Page 1 SERVICE AND REPAIR SERVICE AND REPAIR MANUAL MANUAL 632313 632313 ISSUED DECEMBER 2012 ISSUED DECEMBER 2012 REVISED JUNE 2014 REVISED JUNE 2014...
Page 2: Notes, Cautions, And Warnings
SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact a representative for clarification. 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.
Page 3 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 specifica- tions. Such modifications can cause serious personal injury or death. Bad Boy Buggies prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Page 4: Battery Prolonged Storage
NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. 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 Notes ............................. ii Safety Information .......................... v TITLE SECTION General Information & Routine Maintenance ................A Safety............................B Accelerator............................ C Batteries and Battery Charger....................... D Body.............................. E Brakes............................F Continuously Variable Transmission (CVT) ................... G Direction Selector..........................
Page 6: Notes
TABLE OF CONTENTS NOTES: Page iv Repair and Service Manual...
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 the owner-operator 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. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when approaching sharp or blind turns.
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. VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation.
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 PLATE LOCATION................A-1 STARTING THE VEHICLE WITH A DISCHARGED STARTING BATTERY ....A-1 SERVICING THE VEHICLE..................A-2 TOWING ........................A-2 ROUTINE MAINTENANCE ..................A-2 POWERTRAIN MAINTENANCE .................A-3 BRAKES........................A-3 TIRES ..........................A-3 LIGHT BULB REPLACEMENT ...................A-3 CARE AND CLEANING OF THE VEHICLE ..............A-3...
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: Starting The Vehicle With A Discharged Starting Battery
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 AND VIN PLATE LOCATION The serial number (1) and the VIN number are present at two different locations on the vehicle.
Page 14: Servicing 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. SERVICING THE VEHICLE Some components are heavy, spring loaded, highly corrosive, explosive, may produce amperage or reach high temperatures.
Page 15: Powertrain 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. To prevent severe injury or death resulting from operating a vehicle with improperly oper- ating brake system, the braking system must be properly maintained.
Page 16: Vehicle Care Products
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. Do not use hot water, strong soap or harsh chemical • Multi-purpose Cleaner and Degreaser that con- tains natural, environmentally safe solvents.
Page 17: Trailering
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. TRAILERING Gas Engine To prevent personal injury to occupants of oth- To prevent serious injury or death resulting er highway vehicles, be sure that the vehicle from a possible explosion: and contents are adequately secured to trailer.
Page 18: Hardware
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. HARDWARE • Place the Forward/Reverse switch in the NEUTRAL position. Periodically, the vehicle should be inspected for loose fas- •...
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 ...
Page 20: Capacities And Replacement Parts
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 Axles - drain & replace fluid Rear Suspension - shock oil leakage, worn bushings, ...
Page 21: Safety
SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTES, 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-2 Additional Warnings....................B-2 LIFTING THE VEHICLE ....................B-3 Fig. 1 Lifting the Vehicle ..................B-4 Fig.
Page 22 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 23: Modifications To Vehicle
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES, CAUTIONS, WARNINGS if not treated with utmost caution. Be careful not to place hands, face, feet or body in a location that could expose AND DANGERS them to injury should an unforeseen situation occur.
Page 24: Before Servicing The Vehi- Cle
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BEFORE SERVICING THE VEHI- Additional Warnings Before attempting to inspect or service a vehicle, be sure to read and understand the following warnings: To prevent explosion that could result in severe personal injury or death, keep all smok- ing materials, open flame or sparks away from...
Page 25: Lifting The Vehicle
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Batteries are heavy. Use Carbon monoxide is an odorless gas that is proper lifting techniques formed as a natural part of the incomplete when moving them.
Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use extreme care since the vehicle is extreme- ly unstable during the lifting process. When lifting the vehicle, position jacks and jack stands only on the areas indicated (Ref.
Page 27 ACCELERATOR TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE ......C - 2 System Operation.....................C - 2 Governor Operation ..................C - 2 ACCELERATOR, ROTARY POSITION SENSOR.............C - 2 TROUBLESHOOTING....................C - 2 GOVERNOR CABLE ADJUSTMENT PROCEDURE ..........C - 3 ACCELERATOR/GOVERNOR CABLE ADJUSTMENT..........C - 3 GOVERNOR COMPRESSION SPRING ADJUSTMENT ...........C - 4 ROAD TEST ......................C - 4...
Page 28 ACCELERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and NOTES: Repair and Service Manual Page C-ii...
Page 29: Fig. 1 Accelerator Components
ACCELERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Suspended Accelerator Assembly Accelerator Pedal To Governor Bell Crank Assembly Pedal Switch Throttle Choke Rotary Position Sensor Governor Extension Governor Bell Crank Spring...
Page 30: Accelerator, Governor And Carburetor Linkage
ACCELERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ACCELERATOR, GOVER- ACCELERATOR, ROTARY NOR AND CARBURETOR POSITION SENSOR LINKAGE Rotary position sensor helps to determine the speed of the vehicle in the electric powertrain mode. System Operation Rotary position sensor (3) is connected through the NOTICE...
Page 31: Governor Cable Adjustment Procedure
ACCELERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GOVERNOR CABLE ACCELERATOR/GOVER- ADJUSTMENT PROCEDURE NOR CABLE ADJUSTMENT Tool List Qty. Tool List Qty. Wrench, 1/2"..............2 Wrench, 3/8" ..............1 Properly adjusted, the cable should be short enough to be slightly loose but not too short to be pulling on the lever when at rest (Ref.
Page 32: Governor Compression Spring Adjustment
ACCELERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GOVERNOR COMPRES- Cut and remove safety seal. Hold governor adjuster (10) and loosen the jam nut (11) (Ref. Fig. 3 on page C-4). SION SPRING ADJUSTMENT Pre-adjust governor compression spring (6) by holding governor rod (13) and rotating governor adjuster (10)
Page 33: Batteries And Battery Charger
BATTERIES AND BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. SAFETY ........................D-1 BATTERY ........................D-1 Battery Removal And Installation ................D-2 Starter Battery Removal and Installation ............D-2 DC/DC Convertor Replacement................D-3 Electric Powertrain Batteries Removal and Installation........D-3 BATTERY MAINTENANCE ..................D-4 At each Charging Cycle ..................D-4 Monthly.......................D-4 Electrolyte Level and Water................D-4...
Page 34 BATTERIES AND BATTERY CHARGER 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 35: Safety
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY Overfilling batteries may result in electro- lyte being expelled from the battery during the charge cycle. Expelled electrolyte may NOTICE cause damage to the vehicle and storage facility.
Page 36: Battery Removal And Installation
BATTERIES AND BATTERY CHARGER 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 Starter Battery Removal and Positive To Gas To Main Solenoid Harness Installation Negative Tool List...
Page 37: Dc/Dc Convertor Replacement
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DC/DC Convertor Replacement Electric Powertrain Batteries Removal and Installation Tool List Qty. Insulated wrench, 1/2” ..........1 Tool List Qty.
