E-Z-GO RXV GASOLINE Service & Repair Manual
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E-Z-GO RXV GASOLINE Service & Repair Manual

Gasoline powered golf cars & personal vehicles; 611104
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RXV GASOLINE SERVICE & REPAIR
611104
ISSUED FEBRUARY 2009
REVISED APRIL 2010

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Summary of Contents for E-Z-GO RXV GASOLINE

  • Page 1 RXV GASOLINE SERVICE & REPAIR 611104 ISSUED FEBRUARY 2009 REVISED APRIL 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 prevent 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: 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 Owner’s Manual and Service Guide...

  • 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 WHEELS AND TIRES ........................D FRONT SUSPENSION AND STEERING ..................E SPEED CONTROL........................... F ENGINE............................
  • Page 6 TABLE OF CONTENTS Notes: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    S A F E T Y I N F O R M ATI O N This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.

  • Page 8: General Operation

    S A F E T Y I N F O R M AT I O N nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi- nances. Refer to GENERAL SPECIFICATIONS for vehicle seating capacity. 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 S A F E T Y I N F O R M ATI O N • Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. •...
  • Page 10 S A F E T Y I N F O R M AT I O N 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 LOCATION ................. A - 1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY........ A - 1 SERVICING THE VEHICLE ..................A - 2 TOWING ........................A - 2 ROUTINE MAINTENANCE ..................
  • 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 Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings Thank you for purchasing this vehicle. This repair manu- Serial Number al contains information that will assist you in repairing and maintaining this vehicle.

  • Page 14: Servicing The Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. starter/generator may not be adequate to maintain bat- A vehicle requiring repair indicates the vehicle is no tery charge.

  • Page 15: Routine Maintenance

    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 DO NOT tow more than three vehicles at a To activate the direction selector, pull the neutral lock time.

  • Page 16: Vehicle Cleaning And Care

    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. The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water and mild detergent is re- To prevent severe injury or death resulting quired to preserve the painted surfaces.

  • Page 17: Winter Or Prolonged Storage

    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 HARDWARE Secure the vehicle and contents. Never ride on the vehicle being transport- Periodically, the vehicle should be inspected for loose fasteners.

  • Page 18: Brakes

    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. 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 19 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 REMARKS Wiring - loose connections, broken or missing insula- tion Carburetor Linkage - attachment C&A C&A C&A...
  • Page 20 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. REMARKS Throttle/Governor Linkage - operation & governed speed Air Filter Element - check & replace as necessary Drive Belt - cracks, frayed, excessive wear Fig.
  • Page 21 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: Repair and Service Manual Page A-9...
  • Page 22 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-10 Repair and Service Manual...

  • Page 23: Safety

    SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTES, CAUTIONS AND WARNINGS ................1 IMPORTANT SAFETY WARNING ..................1 MODIFICATIONS TO VEHICLE..................1 GENERAL MAINTENANCE....................1 BEFORE SERVICING THE VEHICLE................1 Battery Removal and Installation................2 LIFTING THE VEHICLE ....................3 LIST OF ILLUSTRATIONS Fig.
  • Page 24 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 25: Modifications To Vehicle

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. NOTICES, CAUTIONS AND WARN- Always use the appropriate tools listed in the tool list and wear approved safety equipment. INGS MODIFICATIONS TO VEHICLE Throughout this manual, the following NOTICES, CAU-...
  • Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Always turn the key switch to ‘OFF’ and an explosion and severe personal injury or remove the key before disconnecting a live death.

  • Page 27: Lifting The Vehicle

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. in front and behind the wheels not being NOTICE raised. Use extreme care since the vehicle is extremely unstable during the lifting process. In the following text, there are references to removing/installing bolts etc.
  • Page 28 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Lower the jack and test the stability of the vehicle on the two jack stands. Place the jack at the center of the front axle. Raise the vehicle and position jack stands under the frame cross- member as indicated.
  • Page 29 SAFETY 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 B-5...
  • Page 30 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-6 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. If the vehicle is equipped with a sun top and windshield; remove these items before proceeding. Instructions for removal of the sun top and windshield are located in the Weather Protection section of this manual.

