Page 1 Repair & Service Manual GASOLINE POWERED VEHICLE 634468-K ISSUED OCTOBER 2013 REVISED MARCH 2018...
Page 2: Safety
SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
Page 3 TXT SHUTTLE 2+2 STARTING MODEL YEAR 2014 DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically E-Z-GO, and therefore is subject to change without notice.
Page 4: General Information
GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
Page 5: Table Of Contents
TABLE OF CONTENTS TITLE PAGE SAFETY ......................... INSIDE COVERS GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C BRAKES............................D FRONT SUSPENSION AND STEERING ..................E SPEED CONTROL........................... F ENGINE............................G FUEL SYSTEM ..........................H CONTINUOUSLY VARIABLE TRANSMISSION (CVT)..............
Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...
Page 7: Safety Information
SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer.
Page 8: General Operation
SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specification.
Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated. •...
Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page viii...
Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LABEL LOCATION ..............A - 1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY .........A - 1 SERVICING THE VEHICLE..................A - 1 FUEL ........................A - 2 FUEL TANK......................
Page 12: General Information & Routine Maintenance
GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-ii...
Page 13: Serial Number Label Location
GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LABEL LOCATION The vehicle is equipped with a starter/generator. When starting the engine, the starter/generator functions as a Two serial number and manufacture date code plates are starter and with the engine running, it functions as a gen- on the vehicle.
Page 14: Service Operation
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. FUEL It is in the best interest of both vehicle owner and servicing dealer, to carefully follow the procedures recommended in this manual.
Page 15: Fig. 3 Fuel Tank
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. Early production fuel tanks require enough space for the smoke in an area where vehicles are being expansion of the gasoline.
Page 16: Fig. 5 Neutral Lock
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. Rack Ball Joint Hole in Direction Selector Cam Unlocked View from Underside of Vehicle Fig.
Page 17: Top And Windshield
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. TIRES electrical items which could produce a spark. Tire condition should be inspected on a daily basis. Infla- Store vehicle in a clean, dry area.
Page 18: Care And Cleaning Of The Vehicle
GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Do not engage the park brake, but secure the car from rolling. • While engine is still warm, change oil.
Page 19: Torque Specifications
GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.
Page 20: 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 C&A - CHECK & ADJUST CL - CLEAN R - REPLACE ...
Page 21: Fig. 8 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. REMARKS Steering Assembly - excessive play, loose or missing      ...
Page 22 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page A-10...
Page 23: Section Title
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 - 1 Battery Removal &...
Page 24 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-ii...
Page 25 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE, CAUTIONS, WARNINGS AND expose them to injury should an unforeseen situation DANGERS occur. Always use the appropriate tools listed in the tool list and Throughout this manual, the following NOTICE, CAU- wear approved safety equipment.
Page 26: Battery Removal And Installation
SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always turn the key switch to ‘OFF’ and metal container to prevent can from contact- remove the key before disconnecting a live ing battery terminals which could result in an circuit.
Page 27: 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. the bolt from the battery hold down and remove the bat- tery (Ref. Fig. 1). When lifting the vehicle, position jacks and BATTERY - jack stands only on the areas indicated.
Page 28 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-4...
Page 29: Body
BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ........................C - 1 General ...........................C - 1 BODY COMPONENT REPLACEMENT ..............C - 1 Instrument Panel Replacement ..................C - 1 Cowl Replacement ......................C - 4 Rocker Panel Replacement .....................C - 4 Front Shield Replacement ....................C - 4 Body Replacement ......................C - 4 Rear Bumper Replacement ....................C - 5...
Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page C-ii...
Page 31: Body
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY Drill Out Rivet NOTICE Pop Rivet Head Only In the following text, there are references to removing/installing bolts, etc.
Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Fig. 2 FUEL GAUGE Gasket Nut Front of Vehicle Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...
Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 3 Fig. 3 Body Components (Rear) Repair and Service Manual Page C-3...
Page 34: Cowl Replacement
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The instrument panel (6) may now be pulled away from As the rocker panel is removed, be sure to catch the the cowl.
Page 35: Rear Bumper Replacement
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Bumper Replacement NOTICE Tool List Qty. Electric/Air drill .............1 Prior to removing the rear body, the foot rest or cargo bed, as Drill bit, 7/32"...
Page 36: Larger Scratches
BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use a polishing compound (3M Finesse or auto- not supply these materials due to the variety of paint motive grade) to renew gloss and to further blend manufacturers and the preferences of the individual and transition newly painted surface.