Page 38: Battery Maintenance
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY MAINTENANCE (15-20 Nm) tight enough to prevent movement of the battery, but not to cause distortion of the battery cases. Tool List Qty.
Page 39 BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 6 Water Purity Table Fig. 5 Correct Electrolyte Level Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it does not exceed the impurity levels specified in the Do not overfill batteries.
Page 40: Cleaning Batteries
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cleaning Batteries in order to remove any residue that could cause the self discharge of the battery. Rinse the entire area with low When cleaning the outside of the batteries and pressure clear water.
Page 41: 48V Battery Set Charging
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • The charger connector is fully inserted into the vehicle receptacle. • The charger connector/cord set is protected from damage and is located in an area to prevent injury that may result from personnel running over or trip- ping over the cord set.
Page 42: Troubleshooting
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING Cylinder Bulb Float In general, troubleshooting will be done for two distinct Thermometer reasons. First, a battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer’s warranty.
Page 43: Using A Hydrometer
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Using a Hydrometer Electrolyte Temperature 1. Draw electrolyte into the hydrometer several times ° F °...
Page 44: Portable Charger Installation
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Portable Charger Installation surface with the fins vertical. More airflow from below the charger will help cool the fins, so placement above open areas or areas with cut-outs for airflow is desirable.
Page 45: Understanding The Charger
BATTERIES AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Understanding the Charger then again three flashes and a pause - Battery Charge Time-out: Charge time exceeded. This may indicate a problem with the battery pack or that the When the charger is plugged into the vehicle’s charger charger output current was severely reduced due to...
Page 46 BATTERIES AND BATTERY CHARGER 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-12...
Page 47: Body
BODY TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL ......................... E - 1 COMPONENT REPLACEMENT ................E - 1 Instrument Panel Replacement ................ E - 3 Control Panel Replacement................E - 3 Cowl Replacement ................... E - 4 Front Bumper Replacement................E - 4 Rocker Panel Replacement................
Page 48 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 E-ii...
Page 49: General
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL removed. The following illustrations indicate the assembly methods for the various components. NOTICE Drill Out Rivet Head Only In the following text, there are references to removing/installing Pop Rivet bolts etc.
Page 50 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Front Fender (Passenger Side) Instrument Panel Front Fender (Driver Side) Control Panel Floor Mat Front of Vehicle Side Panel (Passenger Side) Side Panel...
Page 51: Instrument Panel Replacement
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Instrument Panel Replacement Pull control panel away from the instrument panel. Assemble in reverse order of disassembly. Tool List When installing a replacement control panel, a new label Drill ................
Page 52: Cowl Replacement
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cowl Replacement Front Bumper Replacement Tool List Front bumper is a part of lower OPS, see Section P “Lower OPS Replacement”.
Page 53: Side Panel Replacement
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Drill out rivets (27) securing side panel to seat support panel (28) (Ref Fig. 9 on page E-5). Drill out rivets (29) securing side panel to frame (Ref Fig.
Page 54 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Rear Fender (Passenger Side) Rear Fender (Driver Side) Valence Panel Tail Lights Fig. 10 Body Components (Rear), (For Vehicles With Flip Seat) Repair and Service Manual Page E-6...
Page 55: Rear Fender Replacement (For Vehicles With Flip Seat)
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Fender Replacement (for vehicles with Valance Panel Replacement (only for vehi- flip seat) cles with flip seat) Tool List Qty.
Page 56 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Rear Fender (Passenger Side) Tail Light Bracket Rear Bumper Rear Fender (Driver Side) Hitch Fig. 13 Body Components (Rear) (For Vehicles With Truck Bed) Repair and Service Manual Page E-8...
Page 57: Rear Fender Replacement (For Vehicles With Truck Bed)
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Fender Replacement (for vehicles with Hitch Replacement (only for vehicles with Truck Bed) Truck Bed) Tool List Qty.
Page 58 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 E-10...
Page 59: Brakes
BRAKES TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. GENERAL ............F-2 How the Hydraulic System Works...............
Page 60 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 F-ii...
Page 61 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Caliper Caliper Front Brake Line Part Of Reservoir Frame Rotor To Master Cylinder Master Cylinder Rotor Bellcrank Front Brake Line Linkage Rod Rear Brake...
Page 62: General
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Brake Line Crush Washers Wheel Cylinder Brake Drum Brake Shoe Fig. 2 Rear Wheel Brake Components GENERAL cylinders which returns the brake fluid to its original position within the master cylinder.
Page 63: Front Wheel Brake
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The rear brake includes a parking feature consisting of a NOTICE lever and strut. The lever is applied by a cable attached to the parking brake lever (hand operated).
Page 64: Brake Fluid
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MASTER CYLINDER battery, which could result in an explosion and severe personal injury or death. Just like any other brake part, the master cylinder will eventually require replacement.
Page 65: Replacement Of Wear Items
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove two lock nuts (11) and two bolts (12) and remove master cylinder (1) from master cylinder bracket. Mount master cylinder to master cylinder bracket using new lock nuts.
Page 66: Rear Brake Drum Removal And Installation
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bearing Adjustment procedures, see FRONT SUSPENSION AND STEERING. Spindle Replacement Do not back off castellated nut to install cotter pin. See FRONT SUSPENSION AND STEERING.
Page 67: Cleaning And Inspection
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cleaning and Inspection Do NOT touch any of the wheel brake mechanism except as instructed. The drum must not be turned to ‘true’ a worn Do NOT use a commercial brake cleaner unless the friction surface.
Page 68: Reassembly
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Check springs (33 and 34) for loss of tension and Place upper end of shoe webs against wheel cylinder damage.
Page 69: Adjustment
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjustment Loosen the four allen head bolts (40) and lock nuts (41) securing the wheel brake backing plate (25) to the Adjust brake shoes until a light drag is felt while rotating flange on the axle tube (Ref Fig.
Page 70: Bleeding Sequence
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Primary brake line was disconnected from the Check the master cylinder fluid level frequently during flexible brake hose bleeding and keep the reservoirs at least one-half full.
Page 71: Brake Pedal Removal And Installation
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKE PEDAL REMOVAL AND Brake pedal installation is in the reverse order of disassembly. INSTALLATION Use a new cotter pin (53) when installing the linkage rod Tool List Qty.
Page 72 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Boot Center Console Parking Brake Lever Support Bracket Equalizer Parking Brake Lever Cable Jam Nut Clevis Pin Parking Brake Cable Cotter Pin Part of Frame...
Page 73: Parking Brake
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PARKING BRAKE Adjustment The parking brake adjustment is made at the equalizer The rear brake includes a parking feature consisting of a (59) on the end of the parking brake lever cable (58) wheel brake lever and strut.
Page 74 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 F-14...
Page 75: Continuously Variable Transmission (Cvt)
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL ........................G-1 CLUTCHES ........................ G-1 Primary Clutch ....................G-1 Secondary Clutch ....................G-1 Increased Load....................G-2 Equilibrium......................G-2 Primary Clutch Removal ..................G-2 Primary Clutch Installation ................. G-3 Secondary Clutch Removal ................
