wire Connections Tool List Qty. Spark Plug Socket,13/16" ..........1 FROM Feeler Gauge, wire type ..........1 Ratchet &...
  • Page 101 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. adjusted valves, spark plug wires which are in poor con- Attach the compression gauge (1) to the adapter (2) and dition or poor quality fuel could also contribute to the insert firmly into the plug hole.
  • Page 102 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If cylinder compression is lower than 9 kgf/cm (128 psi), Then check the valve clearance with a feeler gauge (7), check the following: measure the valve clearance between the rocker arm (8) and the valve stem end.
  • Page 103 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 1. Disconnect Battery ground wire. 2. Disconnect air hose at carburetor. 3. Jack up rear of vehicle as directed in Section B of this Do NOT overtighten.
  • Page 104 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the vehicle and using a 19mm combo wrench, remove mended for mounting hardware. the bolt from the driven clutch. With the assistance of a hoist or another person, lower 20.
  • Page 105 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 G-11...
  • Page 106 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 G-12...

  • Page 107: Fuel System

    FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. GENERAL ......................... H - 1 CARBURETOR OPERATION ................... H - 2 Float System ....................H - 2 Pilot Jet System ....................H - 2 Main Jet System....................H - 2 Carburetor Service ...................
  • Page 108 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 H-ii...

  • Page 109: General

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CARB Canister Fuel Filter Fuel Shut Off Valve Fuel Line to Fuel Pump Carburetor Fuel Gauge Sending Unit Fuel Tank Fig.

  • Page 110: Carburetor Operation

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. venturi as atomized air/fuel and is mixed with intake air and delivered to the engine. Carburetor Service FUEL Leave 1”...

  • Page 111: Fuel System Component Service And Replacement

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. bullet end of the choke cable can be removed from the carburetor choke plate (1). Fig. 4 Choke Cable and Housing At the seat panel, remove the nut (6) and lock washer (7) securing the outer cable to the bezel (8).

  • Page 112: Carburetor Removal

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. no sharp bends or kinks in the cable before firmly tight- ening the nuts at both ends of the cable. Fig.

  • Page 113: Float Level Alignment

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Float Chamber Stem Float Valve Float Carburetor Body Float should be aligned so that its top is parallel or “slightly above”...
  • Page 114 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. a negative pressure moves the diaphragm within the the fuel tank on the passenger side of the vehicle fuel pump (1) (Ref.
  • Page 115 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CARBON CANISTER The fuel filter, tank, hoses and cap should be checked (Ref. Fig. 11) frequently for leaks, or signs that the cap vent or filter have become clogged.
  • Page 116 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 H-8...
  • Page 117 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL ........................J - 1 CLUTCHES ........................J - 1 Drive Clutch ......................J - 1 Driven Clutch ....................J - 2 Increased Load ....................J - 2 Equilibrium ......................J - 2 Removing the Drive Belt..................J - 2 Drive Belt Service....................J - 2 Drive Clutch Removal ..................J - 2...
  • Page 118 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 J-ii...

  • Page 119: Driven Clutch

    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 Belt Drive Clutch Fig. 1 Continuously Variable Transmission System (CVT) GENERAL moveable sheave inwards. The drive belt is engaged by the clutch sheaves and begins to rotate.

  • Page 120: Continuously Variable Transmission (Cvt)

    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 The driven clutch sheaves are closed at rest which results in the drive belt being held at the outer diameter of the driven clutch.

  • Page 121: Fig. 3 Cvt Components

    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. Use only sockets designed for use with an spring hanger using a 15 mm socket and a 15 mm impact wrench.

  • Page 122: Drive Clutch Installation

    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. Drive Clutch Installation Driven Clutch Repair (Ref. Fig. 3) Clean both the engine crankshaft and the drive clutch bore.
  • Page 123 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 J-5...
  • Page 124 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 J-6...
  • Page 125 DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ..................K - 2 Removing Direction Selector................K - 2 Replacing a Micro Switch ................. K - 2 Shift Cable Adjustment..................K - 2 Neutral Lock Operation ..................K - 2 LIST OF ILLUSTRATIONS Fig.
  • Page 126 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 K-ii...

  • Page 127: Direction Selector

    DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Direction Selector Repair and Service Manual Page K-1...
  • Page 128 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIRECTION SELECTOR bracket (4) to the seat frame and remove direction selector from body. Before removing a suspected faulty micro switch, Replacing a Micro Switch ensure the electrical wires are firmly attached and the wire is in good condition.
  • Page 129 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To activate the direction selector, pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole (3) in the direction selector cam.
  • Page 130 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 K-4...
  • Page 131 ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS ..................L - 1 STARTER ......................... L - 1 GENERATOR......................L - 1 WIRING ........................L - 1 TESTING IGNITION CIRCUIT................... L - 1 Testing the Magneto ..................L - 5 TESTING STARTING CIRCUIT ................
  • Page 132 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 L-ii...