  • 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. splash guard (21) to vehicle.(Ref. Fig. 2) Reassemble in reverse order. Replace any worn or damaged hardware as required. Fig.

  • Page 37: Seat Back Assembly

    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 Seat Back Assembly Fender Liner (Ref.

  • Page 38: Rear Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Rear Body (Ref. Fig. 10) ITEM TORQUE SPECIFICATION Tool LIst Qty. Torx Bit, T-45IP ............1 26, 30, 33, 34 13 - 16 ft.

  • 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. Fig. 11 2 + 2 Rear Facing Seat & Foot Rest 2 + 2 Rear Facing Seat & Foot Rest Tool LIst Qty.
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 5. To separate the seat back assembly (15) from the mounting brackets (17) remove the four torx head screws (16), two from each bracket.

  • Page 41: Floorboard

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Floorboard removed the foot rest assembly (29) may be removed from the vehicle by sliding it backwards and off of the two remaining bolts.

  • Page 42: Body Care And Maintenance

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Light Scratches ITEM TORQUE SPECIFICATION Tools & Supplies List Qty. 44, 46 13 - 16 ft. lbs. (18 - 22 Nm) Spray Bottle of Water ...........1 Variable Speed Rotary Buffer ........1 3-M 39001 Medium Cut Rubbing Compound ..1 qt.

  • Page 43: Minor Scratches

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Minor Scratches Wet Sanding Block ............1 Soft Clean Cotton Cloths Tools & Supplies List Qty. Masking Tape Bottle of Touch-up Paint ..........1 Bottle of Alcohol ............
  • Page 44 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-12 Repair and Service Manual...

  • Page 45: 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 Wheel and Tire Installation ................. D - 2 Repair and Service Manual Page D-i...
  • Page 46 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 47 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. WHEEL AND TIRE SERVICE Tire inflation should be determined by the condition the terrain. See GENERAL SPECIFICATIONS section for Tools List Qty.

  • Page 48: 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. Wheel Installation the tapered end is against the wheel rim; and tighten in a ‘cross sequence’ pattern; then, tighten lug nuts to specified torque in 20 ft.

  • Page 49: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ......................E - 1 Tire Wear Diagnosis..................E - 2 Wheel Alignment ....................E - 2 Hub Assembly ....................E - 3 Spindle Assembly..................... E - 3 Struts .......................
  • Page 50 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 E-ii Repair and Service Manual...

  • Page 51: 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 PASSENGER SIDE SPINDLE ASSEMBLY INTERMEDIATE SHAFT TIE ROD END STRUT ASSEMBLY A-ARM ASSEMBLY DRIVER’S SIDE SPINDLE ASSEMBLY...

  • Page 52: 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 53: 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 54: 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 55: 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 56: 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. 4. Apply upward pressure to the steering wheel by plac- ing a plastic faced hammer against the steering wheel ITEM TORQUE SPECIFICATION retaining nut.

  • Page 57: Steering Column Assembly And Yoke

    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. white stress lines. If stress lines are present, replace clipboard with a new one. Steering Column 11.

  • Page 58: 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 59 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. 4. Repeat steps 3 through 5 for the remaining tie rod 9. Remove steering box from the driver’s side of the end.
  • Page 60 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 E-10 Repair and Service Manual...

  • Page 61: Speed Control

    SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. SYSTEM OPERATION ..................F - 1 Governor Operation ..................F - 1 TROUBLESHOOTING ....................F - 2 SPEED CONTROL....................F - 2 Throttle Rod Adjustment .................. F - 2 Accelerator Cable Removal at Governor ............
  • Page 62 SPEED CONTROL 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 63: System Operation

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Pedal Assembly Accelerator Cable Throttle Rod Governor Lever - Upper Governor Lever - Lower Governor Spring Carburetor Fig.

  • Page 64: Troubleshooting

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. NOTICE Be sure to follow the sequence indicated when making linkage adjustments. Driving above governed speed could cause a loss of vehicle control and possible injury or death.

