Textron EZGO RXV 2016 Technician's Repair And Service Manual
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Textron EZGO RXV 2016 Technician's Repair And Service Manual

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RXV
TECHNICIAN'S REPAIR AND SERVICE MANUAL
Gasoline Powered Vehicle
647701-A
ISSUED OCTOBER 2015
REVISED JANUARY 2016

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Summary of Contents for Textron EZGO RXV 2016

  • Page 1 TECHNICIAN’S REPAIR AND SERVICE MANUAL Gasoline Powered Vehicle 647701-A ISSUED OCTOBER 2015 REVISED JANUARY 2016...
  • Page 2 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, vehicles may coast at faster speeds than those encountered on a flat surface. To prevent loss of vehicle control and pos- sible injury, speeds should be limited to no more than the maximum level ground speed indicated in GENERAL SPECIFICATIONS.
  • Page 3 Textron Specialized Vehicles reserves the right to incorporate engineering and design changes to products in this manual, without obliga- tion to include these changes on units sold previously. The information contained in this manual may be revised periodically by Textron Specialized Vehicles, and therefore is subject to change without notice.
  • Page 4 GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA). 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: Safety Information

    For any questions or concerns, contact the closest representative, or write to the address on the back cover of this pub- lication, Attention: Customer Care Department. Textron Specialized Vehicles (TSV) reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.

  • Page 6: Ventilation

    SAFETY INFORMATION • Reduce speed and use caution when driving over loose terrain. • Reduce speed and use caution when driving in areas where pedestrians are present. • Keep enough distance between vehicles to stop safely. MAINTENANCE ALWAYS: • Replace damaged or missing warning, caution or information labels. •...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION GENERAL ......................... iii GENERAL OPERATION ....................iii MAINTENANCE ........................iv VENTILATION ........................iv GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION ................1 VEHICLE WITH A DISCHARGED BATTERY ..............1 STARTING VEHICLE ON A HILL ..................1 SERVICING THE VEHICLE ....................
  • Page 8 TABLE OF CONTENTS BEFORE SERVICING VEHICLE ..................9 Battery Removal and Installation ............... 10 LIFTING THE VEHICLE ....................11 How to lift the entire vehicle: ................11 How to lift the rear of the vehicle only: ............... 12 How to Lift the Front of the Vehicle Only: ............12 Lower the Vehicle: ....................
  • Page 9 TABLE OF CONTENTS FRONT SUSPENSION AND STEERING MAINTENANCE ......................31 Tire Wear Diagnosis ................... 31 Wheel Alignment ....................32 Hub Assembly ....................33 Spindle Assembly ....................33 Struts ........................33 Control Arm Assembly ..................34 Clipboard and Steering Wheel ................35 Installation ......................
  • Page 10 TABLE OF CONTENTS Clean the Air Filter Element ................50 STARTER/GENERATOR BELT TENSION ..............50 Adjusting the Belt ....................51 STARTER/GENERATOR REPLACEMENT ..............51 COOLING SYSTEM CLEANING ..................52 SPARK PLUG ......................... 52 CYLINDER HEAD ......................53 Compression Leak Down Test ................53 Rocker Cover Removal ..................
  • Page 11 TABLE OF CONTENTS FUEL PUMP ........................66 Fuel Pump Replacement ..................66 Fuel Lines and Filter ................... 66 Early Production Vehicles .................. 66 Late Production Vehicles ................... 66 FUEL TANK REMOVAL....................69 CARBON CANISTER ...................... 69 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) GENERAL ........................
  • Page 12 TABLE OF CONTENTS TESTING THE IGNITION CIRCUIT ................83 Testing the Magneto ..................86 TESTING THE STARTING CIRCUIT ................87 TESTING THE CHARGING CIRCUIT ................87 INSPECTION ........................88 STARTER/GENERATOR ....................89 Starter/Generator Removal ................89 Disassembly ....................... 89 Repair and Replacement ................... 89 VOLTAGE TEST FOR BATTERY ...................
  • Page 13 TABLE OF CONTENTS Parts Replacement vs. Repair ................. 102 Adjusting Brake Pedal Free Travel ..............102 Brake Drum Removal and Installation .............. 103 Wheel Brake Service ..................104 Backing Plate/Entire Wheel Brake Assembly Removal and Installation ..105 Brake Shoe and Adjuster Replacement ............106 Brake Cable Snap Ring Removal ..............
  • Page 14 TABLE OF CONTENTS REAR VIEW MIRROR WITH CANOPY .................124 Mirror Bracket Installation .................124 Mounting Mirror to Bracket ................124 REAR VIEW MIRROR WITHOUT CANOPY ..............125 FAULT TESTING GASOLINE VEHICLE PERFORMANCE ...............129 FUEL ACCUMULATION IN THE CRANKCASE ............133 CARBURETOR ......................134 STARTER / GENERATOR ....................135 SUSPENSION AND STEERING ...................136 BRAKE SYSTEM ......................136 GENERAL SPECIFICATIONS...