Page 37 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page C-7...
Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page C-8...
Page 39: Brakes
BRAKES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. BRAKES SYSTEM OVERVIEW ................D - 1 General Description......................D - 1 How the Service Brake Works ...................D - 2 Equalizer Link........................D - 2 Automatic Adjuster Mechanism ..................D - 2 How the Parking Brake Works ..................D - 2 Compensator Assembly ....................D - 3 Kick-Off Actuating Linkage ....................D - 3 TROUBLESHOOTING FLOWCHART................D - 4...
Page 40: Brakes
BRAKES TABLE OF CONTENTS FOR SECTION ‘D’ (CONT.) SECTION TITLE PAGE NO. Fig. 20 Brake Assembly......................D - 15 Fig. 21 Wheel Brake Lubrication Points ..................D - 16 Fig. 22 Backing Plate Removal and Installation................. D - 17 Fig. 23 Brake Shoes and Springs ..................... D - 18 Fig.
Page 41: Brakes System Overview
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Torsion Springs Parking Brake Pedal Push Nut Hinge Pin Identification Hole Service Brake Pedal Pedal Latch Spacer Catch Bracket Kick Off Cap Screw Brake Pedal Pivot Bolt...
Page 42: How The Service Brake Works
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. How the Service Brake Works Depressing the service brake pedal pulls the compensa- tor assembly and equalizer link, which are connected to the brake cables (Ref.
Page 43: Compensator Assembly
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.
Page 44: Troubleshooting Flowchart
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of: Includes...
Page 45 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure. Replace Free Movement of Torque Lug Nuts.
Page 46: Troubleshooting Table
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING TABLE Test (PBPT), and Aggressive Stop Test is performed (Ref. Fig. 5). Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Condition Possible Cause...
Page 47 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Unequal braking (one wheel locks Wheel not locking is not adjusting Check brake operation of wheel that is not locking while other rotates) Sticky/dragging cable...
Page 48: Troubleshooting And Inspection
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPEC- TION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this break-in period, it is not uncommon for the brake pedal free travel (and the effort required to latch the parking 1/4"...
Page 49 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cables and linkages or initial break-in of components. has been released (Ref. Fig. 18). If the clevis pins are Not enough pedal free travel may indicate improper not loose, but brake pedal free travel is correctly adjustment of the wheel brake or the brake linkage.
Page 50: Periodic Brake Performance Test (Pbpt)
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point Push (No Gap) Catch Screw Bracket...
Page 51: Aggressive Stop Test
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cles, several vehicles should be tested when new and should stop aggressively. The wheel brakes may or may the range of stopping locations or distances recorded.
Page 52: Wheel Brake Inspection
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. friction surface being significantly worn and leaving a ledge of unworn drum. Inspect the splines for galling, wear and corrosion. If any of these problems are found, the drum must be replaced.
Page 53 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If the adjuster arm engages the star wheel but fails to Travel”. This includes all linkage and wheel brake com- rotate it, the adjuster assemblies must be replaced ponents.
Page 54: Maintenance And Repairs
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE AND REPAIRS essential to proper brake function. Too much pedal free travel will limit braking capability. Too little pedal free Tool List Qty.
Page 55: 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. Brake Drum Removal and Installation Drive again and brake aggressively 10 times. Repeat the previous step(s) until the pedal free travel Remove the dust cap (1) to gain access to the castel- does not change during the aggressive braking.
Page 56: Wheel Brake Service
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To install the brake drum, clean the axle shaft and the Clean backing plate with a commercial brake cleaner. splines on the brake drum to remove dirt, grease and Allow to dry completely.
Page 57: Backing Plate/Entire Wheel Brake Assembly 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. Replace the springs one side at a time, using the other the brake springs and remove the brake shoes (Ref. Fig. side as a guide.
Page 58 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP PULL ADJUSTER ASSEMBLY Fig. 23 Brake Shoes & Springs Repair and Service Manual Page D-18...
Page 59: Brake Shoe Installation
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Installation The brake shoe end is pointed and engages the back- side of the adjuster.There is a 17L stamped into brake shoe (Ref.
Page 60: Brake Cable And Equalizer Assembly 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 Cable and Equalizer Assembly Brake Pedal Removal and Installation Removal and Installation Disconnect the compensator assembly (1) from the brake pedal by removing the cotter pin (2) and the clevis pin (3).