  • Page 65: Accelerator Cable Removal At Governor

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Accelerator Cable Removal at Governor Accelerator Pedal To remove the accelerator cable (9) from the governor, loosen the nuts (13) securing the cable to the accelera- Pedal Cover tor cable bracket (14) at the rear axle and unhook the spring from the upper governor lever (15)(Ref Fig.

  • Page 66: Road Test

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Confirm the accelerator pedal arm contacts the acceler- ator pedal bracket when in the released position (Ref Fig.
  • Page 67 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. ITEM TORQUE SPECIFICATION 15 - 17 ft. lbs (20 - 23 Nm) 17- 26 in. lbs (2 - 3 Nm) 15 - 20 in.
  • Page 68 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page F-6 Repair and Service Manual...

  • Page 69: 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 - 4 STARTER/GENERATOR BELT TENSION ...............
  • Page 70 ENGINE 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 71: Powertrain Maintenance

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. For further engine information, see Engine Shop Rebuild and Service Parts Manual. Maximum Oil Level Fill Cold Engine For Hot Engine To This Point Do Not Overfill...
  • Page 72 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. HEAVY DUTY WORK 10W-40 10W-30 Be careful of hot oil when drained. It may be hot enough to burn you severely LIGHT DUTY WORK Place the oil drain pan under the oil drain plug (1) found 10W-30...

  • Page 73: Air Filter Inspection/Replacement

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. from the engine and allow the oil to drain into the oil NOTICE drain pan (Ref. Fig. 5). The ‘O’ ring (5) may remain on engine (6) or filter (7) (Ref.

  • Page 74: Cleaning The Air Filter Element

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. STARTER/GENERATOR BELT TEN- SION Tool List Qty. Belt Tension Gauge .............1 Wrench, 13 mm............1 Wrench, 14 mm............2 Wrench, 15 mm............1 Ratchet ................1 Socket, 13 mm"............1 Socket, 15 mm .............1...

  • Page 75: Adjusting The Belt

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Re-tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) Using a socket and open end wrench, tighten the tension using the same technique.

  • Page 76: Cooling System Cleaning

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Operation in wet or damp weather or overly fresh cut grass may result in a variety of debris accumulating and adhering to the internal shroud and fins of the cooling system.

  • Page 77: Four Cycle Engine

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. FOUR CYCLE ENGINE Engine Specifications Engine Model ..........FJ400-D Type........Four Cycle, Overhead Valve Number Of Cylinders........... 1 Displacement............401 Cc Rated Horsepower ..........13 Hp Spark Plug Type ........

  • Page 78: Rocker Cover Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 1. Gas leakage around the cylinder head - replace the Then check the valve clearance with a feeler gauge (7), damaged head gasket and check the cylinder head for measure the valve clearance between the rocker arm (8) warp.

  • Page 79: Engine Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 2. Disconnect air hose at carburetor. 3. Jack up rear of vehicle as directed in Section B of this manual.

  • Page 80: Controls And Wiring

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. the bolt from the driven clutch. vertically through the engine compartment using a hoist or with the assistance of another person. 20.
  • Page 81 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. NOTICE In some extreme cases, the clutch will be resistant to removal In stubborn cases the clutch removal tool should be removed and the cavity filled with grease.
  • Page 82 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page G-12 Repair and Service Manual...
  • Page 83 FUEL & AIR SYSTEM TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. GENERAL......................... H - 1 CARBURETOR OPERATION ................... H - 2 Float System ....................H - 2 Pilot Jet System ....................H - 2 Main Jet System....................H - 2 Carburetor Service ...................
  • Page 84 FUEL & AIR SYSTEM 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 85: General

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Siphon Tube Assembly Shut Off Valve Sending Unit Fuel Filter Fuel Pump Filler Cap Fuel Tank To Crankcase Carburetor Fig.

  • Page 86: Carburetor Operation

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. CARBURETOR OPERATION restricts the air flow into the carburetor which enriches the air/fuel ratio. The carburetor consists of four different systems: Choke Operation •...

