Ezgo 611103 Service & Repair Manual
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Ezgo 611103 Service & Repair Manual

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RXV ELECTRIC SERVICE & REPAIR
611103
ISSUED FEBRUARY 2009
REVISED JULY 2010

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  • Page 1 RXV ELECTRIC SERVICE & REPAIR 611103 ISSUED FEBRUARY 2009 REVISED JULY 2010...

  • Page 2: Safety

    SA FE TY 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 TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124 SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 INTERNATIONAL: SALES PHONE: 001-706-798-4311, FAX: 001-706-771-4609 E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852...

  • Page 4: General Information

    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 MODELS ............................i GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D ELECTRONIC SPEED CONTROL (AC MOTOR)................E FRONT SUSPENSION ........................
  • Page 6 TABLE OF CONTENTS Notes: Page iv Repair and Service Manual...

  • Page 7: Safety Information

    SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with proce- dures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 all Notices, Cautions and Warnings. Notes: Page viii Repair and Service Manual...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 TOWING ........................A - 2 PARKING BRAKE ....................A - 3 SERVICING VEHICLE ....................A - 3 ROUTINE MAINTENANCE ..................A - 3 REAR AXLE......................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page A-ii Repair and Service Manual...

  • Page 13: General Information & Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. Thank you for purchasing this vehicle. This repair man- Serial Number ual contains information that will assist you in repairing and maintaining this vehicle.

  • Page 14: Fig. 5 Run Tow Switch

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. TOWING Never use ropes or chains to tow vehicle(s). Tow bars are available from the E-Z-GO Service Parts Depart- ment.

  • Page 15: Parking Brake

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. With the switch in the ‘TOW’ or (on CE vehicles) mounting holes with the holes in the body, push the cen- position and the key in ’N’.

  • Page 16: Vehicle Cleaning And Care

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. REAR AXLE Occasional cleaning and waxing with non-abrasive prod- ucts designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the painted The only maintenance required for the first five years or surfaces.

  • Page 17: Hardware

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. When transporting vehicle below highway speeds, fied by 6 marks on the head. Metric hardware is marked check for tightness of hardware and cracks in sun top at on the head with 8.8 or 10.9.

  • Page 18: Tires

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • Page 19 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page A-7...
  • Page 20 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page A-8 Repair and Service Manual...
  • Page 21 SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTES, CAUTIONS AND WARNINGS ..............B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE................B - 1 GENERAL MAINTENANCE..................B - 1 BEFORE SERVICING THE VEHICLE............... B - 1 Additional Warnings ..................
  • Page 22 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page B-ii Repair and Service Manual...

  • Page 23: Modifications To Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. NOTICES, CAUTIONS, WARNINGS Always use the appropriate tools listed in the tool list and wear approved safety equipment. AND DANGERS MODIFICATIONS TO VEHICLE Throughout this manual, the following NOTICES, CAU-...

  • Page 24: Safety

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Always turn the key switch to ‘OFF’ and acid solution which can cause severe burns remove the key before disconnecting a live to the skin and eyes.
  • Page 25 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ATTACH NEGATIVE WIRE FROM ACCESSORY TO (-) BATTERY TERMINAL ATTACH POWER WIRE FROM ACCESSORY TO (+) BATTERY TERMINAL Fig.
  • Page 26 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RESISTOR CONTROLLER CHARGER RECEPTACLE BATTERY STRAP BATTERY HOLD DOWN BATTERY TRAY Fig. 2 Batteries, Charger Receptacle & Controller BATTERY REMOVAL &...
  • Page 27 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 2. Using an insulated wrench, disconnect the main nega- tive (-) battery cable, BL-. 3. Using an insulated wrench, disconnect the main posi- tive (+) battery cable, BL+.