Page 61: Parking Brake Catch Bracket 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. Remove the two bolts (1) and nuts (2) which secure the catch bracket. Replace the catch bracket with a new one, replace and tighten the hardware to 85 - 95 in.
Page 62: Parking Brake Release Linkage Removal And Replacement
BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Kick-Off Cam Removal, heads in the kick-off cam should be approximately 1/4" - Replacement and Installation 3/8”...
Page 63 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 D-23...
Page 64 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page D-24 Repair and Service Manual...
Page 65: Front Suspension And Steering
FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE .......................E - 2 Lubrication........................E - 2 Wheel Bearing and King Pin Bushing Inspection ............. E - 2 Wheel Bearing Packing ....................E - 2 Wheel Bearing Adjustment ....................
Page 66 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-ii...
Page 67 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 of Vehicle Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit...
Page 68: Maintenance
FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE NOTICE Do not use more than three pumps of grease in any In the following text, there are references to removing/installing bolts, etc.
Page 69: Wheel Bearing Adjustment
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. Clean all bearings, grease seal, hub and dust cap in sol- Replace the dust cap (1) and lower vehicle per SAFETY vent and dry thoroughly.
Page 70 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. ment taken at the front of the tires should be 0" - 1/8" (0 - 3 mm) less than the rear. Remove Bolt Rear Intermediate...
Page 71: Front Suspension
FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Front of Vehicle Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
Page 72: Front Axle Replacement
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 Replacement of washer (22) and remove it from end of bolt. Remove Tool List Qty.
Page 73: Hub Replacement
FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To detach driver side spring: When front springs are replaced, the front axle must be aligned to the frame.
Page 74: Wheel Bearing And Race Replacement
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. Wheel Bearing and Race Replacement Tool List Qty. Non-ferrous punch ............1 Front of Vehicle Ball peen hammer............1 Bearing driver ..............1 Remove hub (1) from spindle (Ref.
Page 75: Steering
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 Front of Vehicle Flat Section Fig. 11 Steering Components Rack Ball Joint Replacement Remove passenger side front wheel and turn steering Tool List Qty.
Page 76: Tie Rod Inspection/Replacement
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. Using measurement made earlier, thread jam nut and new Grasp the tie rod (8) at ball joints (6) and check for any rack ball joint to previous location on rack extension and vertical motion which would indicate a worn condition and set jam nut hand tight.
Page 77: Bellows Replacement
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. required in order to insert a new cotter pin. Maximum torque is 50 ft. lbs. (70 Nm). Install front wheel(s) per WHEELS AND TIRES section and lower vehicle per SAFETY section.
Page 78: Spindle Replacement
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 cotter pin (1) and loosen castellated nut (2) until tie rod ball joint (3) threads are protected (Ref.
Page 79: Rack And Pinion Unit Disassembly And Inspection
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. Rack and Pinion Unit Disassembly and Inspection Tool List Qty. Vice ................1 Socket, 3/8" ..............1 Ratchet ................
Page 80: Rack And Pinion Unit Replacement
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. Rack and Pinion Unit Replacement Set proper rack extension-to-rack and pinion unit clear- Tool List Qty.
Page 81: Steering Wheel Replacement
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. Approximately 1/8" Thick Washer Step 1 Step 2 Fig. 20 Clipboard Removal Loosen the steering wheel retaining nut (6) two to three turns (Ref.
Page 82: Steering Shaft And Column Replacement
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. ahead position, align the steering wheel on the steering Remove the four bolts (5) and washers (6) that secure shaft and slide wheel on shaft.
Page 83 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page E-17...
Page 84 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page E-18...
Page 85: Speed Control
SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. SYSTEM OPERATION ..................F - 1 Pedal Box Operation ......................F - 1 Governor Operation......................F - 2 TROUBLESHOOTING....................F - 2 SPEED CONTROL ....................F - 2 Accelerator Cable Removal at Governor ................
Page 86 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-ii...
Page 87: System Operation
SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Governor Lever - Upper Governor Lever - Lower Accelerator Governor Compression Spring Spring Fig. 1 Accelerator and Speed Control System SYSTEM OPERATION NOTICE Pedal Box Operation...
Page 88 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Governor Operation Until the vehicle reaches its governed speed, the vehicle will continue to accelerate in relation to the accelerator pedal position.