Page 76 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 G-ii...
Page 77: General
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. Transmission Belt Secondary Clutch Starter/Generator Belt Primary Clutch Fig. 1 Continuously Variable Transmission (CVT) GENERAL The ratio is greatly decreased and provides maximum speed.
Page 78: Increased Load
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. Equilibrium As the secondary clutch (2) slows, the belt rides lower in the primary clutch sheaves. The secondary clutch com- The CVT functions because the primary and secondary pensates by closing in response to the torsion spring clutches maintain equilibrium.
Page 79 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. Install the lock washer (17) and the large flat washer (18) onto the bolt (16). Use a strap wrench to hold the clutch when necessary.
Page 80: Secondary 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. Secondary Clutch Installation Transmission Belt Service Coat the rear axle input shaft with a light coating of anti- The transmission belt will require no service unless the seize compound and slide the clutch onto the shaft (Ref.
Page 81: Direction Selector
DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. DIRECTION SELECTOR .....................H-2 FNR Actuator Replacement ................H-2 FNR Differential Lever Replacement ..............H-2 Anti-Rotation Bracket Replacement..............H-3 Checking the FNR System .................H-5 TROUBLESHOOTING....................H-5 Fault Code Description ..................H-6 LIST OF ILLUSTRATIONS Fig.
Page 82 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 H-ii...
Page 83 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FNR Differential Lever Neutral Clamp Weldment Differential Anti-Rotation Bracket Actuator Cover Actuator Actuator Mounting Plate Actuator Support Bracket Fig.
Page 84 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 Remove the bolt (6) securing the actuator (1) to the actuator mounting bracket (3) and actuator support bracket (7).
Page 85 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. proper placement. Tighten the hardware to torque values specified below: Remove nut (18) and washer (19) securing the Item Torque Specification differential lever (4) to the neutral clamp weldment (5).
Page 86 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjusting the FNR System Tools List Qty. Wrench, 7/16" .............. 1 Socket, 7/16" ............... 1 Ratchet ................ 1 Torque wrench, ft.
Page 87 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Checking the FNR System • Vehicle will shift into REV, but not FWD: Loosen the adjustment nut (18) and rotate the FNR Tools List Qty.
Page 88: Fault Code Description
DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Code Description LED Code Description Possible Cause Watchdog Reset No Longer Visible Invalid Direction Switch Input This means the powertrain controller is receiving two or more 48V signals from the key switch, for example the con- troller believes that the user is asking for Forward and Re-...
Page 89 ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GAS POWERTRAIN ELECTRICAL SYSTEM ............. J-1 Circuits and Controls ..................J-3 Testing Gas Engine Starting Circuit..............J-3 Testing Engine Charging Circuit ................. J-3 VOLTAGE TEST FOR STARTING BATTERY ............. J-4 MAIN HARNESS ......................
Page 90 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 J-ii...
Page 91: Gas Powertrain Electrical System
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GAS POWERTRAIN ELECTRICAL SYSTEM Negative (-) Battery Cables Positive (+) Battery Cables Main Harness (Fuel Guage, Throttle Enable) To Solenoid To Voltage Regulator...
Page 92 ELECTRICAL ELECTRICALRead all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings Fig. 2 Gas Powertrain And 4WD Electrical Schematic Repair and Service Manual Page J-2...
Page 93: 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. 1. Check the battery for a voltage reading which Circuits and Controls should be between 12.2 and 12.5 volts. Inspect for The electrical system is a 12 volt negative ground loose or dirty battery post connections.
Page 94: Voltage Test For Starting Battery
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2. Check charging circuit component terminals for NOTICE proper, clean, tight connections. 3. Check for charging voltage as follows: If the temperature of the battery or the ambient temperature is (a) Lift the entire vehicle (see procedure to lift the below 60°...
Page 95: Main Harness
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAIN HARNESS NOTICE Power Supply Due to the resistance of the wires involved within the harness, voltage readings may be somewhat lower than battery voltage. Tool List Qty.
Page 96 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Main Harness Slow Blow Fuse Block Fuse Holder Slow Blow Fuse Powertrain Controller Main Harness Controller Fig. 4 Inline Fuses Repair and Service Manual Page J-6...
Page 97 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 5 Main Harness Wiring Diagram Page J-7 Repair and Service Manual...
Page 98 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 6 Accessory Wiring Diagram Repair and Service Manual Page J-8...
Page 99: Accessory Wiring
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accessory Wiring NOTICE After determining that there is power to the fuse panel, Following Procedure is applicable for vehicles with LED Head and the fuse is good, continue checking the circuit using lights.
Page 100 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Taillight Bulb Installation For Vehicle With Flip Seat Taillight Bulb Installation For Vehicle Without Flip Seat Front of Vehicle Front of Vehicle Main...
Page 101: Electronic Speed Control
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRONIC SPEED CONTROL Controller Speed Sensor Front of Vehicle The speed sensor uses a sealed sensor to read the Controller impulses of a ring magnet attached to the armature shaft Solenoid...
Page 102 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 10 Electric Powertrain Electrical Schematic Repair and Service Manual Page J-12...
Page 103 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 1224 Curtis Controller (Speed Controller) Powertrain Controller Fig. 11 Powertrain Controller and Speed Controller Page J-13 Repair and Service Manual...
Page 104: Controller Replacement
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rotary Position Sensor Replacement Tool List Qty. Phillips screwdriver............1 To prevent electrical shock, the BL- wire must be removed before discharging the controller by shorting the B+ and B- terminals of the con- troller with a large screwdriver.
Page 105 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Controller Bracket NOTICE Front of Vehicle Note the location of the wiring on the controller before remov- ing wiring from solenoid.Using an insulated wrench, remove the BL- wire from the battery.
Page 106: Troubleshooting
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. no longer indicated, a failed conductor or device is TROUBLESHOOTING indicated. General In order to effectively troubleshoot the circuits that Testing Battery Voltage include the headlights, taillights and gauges, the technician must be able to use the wiring diagram and a...
Page 107: Testing A Switch For Continuity
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Testing A Switch For Continuity Testing A Solenoid For Continuity Place one probe on one of the large terminals and the Place one probe on one contact of the switch, place the other probe on the second large terminal Continuity second probe on the second terminal of the switch...
Page 108 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 J-18...
Page 109: Engine
ENGINE TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. GENERAL ........................K-2 POWERTRAIN MAINTENANCE .................K-2 Removing Debris ....................K-2 Oil Capacity ......................K-2 Oil Recommendations ..................K-2 Checking the Oil Level..................K-2 Changing the Oil....................K-3 Changing the Oil Filter ..................K-4 AIR FILTER MAINTENANCE ..................K-4 Pre-Cleaner Service ...................K-4 Cartridge Service....................K-4 SPARK PLUGS ......................K-5...
Page 110 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 K-ii...
Page 111 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Exhaust Pipes Not Shown For Clarity Oil Fill Dipstick Air Filter Starter/Generator Starter/Generator Belt Oil Filter Oil Drain Valve Fig.