  • Page 28: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. LIFTING THE VEHICLE Hex Nut Washer Tool List Qty. Battery Strap Floor Jack ..............1 Jack Stands ..............4 Wheel Chocks..............4 Some servicing operations may require the front, rear or Battery Hold Down the entire vehicle to be raised.
  • Page 29 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. To raise only the front or rear of the vehicle, place the wheel chocks in front and behind the rear wheels. The jack may be left under the center front of the frame while the front end of the vehicle is on the jack stands.
  • Page 30 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page B-8 Repair and Service Manual...

  • Page 31: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. BODY ........................C - 1 General ......................C - 1 BODY COMPONENT REPLACEMENT ..............C - 2 Front Bumper ....................C - 2 Rocker Panels....................C - 2 Floor Mat......................C - 2 Cowl and Instrument Panel ................
  • Page 32 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page C-ii Repair and Service Manual...

  • Page 33: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. INSTRUMENT PANEL INSTRUMENT PANEL TRIM SEAT BACK COWL SWEATER BASKET ASSEMBLY FLOOR MAT REAR BODY BUMPER UPPER ROCKER PANEL BAG WELL LOWER ROCKER PANEL STRUT COVER...

  • Page 34: Body Component Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. BODY COMPONENT REPLACE- Rocker Panels (Ref. Fig. 4) MENT Tool List Qty. Torx bit, T-45IP.............1 The body components can be replaced by removing the Ratchet ................1 securing hardware, replacing the component and install- Torque Wrench, in.

  • Page 35: Cowl And Instrument Panel

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Using an insulated wrench, disconnect the bat- tery cable at the negative (-), BL-, battery ter- minal. If the vehicle is equipped with a sun top and windshield; remove these items before proceeding.

  • Page 36: Front Splash Guard

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 5. Remove three self threading nuts (20) securing the Front Splash Guard (Ref. Fig. 9) cup holder assembly (15) to the instrument panel. Tool List Qty.

  • Page 37: Sweater Basket

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 10 Golf Car Rear Body, Sweater Basket, Rear Bumper & Fender Liner Sweater Basket (Ref. Fig. 10) ITEM TORQUE SPECIFICATION Tool LIst...

  • Page 38: Fender Liner

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 6. Remove two torx screws (33) securing each hinge plate (32) along the front edge of the rear body then ITEM TORQUE SPECIFICATION remove both hinge plates.

  • Page 39: Rear Facing Seat & Foot Rest

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Installation is in the reverse order of removal. Replace any worn or damaged hardware with new as ITEM TORQUE SPECIFICATION required.
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 3. Loosen the torx head bolts (23) and nuts (22) (Ref. Fig. 15) that secure the seat back mounting brackets and hip restraint to the seat back support (14).
  • Page 41 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. rear of the vehicle completely. Once the bolts are removed the foot rest assembly (29) may be removed ITEM TORQUE SPECIFICATION from the vehicle by sliding it backwards and off of the...

  • Page 42: Floorboard

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Floorboard Tool LIst Qty. Torx Bit, T-50 ............... 1 Ratchet ................ 1 Insulated Wrench 9/16" ..........1 Torque Wrench, ft. lbs..........1 Before the floorboard can be removed the lower and upper rocker panels, the floor mat, the pedal cover, accel- erator and brake pedal assemblies, the instrument panel...

  • Page 43: Cleaning

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. BODY CARE MAINTENANCE 3-M 39009 Polishing Pad Glaze (for dark colors) ...1 qt. 3-M 05995 Polishing Pad Glaze (for light colors) ...1 qt. Coarse Cut Foam Compound Pad for Buffer....1 Cleaning Fine Cut Polish Pad for Buffer ........1...

  • Page 44: Larger Scratches

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Sandpaper, 1500 Grit wet or dry........1 the can for a minimum of one minute to mix the paint and achieve the best color match.
  • Page 45 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page C-13...
  • Page 46 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page C-14 Repair and Service Manual...