  • Page 15: General Information And Routine Maintenance

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION VEHICLE WITH A DISCHARGED BAT- TERY Three serial number and manufacture date code labels are on the vehicle.

  • Page 16: Servicing The Vehicle

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERVICING THE VEHICLE temperatures. Gasoline, carbon monoxide, battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders, if not treated with the utmost caution.

  • Page 17: Fuel Tank

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Late Production Fuel Tank Late production fuel tanks can be identified by the loca- tion of the fuel cap which is located in the rear of the top of the tank as shown Oxygenated or reformulated gasoline, is mixed with Late production fuel tanks are designed to allow for fuel...

  • Page 18: Routine Maintenance

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. accessories can cause the discharge of the battery even formance. It is useful as a method of identifying subtle if the engine is running and the generator is operating.

  • Page 19: Hauling

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CANOPY AND WINDSHIELD locked in the neutral position. To unlock the direction selector, pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector cam.

  • Page 20: Vehicle Cleaning And Care

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE CLEANING AND CARE • Turn the Key Switch to OFF position, and leave the Forward/Reverse switch in the NEUTRAL position during storage.

  • Page 21: Hardware

    GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Multi-purpose Battery Protectant (P/N27619G01) formulated to form a long-term, flexible, non- tacky, dry coating that will not crack, peel or flake over a wide temperature range.
  • Page 22 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 23: Safety

    SAFTEY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY NOTICES, CAUTIONS, WARNINGS MODIFICATIONS TO VEHICLE AND DANGERS Do not modify the vehicle in any manner that will change the weight distribution of the vehicle.

  • Page 24: Battery Removal And Installation

    SAFTEY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always remove the key from key switch before Never work around or operate a vehicle in an you disconnect an active circuit. environment that does not ventilate exhaust gases from the area.

  • Page 25: Lifting The Vehicle

    SAFTEY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE Tighten the bolt (1) and screw (2) to torque value speci- fied below. Tool List Qty. Item Torque Specification Floor Jack ..............1...

  • Page 26: How To Lift The Rear Of The Vehicle Only

    SAFTEY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lower the jack and test the stability of the vehicle on the jack stands. How to lift the rear of the vehicle only: Install wheel chocks in front and behind each front wheel.
  • Page 27 SAFTEY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 28 SAFTEY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 29: Body

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Figure 1 Body GENERAL Body component replacement can be accomplished with a minimum of specialized tools. Most body components are held in place with removable hardware such as nuts, bolts and screws.

  • Page 30: Body Component Replacement

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY COMPONENT REPLACEMENT Remove the upper rocker panel (2) by removing the two remaining torx screws (3). Front Bumper Removal is the same for both sides of the vehicle.

  • Page 31: Cowl And Instrument Panel

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installation is reverse order of removal. Replace any worn holder with both hands and pull away from the instru- or damaged hardware as required.

  • Page 32: Front Splash Guard

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installation is reverse order of removal. Replace any worn Remove two ratchet rivets (22) securing front splash or damaged hardware as required. guard (21) to vehicle (Figure 9).