  • Page 87: Fuel System

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Choke Cable and Housing Installation If the element is in acceptable condition, loose dirt may be removed by tapping the filter lightly.

  • Page 88: Carburetor Disassembly

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Disconnect the fuel line (12) from the carburetor and Remove the nuts (13), PCV valve (14), gaskets (15) and plug the fuel line.

  • Page 89: Float Level Alignment

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Float Chamber Stem Float Valve Float Carburetor Body Float should be aligned so that its top is parallel or “slightly above”...

  • Page 90: Fuel Pump

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. FUEL PUMP NOTICE The fuel pump is mounted on the gasoline tank on the The length of the pulse hose from the fuel pump is important for efficient pump operation.

  • Page 91: Fuel Tank Removal

    FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. magneto in order to prevent an ignition spark that could ignite the fuel/vapor. Never permit smoking or an open flame in an area that con- tains fuel/vapor.
  • Page 92 FUEL & AIR SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page H-8 Repair and Service Manual...

  • Page 93: 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 ......................J - 2 Removing the Drive Belt ...................J - 2 Drive Belt Service .....................J - 2 Drive Clutch Removal ..................J - 2...
  • Page 94 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 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 95: General

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 96: Drive Clutch

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 97 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Use only sockets designed for use with an hanger. Remove the front eyebolt from the spring impact wrench.

  • Page 98: Drive Clutch Installation

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Drive Clutch Installation Driven Clutch Repair (Ref. Fig. 3) Clean both the engine crankshaft and the drive clutch NOTICE bore.
  • Page 99 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 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 J-5...
  • Page 100 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page J-6 Repair and Service Manual...
  • Page 101 DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ..................K - 2 Direction Selector..................... K - 1 Micro Switch..................... K - 1 Shift Cable Adjustment..................K - 2 Neutral Lock Operation ..................K - 2 LIST OF ILLUSTRATIONS Fig.
  • Page 102 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page K-ii Repair and Service Manual...

  • Page 103: Direction Selector

    DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Mounting Bracket with Bushing Direction Selector Neutral Lock Pin Shaft Neutral Lock Bracket Direction Push - Pull Cable Selector Handle Push - Pull Cable...
  • Page 104 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Installation of the direction selector assembly and han- Required adjustment should be minimal. Adjust the dle are the reverse of removal. Tighten hardware to the threaded fitting at the forward cable mount while selec- specified torque.
  • Page 105 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 5 Neutral Lock Return to Run Position Repair and Service Manual Page K-3...
  • Page 106 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page K-4 Repair and Service Manual...
  • Page 107 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 108 ELECTRICAL 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 109: Circuits And Controls

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. CIRCUITS AND CONTROLS WIRING The electrical system is a 12 volt negative ground sys- tem (Ref. Fig. 1) (Ref. Fig. 2) consisting of a: •...
  • Page 110 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. RED/WHT RED/WHT Fig. 1 Electrical System Wiring Diagram Repair and Service Manual Page L-2...
  • Page 111 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Electrical Controller Voltage Starter/Generator Regulator Reverse Buzzer Solenoid Relay Frame Battery Frame To Magneto Direction Selector Hour Meter Accelerator Pedal To Fuel Gauge (not shown)

  • Page 112: Testing The Magneto

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Look for a blue electrical arc at the spark plug elec- trode. 3. If there is either a weak arc or no arc, try a new spark plug, then check the condition and the tightness of the spark plug wire.

  • Page 113: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. TESTING STARTING CIRCUIT (c) If “0” voltage is not indicated while the accelerator pedal is pressed, replace the solenoid. TESTING CHARGING CIRCUIT To prevent the possibility of injury resulting Tool List...
  • Page 114 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. wire to ground. If the voltage rises above its 2. Inspect the brush assembly for wear and damage to prior reading, replace the regulator.
  • Page 115 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. brushes worn to less than 11/16" (17 mm) in length or NOTICE to the line marked on the brush. In general, starter/generator service is best performed by 3.