Page 112: Powertrain Maintenance
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Oil Recommendations The oil must be high quality detergent oil classified “For This section describes procedures for performing Service SF, SG, SH, SJ”...
Page 113: Changing The Oil
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. engaged. Use a cloth to wipe clean the oil dipstick handle and oil fill cap (7) (Ref. Fig. 4 on page K-3). This is Maximum oil level necessary to prevent debris from falling into the engine.
Page 114: Air Filter Maintenance
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pre-Cleaner Service Add 1 quart (1 liter) of oil. Start and drive vehicle at a slow speed long enough to warm the oil. Stop and turn Carefully remove pre-cleaner (12) from cartridge (11) off vehicle on a level surface and wait 30 seconds for the and wash it in liquid detergent and water.
Page 115: Spark Plugs
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ® SPARK PLUGS The OHV V-Twin engine uses a Magnetron ignition consisting of an ignition armature with a self-contained Tool List Qty.
Page 116 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE TESTING (g) Starter belts that drag or slip will affect the com- pression reading. Adjust belt as necessary. Refer Tool List Qty.
Page 117: Engine Removal
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE REMOVAL Drain oil from engine. Loosen clamp and remove muffler from the bracket. See Tool List Qty. “MUFFLER REPLACEMENT”...
Page 118 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Differential Lock Cable Fuel Pump Bracket Differential Cap Pump And Plug Fuel Line Fuel Line White Wire Fig. 11 Disconnect Differential Lock Cable White Wire to Engine Stop to Electronic...
Page 119: Engine Installation
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Loosen remove starter/generator belt. If installing a replacement engine: STARTER/GENERATOR section. • Attach starter/generator. See STARTER/GENERA- Remove drive clutch. See CONTINUOUSLY VARIABLE TOR section.
Page 120: Muffler Replacement
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A new push nut must be used when installing the accel- To prevent the possibility of personal injury, erator cable to the governor.
Page 121 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Engine Front of Vehicle Fig. 14 Exhaust Replacement Repair and Service Manual Page K-11...
Page 122 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 K-12...
Page 123: Front Axle, Front Suspension And Steering
FRONT AXLE, FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. FRONT SUSPENSION ....................L-2 Front Strut Assembly Replacement ..............L-2 A-Arm Assembly Replacement ................L-2 FRONT AXLE ......................L-3 Front Axle Replacement ..................L-3 CV Joint Boot Replacement................
Page 124 FRONT AXLE, 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 L-ii...
Page 125 FRONT AXLE, 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 Axle and Differential Not Shown For Clarity. - Includes Items 19 - 21 Fig.
Page 126: Front Suspension
FRONT AXLE, 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 Lift and support vehicle per SAFETY section. Remove the front wheel. Refer to WHEELS AND TIRES NOTICE section.
Page 127: Front Axle Replacement
FRONT AXLE, 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 cotter pin (10), nut (9), and flat washers (8) Remove the cotter pin (24), castle nut (25), and flat from the bottom of the front strut assembly (1) at the A- washer (26) from the end of the front axle (27) (Ref.
Page 128: Cv Joint Boot Replacement
FRONT AXLE, 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. CV Joint Boot Replacement Loosen the locknut (32) two to three turns. DO NOT REMOVE NUT AT THIS TIME.
Page 129 FRONT AXLE, 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. Fig. 5 Steering Components page L-5). Remove the yoke bolts (38), lock washers (40) and nut (39) to remove the steering yoke (37) from Steering Column Replacement the steering column (34) and steering rack (41).
Page 130: Steering Rack Replacement
FRONT AXLE, 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. Steering Rack Replacement length. See “Steering Rack Replacement” on page L-6. Removed the rack end ball joint (44) from the steering Tool List Qty.
Page 131: Wheel Alignment
FRONT AXLE, 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. contacted. Rotate the wheel to the right while counting the number of turns required to contact the right hand stop.
Page 132 FRONT AXLE, 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 L-8...
Page 133: Fuel System
FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. GENERAL ........................M-2 FUEL .......................... M-2 FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT ......M-2 Fuel Lines and Filters ..................M-3 Fuel Pump ......................M-3 Fuel Tank ......................M-3 CHOKE SYSTEM .......................
Page 134 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 M-ii...
Page 135 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fuel Pump Fuel Line From Tank Fuel Hose Fuel Filter Fuel Cap Fuel Level Sensor Fuel Shut Off Valve...
Page 136: 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. GENERAL Do not over fill the fuel tank. Allow adequate space for the expansion of gasoline. Leave at least 1" (2.5 cm) space below bottom of filler neck (Ref.
Page 137: Choke System
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The fuel filter, tank, hoses and cap should be checked Fuel Pump frequently for leaks or signs that the cap vent or filter Tool List Qty.
Page 138: Prolonged Storage
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the choke plate fully opens and closes using the knob. NOTICE Check the cable to be sure that there are no sharp bends or kinks in the cable before firmly tightening the jam nuts.
Page 139: Motor
MOTOR TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. GENERAL ........................N-1 Motor Removal ....................N-1 Motor Disassembly .....................N-1 Bearing Replacement ..................N-2 Brush Replacement ....................N-3 Motor Assembly....................N-3 Motor Tests ......................N-3 Motor Installation ....................N-4 LIST OF ILLUSTRATIONS Fig. 1 Disconnect Battery Cable ................N-1 Fig.
Page 140 MOTOR 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 141: Motor Removal
MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Battery 3 To Controller Do not hold vehicle on hill by using accelerator and Battery 1 motor. Leaving the motor in a stalled condition for more than 3-4 seconds will raise the commutator bars result- ing in unacceptable noise and accelerated brush wear and cause permanent damage to motor.
Page 142: Bearing Replacement
MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Motor Components Bearing Replacement Push back each brush until its spring (3) is resting against the side of the brush. This keeps the brushes out Tool List Qty.
Page 143: Brush Replacement
MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove brushes and replace with new brush NOTICE replacement kit. Locate springs against the side of each brush. If brushes are to be replaced, proceed now to “Brush Replace- ment”...
Page 144: Motor Installation
MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Motor Installation Tool List Qty. Socket, 7/16” ............... 1 MOTOR WIRING Rachet..............1 Motor Wire Torque wrench, in. lbs..........1 Terminal Marker From...
Page 145: Operator Protection System
OPERATOR PROTECTION SYSTEM TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. SEATING ........................P-1 Front Seats Removal and Installation ..............P-1 Rear Seats Removal and Installation..............P-1 Front Seat Belt Removal And Installation ............P-4 Rear Seat Belt Removal And Installation ............P-5 Front Seat Belt Buckle Latch Replacement ............P-5 Rear Seat Belt Buckle Latch Replacement ............P-6 UPPER OPERATOR PROTECTION SYSTEM ............P-6...
Page 146 OPERATOR PROTECTION 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 P-ii...
Page 147 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SEATING To remove the seat back cushion (9), remove the screws (10) and lock washers (11) securing the back rest cushion (9) to the seat back plate (8).
Page 148 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 3 Rear Seat Removal Repair and Service Manual Page P-2...