  • Page 47: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ................... D - 1 Tire Repair ....................... D - 1 Wheel Installation..................... D - 2 LIST OF ILLUSTRATIONS Fig. 1 Tire Mounting & Cross Sequence for Tightening ......... D - 2 Repair and Service Manual Page D-i...
  • Page 48 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page D-ii Repair and Service Manual...
  • Page 49 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. turf. For vehicles being used on paved or hard surfaces, WHEEL AND TIRE SERVICE tire inflation pressure should be in the higher allowable Tools List Qty.

  • Page 50: Wheel Installation

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. the tapered end is against the wheel rim; and tighten in a Wheel Installation ‘cross sequence’ pattern; then, tighten lug nuts to specified torque in 20 ft.
  • Page 51 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page D-3...
  • Page 52 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page D-4 Repair and Service Manual...
  • Page 53 ELECTRONIC SPEED CONTORL (AC MOTOR) TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL......................... E - 1 Accelerator Pedal Assembly ................E - 2 Solenoid Replacement ..................E - 3 Controller ......................E - 5 LIST OF ILLUSTRATIONS Fig.

  • Page 54: Electronic Speed Control (Ac Motor)

    ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page E-ii Repair and Service Manual...
  • Page 55 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Controller Reverse Warning Indicator Run/Tow Switch Accelerator Pedal Pedal Cover Fig. 1 Electronic Speed Control GENERAL The recommended method for removing christmas tree...
  • Page 56 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Pedal Cover Christmas Tree Rivet Fig. 3 Pedal Cover Accelerator Pedal Assembly 2. Remove pedal cover. Tool List Qty.
  • Page 57 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Solenoid Replacement Notched Pry Bar ............1 Ratchet ................1 Torque Wrench, in. lbs..........1 Torx Bit, T-45 IP ............1 Wire Cutters..............1 Wire Stripper ..............1 Wire Terminal Crimping Tool........1...
  • Page 58 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. the ring terminals and crimp both ends. Splash Shield 1/2” (1.3 cm) Ring terminals #10 stud, 18/21 gauge Connecting stripped wires to Ring Terminal Solenoid...
  • Page 59 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. the back terminal of the solenoid (4) and the white Wrench, 15 mm ............1 wire (12) to the resistor, secure in place using a hex Notched Pry Bar ............1 nut (5).
  • Page 60 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 5. Disconnect the Red wire from the controller B+ termi- lifting up on the locking tab and pulling the connector nal to the back terminal of the solenoid.
  • Page 61 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Make sure that the red wire (17) and black wire (18) from the wire harness to the solenoid are located as shown.
  • Page 62 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page E-8 Repair and Service Manual...

  • Page 63: Front Suspension

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. MAINTENANCE ......................F - 1 Tire Wear Diagnosis..................F - 2 Wheel Alignment ....................F - 2 Hub Assembly ....................F - 3 Spindle Assembly..................... F - 3 Struts .......................
  • Page 64 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page F-ii Repair and Service Manual...

  • Page 65: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. STEERING WHEEL STEERING COLUMN ASSEMBLY HUB ASSEMBLY INTERMEDIATE SHAFT PASSENGER SIDE SPINDLE ASSEMBLY TIE ROD END STRUT ASSEMBLY DRIVER’S SIDE SPINDLE ASSEMBLY A-ARM ASSEMBLY...

  • Page 66: Wheel Alignment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. of the tread. Wear on either side of a correctly inflated the wheels in line with the body of the vehicle it will tire indicates a tire that is out of alignment.

  • Page 67: Hub Assembly

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 6. To adjust the wheel alignment, loosen the tie rod jam mended that locking nuts be replaced after a maxi- nut (1) and turn the tie rods and equal number of turns mum of 5 removals until the correct alignment is achieved.

  • Page 68: Struts

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Struts (Ref Fig. 5) Tool List Qty. Wrench, 15mm ............1 Socket, 15mm Deep-Well..........1 Ratchet ................