  • Page 133: Circuits And Controls

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CIRCUITS AND CONTROLS tery. If it is fully charged, current is controlled at 3 to 5 amps. The electrical system is a 12 volt negative ground sys- tem (Ref.
  • Page 134 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Electrical System Wiring Diagram Repair and Service Manual Page L-2...
  • Page 135 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 2 Electrical System Wiring Diagram Repair and Service Manual Page L-3...
  • Page 136 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Electrical Controller Starter/Generator Voltage Regulator Reverse Solenoid Buzzer Relay Frame Battery Frame To Magneto Direction Selector Hour Meter Accelerator Pedal Fuel Gauge...

  • Page 137: Testing The Magneto

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. good, and with a spark plug installed in the cylinder, place on a clean grounded engine surface, (muffler, cylinder, etc.).

  • Page 138: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TESTING STARTING CIRCUIT (b) Press the accelerator pedal. The DVOM will indi- cate “0” voltage if the solenoid contacts are closed. (c) If “0”...

  • Page 139: Inspection

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. winding (green lead) is not grounded. If it is not, Inspection replace the regulator. 1. Inspect the commutator for wear or damage. 8) If the reading is below 14 volts, disconnect the 2.

  • Page 140: Battery Voltage Test

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. brushes worn to less than 11/16" (17 mm) in length or NOTICE to the line marked on the brush. 3.

  • Page 141: 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. gauges, the technician must be able to use the wiring diagram and a DVOM. The wiring diagram shows the path followed by a volt- Do not overcharge battery.
  • Page 142 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use the wiring diagram (Ref. Fig. 11) to check correct NOTICE wiring and wire routing. If there is power at the fuse end of the wire, there must also be power at the other end of If any DVOM readings indicate a faulty wire, it is recommended the wire at the switch or electrical accessory, and even-...
  • Page 143 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHITE BROWN GRAY GRAY BLACK BLACK GRAY BLACK BLACK BLACK BLUE BLUE/WHITE BLACK BLACK WHITE Fig. 11 Accessory Wiring Diagram Repair and Service Manual Page L-11...
  • Page 144 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 L-12...

  • Page 145: Mechanical Brakes

    MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW ..................M - 1 General Description ..................M - 1 How the Service Brake Works................M - 1 Equalizer Link ....................M - 2 Automatic Adjuster Mechanism ................M - 2 How the Parking Brake Works .................M - 2 Compensator Assembly ...................M - 3 Kick-Off Actuating Linkage ................M - 3...
  • Page 146 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘M’ (CONT.) SECTION TITLE PAGE NO. Fig. 19 Checking Parking Brake Latching Pressure ..........M - 13 LIST OF ILLUSTRATIONS (CONT.): Fig. 20 Brake Assembly ..................M - 14 Fig. 21 Wheel Brake Lubrication Points ...............M - 15 Fig.
  • Page 147 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 148 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 Brake Lever the left and right brake cables. Each brake cable pulls a brake lever which pushes the rear brake shoe against the brake drum.
  • Page 149 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 150 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 151 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 while other rotates) Sticky/dragging cable...
  • Page 152 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 153 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 154 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 155 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 156 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 The drum must not be turned to “true” a worn sides of the vehicle (Ref.
  • Page 157 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 158 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 159 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 160 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 161 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 162 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 163 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 164 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 165 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 166 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 M-20...

  • Page 167: Rear Suspension

    Rear Leaf Spring Removal ................N - 2 Rear Leaf Spring Installation ................N - 2 LIST OF ILLUSTRATIONS Fig. 1 Rear Suspension ..................N - 1 Fig. 2 Rear Suspension (Express L4, Express S4, TERRIAN 500 & 1000)..N - 3 Repair and Service Manual Page N-i...
  • Page 168 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 N-ii...
  • Page 169 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 Cupped Shock Washer Frame Rubber Shock Bushing Front of the Vehicle Spacer For Terrian 1000 Shock Bushing Absorber...
  • Page 170 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Shock Absorber Removal Socket, 1/2"..............1 Socket, 9/16"..............1 Raise the rear of the vehicle in accordance with the instructions provided in Section ‘B’...
  • Page 171 For Express L4, Express S4 &Terrian 500 Front of the Vehicle For Terrian 1000 Alternate Upper Leaf Spring Plate with Bumper Fig. 2 Rear Suspension (Express L4, Express S4, Terrian 500 &1 000) Repair and Service Manual Page N-3...
  • Page 172 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 N-4...