Page 89 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Removal at Pedal Box Accelerator Cable Adjustment To access the micro switch, remove the rocker panel (4), lift To adjust the accelerator cable, position the cable in the the floor mat (5) and remove the access cover (6) from the accelerator cable bracket at the rear axle so that the throt-...
Page 90: Pedal Box Adjustments
SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PEDAL BOX ADJUSTMENTS To access the micro switch, remove the rocker panel, lift the floor mat and remove the access cover from the floor Tool List Qty.
Page 91 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (Time in seconds / 3600). For example: (300 ft. / 5280) / (13.6 sec. / 3600) = 15 MPH or (100 m / 1000) / (15 sec. / 3600) = 24 KPH.
Page 92 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page F-6...
Page 93: Engine
ENGINE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE ................G - 1 Checking the Oil Level......................G - 1 Changing the Oil.......................G - 1 AIR FILTER INSPECTION/REPLACEMENT ............G - 3 Cleaning the Air Filter Element ..................G - 3 STARTER/GENERATOR BELT TENSION ...............
Page 94 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page G-ii...
Page 95: Powertrain Maintenance
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further engine information, see Engine Shop Rebuild The engine can be operated safely as long as oil is and Service Parts Manual.
Page 96 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Before installing the drain plug clean the area around the drain plug mount with a lint free cloth and inspect the NOTICE drain plug (1) for damage;...
Page 97: Air Filter Inspection/Replacement
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. AIR FILTER INSPECTION/REPLACE- engine until the seal contacts mounting surface of the MENT engine. Then turn the filter 2/3 to 3/4 rotation by hand. Pour in the specified type and amount of oil.
Page 98 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36 kg).
Page 99: Adjusting The Belt
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjusting the Belt generator adjuster until the starter/generator belt can be removed from the drive clutch (Ref. Fig. 12). Remove the Loosen the two pivot bolts (13) and nuts (14) on the starter/ starter/generator pivot bolts (13) and lift starter/generator generator.
Page 100: Spark Plug
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Operation in wet or damp weather or overly fresh cut grass Fouled spark plugs are indicated by a wet, black appear- may result in a variety of debris accumulating and adhering ance.
Page 101: Rocker Cover Removal
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Attach the compression gauge (1) to the adapter (2) and If cylinder compression is lower than 9 kgf/cm (128 psi), insert firmly into the plug hole.
Page 102: Valve Clearance Adjustment
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Valve clearance (when cold): Inlet, Exhaust 0.10 - 0.15 ITEM TORQUE SPECIFICATION mm (0.004 - 0.006 in.). 61 in. lbs (6.9 Nm) Do NOT overtighten.
Page 103: Controls And Wiring
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 16. Remove muffler bolts from muffler stack. NOTICE 17. Remove the passenger side hub cap if equipped and remove the wheel and tire assembly.
Page 104: Drive Clutch Removal
ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Install one rear horizontal and one front bottom engine bolt through the casting and engine and lightly snug in place.
Page 105 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page G-11...
Page 106 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page G-12...
Page 107: Fuel System
FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. GENERAL ........................ H - 2 Early Production Fuel Tank .................... H Late Production Fuel Tank ....................H CARBURETOR OPERATION .................. H - 3 Float System ........................H Pilot Jet System ......................H Main Jet System ......................
Page 108 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-ii...
Page 109 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fuel Filter CARB Canister Fuel Shut Off Valve Fuel Line to Fuel Pump Carburetor Fuel Gauge Sending Unit Fuel Tank Pulse Line to Crankcase Line...
Page 110: General
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL Early Production Fuel Tank Illustrations in this section may include components used on vehicles that comply with requirements of the California Air Resource Board (CARB).
Page 111: Carburetor Operation
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CARBURETOR OPERATION The carburetor consists of four different systems: • Float system • Pilot jet system • Main jet system •...
Page 112: 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. FUEL SYSTEM COMPONENT install the lock washer (7) and nut (6) finger tight. Slide SERVICE AND REPLACEMENT the threaded portion of the housing through the carbure- tor mounted bracket (5) and attach the nuts (3) to the Choke Cable and Housing Removal...
Page 113: Carburetor Removal
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 6 Carburetor Operation Carburetor Removal Carburetor Disassembly Tool List Qty. Tool List Qty. Socket, 12 mm.............1 Socket, 10 mm ............
Page 114: Float Level Alignment
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. and spring (10) can be used to drain the fuel from the Float Chamber Stem bowl without removing the bowl. Float Valve Float...