Page 149 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the bolts (28), flat washers (29), and locknuts (30) to remove the footrest (18) from the vehicle Seat Bottom Assembly Includes Items 50- 53 Remove the bolts (32), flat washers (33), and locknuts (34) to remove the rear deck board (31) from the seat...
Page 150 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hinged Deck Board Assembly Includes Items 36 - 39 Front of Vehicle Fig. 5 Rear Seat Components the bolts (62) and nuts (63).
Page 151 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle OPS Frame Fig. 7 Rear Seat Belt Removal Fig. 6 Front Seat Belt Removal Rear Seat Belt Removal And Installation NOTICE Rear seat is optional in this vehicle.
Page 152 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Item Torque Specification Front of Vehicle 74, 124 45 - 55 ft lbs. (61.01 - 74.56 Nm) Lower OPS Fig.
Page 153 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Install the headrests in reverse order of removal. Tighten Remove the windshield. Refer to WEATHER the hardware to the torque values specified below: PROTECTION section.
Page 154 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Lower OPS Fig. 13 Upper OPS Removal LOWER OPERATOR PROTEC- Remove the bolts (97), flat washers (98) and lock nuts (99) from the front bumper (96).
Page 155 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. OPS Bottom Part of Frame Part of Frame Fig. 14 Front Bumper Removal Lower OPS Rear Weldment Removal And If rear seats are installed on the vehicle, remove the rear seats buckle latch.
Page 156 OPERATOR PROTECTION SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Front of Vehicle Part of Frame Fig. 15 Lower OPS Rear Weldment Removal Repair and Service Manual Page P-10...
Page 157: Paint
PAINT TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. PAINTING........................Q-1 Minor Scratches....................Q-1 Larger Scratches ....................Q-1 Complete Panel Repair ..................Q-1 Repair and Service Manual Page Q-i...
Page 158 PAINT 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 Q-ii...
Page 159: Larger Scratches
PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING Larger Scratches For larger scratches, the manufacturer suggests the Follow the paint manufacturer’s recommendations for following steps be taken to repair the Durashield™ body: specific painting procedures and information.
Page 160 PAINT 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 Q-2...
Page 161: Rear Axle And Suspension
REAR AXLE AND SUSPENSION TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. REAR AXLE ........................R-2 Maintenance .......................R-2 Checking the Lubricant Level ................R-2 Differential Lock Cable Adjustment..............R-2 Rear Axle Removal.....................R-2 Rear Axle Installation..................R-4 REAR SUSPENSION ....................R-5 General.......................R-5 Shock Absorber Removal ...................R-5 Shock Absorber Installation ................R-5 Rear Spring Removal ..................R-5 Rear Spring Installation ..................R-5...
Page 162 REAR AXLE AND 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 R-ii...
Page 163 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Shock/Stop Frame Mount Shock Spring Absorber Alternate Configuration Shock/Stop Mount Rear Axle Rear Axle Link Spring Subframe U-Bolt...
Page 164 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE Back off front jam nut (11) one turn and hold while tightening rear jam nut (12). Maintenance The rear axle (1) is provided with a lubricant level check plug located on the driver side at rear of housing.
Page 165 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove truck bed per TRUCK BED section. To reduce the possibility of personal injury, fol- low the lifting procedure in Section B of this manual.
Page 166: Rear Axle Installation
REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Differential Anti-Rotation Bracket Fig. 8 Detach Differential Link The differential makes the rear axle assembly Fig.
Page 167 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten secondary clutch bolt to torque specified in Shock Absorber Installation CONTINUOUSLY VARIABLE TRANSMISSION section. Shock absorber (4) installation is in the reverse order of Install muffler bracket to the axle.
Page 168 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Rear Spring Shackle Assembly Alternate Configuration Fig. 9 Rear Suspension Repair and Service Manual Page R-6...
Page 169: Starter/Generator
STARTER GENERATOR TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. STARTER/GENERATOR .....................S-1 Starter Mode.......................S-1 Generator Mode ....................S-1 STARTER/GENERATOR BELT TENSION ..............S-1 Adjusting Belt Tension ..................S-2 STARTER GENERATOR REPLACEMENT ..............S-2 Starter/Generator Removal.................S-2 Starter/Generator Installation ................S-2 Starter/Generator Disassembly ................S-3 Starter/Generator Inspection ................S-3 Testing of Starter Generator ................S-4 Starter/Generator Repair ..................S-4 LIST OF ILLUSTRATIONS...
Page 170 STARTER GENERATOR 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 171: Starter/Generator Belt Tension
STARTER GENERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR Starter Mode At the time of installation, the belt must not be rolled over the installed edges of the starter/generator or drive When starting the engine, the field coils are in series clutch pulleys.
Page 172: Starter Generator Replacement
STARTER GENERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjusting Belt Tension generator belt (4). Remove adjusting bolt (2) and pivot bolts (3) and remove starter/generator from vehicle. Loosen front and back pivot bolts (3) of starter/generator (Ref.
Page 173: Starter Generator
STARTER GENERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Reconnect negative (-) battery cables and tighten Starter/Generator Disassembly hardware to 60 in. lbs. (7 Nm). Tool List Qty.
Page 174: Testing Of Starter Generator
STARTER GENERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Testing of Starter/Generator 1. Commutator - Clean with a soft, clean cloth. 2. Replace any damaged or cracked brush holders or Tool List Qty.
Page 175 STARTER GENERATOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Puller Bearing Adapter (Puller) Fig. 8 Bearing Removal Brush Spring Brush Brush Spring Position for Spring Position Removing/Replacing for Installed Brushes Brushes...
Page 176 STARTER GENERATOR 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-6...
Page 177: Troubleshooting
TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. GAS POWERTRAIN TROUBLE SHOOTING .............. T-1 Engine Troubleshooting..................T-1 Gas Powertrain Performance ................T-1 Starter/Generator Troubleshooting ..............T-5 SUSPENSION AND STEERING.................. T-6 CURTIS CONTROLLER ....................T-7 General....................... T-7 Navigation ......................T-7 Changing Data Value ..................
Page 178 TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘T’ (CONT.) SECTION TITLE PAGE NO. LIST OF ILLUSTRATIONS Fig. 1 Gas Powertrain Performance Troubleshooting ..........T-1 Fig. 2 Starter/Generator Troubleshooting ..............T-5 Fig. 3 Suspension And Steering Troubleshooting .............T-6 Fig. 4 Curtis Handheld Programmer .................T-7 Fig.
Page 179: Gas Powertrain Trouble Shooting
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GAS POWERTRAIN TROUBLE- SHOOTING Engine Troubleshooting For engine troubleshooting, diagnostic and repair procedures, refer to Briggs & Stratton® Repair Manual (P/N 627655) for Vanguard™...
Page 180 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 STARTER TURNS SLOWLY Terminals are loose or corroded Retighten or clean Weak battery Charge battery Leads are nearly broken or connec- Check for any defect of leads at bend tions are faulty...