  • Page 69: A-Arm Assembly

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Tie Rod End Tie Rod End Nut Fig. 5 Hub, Spindle, Strut and A-Arm Assemblies A-Arm Assembly 2.

  • Page 70: Clipboard And Steering Wheel

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ing a plastic faced hammer against the steering wheel retaining nut. Strike the plastic faced hammer sharply ITEM TORQUE SPECIFICATION with a ball peen hammer.
  • Page 71 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. clipboard with a new one. 11. Carefully press the top two tabs into the matching Steering Column slots in the steering wheel, then press the bottom two Assembly...

  • Page 72: Rod End / Ball Joint

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. yoke onto the shaft. Do not tighten the upper cross Inspect rod end or ball joint by grasping the end and bolt and nut.
  • Page 73 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. spindle arm. steering box (16) to the vehicle frame. 4. Repeat steps 3 through 5 for the remaining tie rod 9.
  • Page 74 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page F-10 Repair and Service Manual...

  • Page 75: Motor & Motor Brake

    MOTOR & MOTOR BRAKE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL.........................G - 1 Motor........................ G - 1 Motor Brake ..................... G - 3 Bearing Encoder ....................G - 4 LIST OF ILLUSTRATIONS Fig. 1 Motor ......................G - 1 Fig.
  • Page 76 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page G-ii Repair and Service Manual...
  • Page 77 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Wires to Controller Wires to Motor Motor Brake Harness Fig. 1 Motor GENERAL 3. With an insulated wrench, disconnect the negative (-) battery, BL-, cable from the battery.
  • Page 78 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. recent motor has only one set of wires routed from Fig. 3 Motor Connections (Later Vehicles) under the housing.
  • Page 79 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Motor Brake The motor brake may be removed with the motor still in the vehicle or the motor and motor brake can be removed from the vehicle as a unit.
  • Page 80 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 7 Motor Brake DO NOT drop the brake assembly. Dropping or hitting the brake assembly will damage it. INSTALLATION 1.
  • Page 81 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Bearing Encoder gage the shaft from the encoder bearing. 9. Remove four long hex head bolts (L) and washers (M) Motor brake and Motor need to be removed from the from the motor, retain the bolts and washers for use in axle shaft before removing the encoder (For the removal...
  • Page 82 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. shown below. 5. Tighten all the hardware to the specified torque value. 6. Re-install motor end cap back to the stator and secure with the bolts (L) and washers (M) (removed in step 9 under removal section), tighten to specified torque value.
  • Page 83 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page G-7...
  • Page 84 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page G-8 Repair and Service Manual...
  • Page 85 BATTERIES & CHARGING TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. SAFETY ........................H - 1 BATTERY ......................... H - 2 BATTERY MAINTENANCE ..................H - 2 At Each Charging Cycle ................... H - 2 Monthly ......................H - 2 Electrolyte Level and Water ................
  • Page 86 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page H-ii Repair and Service Manual...

  • Page 87: Batteries & Charging

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RESISTOR CONTROLLER CHARGER RECEPTACLE BATTERY STRAP BATTERY HOLD DOWN ACCESSORY HARNESS BATTERY TRAY Fig. 1 Batteries and Charging Receptacle SAFETY starting work on the vehicle.

  • Page 88: Battery

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Always wear a safety shield BATTERY MAINTENANCE or approved safety goggles Tool List Qty. when adding water or charging batteries.

  • Page 89: Cleaning Batteries

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. This level will leave approximately 1/4" - 3/8" (6 - 10 Automatic watering devices such as the one included in mm) of space between the electrolyte and the vent tube.
  • Page 90 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. tion to the batteries special attention should be paid to lugs provided. Do not attempt to lift a battery metallic components adjacent to the batteries which with only one strap, this may break lifting lugs should also be sprayed with the baking soda solution.
  • Page 91 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Hex Nut Washer 8. Check the area surrounding the battery tray for corro- sion. If any corrosion is found, it should be immedi- Battery Strap ately removed with a putty knife and a wire brush (for metal surfaces) or a plastic bristle brush (for plastic...