  • Page 116: Troubleshooting

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. STORAGE OF BATTERY gauges, the technician must be able to use the wiring diagram and a DVOM. A battery that is removed from service for storage must The wiring diagram shows the path followed by a volt- be cared for as follows: age or signal from its origination point to its destination.
  • Page 117 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. POWER SUPPLY ACCESSORY WIRING After determining that there is power to the fuse panel, Tool List Qty. and the fuse is good, continue checking the circuit using DVOM................
  • Page 118 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. BLU/WHT Fig. 10 Accessory Wiring Diagram Repair and Service Manual Page L-10...
  • Page 119 ELECTRICAL 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 L-11...
  • Page 120 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page L-12 Repair and Service Manual...
  • Page 121 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW ..................M - 1 General Description ..................M - 1 How the Service Brake Works................M - 1 Equalizer Link ....................M - 2 Automatic Adjuster Mechanism ................M - 2 How the Parking Brake Works .................M - 2 Kick-Off Actuating Linkage ................M - 3 TROUBLESHOOTING AND INSPECTION ...............M - 3...
  • Page 122 MECHANICAL BRAKES 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 123: Brakes

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Parking Brake Pedal Cover Brake Pedal Cover Bumper Brake Pedal Bumper Bracket Brake Arm Mount Closeout Bellcrank Bearing PASSENGER SIDE BRAKE Mount Bolts Bellcrank...
  • Page 124 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. the brake drum. When the rear shoe contacts the brake Automatic Adjuster Mechanism drum, it can no longer move rearward. Additional pedal (and cable) travel causes the actuator bracket (moving anchor) to move and applies force to the front shoe, Never manually adjust the brakes at the star wheel.
  • Page 125 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. the tension in the brake linkage. The Parking Brake can be released by two methods: 1. Depressing the service brake, which permits the Satisfactory brake performance does not eliminate the need for routine brake testing and inspection as shown spring loaded Parking Brake pedal to return to its orig-...
  • Page 126 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. confirm smooth operation of the hinge mechanism 8. Check the condition and operation of the parking brake latching mechanism. The parking brake should latch firmly and release as soon as the accelerator pedal is depressed.
  • Page 127 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. stopping location or stopping distance. For fleets of vehi- the test area and remove foot from pedal. The vehicle cles, several vehicles should be tested when new and should stop aggressively.
  • Page 128 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Do not disturb adjuster mechanisms. Remove excess dust and dirt from the drum with a brush. The brake adjuster mechanism must expand and release fully to function.
  • Page 129 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Adjuster Housing A backing plate assembly that shows any indi- Wheel Brake Lever Actuator Piston cation of galling or gouging is not repairable and must be replaced with a new wheel brake assembly.
  • Page 130 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Straight Blade Screwdriver, Narrow ......1 Pliers ................1 Front of Vehicle Vernier/Dial Calipers ............1 Plastic Tipped Hammer..........1 Puller (P/N 15947-G1) ..........1 Light Shoe Spring Pry Bar .................1 Dust Mask ..............1...
  • Page 131 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Use #1 Screwdriver (.125 “) to adjust for proper Free Travel Position Fig. 10 Free Travel Adjustment The correct brake pedal free travel should be set to 3/4"...
  • Page 132 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Fig. 11 Brake Assembly Brake Drum Removal and Installation Remove the dust cap (1) to gain access to the castel- If the drum does not slide from the brake assembly, the lated nut (2) and the cotter pin (3) (Ref.
  • Page 133 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Check to ensure the nose of drum hub is beyond the ing plate and the brake shoes be lubricated. Be careful not to allow lubricant to contact the braking portion of end of the axle splines.
  • Page 134 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Backing Plate/Entire Wheel Brake Assembly Remove the clevis pin securing the brake cable to the brake lever. Removal and Installation Installation is the reverse of removal.
  • Page 135 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Adjust the brake pedal free travel. “Adjusting Brake Pedal Free Travel” on Page M 8 Be sure that the adjusting screw is screwed into the Brake Cable Snap Ring Removal star wheel nut until only 1 - 2 threads are exposed Rotate the ring to find the crease.
  • Page 136 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. DRIVER SIDE PASSENGER SIDE AT BRAKE PEDAL Fig. 17 Brake Cable, Equalizer and Compensator BRAKE TROUBLESHOOTING Refer to the following troubleshooting table in Section S only after the thorough visual inspection, Periodic Brake Performance Test (PBPT), and Aggressive Stop Test have been performed.
  • Page 137 MECHANICAL BRAKES 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 M-15...
  • Page 138 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page M-16 Repair and Service Manual...
  • Page 139 REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. GENERAL......................... N - 1 SHOCK ABSORBER ....................N - 1 REAR LEAF SPRING ....................N - 3 LIST OF ILLUSTRATIONS Fig. 1 Rear Suspension ..................N - 1 Fig.
  • Page 140 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 N-ii Repair and Service Manual...