Page 181 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 Fuel pump faulty Repair or replace Insufficient fuel level...
Page 182 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 BACKFIRING Accelerator limit switch out of adjust- Adjust ment Loose muffler or leaking gasket Repair Carburetor throttle lever motion re- Repair...
Page 183: Starter/Generator Troubleshooting
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Starter/Generator Troubleshooting Condition Possible Cause Correction STARTER IS NOISY Bolts are loose Tighten to correct torque Starter/generator has foreign matter Clean starter/generator interior inside Bearings are faulty...
Page 184: Suspension And Steering
TROUBLESHOOTING Read all of Section B 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 STIFF STEERING Water has entered steering box and...
Page 185: Curtis Controller
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CURTIS CONTROLLER Insert the Molex plug into the receptacle on the face of the controller. The status light will flash if a fault is detected (Ref.
Page 186 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Menu Submenu 1 Submenu 2 Data Range Default Units Hand Held Value Access Program M1 - ACC Rate .1 - 5.0 Seconds M2 - ACC Rate...
Page 187 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Faults System Faults Display active faults. Fault History Display past faults. Clear fault History Clear past faults. Functions Settings Get Settings From OK/ABORT...
Page 188: Fault Code Chart
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fault Code Chart 1311 Controller Explanation Possible Cause Code Response Display HW Fail safe Self test or watch dog Vehicle Disabled 1.
Page 189 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Main Contact Main contactor welded Reduced 1. Main contactor (solenoid) is stuck Welded performance closed. 2. Check for short in contactor primary circuit.
Page 190: Curtis Handheld Diagnostic Tool Function
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Curtis Handheld Diagnostic Tool Function The first screen observed will be the menu options list. The M1 acceleration rate is the only one used on the Ambush.
Page 191 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EMR REV Input, AUX Cont, and Brake Output are not used on the Ambush. The only two values used on this screen is Fault 1 Output and Control State.
Page 192 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The technician will be prompted whenever setting changes are made. The information menu selection gives general infor- mation about the speed controller. Controller information will be required for trouble –...
Page 193: Electrical Troubleshooting
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL TROUBLESHOOT- fault is detected. The first number of the code will be flashed by the key switch LED. The second number of the code will be flashed by the mode switch after a short pause (Ref.
Page 194: Component Testing
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. COMPONENT TESTING Voltmeter Before performing any test of wiring compo- nents, disconnect the battery cables from the battery posts to prevent electrical shock or explosion (Refer to Safety section).
Page 195: State Of Charge (Soc) Meter - Testing
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SOC Meter Mode Switch Optional Key Switch Light Plugs Low Oil Light Black Out Switch Fuel Gauge Fig. 12 Control Panel Back Key Switch SOC Meter SOC Meter...
Page 196: Low Oil Indicator (Light) - Testing
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fuel Gauge Low Oil Light Fig. 15 Fuel Gauge Fig. 16 Low Oil Indicator Low Oil Indicator (Light) - Testing Powertrain Control Switch - Testing Turn the key to gas mode, place the positive meter Figure 17 on page T-18 gives the various voltages to be...
Page 197: Black Out Switch - Testing
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Black Out Orange wire connection Red wire connection Switch should have 48V with should have 48V with the key in the on position the key in the on and the black out switch position and the black...
Page 198: Electronic Speed Sensor - Testing
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 20 Speed Sensor and Convertor Plug DC To DC Convertor Plug Testing The DC to DC convertor plug should be checked Fig.
Page 199 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 48 - 0V This pin is the activation ground for the 0 - 5V with Ground speed controller throttle solenoid activation...
Page 200: Electronic Speed Controller Pin Connectors - Testing
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Electronic Speed Controller Pin Connectors Motor - Testing - Testing Disconnect all the wires from the motor terminals A1, A2, F1, and F2 posts (Ref.
Page 201: Truckbed
TRUCK BED TABLE OF CONTENTS FOR SECTION ‘U’ SECTION TITLE PAGE NO. TRUCK BED REPLACEMENT (MANUAL LIFT)............U-2 TRUCK BED REPLACEMENT (ELECTRIC LIFT) ............U-3 LIST OF ILLUSTRATIONS Fig. 1 Rotomold Truck Bed - Components............... U-1 Fig. 2 Aluminum Truck Bed - Components .............. U-2 Fig.
Page 202 TRUCK BED 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 U-ii...
Page 203 TRUCK BED Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rotomold Truck Bed - Electric Lift Truck Bed Front of Vehicle Actuator Actuator May Be Rotated 90° On Some Models Rotomold Truck Bed - Manual Lift Truck Bed...
Page 204 TRUCK BED Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Aluminum Truck Bed - Electric Lift Truck Bed Front of Vehicle Actuator May Be Rotated 90° On Some Models Actuator Aluminum Truck Bed - Manual Lift Truck Bed...
Page 205 TRUCK BED Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCK BED REPLACEMENT (MANUAL LIFT) Tool List Qty. Back brace ..............2 Needle nose pliers............1 The truck bed is heavy and awkward to handle. To prevent possible personal injury, it is Frame strongly recommended that an assistant or...
Page 206 TRUCK BED Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCK BED REPLACEMENT (ELECTRIC LIFT) Tool List Qty. Back brace..............2 Needle nose pliers............1 The truck bed is heavy and awkward to handle. To prevent possible personal injury, it is strongly recommended that an assistant or Frame...
Page 207: Weather Protection
WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘V’ SECTION TITLE PAGE NO. GENERAL ........................V-1 Trailering ......................V-1 CANOPY TOP ......................V-1 Canopy Top Removal ..................V-1 SPLIT WINDSHIELD ....................V-2 Split Windshield Removal ...................V-2 FULL WINDSHIELD ....................V-4 Full Windshield Removal ..................V-4 LIST OF ILLUSTRATIONS Fig.
Page 208 WEATHER PROTECTION 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 V-ii...
Page 209: Canopy Top
WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Remove windshield before trailering. Maximum speed with top is 50 mph (80 kph). If the vehicle is to be transported on a trailer at highway The canopy top does not provide protection speeds, the windshield and canopy top must be from roll over or falling objects.
Page 210: Split Windshield
WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD Split Windshield Removal Tool List Qty. Socket, 7/16" ............... 1 Socket, 3/8" ..............1 Socket, 9/16" ............... 1 Socket, 1/2"...
Page 211 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Split Windshield Assembly Part Of Upper Ops Front Of Vehicle Fig. 2 Split Windshield Repair and Service Manual Page V-3...
Page 212: Full Windshield
WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD Pull to remove the velcro attachment of the textile skirt- place holder (18) which will now free the full windshield assembly (12) completely from the vehicle.
Page 213: Wheels And Tires
WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘W’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE..................W-2 Tire Repair......................W-2 Wheel Installation ....................W-3 LIST OF ILLUSTRATIONS Fig. 1 Wheels and Tires ..................W-1 Repair and Service Manual Page W-i...
Page 214 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 W-ii...
Page 215 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tire Style May Vary Valve Stem Is Always Front of Vehicle To Outside Of Wheel Always Replace Dust Cap 'CROSS SEQUENCE' Fig.