Page 115: Fuel Pump Replacement
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 9). This movement draws fuel from the fuel tank into the Installation is in the reverse order of disassembly. Be fuel pump chamber.
Page 116: Fuel Tank Removal
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL TANK REMOVAL to the CARB cannister, if the vehicle is equipped with one. Tool List Qty. Early Production Vehicles Wrench, 5/16"...
Page 117: Carbon Canister
FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CARBON CANISTER Tool List Qty. Flat blade screw driver ..........1 Fig. 11 CARB Canister To remove the CARB canister, disconnect the EVAP hose (3) from the CARB cannister (4).
Page 118 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-10...
Page 119: Continuously Variable Transmission (Cvt)
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL ........................J - 1 CLUTCHES ........................J - 1 Drive Clutch ........................J - 1 Driven Clutch ........................J - 2 Increased Load ......................... J - 2 Equilibrium........................
Page 120 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-ii...
Page 121: 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. Driven Clutch Drive Belt Drive Clutch Fig. 1 Continuously Variable Transmission System (CVT) GENERAL moveable sheave inwards. The drive belt is engaged by the clutch sheaves and begins to rotate.
Page 122: Fuel Tank
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driven Clutch The driven clutch sheaves are closed at rest which results in the drive belt being held at the outer diameter of the driven clutch.
Page 123 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use only sockets designed for use with an the spring hanger. Remove the front eyebolt from the impact wrench.
Page 124: Storage
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Drive Clutch Installation Driven Clutch Repair NOTICE Clean both the engine crankshaft and the drive clutch bore.
Page 125 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-5...
Page 126 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-6...
Page 127: Direction Selector
DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ...................K - 2 Removing Direction Selector .................... K - 2 Replacing a Micro Switch ....................K - 2 Shift Cable Adjustment ..................... K - 2 Neutral Lock Operation..................... K - 2 LIST OF ILLUSTRATIONS Fig.
Page 128 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page K-ii...
Page 129 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FOR VEHICLES MANUFACTURED FROM APRIL 2014 Fig. 1 Direction Selector Repair and Service Manual Page K-1...
Page 130: Hardware
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 Replacing a Micro Switch Before removing a suspected faulty micro switch, To replace a micro switch (5), remove the attaching ensure the electrical wires are firmly attached and the hardware.
Page 131 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To activate the direction selector, pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole (3) in the direction selector cam.
Page 132 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page K-4...
Page 133: Electrical
ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS ..................L - 1 STARTER ......................... L - 1 GENERATOR......................L - 1 WIRING ........................L - 1 TESTING IGNITION CIRCUIT................... L - 1 Testing the Magneto ......................L - 4 TESTING STARTING CIRCUIT ................
Page 134 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-ii...
Page 135: Circuits And Controls
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CIRCUITS AND CONTROLS WIRING The electrical system is a 12 volt negative ground sys- tem (Ref. Fig. 1) (Ref. Fig. 2) consisting of: •...
Page 136 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Electrical System Wiring Diagram Repair and Service Manual Page L-2...
Page 137 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Electrical Controller Starter/Generator Voltage Regulator Reverse Solenoid Buzzer Relay Frame Battery Frame To Magneto FOR VEHICLES MANUFACTURED BEFORE 18 AUGUST 2014 Brake Direction Selector Pedal...
Page 138: Testing The Magneto
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (b) Turn over the engine with the starter. Look for a blue electrical arc at the spark plug electrode. 3.
Page 139: Testing Starting Circuit
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TESTING STARTING CIRCUIT (b) Press the accelerator pedal. The DVOM will indi- cate “0” voltage if the solenoid contacts are closed. (c) If “0”...
Page 140: Starter/Generator Removal
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INSPECTION winding (green lead) is not grounded. If it is not, replace the regulator. 1. Inspect the commutator for wear or damage. 8) If the reading is below 14 volts, disconnect the 2.
Page 141: Battery Voltage Test
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 2. Replace any damaged or cracked brush holders or NOTICE brushes worn to less than 11/16" (17 mm) in length or to the line marked on the brush.
Page 142: Storage Of Battery
ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING In order to effectively troubleshoot the circuits that include the horn, lighting, brake/turn signals and Do not overcharge battery. gauges, the technician must be able to use the wiring STORAGE OF BATTERY diagram and a DVOM.
Page 143 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. POWER SUPPLY the fuse is in good condition. No reading indicates a faulty fuse; replace with a good 15 amp fuse. Tool List Qty.