  • Page 33: Sweater Basket

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Sweater Basket Fender Liner Tool List Qty. Tool List Qty. Torx Bit, T-47IP............1 Notched Pry Bar ............1 Socket, 15 mm, Deep-well .......... 1 The fender liner can be removed without removing the Ratchet ................

  • Page 34: Rear Bumper

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 10. Lift the rear body, pivot the seat opening upward and the rear body of the vehicle (Figure 10). towards the back of the vehicle to clear the seat back Remove two torx head screws (35) from the bag well supports.

  • Page 35: Rear Facing Seat And Foot Rest

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2 + 2 REAR FACING SEAT AND FOOT Remove the hex head bolt (20) and nut (21) from the lower leg of the driver side hip restraint (Figure 14).

  • Page 36: Floorboard

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 11. Remove two torx head bolts (28) from the bagwell floor (Figure 17). Figure 17 Rear Facing Seat Foot Rest Figure 19 Seat Back Support 12.

  • Page 37: Bagwell Closeout

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installation is in the reverse order of removal. Replace any worn or damaged hardware. BODY CARE MAINTENANCE Cleaning Tools and Supplies List Qty.

  • Page 38: Minor Scratches

    BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Minor Scratches Complete Panel Repair To repair minor scratches, the manufacturer of the In situations where large panels or areas must be painted, Durashield™...
  • Page 39 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 647701 Repair and Service Manual...
  • Page 40 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 647701...

  • Page 41: Wheels And Tires

    WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEELS AND TIRES WHEEL AND TIRE SERVICE Tire Repair The vehicle is fitted with low-pressure tubeless tires Tool List Qty.
  • Page 42 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For models with a 1/4” wheel spacer, reinstall spacer before installing wheel/tire. With the valve stem to the outside of wheel, install the wheel onto the hub with lug nuts.
  • Page 43 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 44 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 45: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION AND STEERING Figure 1 Front Suspension and Steering MAINTENANCE Routine maintenance of the front suspension and steer- Hardware that is removed must be installed in its origi- ing consists of: nal position unless otherwise specified.

  • Page 46: Wheel Alignment

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 2 Tire Wear Wheel Alignment Tool List Qty. Tape Measure.............. 1 Paint Marker, White ............. 1 Wrench, 12 mm Open End ..........

  • Page 47: Hub Assembly

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Loosen the nut (21) securing the tie rod end (22) to the spindle arm until it is flush with the end of the tie rod end (Figure 5).

  • Page 48: Control Arm Assembly

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the nuts (20) to torque value specified below. Item Torque Specification 20 - 25 ft. lbs (27 - 34 Nm) Figure 5 Hub, Spindle, Strut and Control Arm Assemblies Control Arm Assembly Inspect the sleeve (15) for wear or pitting.

  • Page 49: Clipboard And Steering Wheel

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the bolts (11, 17, 18, 19) to the torque value spec- steering wheel retaining nut or the end of the ified below.

  • Page 50: Steering Column Assembly And Yoke

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Column Assembly and Yoke Turn the steering column assembly to the left 10° to disengage the locking tabs. Lift the steering column Tool List Qty.

  • Page 51: Tie Rod End / Ball Joint

    FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. d. If the steering wheel is not oriented properly, Replace the other tie rod end if necessary. remove the yoke from the steering box pinion Check the wheel alignment and correct if necessary.
  • Page 52 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 12 Steering Box...
  • Page 53 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 54 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 55: Speed Control

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPEED CONTROL Figure 1 Accelerator and Speed Control System SYSTEM OPERATION Pedal Box Operation The linkages that control the accelerator mechanism, When you press the accelerator, the accelerator rod governor and carburetor are designed to operate as an moves towards the rear of the vehicle by overcoming the...

  • Page 56: Fault Testing

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. When the governed speed is reached, the ground speed governor in the rear axle assembly operates against the accelerator cable/governor spring and closes the throttle lever until the correct governed speed is achieved (Figure Remove the negative (-) battery cable from the...