  • Page 92: Prolonged Storage

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. BL+ Red Wire Black Wire from from Solenoid Charger Receptacle BL- Black Wire from Controller Black Wire from Harness Red and Grey Wires from Charger Receptacle...

  • Page 93: Battery Charging

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. • 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 tripping over the cord set.

  • Page 94: Using A Hydrometer

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. specific gravity of the electrolyte. The greater the con- C). High quality hydrometers are equipped with an inter- centration of sulfuric acid, the more dense the electro- nal thermometer that will measure the temperature of the lyte becomes.
  • Page 95 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 12 Hydrometer Temperature Correction Repair and Service Manual Page H-9...
  • Page 96 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page H-10 Repair and Service Manual...

  • Page 97: Battery Charger

    BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘I’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................I - 1 PORTABLE CHARGER INSTALLATION ..............I - 1 UNDERSTANDING THE CHARGER ................I - 2 LED DISPLAY INFORMATION...................I - 2 LED Operation Codes ..................I - 2 LED Fault Codes....................I - 2 MAINTENANCE INSTRUCTIONS ................I - 2 LIST OF ILLUSTRATIONS...
  • Page 98 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page I-ii Repair and Service Manual...
  • Page 99 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. CHARGER DESCRIPTION cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way –...

  • Page 100: Maintenance Instructions

    BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. LED Fault Code: NOTICE RED FLASH: Light turns on briefly, but does not Looping the DC cord through the steering wheel when charg- flash after that - check for valid AC voltage.
  • Page 101 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page I-3...
  • Page 102 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page I-4 Repair and Service Manual...

  • Page 103: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL........................J - 1 Brake Pedal Assembly ..................J - 1 LIST OF ILLUSTRATIONS Fig. 1 Brake Pedal....................J - 1 Fig. 2 Christmas Tree Rivet Removal ..............J - 1 Fig. 3 Pedal Cover....................J - 2 Fig.
  • Page 104 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page J-ii Repair and Service Manual...
  • Page 105 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Accelerator Pedal Brake Pedal Pedal Cover Fig. 1 Brake Pedal GENERAL The recommended method for Christmas Tree removing christmas tree rivets is Fastener For information on the Motor Brake see the Motor sec- to slide a notched pry bar under...
  • Page 106 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Using an insulated wrench, disconnect the bat- tery cable at the negative (-), BL-, battery ter- minal. To access the pedal assembly, remove the upper rocker panels, the lower rocker panels and the floormat (refer to page C2 for removal of rocker panels and floormat).
  • Page 107 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 12. Reconnect electrical harness to rotary position sensor (8) and to the brake switch (10). 13. Place pedal assembly (5) in position on the floorboard and secure with four socket head hex screws (6).
  • Page 108 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page J-4 Repair and Service Manual...