Page 144 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. EARLY PRODUCTION FUSE BLOCK VEHICLES FUSE BLOCK TURN SIGNAL BRAKE LIGHT SWITCH FUSE BLOCK FUSE BLOCK Fig. 10 Accessory Wiring Diagram Repair and Service Manual Page L-10...
Page 145 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LATE PRODUCTION FUSE BLOCK VEHICLES FUSE BLOCK TURN SIGNAL SOL COIL+ BRAKE LIGHT SWITCH PUSH ON 31 FUSE BLOCK FUSE BLOCK Fig.
Page 146 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page L-12...
Page 147: Rear Suspension
REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................M - 1 General..........................M - 1 Shock Absorber Removal ....................M - 1 Shock Absorber Installation ..................... M - 1 Rear Spring Removal ...................... M - 1 Rear Spring Installation ....................
Page 148 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page M-ii...
Page 149 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of dis- assembly except that the shock absorber nuts (1,3) NOTICE must be tightened until the shock absorber bushings (4) expand to the diameter of the shock absorber washer...
Page 150 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Vinyl Cap Front of Vehicle Fig. 1 Rear Suspension Repair and Service Manual Page M-2...
Page 151 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Vinyl Cap Front of Vehicle Fig. 2 Rear Suspension (2+2 Vehicle Only) Repair and Service Manual Page M-3...
Page 152: Rear Axle Removal
REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE REMOVAL the governor and remove the cable. See SPEED CON- TROL section. Remove the linkage rod off of the gover- Tool List Qty.
Page 153 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page M-5...
Page 154 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page M-6...
Page 155: Rear Axle
REAR AXLE TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. NEUTRAL LOCK......................N - 1 REAR AXLE .........................N - 1 Checking the Lubricant Level .................... N - 1 REAR AXLE DISASSEMBLY ..................N - 2 Axle Shaft Removal and Disassembly ................N - 2 Axle Shaft Seal Removal and Replacement ..............
Page 156 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page N-ii...
Page 157: Neutral Lock
REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE For further axle information, see Four Cycle Transaxle Shop Rebuild and Service Parts Manual. The rear axle is provided with a lubricant level check Refer to REAR SUSPENSION section for axle removal.
Page 158: Rear Axle Disassembly
REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE DISASSEMBLY Remove the outer snap ring from the axle tube (Ref. Fig. 3). 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 159: Axle Shaft Seal Removal And Replacement
REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Seal Removal and Replacement Tools List Qty. Internal snap ring pliers ..........1 Seal puller ..............1 Plastic faced hammer..........
Page 160 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page N-4...
Page 161: List Of Illustrations
WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE..................P - 1 Tire Repair ..........................P - 1 Wheel Installation........................P - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tire Installation....................P - 2 Repair and Service Manual Page P-i...
Page 162 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 P-ii...
Page 163: 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 should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section Tools List Qty.
Page 164: 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 With the valve stem to the outside, mount the wheel onto the hub with lug nuts (1). Finger tighten lug nuts (1) as shown.
Page 165 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 P-3...
Page 166 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 P-4...
Page 167: Weather Protection
WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. SUN TOP AND WINDSHIELD ..................Q - 1 Trailering ..........................Q - 1 SUN TOP........................Q - 1 Rear Struts Installation......................Q - 1 Front Strut Installation ......................Q - 1 Sun Top Installation ........................
Page 168 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 Q-ii...
Page 169: Sun Top And Windshield
WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Struts Installation SUN TOP AND WINDSHIELD Using a plastic faced hammer, tap end caps (5) into the top of the rear struts (3, 4) (Ref.
Page 170 WEATHER PROTECTION 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 of Vehicle DETAIL C (FRONT) Driver Side DETAIL D (REAR) DETAIL A DETAIL B Fig.
Page 171: Front Strut Installation
WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP 2+2 Sun Top Installation Tool List Qty. Place sun top onto struts. Plastic faced mallet ............. 1 At front of vehicle, secure sun top loosely with bolts (11), Wrench, 1/2"..............
Page 172 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle 18 19 DETAIL D (Rear) Front of Vehicle DETAIL A DETAIL B (Outside Tubing On Sun Top) Front of Vehicle DETAIL C...
Page 173 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPILT WINDSHIELD To secure windshield when lowered, press edge of wind- shield firmly into lower latches (See Detail B). Tool List Qty.