  • Page 57: Accelerator Cable Removal At Governor

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the bolt (18) to the torque value specified below. Item Torque Specification 60 - 72 in. lbs (7 - 8 Nm) Accelerator Cable Removal at Governor To remove the accelerator cable (9) from the governor, loosen the nuts (13) securing the cable (9) to the acceler-...

  • Page 58: Accelerator Pedal Assembly

    SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Test drive the vehicle and confirm that the compression pedal assembly to the floorboard and the two torx screws spring adjustment results in the maximum governed (4) from the throttle switch (5).
  • Page 59 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 7 Accelerator Pedal...
  • Page 60 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 61: Engine

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE GENERAL Remove the dipstick and wipe off the entire area with a lint free cloth. For further engine information, see Engine Shop Rebuild and Service Parts Manual.

  • Page 62: Changing The Oil

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Changing the Oil Tool List Qty. Socket, 19 mm............. 1 Ratchet ................ 1 Extension, 8" ............... 1 Oil Filter Wrench............1 Oil Drain Pan ...............

  • Page 63: Air Filter Inspection/Replacement

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 6 Remove Oil Filter Clean the area around filter. Place the oil drain pan under the filter area. Remove the filter (4) from the engine and allow the oil to drain into the oil drain pan (Figure 6).

  • Page 64: Clean The Air Filter Element

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The air filter assembly on the vehicle is a dry unit. Do During installation, the belt must not be rolled over not use oil on the filter element or any part of the unit.

  • Page 65: Adjusting The Belt

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR REPLACE- Adjusting the Belt MENT Loosen the two pivot bolts (13) and nuts (14) on the starter/generator. Hold the lower nut (11) and loosen the Tool List Qty.

  • Page 66: Cooling System Cleaning

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 15 Cleaning Cooling System with Air SPARK PLUG Tool List Qty. Figure 13 Starter/Generator Wire Connections Spark Plug Socket,13/16” ..........1 Feeler Gauge, Wire Type..........1 Ratchet ................1 From...

  • Page 67: Cylinder Head

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A fouled spark plug is indicated by an electrode with a Compare the reading of the compression gauge with wet, black appearance.

  • Page 68: Valve Clearance Adjustment

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Check the valve clearance with a feeler gauge (7). Mea- Remeasure any clearance that was adjusted. Readjust if sure the valve clearance between the rocker arm (8) and necessary.

  • Page 69: Controls And Wiring

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lift rear of vehicle as directed in the SAFETY sec- 24. Remove the four bolts from the engine support tion.

  • Page 70: Drive Clutch Removal

    ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DRIVE CLUTCH REMOVAL To decrease the risk 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.
  • Page 71 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 72 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 73: Fuel System

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL SYSTEM Figure 1 Fuel System...
  • Page 74 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 2 Fuel System...

  • Page 75: General

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL To decrease the risk of serious injury or death Hardware that is removed must always be installed in its resulting from a possible explosion, do not original position unless otherwise specified.

  • Page 76: Late Production Fuel Tank

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. needle valve. The float maintains the correct fuel level within the float chamber and it is not adjustable. As fuel is consumed from the float chamber, the float drops which allows the needle valve to admit additional fuel.

  • Page 77: Choke Adapter Installation

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For vehicles manufactured from January 3, 2016: To remove the choke adapter (8), remove the four screws (9), securing the choke adapter (8). Installation is the reverse order of removal.

  • Page 78: Carburetor Removal

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Carburetor Removal Feed the choke cable assembly (4) through the hole in the bezel (8) (Figure 6). Insert the cable and bezel into Tool List Qty.

  • Page 79: Float Level Alignment

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. to wear or clogging of internal passages with foreign Check for free movement of the choke shaft before material.

  • Page 80: Fuel Pump

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL PUMP Fuel Lines and Filter Tool List Qty. The fuel pump is mounted on a bracket attached to the seat support near the fuel tank.
  • Page 81 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 11 Fuel lines, fuel tank and filter...
  • Page 82 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 12 Fuel lines, fuel tank and filter...