  • Page 173: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. NEUTRAL LOCK ..........................P - 1 REAR AXLE ............................P - 1 Checking the Lubricant Level .....................P - 1 REAR AXLE DISASSEMBLY ......................P - 2 Axle Shaft Removal and Disassembly ................P - 2 Axle Shaft Seal Removal and Replacement ..............P - 3 Axle Shaft Replacement .....................P - 3 LIST OF ILLUSTRATIONS...
  • Page 174 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 P-ii...
  • Page 175 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE For further axle information, see Four Cycle Transaxle Shop Rebuild and Service Parts Manual. The rear axle is provided with a lubricant level check Refer to REAR SUSPENSION section for axle removal.
  • Page 176 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE DISASSEMBLY The rear axle is a precision assembly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment.
  • Page 177 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 Seal Removal and Replacement Tools List Qty. Internal Snap Ring Pliers..........1 Seal Puller ..............1 Plastic Faced Hammer ..........
  • Page 178 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 P-4...

  • Page 179: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. TROUBLESHOOTING ....................S - 1 Gasoline Vehicle Performance ................S - 1 Starter Does Not Turn ..................S - 1 Starter Turns Slowly ..................S - 1 Starter Rotates but Vehicle Doesn’t Start or Hard to Start........ S - 1 Engine Runs Rough or Loss of Power .............
  • Page 180 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 S-ii...

  • Page 181: 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. GASOLINE VEHICLE PERFORMANCE Condition Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and retighten Poor wiring connections...

  • Page 182: Engine Runs Rough Or Loss Of Power

    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 Fuel pump faulty Repair or replace Fuel line clogged or clamp loose Clean or replace if required Cracked or broken fuel line Replace with new hose Main jet blocked...

  • Page 183: 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 184: 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 magneto Check and replace if required...

  • Page 185: 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 Damaged governor spring Replace CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm...

  • Page 186: 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 187: 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 188: 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 189: 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 190: 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 191 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 S-11...
  • Page 192 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 S-12...

  • Page 193: General

    TERRAIN 1000 ......................T - 8 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions for EXPRESS L4 & EXPRESS S4 ........T - 3 Fig. 2 Vehicle Incline Specifications and Turning Clearance Diameter for EXPRESS L4 & EXPRESS S4 ..............T - 4 Fig.
  • 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 T-ii...
  • Page 195 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: EXPRESS L4 TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No: 618864 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...
  • Page 196 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: EXPRESS S4 TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No: 618862 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 Overhead valve Fixed float bowl with remote pulse fuel pump...
  • Page 197 (124.0 cm) 5.5 in (15.0 cm) 80.5 in. 65.5 in (166.0 cm) (203.0 cm) 107.0 in (272.0 cm) Front 38.0 in. (97 cm) 46.5 in. Rear (118.0 cm) 38.5 in. (98 cm) EXPRESS L4 Repair and Service Manual Page T-3...
  • Page 198 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER EXPRESS S4 20.5 ft (6.3 m) EXPRESS L4 20.5 ft (6.3 m) Repair and Service Manual Page T-4...
  • Page 199 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 250 TYPE: GASOLINE POWERED TRUCK MODEL YEAR: 2012 Part No:. 618855 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: Overhead valve...
  • Page 200 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 49.0 in 15.0 in (124.0 cm) (38.0 cm) 9.5 in (24.0 cm) 4.3 in (15.0 cm) 65.5 in (166.0 cm) (Front) 37.0 in (94.0 cm) 103.0 in (260.0 cm)

  • Page 201: General Specifications

    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 500 TYPE: GASOLINE POWERED TRUCK MODEL YEAR: 2012 Part No: 618856 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: Overhead valve...
  • Page 202 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 1000 TYPE: GASOLINE POWERED TRUCK MODEL YEAR: 2012 Part No: 618859 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 Overhead valve Valve Train:...
  • Page 203 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 15.0 in 103.0 in (260.0 cm) (38.0 cm) 10.0 in (25.0 cm) 49.0 in (124.0 cm) 28.75 in 79.5 in (73.0 cm) (186.0 cm)
  • Page 204 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER TERRAIN 500 20.5 ft (6.3 m) TERRAIN 1000...
  • Page 205 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-11...
  • Page 206 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-12...
  • Page 208 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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