Page 174: 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 Insert screw (4) through washer (5), rubber grommet (6) and existing hole in front strut. Secure with washer (5) Tool List Qty.
Page 175 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 Q-7...
Page 176 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 Q-8...
Page 177: Troubleshooting
TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. GASOLINE VEHICLE PERFORMANCE ..............R - 1 Starter Does Not Turn ......................R - 1 Starter Turns Slowly ......................R - 1 Starter Rotates but Vehicle Doesn’t Start or Hard to Start..........R - 1 Engine Runs Rough or Loss of Power................R - 2 Poor Low Speed Performance..................R - 3 Poor Midrange or High Speed Performance ..............R - 3...
Page 178 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page R-ii...
Page 179: Gasoline Vehicle Performance
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GASOLINE VEHICLE PERFORMANCE Condition Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and retighten Poor wiring connections...
Page 180: Engine Runs Rough Or Loss Of Power
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Fuel pump faulty Repair or replace Fuel line clogged or clamp loose Clean or replace if required Cracked or broken fuel line Replace with new hose Main jet blocked...
Page 181: Poor Low Speed Performance
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR LOW SPEED Plugged gas tank vent Clean or repair PERFORMANCE Choke on Push choke in Carburetor float level incorrect Check/Replace float Clutches not shifting out...
Page 182: Repeated Spark Plug Fouling
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction REPEATED SPARK PLUG Wrong spark plug type Replace with correct spark plug FOULING Wrong spark plug gap Check and adjust if required Faulty magneto Check and replace if required...
Page 183: Erratic, Surging, Or Sudden Change In Governed Speed
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction ERRATIC, SURGING, OR SUDDEN Damaged governor spring Replace CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm...
Page 184: Operation And Application
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction OPERATION AND APPLICATION Engine not reaching full temperature Increase run time intervals to build higher cylinder temperature Continuous use at 1/4 throttle or less at low Instruct operator...
Page 185: Poor High Speed Operation
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR HIGH SPEED OPERATION Fuel pump faulty Replace fuel pump Loose main jet Tighten main jet Incorrect fuel level in float bowl Adjust float Dirt in fuel tank or hoses...
Page 186: Rectification Is Imperfect
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction RECTIFICATION IS IMPERFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough...
Page 187: Steering Pulls To One Side
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure Dragging wheel brakes Service brake system Suspension component failure Repair...
Page 188: Neither Wheel Locks When Park Brake Is Latched
TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction NEITHER WHEEL LOCKS WHEN Incorrect cable adjustment Return to factory specification PARK BRAKE IS LATCHED. (NOTE: Excessive brake pedal free travel Adjust per manual AT FULL SPEED THE WHEELS MAY...
Page 189 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page R-11...
Page 190 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page R-12...
Page 191: General Specifications
GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. TXT GAS - FLEET.....................S - 1 TXT GAS - FREEDOM ....................S - 2 TXT GAS - SHUTTLE 2+2..................S - 3 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions (Fleet) ...................S - 4 Fig.
Page 192 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page S-ii...
Page 193 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: TXT FLEET GOLF CAR TYPE: GASOLINE POWERED FLEET GOLF CAR MODEL YEAR: 2014 Part No:. 625111 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki...
Page 194 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: TXT FREEDOM GOLF CAR TYPE: GASOLINE POWERED FREEDOM GOLF CAR MODEL YEAR: 2014 Part No:. 625113 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki...
Page 195 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE™ 2+2 TXT TYPE: GASOLINE PERSONNEL CARRIER MODEL YEAR: 2014 Part No:. 625115 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki Overhead valve Fixed float bowl with remote pulse fuel pump...
Page 196 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 67.5 in. (171 cm) 46.5 in. (118 cm) Front 4.5 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance...
Page 197 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 67.5 in. (171 cm) 46.5 in. (118 cm) Front 4.5 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance...
Page 198 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 76 in. (193 cm) 46.5 in. (118 cm) Front 4.5 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance...
Page 199 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% GRADE or 14 25% GRADE or 14 MAX TURNING CLEARANCE DIAMETER 19 ft.
Page 200 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page S-8...
Page 201 Be aware that a vehicle requiring repair indicates that the vehi- NOTICE cle is no longer functioning as designed and therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, removing or replac- Read the following warnings before attempting to operate the ing any components that are not operating correctly, take time vehicle: to consider the safety of yourself and others around you should...
Page 202 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.

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