Body Component Replacement; General - Cushman HAULER 1200 Repair Manual

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise
specified. If the torque values are not specified,
refer to the Torque Specifications table in the GEN-
ERAL INFORMATION AND ROUTINE MAINTENANCE
section.

GENERAL

To decrease the risk of possible
injury or death from battery explo-
sion, batteries must always be
removed before any service that will generate
sparks or repairs that require welding or cutting.
Use a sharp drill bit when removing the rivets on the
side of the vehicle. Use extreme care 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 an internal component.
Put a protective piece of sheet metal between the
battery and the rivet as protection. Use of a drill
depth stop provides additional protection.
Body component replacement can be accomplished with
a minimum of specialized tools. Most body components
are held in place with conventional removable hardware.
Some components are mounted with pop rivets which
require the rivet head be removed in order to push out the
shank of the rivet. The rivet head can be removed by drill-
ing into the head with a sharp drill bit that is slightly
larger than the shank of the rivet (Figure 1). Use care
when drilling to decrease the risk of the drill bit from being
forced through and damaging components located imme-
diately behind the rivet. The best way to decrease the risk
of this from occurring is to use a sharp drill bit that
requires very little pressure to cut, and to place a piece of
protective sheet metal between the surface being drilled
and components directly behind it.
653045
BODY

BODY COMPONENT REPLACEMENT

Body components can be replaced by removing securing
hardware, replacing the component and securing with
hardware in same orientation.
Push pin with
screwdriver
from rear side
Repair and Service Manual
Pop Rivet
Figure 1 Drill Out Metal Rivet
OR
Figure 2 Drive Rivet Removal
Ratchet
Fastener
Figure 3 Remove Ratchet Fastener
BODY
B
Drill out rivet
head only
Drive pin through
with punch from
front
Remove fastener
with pry bar
13