Page 216: Wheel And Tire Service
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 will depend on the type of tires fitted but under no condition should inflation pressure be higher than recommended on the tire sidewall.
Page 217: Wheel Installation
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 Do not tighten lug nuts to more than 75 ft. lbs. (101.68 Nm) torque. NOTICE It is important to follow the ‘cross sequence’...
Page 218 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 W-4...
Page 219: General Specifications
GENERAL SPECIFICATION TABLE OF CONTENTS FOR SECTION ‘X’ SECTION TITLE PAGE NO. AMBUSH - GAS / ELECTRIC PARALLEL DRIVE VEHICLE ........X-1 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions..................X-2 Fig. 2 Vehicle Incline Specification and Turning Clearance Diameter .......X-3 Repair and Service Manual Page X-i...
Page 220 GENERAL SPECIFICATION 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 X-ii...
Page 221 GENERAL SPECIFICATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: BAD BOY BUGGIES - AMBUSH TYPE: GAS / ELECTRIC PARALLEL DRIVE VEHICLE MODEL YEAR: 2013 Part No:. 626640...
Page 222 GENERAL SPECIFICATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 75.5” (192 cm) 53” (134.6 cm) 79.5” 43.25” (202 cm) (110 cm) 115.5” rear wheels (293.4 cm) 43.75”...
Page 223 GENERAL SPECIFICATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Maximum Recommended Ramp Grade Maximum Recommended Side Tilt 25% or 14° Max. 25% or 14° Max. TURNING CLEARANCE DIAMETER Approx.
Page 224 GENERAL SPECIFICATION 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 X-4...
Page 225: Limited Warranty
LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION ‘Y’ SECTION TITLE PAGE NO. EMISSION CONTROL SYSTEM WARRANTY STATEMENT ........Y-1 ENGINE OWNER WARRANTY POLICY ..............Y-1 Repair and Service Manual Page Y-i...
Page 226 LIMITED WARRANTY 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 Y-ii...
Page 227: Emission Control System Warranty Statement
LIMITED WARRANTY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EMISSION CONTROL SYSTEM WARRANTY STATEMENT (Owner’s Defect Warranty Rights and Obligations) ® Refer to the Briggs & Stratton Operating &...
Page 228 LIMITED WARRANTY 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 Y-2...
Page 229: Title
APPENDIX A TABLE OF CONTENTS FOR SECTION ‘APPENDIX A’ TITLE PAGE NO. BRIGGS & STRATTON OPERATOR’S MANUAL ............1 General Information....................... 5 Power Rating......................... 5 Operator Safety ........................5 Features and Controls ......................6 Operation ..........................7 Oil Recommendations ..................... 7 How To Check/Add Oil ....................
Page 230 APPENDIX A 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 Appendix-A-ii...
Page 231 Operator’s Manual Manual del Operario Manuel de l’opérateur Model 290000 Vanguardt Model 350000 Vanguardt Gasoline Gasoline Model 300000 Vanguardt Model 380000 Vanguardt Gasoline Gasoline Copyright E 2012 Briggs & Stratton Corporation, Milwaukee, WI, USA. All rights reserved. Form No. 279771TRI Briggs &...
Page 232 VanguardEngines.com...
Page 234 VanguardEngines.com...
Page 235: General Information
General Information This manual contains safety information to make you aware of the hazards and risks WARNING associated with engines and how to avoid them. It also contains instructions for the The engine exhaust from this product contains chemicals known to the State of proper use and care of the engine.
Page 236 WARNING WARNING Engines give off carbon monoxide, an odorless, colorless, poison gas. Unintentional sparking can result in fire or electric shock. Breathing carbon monoxide can cause nausea, fainting or death. Unintentional start-up can result in entanglement, traumatic amputation, or laceration. Fire hazard Start and run engine outdoors.
Page 237: Features And Controls
Features and Controls 3. Remove the dipstick and check the oil level. It should be at the top of the full indicator (B) on the dipstick. 4. If low, add oil slowly into the engine oil fill (C). Do not overfill. After adding oil, wait Compare the illustration with your engine to familiarize yourself with the location of one minute and then recheck the oil level.
Page 238: How To Stop The Engine
Maintenance We recommend that you see any Briggs & Stratton Authorized Dealer for all WARNING maintenance and service of the engine and engine parts. Fuel and its vapors are extremely flammable and explosive. NOTICE: All the components used to build this engine must remain in place for proper Fire or explosion can cause severe burns or death.
Page 239: How To Replace The Spark Plug
How To Replace The Spark Plug - Figure 5 How To Service The Air Filter - Figure 11 Check the gap (A, Figure 5) with a wire gauge (B). If necessary, reset the gap. Install and tighten the spark plug to the recommended torque. For gap setting or torque, see the WARNING Specifications section.
Page 240: Storage
Storage use Briggs & Stratton Advanced Formula Fuel Treatment & Stabilizer, available wherever Briggs & Stratton genuine service parts are sold. For engines equipped with a FRESH START ® fuel cap, use Briggs & Stratton FRESH ® START available in a drip concentrate cartridge. WARNING There is no need to drain gasoline from the engine if a fuel stabilizer is added according Fuel and its vapors are extremely flammable and explosive.
Page 241: Briggs & Stratton Engine Warranty Policy
BRIGGS & STRATTON ENGINE WARRANTY POLICY April 2012 LIMITED WARRANTY Briggs & Stratton warrants that, during the warranty period specified below, it will repair or replace, free of charge, any part that is defective in material or workmanship or both. Transportation charges on product submitted for repair or replacement under this warranty must be borne by purchaser.
Page 242 California, U.S. EPA, and Briggs & Stratton Corporation Emissions Control Warranty Statement January 2012 Your Warranty Rights And Obligations The California Air Resources Board, U.S. EPA, and Briggs & Stratton (B&S) are pleased Owner’s Warranty Responsibilities: to explain the emissions control system warranty on your Model Year 2012--2013 As the engine/equipment owner, you are responsible for the performance of the ...
Page 243: Seguridad Del Operario
Información General Este manual contiene información de seguridad para que usted tome conciencia de los ADVERTENCIA peligros y riesgos asociados con los motores, y cómo evitarlos. También contiene Ciertos componentes en este producto y sus accesorios relacionados contienen instrucciones para el uso y cuidado apropiados del motor. Ya que Briggs & Stratton químicos que el Estado de California considera que ocasionan cáncer, defectos Corporation no conoce necesariamente cuál equipo impulsará...
Page 244 ADVERTENCIA ADVERTENCIA Dar arranque al motor crea chispeo. El funcionamiento de los motores produce calor. Las partes de los motores, especialmente el mofle, se calientan demasiado. El chispeo puede encender los gases inflamables cercanos. Pueden ocurrir graves quemaduras a causa de su contacto. Podría ocurrir una explosión o un incendio.