  • Page 83: Fuel Tank Removal

    FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL TANK REMOVAL Tool List Qty. Wrench, 5/16”.............. 1 Socket, 5/16” ............... 1 Ratchet ................ 1 Drip Pan ..............1 Insulated wrench, 1/2”...
  • Page 84 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 13 CARB Canister and CARB Hoses installation...
  • Page 85 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 86 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 87: Continuously Variable Transmission (Cvt)

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Figure 1 Continuously Variable Transmission System (CVT) GENERAL As the engine speed continues to increase, the primary clutch sheave continues to move inwards forcing the The power transmission from the engine to the rear axle transmission belt to the outer diameter of the primary...

  • Page 88: Secondary Clutch

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Secondary Clutch The secondary clutch sheaves are closed at rest which results in the transmission belt being held at the outer diameter of the secondary clutch.
  • Page 89 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not allow the fingers to become trapped between the belt and clutch sheave. Use only sockets designed for use with an In some case the clutch can not separate from the impact wrench.

  • Page 90: Primary Clutch Installation

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Primary Clutch Installation Install the clutch puller bolt until it bottoms out. Remove the clutch, then remove the clutch puller bolt and slide the clutch from the rear axle input shaft.
  • Page 91 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 92 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 93: Direction Selector

    DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIRECTION SELECTOR Figure. 1 Direction Selector DIRECTION SELECTOR Socket, 5/16”..............1 Wrench, 7/16” ..............1 Before you remove a suspected faulty micro switch, make Wrench, 5/16”...

  • Page 94: Replacing A Micro Switch

    DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjust the cable (9) at the forward cable mount until the directions selector cam contacts the reverse stop and when moved to forward (F) contacts the forward stop.
  • Page 95 DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 96 DIRECTION SELECTOR Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 97: Circuits And Controls

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL CIRCUITS AND CONTROLS regard to engine speed. However, the charging current will vary depending on the condition of the battery. If it is The electrical system is a 12 volt negative ground system fully charged, current is controlled at 3 to 5 amps.
  • Page 98 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The engine can be stopped by turning the key switch to the OFF position. When the accelerator pedal is released, the limit switch contacts open and the ignition circuit is de- energized.
  • Page 99 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 2 Main Harness Wiring Diagram...

  • Page 100: Testing The Magneto

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not arc spark plug wire to ground. Connect to a known good spark plug and ground plug to a clean metal surface (muffler, cylinder, etc.).

  • Page 101: Testing The Starting Circuit

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. position and a visual signal ( ) with the switch in the OFF position. If the meter does not register, replace the switch.

  • Page 102: Inspection

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. a. Raise the vehicle (see procedure in SAFETY (green lead) is not grounded. If it is not, replace section) so that both rear wheels are free to the regulator.

  • Page 103: Starter/Generator

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR Starter/Generator Removal See ENGINE section. Disassembly Tool List Qty. DVOM................1 Wrench, 24mm ............1 Wrench, 10mm ............1 Figure 8 Bearing Removal Wrench, 6mm ..............

  • Page 104: Storage Of Battery

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hydrogen gas formed during battery charging is explosive. Avoid any electrical spark or open flame near battery. If the temperature of the battery or the ambient tempera- ture is below 60°...

  • Page 105: Power Supply

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. When no battery voltage is found, the problem is between the point where no voltage is detected, and the last place that voltage was detected.

  • Page 106: Turn Signal (If Equipped)

    ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 10 Headlight replacement Figure 11 Taillight replacement Turn Signal (if equipped) Make sure that the vehicle key switch is in the OFF posi- tion and the key has been removed.
  • Page 107 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 12 Accessory Wiring Diagram...
  • Page 108 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 109 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKES Figure 1 Mechanical Brake System...

  • Page 110: Brake System Overview

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE SYSTEM OVERVIEW General Description This vehicle has a mechanically activated rear drum brake system. The brake system has a service brake and parking brake pedal, parking brake release linkage, equalizer link, brake cables and wheel brake assemblies which adjusts automatically (Figure 1).