  • Page 109: Electrical Components & Wiring

    ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. MAIN WIRING HARNESS..................K - 1 Replacing the Main Wiring Harness ..............K - 1 REPLACING ELECTRICAL COMPONENTS............K - 6 Run/Tow Switch ....................K - 6 Reverse Warning Indicator................
  • Page 110 ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO. Fig. 27 Turn Signal Bulb Replacement ..............K - 14 Fig. 28 Trim Panel Hardware ................K - 15 Fig. 29 Head Light Switch ..................K - 15 Fig.
  • Page 111 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. DIAGNOSTIC PLUG INSTRUCMENT PANEL WIRING HARNESS MOTOR CHARGER RECEPTACLE BATTERY BANK Fig. 1 Main Electrical Harness MAIN WIRING HARNESS To access the main wiring harness for replacement it is necessary to remove the upper and lower rocker panels,...
  • Page 112 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. instrument panel along the upper edge then grip the troller heat sink, raise splash shield and move it out of ball holder with both hands and pull away from the the way.
  • Page 113 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. yellow wire (21) from wire harness. Remove two Splash Shield smaller hex nuts (28) from the small terminal posts and disconnect black wire (23) and red wire (24) from the wire harness.
  • Page 114 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 28. NEW WIRE HARNESS: Disconnect the connectors of from the main wire harness connector as shown in motor brake (31), the temperature sensor (32) from detail below.
  • Page 115 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 12 Cup Holder i) Route the wires (14) for the key switch and the optional fuel gauge/state of charge meter through the guide (15) on the front splash shield and the connectors for the key switch and the optional fuel...
  • Page 116 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Sensor Resistor Heatsink Red Wire from Solenoid to Red Wire from Controller B+ Solenoid to Controller B+ Controller Fig.
  • Page 117 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. the adaptor harness to the main wire harness con- nector as shown in detail below. Adaptor Main Wire Harness Harness...
  • Page 118 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 34. Replace the controller splash shield and secure it to 6. Remove the upper nut and seal (7) from the new the body with two Torx head screws.
  • Page 119 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. battery terminal using an insulated wrench. 2. Remove three plastic rivets securing the controller splash shield; two on the rear body and one from con- troller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires.
  • Page 120 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Repair and Service Manual Page K-10...
  • Page 121 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. BLK/WHT RED/WHT LT.BLUE Fig. 25 Main Wiring Harness Repair and Service Manual Page K-11...
  • Page 122 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 26 Accessory Wiring Harness Repair and Service Manual Page K-12...
  • Page 123 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Headlight/Turnsignal Relay Fuse Holders Accessory Harness Horn Front Splash Shield Horn Button Brake Light/Turnsignal Rear Splash Shield Fig.
  • Page 124 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 5. Remove the three fuse holders from the controller splash shield. 6. Disconnect the tail light wiring connectors. 7.
  • Page 125 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. REPLACING ELECTRICAL ACCESSO- remove. RIES 2. Disconnect the accessory harness from the light bulb. 3. Connect the accessory harness to the light bulb. 4.
  • Page 126 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Turn Signal Switch Replacement Make sure that the vehicle key switch is in the ’OFF’ position and the key has been removed.
  • Page 127 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Tail Light Assembly Replacement Horn Button Replacement Make sure that the vehicle key switch is in the ’OFF’ Make sure that the vehicle key switch is in the ’OFF’...
  • Page 128 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page K-18 Repair and Service Manual...
  • Page 129 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Repair and Service Manual Page K-19...
  • Page 130 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page K-20 Repair and Service Manual...

  • Page 131: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. GENERAL ........................L - 1 SHOCK ABSORBER ....................L - 1 REAR LEAF SPRING ....................L - 2 LIST OF ILLUSTRATIONS Fig. 1 Rear Suspension ..................L - 1 Fig. 2 Shock Absorber ..................L - 2 Fig.
  • Page 132 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page L-ii Repair and Service Manual...
  • Page 133 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Frame Shock Absorber Shackle Leaf Spring Leaf Spring bracket Rear Axle Fig. 1 Rear Suspension GENERAL SHOCK ABSORBER (Ref Fig.
  • Page 134 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 7. Install the hex head bolt (5) and washer (4) through ing any repair procedure. Never work on a the lower end of the shock (3) into the mounting vehicle that is supported by a jack alone.
  • Page 135 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. (16) can now be removed from the vehicle. 14. Align the pin on the leaf spring (16) with the hole in the axle bracket and install the leaf spring plate (2) on to 6.
  • Page 136 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page L-4 Repair and Service Manual...

  • Page 137: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE...................M - 1 Checking Torque to Rotate ................M - 1 Replacing the Lubricant ...................M - 1 Fill Procedure For Axles Fitted With Fill Plugs ..........M - 2 REAR AXLE DISASSEMBLY ...................M - 2 Rear Hub......................M - 2 Axle Shaft, Bearing and Seal Removal and Disassembly ........M - 3...
  • Page 138 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page M-ii Repair and Service Manual...

