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Ezgo Manuals
Utility Vehicle
EXPRESS L4
Technician's repair and service manual
Ezgo EXPRESS L4 Technician's Repair And Service Manual
Gasoline powered utility vehicle
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Also See for EXPRESS L4
:
Owner's manual
(82 pages)
,
Service manual
(192 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Safety
General Information
Table of Contents
Safety Information
General Information & Routine Maintenance
Serial Number Location
Servicing the Vehicle
Starting the Vehicle with Adischarged Battery
Fuel
Towing
Powertrain Maintenance
Routine Maintenance
Brakes
Tires
Top and Windshield
Trailering
Winter or Prolonged Storage
Care and Cleaning of the Vehicle
Hardware
Vehicle Care Products
Torque Specifications
Periodic Service Schedule
Safety
Safety
Body
General
Body Componenet Replacement
Body
Minor Scratches
Larger Scratches
Complete Panel Repair
Wheels and Tires
Front Suspension and Steering
Speed Control
Engine
Fuel System
General
Carburetor Operation
Float System
Pilot Jet System
Main Jet System
Carburetor Service
Choke System
Choke Operation
Fuel System Component Service and Replacement
Choke Cable and Housing Removal
Choke Cable and Housing Installation
Carburetor Removal
Carburetor Disassembly
Float Level Alignment
Carburetor Installation
Fuel Pump
Continuously Variable Transmission (Cvt)
Driven Clutch
Fig. 1 Continuously Variable Transmission System (CVT)
Continuously Variable Transmission (Cvt)
Clutches
Increased Load
Equilibrium
Removing the Drive Belt
Drive Belt Service
Drive Clutch Removal
Fig. 2 Removing the Drive Belt
Fig. 3 CVT Components
Drive Clutch Installation
Storage
Direction Selector
Electrical
Circuits and Controls
Generator
Starter
Testing Ignition Circuit
Testing the Magneto
Wiring
Testing Charging Circuit
Testing Starting Circuit
Inspection
Starter/Generator
Disassembly
Battery Voltage Test
Dvom (Digital Volt Ohm Meter)
Power Supply
Storage of Battery
Troubleshooting
Mechanical Brakes
Rear Suspension
Rear Axle
Troubleshooting
Gasoline Vehicle Performance
Starter Does Not Turn
Starter Turns Slowly
Engine Runs Rough or Loss of Power
Poor Low Speed Performance
Poor Midrange or High Speed Performance
Engine Overheating
Repeated Spark Plug Fouling
Carburetor Floods Engine
Excessive Smoking
Backfiring
Erratic, Surging, or Sudden Change in Governed Speed
Fuel Accumulation in the Crankcase
Fuel Distribution
Mechanical
Operation and Application
Carburetor
Overflow Leak
Poor Fuel Economy
Poor Acceleration
Hard Starting
Poor High Speed Operation
Abnormal Combustion (Fuel Mixture)
Loss of Power (Insufficient Fuel)
Loss of Power (Insufficient Air)
Surging
Starter/Generator
Starter Is Noisy
Rectification Is Imperfect
Generator Does Not Charge
Suspension and Steering
Uneven Tire Wear
Stiff Steering
Play in Steering
Vibration
Steering Pulls to One Side
Brake System
Neither Wheel Locks When Park Brake Is Latched
Neither Wheel Locks
Grabbing Brakes (over Sensitive)
Parking Brake Hard to Latch
Parking Brake will Not Stay Latched
General
General Specifications
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Quick Links
1
Wiring
2
Circuits and Controls
Download this manual
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
Table of
Contents
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1
2
3
4
5
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Chapters
Table of Contents
5
General Information & Routine Maintenance
11
Safety
31
Fuel System
107
Continuously Variable Transmission (Cvt)
117
Electrical
131
Troubleshooting
179
Table of Contents
Troubleshooting
STORAGE OF BATTERY
141
TROUBLESHOOTING
179
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This manual is also suitable for:
Express s4
Terrain 250
Terrain 500
Terrain 1000
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