  • Page 141: Rear Suspension

    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 Leaf Spring Shackle Rear Axle Fig. 1 Rear Suspension GENERAL Torx Bit, T-27..............1 Wrench,15 mm ............1 Socket, 15 mm.............1 NOTICE Ratchet ................1...
  • Page 142 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. support the rear of the vehicles on the outer ends of the rear bumper. ITEM TORQUE SPECIFICATION 4.
  • Page 143 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. seize compound to the large flanged urethane bush- 14. Align the pin on the leaf spring (16) with the hole in the ings (26).
  • Page 144 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 N-4 Repair and Service Manual...

  • Page 145: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ’P’ SECTION TITLE PAGE NO. NEUTRAL LOCK ............................... P - 1 REAR AXLE ................................P - 1 Checking the Lubricant Level ........................P - 1 REAR AXLE DISASSEMBLY ............................ P - 2 Axle Shaft Removal and Disassembly ......................P - 2 Axle Shaft Seal Removal and Replacement ....................
  • Page 146 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 P-ii Repair and Service Manual...

  • Page 147: Neutral Lock

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 148 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. REAR AXLE DISASSEMBLY The rear axle is a precision assembly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment.
  • Page 149 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Axle Shaft Seal Removal and Replacement Tools List Qty. Internal Snap Ring Pliers ..........1 Seal Puller ..............1 Plastic Faced Hammer ..........1 Ratchet, 3/8"...
  • Page 150 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 P-4 Repair and Service Manual...

  • Page 151: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD................... Q - 1 WINDSHIELD......................Q - 2 GOLF CAR TOP ....................... Q - 2 2 + 2 TOP........................Q - 4 LIST OF ILLUSTRATIONS Fig. 1 Top and Windshield ..................Q - 1 Fig.
  • 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 Q-ii Repair and Service Manual...
  • Page 153 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Sun top Windshield Fig. 1 Top and Windshield TOP AND WINDSHIELD Trailering The top does not provide protection from roll Personal injury to occupants of other highway over or falling objects.
  • Page 154 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 155 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. the vehicle. Align the mounting holes in each strut with panel. the matching holes in the sweater basket and seat back support, install the hex head bolts (5) and nuts (4) finger tight only.
  • Page 156 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 2 + 2 TOP If vehicle is equipped with a windshield remove it before working with the top. Tool List Qty.
  • Page 157 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, 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 158 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Notes: Page Q-6 Repair and Service Manual...
  • Page 159 TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. TROUBLESHOOTING ....................S - 1 GASOLINE VEHICLE PERFORMANCE..............S - 1 Starter Does Not Turn ..................S - 1 Starter Turns Slowly..................S - 1 Starter Rotates but Vehicle Doesn’t Start or Hard to Start ....... S - 1 Engine Runs Rough or Loss of Power .............
  • Page 160 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page S-ii Repair and Service Manual...
  • Page 161 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings 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 162: Troubleshooting

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 163: Troubleshooting

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings 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 164: Backfiring

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 165: 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 all Notices, Cautions and Warnings 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 166: Operation And Application

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 167: Poor High Speed Operation

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings 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 168: Rectification Is Imperfect

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. 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 169: Steering Pulls To One Side

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings 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 170: 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 all Notices, Cautions and Warnings. 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 171 TROUBLESHOOTING 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 S-11...
  • Page 172 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings Notes: Page S-12 Repair and Service Manual...