  • Page 139: Rear Axle Maintenance

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Motor Motor Brake Axle Fig. 1 Rear Axle clockwise motion. If the axle hub moves at 60 ft. lbs or REAR AXLE MAINTENANCE less replace the differential.

  • Page 140: Fill Procedure For Axles Fitted With Fill Plugs

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. pump. Fill with 25 oz. of Mobile 424 lubricant slowly and replace the fill plug. To reduce the possibility of personal injury, fol- low the lifting procedure in Section B of this manual.

  • Page 141: Rear Hub

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. behind the front wheels and check the stability of the vehicle on the jack stands before start- ITEM TORQUE SPECIFICATION ing any repair procedure.
  • Page 142 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 7. Install the inner snap ring. Bearing Separator To prevent damage to the oil seal, lightly coat the axle shaft with bearing grease and support the shaft during installation.
  • Page 143 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page M-5 Repair and Service Manual...
  • Page 144 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page M-6 Repair and Service Manual...

  • Page 145: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD................... N - 1 WINDSHIELD......................N - 2 GOLF CAR TOP ....................... N - 2 2 + 2 TOP........................N - 4 LIST OF ILLUSTRATIONS Fig. 1 Top and Windshield ..................N - 1 Fig.
  • Page 146 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page N-ii Repair and Service Manual...

  • Page 147: Top And Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Sun top Windshield Fig. 1 Top and Windshield TOP AND WINDSHIELD Trailering Personal injury to occupants of other highway vehicles may occur if vehicle and contents are The top does not provide protection from roll not adequately secured to the trailer.
  • Page 148 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. WINDSHIELD ITEM TORQUE SPECIFICATION Tool List Qty. Torx Bit, 50 IP .............. 1 124 - 142 in. lbs (14 - 16 Nm) Ratchet ................
  • Page 149 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. the vehicle. Align the mounting holes in each strut with the matching holes in the sweater basket and seat back support, install the hex head bolts (5) and nuts DO NOT over tighten fasteners.
  • Page 150 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. If vehicle is equipped with a windshield remove it before 2 + 2 TOP working with the top. Tool List Qty.
  • Page 151 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 3. Lift the top (3) off of the struts and set it aside. 4. Remove the access cover (1) by sliding a flat screw- ITEM TORQUE SPECIFICATION driver under the edge of it and prying it away from the...
  • Page 152 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page N-6 Repair and Service Manual...
  • Page 153 TROUBLESHOOTING AND DIAGNOSTICS TROUBLESHOOTING AND DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘O’ SECTION TITLE PAGE NO. HOW TO USE THE HAND HELD DIAGNOSTIC UNIT ..........O - 1 MENUS ........................O - 1 Diagnostics Report................... O - 1 Battery and Warranty ..................O - 3 Error Messages....................
  • Page 154 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page O-ii Repair and Service Manual...

  • Page 155: How To Use The Hand Held Diagnostic Unit

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. HOW TO USE THE HAND HELD DIAG- HIGHLIGHTED MENU ITEM MENU TITLE NOSTIC UNIT SERVICE MENU The E-Z-GO Hand Held Diagnostic Unit, P/N 606215 is DIAG REPORT used for troubleshooting, tuning, programming and the...
  • Page 156 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. motor by the pedal position. DIAG REPORT 9. MOTOR ACTUAL SPEED: displayed as VOLTAGE ’ACTSPEED’, the next line displays the actual motor 49.28 V speed in RPMs.

  • Page 157: Battery And Warranty

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 16. SOLENOID: displayed as ’SOLENOID’, the next line displays the solenoid state as ’ON’ or ’OFF STATUS SOC BATT ’...