  • Page 111: How The Parking Brake Works

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Testing and Inspection Procedures prying back the adjuster arm and turning the star wheel. Permanent damage to adjuster will result. To find the problem in the mechanical brake system, Adjustment takes place only when the brake is fully inspect the brake pedal and linkage to find worn or dam-...

  • Page 112: Periodic Brake Performance Test (Pbpt)

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. when released. If the pedal does not return fully or is Check the clevis pins. sluggish, the brake pedal bushings and pivot bolt Check clevis pin and snap ring attaching the brake should be inspected (Figure 3).

  • Page 113: Aggressive Stop Test

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. influenced by weather conditions, terrain, road surface condition, accurate vehicle weight (accessories installed) and vehicle speed. No specific braking distance can be reliably specified.

  • Page 114: Wheel Brake Inspection

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. improves, increase speed for the remaining tests. Before the end of the tests, both wheels must lock at approxi- mately the same time and slide straight.
  • Page 115 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A backing plate assembly that shows any indi- cation of galling or gouging is not repairable and must be replaced with a new wheel brake assembly.

  • Page 116: Maintenance And Repairs

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pliers ................1 Vernier/Dial Calipers ............1 Plastic Tipped Hammer..........1 Puller (P/N 15947G1) ..........1 Pry Bar .................1 Dust Mask ..............1 Emery Cloth ..............1 Parts Replacement vs.

  • Page 117: Brake Drum Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not apply the brake when removing the nut as the shoes may not fully retract preventing removal of the brake drum.

  • Page 118: Wheel Brake Service

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 11 Brake Assembly nut and the hole in the axle. Maximum torque is 140 ft. lbs. (190 Nm). Wheel Brake Service Pay particular attention to the location of the inner brake drum washer (6) inside the brake drum, which can be on...

  • Page 119: Backing Plate/Entire Wheel Brake Assembly Removal And Installation

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do NOT use a commercial brake cleaner unless the entire brake has been disassembled. Remove any accumulated brake dust with a brush. Remove the brake shoes.

  • Page 120: Brake Shoe And Adjuster Replacement

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the lock nut to the torque value specified below. Repeat on other side of vehicle. Adjust the brake pedal free travel. See ’Adjusting Brake Pedal Free Travel’.

  • Page 121: Brake Cable Snap Ring Removal

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 15 Setting Adjuster Screw Figure 17 Brake Cable, Equalizer and Compensator Brake Cable Snap Ring Removal Slide the equalizer link of the new assembly over the compensator rod.

  • Page 122: Brake Fault Testing

    BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 18 Pedal Cover Remove four screws (6) securing the brake pedal assembly to the floorboard. (Figure 19) Disconnect the wires from the brake enable switch (8).
  • Page 123 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 124 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 125: Rear Suspension

    REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Figure 1 Rear Suspension REAR SUSPENSION Shock Absorber Tool List Qty. Wheel Chocks..............4 Jack Stands ..............4 Hardware that is removed must be installed in its origi- Floor Jack ..............1 nal position unless otherwise specified.

  • Page 126: Rear Leaf Spring

    REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. and shock absorber bushing (2) from shock mount Remove the rubber bushing (6) from the leaf spring. plate (5) (Figure 2). Retain the axle bracket (17) and leaf spring plate Access from the upper end of the shock absorber (5) (18) removed for future use.
  • Page 127 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 2 Rear Suspension...
  • Page 128 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 129: Rear Axle

    REAR AXLE Read all of SAFETY 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 Trans-axle Activate the direction selector by pulling the neutral lock Shop Rebuild and Service Parts Manual.

  • Page 130: Rear Axle Disassembly

    REAR AXLE Read all of SAFETY 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 131: Axle Shaft Seal Removal And Replacement

    REAR AXLE Read all of SAFETY 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 132 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 133: Weather Protection

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WEATHER PROTECTION Figure 1 Canopy and Windshield CANOPY AND WINDSHIELD Transporting the Vehicle To decrease the risk of personal injury to occu- The canopy does not provide protection from pants of other highway vehicles, be sure that roll over or falling objects.