Page 245: Características Y Controles
Características y Controles 1. Remueva la varilla indicadora de nivel de aceite (A) y límpiela con un trapo limpio (Figura 2). 2. Inserte completamente la varilla indicadora de nivel de aceite. Compare la ilustración con su motor para que se familiarice con la ubicación de las 3.
Page 246: Mantenimiento
Cómo Darle Arranque al Motor - Figura 4 5. Mueva el control del acelerador (B) hacia la posición fast . Opere el motor con el control del acelerador en la posición fast ADVERTENCIA 6. Mueva la palanca del estrangulador (C) hacia la posición choke Nota: Generalmente el estrangulador no es necesario cuando se enciende un motor La retracción rápida de la cuerda de arranque (contragolpe) le halará...
Page 247 Cuadro de Mantenimiento ADVERTENCIA: Los repuestos deben ser del mismo diseño y ser Las Primeras 5 horas instalados en la misma posición que tenían las partes originales. Es posible que otros repuestos no funcionen tan bien, dañen la unidad y hasta pueden ocasionar Cambie aceite ...
Page 248 8. Instale el pre-filtro seco sobre el filtro de aire. NOTIFICACIÓN: No use agua para limpiar el motor. El agua podría contaminar el sistema de combustible. Utilice un cepillo o un trapo seco para limpiar el motor. 9. Instale el filtro de aire y asegúrelo con el retenedor y la tuerca. 10.
Page 249: Especificaciones
Especificaciones Especificaciones del Motor Especificaciones del Motor Modelo 290000 Modelo 350000 Desplazamiento 29,23 in (479 cm Desplazamiento 34,78 in (570 cm Diámetro Interno del Cilindro 2,677 in (68 mm) Diámetro Interno del Cilindro 2,835 in (72 mm) Carrera 2,598 in (66 mm) Carrera 2,756 in (70 mm) Capacidad de Aceite...
Page 250 PÓLIZA DE GARANTIA PARA EL MOTOR BRIGGS & STRATTON Abril 2012 GARANTIA LIMITADA Briggs & Stratton Corporation garantiza que durante el período de grantí especificado más adelante reparará o reemplazará, sin costo alguno, cual(es)quier parte(s) del motor considerada(s) como defectuosas en material, mano de obra o ambos. Los gastos de transporte del producto sometido a reparación o cambio bajo esta Garantía deben ser abonados por el comprador.
Page 251 Declaración de Garantía sobre Control de Emisiones de California, U.S. EPA, Enero 2012 y Briggs & Stratton Corporation Sus Derechos y Obligaciones bajo la Garantía La Junta de Recursos Ambientales de California (CARB), la U.S. EPA y Briggs & Responsabilidades del Propietario de la Garantía: Stratton (B&S) se complacen en explicarles la garantía del sistema de control de Como propietario del motor/equipo, usted es responsable de que se lleve a cabo el ...
Page 252: Sécurité De L'utilisateur
Informations générales Ce manuel contient des informations concernant la sécurité visant à attirer l’attention des AVERTISSEMENT usagers sur les dangers et les risques associés aux moteurs. Il contient aussi des Certains composés de ce produit et de ses accessoires contiennent des produits instructions d’utilisation et d’entretien appropriées à...
Page 253 AVERTISSEMENT AVERTISSEMENT Le démarrage du moteur produit des étincelles. Un moteur en marche produit de la chaleur. Les pièces du moteur, et plus particulièrement le silencieux, deviennent extrêmement chaudes. Les étincelles peuvent enflammer les gaz inflammables à proximité. Les toucher peut provoquer des brûlures sévères. Ceci pourrait provoquer une explosion ou un incendie.
Page 254: Caractéristiques Et Commandes
Caractéristiques et commandes 5. Introduire la jauge à fond. Pression d’huile Comparer l’illustration avec le moteur pour se familiariser avec l’emplacement des Si la pression de l’huile est trop basse, un contacteur de pression (le cas échéant) arrête différents composants et commandes. le moteur ou active un dispositif sonore sur l’équipement.
Page 255: Entretien
Entretien Nous recommandons de voir un Réparateur Agréé Briggs & Stratton pour tout l’entretien AVERTISSEMENT de votre moteur et l’acquisition de pièces. Le combustible et ses vapeurs sont extrêmement inflammables et AVIS: Tous les composants de ce moteur doivent rester à leur place d’origine pour que explosifs.
Page 256 Remarque: Dans certains pays, la législation impose l’emploi de bougies à résistance Entretien du filtre à air - Figure 11 pour supprimer les parasites de l’allumage. Si ce moteur était équipé d’une bougie avec résistance, utiliser le même type de bougie lors de son remplacement. AVERTISSEMENT Inspection du silencieux d’échappement et de l’écran pare-étincelles - Figure 6...
Page 257: Spécifications
Utiliser une brosse ou un chiffon sec pour enlever les débris du protège doigts (A). Système d’alimentation Nettoyer les biellettes, les ressorts et les commandes (B). Ne pas laisser les débris L’essence peut s’éventer lorsqu’elle est conservée plus de 30jours. L’essence périmée combustibles s’accumuler autour et derrière le silencieux d’échappement (C) (Figure 10).
Page 258 APPLICATION DE LA GARANTIE SUR LES MOTEURS BRIGGS & STRATTON Avril 2012 GARANTIE LIMITÉE Briggs & Stratton garantit que, pendant la période de garantie spécifiée ci-dessous, il remplacera ou réparera gratuitement toute pièce du moteur présentant un défaut de matière ou de fabrication ou les deux. Tous les frais de transport du produit destiné à être remplacé ou réparé au titre de la présente garantie restent à charge de l’acheteur. Cette garantie est applicable pendant la période et aux conditions prévues dans le présent document.
Page 259 Déclaration de garantie du système de contrôle des émissions de l’État de Californie, de l’U.S. EPA et janvier 2012 de Briggs & Stratton Corporation Droits et obligations du propriétaire au titre de la garantie Le California Air Resources Board (CARB), l’U.S. EPA et Briggs & Stratton (B&S) ont le Responsabilités du propriétaire au titre de la garantie: plaisir de vous expliquer la garantie du système de contrôle des émissions pour votre En tant que propriétaire d’un moteur/équipement, vous êtes responsable de...
Page 260 VanguardEngines.com...
Page 263 SAFETY NOTICE NOTICE Read the following warnings before attempting to operate the Read and understand the following text and warnings before vehicle: attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. It is virtually impossible to anticipate all possible component failures or the manner in which each component may fail.
Page 264 Bad Boy Buggies 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US E-mail: info@badboybuggies.com For parts and repair contact your local dealer. To locate a local dealer please go online to our website: www.BADBOYBUGGIES.COM © 2011 E-Z-GO Division of Textron Inc.

Bad Boy AMBUSH 632313 Service Manual

Table of Contents

General Information & Routine Maintenance B B

B Accelerator B

Batteries and Battery Charger B B

Batteries and Battery Charger

B Brakes B

B Continuously Variable Transmission (Cvt) B

B Electrical B

Starter Generator B B

Troubleshooting B B

Appendix A

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Bad Boy AMBUSH 632313