  • Page 158: Error Messages

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ERROR MESSAGES SETTING TOP SPEED AND PERFORMANCE PROFILES (read and write) To change the speed, scroll down the list and highlight SERVICE MENU one of the vehicles;...
  • Page 159 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key to ’OFF’ and then back ’ON’. If car does not run proceed to step 2.
  • Page 160 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 161 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Check both +5V and 5V GND to chassis, 1.
  • Page 162 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key switch to ’OFF’ and unplug 23 pin connector from controller.
  • Page 163 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 164 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Measured heat sink temper- 1. Allow time to cool. ature is greater than 85°C Heat Sink Temp (185°F) but less than 115°C...
  • Page 165 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. If this occurs with the key switch turned on: Throttle switch is closed at key start, the throttle switch must be...

  • Page 166: Troubleshooting

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. over time, the obvious place to start is at the headlight DIGITAL VOLT OHM METER that is not functioning. if power is present at the connec- A typical DVOM (digital volt ohm meter) is shown.

  • Page 167: Power Supply

    TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. POWER SUPPLY Tool List Qty. DVOM................1 Check For Loose or Bare Wires Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame.
  • Page 168 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page O-14 Repair and Service Manual...
  • Page 169 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................P - 1 GROUND SYSTEMS ....................P - 1 LIGHTINIG PROTECTION REQUIREMENTS............P - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........P - 1 GROUND NETWORK REQUIREMENTS..............
  • Page 170 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page P-ii Repair and Service Manual...

  • Page 171: Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.

  • Page 172: External Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. REVISION: GS-726-006 TITLE: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 6.

  • Page 173: 10. Equipment Fault And Personal Safety System

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 trating or structurally damaging the building.
  • Page 174 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page P-4 Repair and Service Manual...

  • Page 175: Specifications

    SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. RXV ELECTRIC FLEET VEHICLE SPECIFICATIONS ..........Q - 1 RXV ELECTRIC FREEDOM VEHICLE SPECIFICATIONS........Q - 2 RXV ELECTRIC SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS ....... Q - 3 LIST OF ILLUSTRATIONS Fig.
  • Page 176 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page Q-ii Repair and Service Manual...
  • Page 177 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RXV ELECTRIC - FLEET VEHICLE SPECIFICATIONS Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate) BATTERIES Solid state, 230 Amp capacity SPEED CONTROLLER...
  • Page 178 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RXV ELECTRIC - FREEDOM VEHICLE SPECIFICATIONS Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate) BATTERIES Solid state, 230 Amp capacity SPEED CONTROLLER...
  • Page 179 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RXV ELECTRIC - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS Four 12 Volt deep cycle (70 minute minimum, 140 Amp-Hour discharge rate) BATTERIES Solid state, 230 Amp capacity SPEED CONTROLLER...
  • Page 180 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 68.50” (174 cm) 68.50” (174 cm) 45.7” (116 cm) 45.7” (116 cm) 65.7” (167 cm) 65.7” 35.5” (90 cm) (167 cm) 94.5”...
  • Page 181 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 74” (188 cm) 45.7” (116 cm) 65.7” (167 cm) 35.5” (90 cm) 105.5” (268 cm) 38” (97 cm) 47”...
  • Page 182 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RECOMMENDED MAX RAMP 25% GRADE OR 14° MAX RECOMMENDED MAX SIDE TILT 25% GRADE OR 14° MAX Fig. 3 Vehicle Incline Specifications and Turning Diameter Repair and Service Manual Page Q-6...
  • Page 183 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. .5" 6.0" Ø .50" (1.27cm) (15.4cm) (1.27cm) 4.0" (10.15cm) 1.5" (3.9cm) Ø .24" (.61cm) 5.0" (12.7cm) 1.378" 7.75" (19.7cm) (3.5cm) 10.5"...
  • Page 184 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page Q-8 Repair and Service Manual...
  • Page 185 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 compo- nent failures or the manner in which each component To prevent personal injury or death, ob-...
  • Page 186 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department...

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