  • Page 134: Windshield

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The rated capacity of the trailer must be more than the To reinstall the windshield, hang the windshield on weight of the vehicle (see GENERAL SPECIFICATIONS the front strut using the rubber latches (2) on the top for vehicle weight) and load.
  • Page 135 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. holes, align the holes in the strut with the holes in the Tighten the hex bolts (2, 6) and hex nuts (4) to the frame and insert the hex bolts (6).

  • Page 136: 2 + 2 Canopy

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2 + 2 CANOPY Install four hex bolts (8) and hex nuts (10) through the rear struts (5 and 6) only finger tight. Tool List Qty.
  • Page 137 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 4 2 + 2 Canopy...

  • Page 138: Rear View Mirror With Canopy

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR VIEW MIRROR WITH CANOPY Tool List Qty. Wrench, 12mm ............1 Wrench, 15mm ............1 Ratchet Handle, 3/8”............ 1 Drive T-45 Torx Bit, 3/8”...

  • Page 139: Rear View Mirror Without Canopy

    WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Tighten the bolt (4) to the torque value specified below Item Torque Specification 15 - 17 ft. lbs (20 - 23 Nm) •...
  • Page 140 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Completed mirror and strut is as shown below (Fig- ure 12). Figure 12 Strut with Rear View Mirror installed.
  • Page 141 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 142 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 143: Fault Testing

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING 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 tighten Poor wiring connections...
  • Page 144 FAULT TESTING Read all of SAFETY 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 145 FAULT TESTING Read all of SAFETY 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 146 FAULT TESTING Read all of SAFETY 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 147: Fuel Accumulation In The Crankcase

    FAULT TESTING Read all of SAFETY 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 148: Carburetor

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction CARBURETOR OVERFLOW/LEAK Worn inlet valve or dirty valve seat Replace valve or clean valve seat Worn float mounting tang Replace float Worn float pin...

  • Page 149: Starter / Generator

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction LOSS OF POWER Faulty fuel pump Replace fuel pump (INSUFFICIENT FUEL) Dirty carburetor Clean carburetor Dirt in fuel tank or hoses Clean Clogged fuel filter...

  • Page 150: Suspension And Steering

    FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUSPENSION AND STEERING Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires Damaged or worn components Replace...
  • Page 151 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction System not adjusted properly Check and adjust per manual End of brake cable loose from anchor Check and repair brackets IN EXCESS OF 1"...
  • Page 152 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction PARKING BRAKE HARD TO LATCH Inadequate free play Adjust pedal free travel at spherical nut and check that wheel brake actuators are returning fully.
  • Page 153 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 154 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 155: General Specifications

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS...
  • Page 156 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
  • Page 157 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
  • Page 158 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

  • Page 159: Approximate Vehicle Dimensions

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. APPROXIMATE VEHICLE DIMENSIONS Fig. 1 Fleet and Freedom Vehicle Dimensions...
  • Page 160 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 2 Shuttle 2 + 2 Vehicle Dimensions...

  • Page 161: Turning Diameter And Incline Information

    GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TURNING DIAMETER AND INCLINE INFORMATION Fig. 3 Vehicle Incline Specifications and Turning Diameter...
  • Page 162 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...

  • Page 163: Periodic Service Schedule

    PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires and rims Hardware - loose or missing...
  • Page 164 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REMARKS Tie Rods - excessive play, bent rods, loose or missing hardware Rear Axle - fluid level, oil leakage, noise, loose or missing hardware Rear Axle - replace fluid Rear Suspension - shock oil leakage, worn bushings,...
  • Page 165 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 166 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes:...
  • Page 167 In any product, components will eventually fail to per- form properly as the result of normal use, age, wear or abuse. It is impossible to anticipate all possible component fail- Read the following information and warnings before ures or the manner in which they may fail. operating vehicle: A vehicle requiring repair indicates that it is no longer functioning as designed and therefore should be consid-...
  • Page 168 Textron Specialized Vehicles, 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, TSV Genuine Parts and Accessories Department or at www.shopezgo.com. Copyrighted Material...

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