  • Page 173: Limited Warranty

    LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION ’T’ SECTION TITLE PAGE NO. FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY ..............T - 1 CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT ........T - 3 Repair and Service Manual Page T-i...
  • Page 174 LIMITED WARRANTY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page T-ii Repair and Service Manual...
  • Page 175 VEHICLE WARRANTIES - FEDERAL FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Kawasaki Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 176 VEHICLE WARRANTIES - FEDERAL You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by E-Z-GO when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO Warranty Department at 1-800-241-5855 for the information.
  • Page 177 VEHICLE WARRANTIES - CALIFORNIA (2009) CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and the E-Z-GO Division of Textron Inc. (E-Z-GO) are pleased to explain the evaporative emission control system (EECS) on your 2009 gasoline powered vehicles. In California, new equipment that uses small off-engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
  • Page 178 VEHICLE WARRANTIES Notes: Repair and Service Manual Page T-4...

  • Page 179: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘U’ SECTION TITLE PAGE NO. RXV GAS - FLEET VEHICLE SPECIFICATIONS ............. U - 1 RXV GAS - FREEDON VEHICLE SPECIFICATIONS..........U - 2 RXV GAS - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS........U - 3 Fig.
  • Page 180 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page U-ii Repair and Service Manual...
  • Page 181 GENERAL SPECIFICATIONS RXV GAS - FLEET VEHICLE SPECIFICATIONS BATTERY One 12 Volt Maintenance Free 13 hp (9.7 kW) rated 24.5 cu. inch (401 cc), single cylinder, air cooled, over- ENGINE head valve, pressure fed lubrication, cartridge type full flow oil filter, transis- tor type flywheel magneto AIR CLEANER Replaceable dry cartridge element...
  • Page 182 GENERAL SPECIFICATIONS RXV GAS - FREEDOM VEHICLE SPECIFICATIONS BATTERY One 12 Volt Maintenance Free 13 hp (9.7 kW) rated 24.5 cu. inch (401 cc), single cylinder, air cooled, over- ENGINE head valve, pressure fed lubrication, cartridge type full flow oil filter, transis- tor type flywheel magneto Air Cleaner Replaceable dry cartridge element...
  • Page 183 GENERAL SPECIFICATIONS RXV GAS - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS BATTERY One 12 Volt Maintenance Free 13 hp (9.7 kW) rated 24.5 cu. inch (401 cc), single cylinder, air cooled, over- ENGINE head valve, pressure fed lubrication, cartridge type full flow oil filter, transis- tor type flywheel magneto AIR CLEANER Replaceable dry cartridge element...
  • Page 184 GENERAL SPECIFICATIONS 68.50” (174 cm) 45.7” (116 cm) 65.7” (167 cm) 35.5” (90 cm) 94.5” (240 cm) 38” (97 cm) 47” (119 cm) Fig. 1 Fleet & Freedom Vehicle Dimensions Page U-4 Repair and Service Manual...
  • Page 185 GENERAL SPECIFICATIONS 74” (188 cm) 45.7” (116 cm) 65.7” (167 cm) 35.5” (90 cm) 105.5” (268 cm) 38” (97 cm) 47” (119 cm) Fig. 2 Shuttle 2 + 2 Vehicle Dimensions Owner’s Guide Page U-5...
  • Page 186 GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP 25% GRADE OR 14° MAX RECOMMENDED MAX SIDE TILT 25% GRADE OR 14° MAX Fig. 3 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter Page U-6 Repair and Service Manual...
  • Page 187 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. Notes: Owner’s Guide Page U-7...
  • Page 188 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings. Notes: Page U-8 Owner’s Guide...
  • Page 189 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 Read the following warnings before attempting to operate the working on any vehicle. When diagnosing, removing or replac- ing any components that are not operating correctly, take time vehicle: to consider the safety of yourself and others around you should...
  • Page 190 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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