E-Z-GO TXT FLEET Technician's Repair And Service Manual
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E-Z-GO TXT FLEET Technician's Repair And Service Manual

Gasoline powered personnel carriers
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614276
TECHNICIAN'S
REPAIR AND SERVICE MANUAL
GASOLINE POWERED PERSONNEL
CARRIERS
ISSUED FEBRUARY 2010

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Summary of Contents for E-Z-GO TXT FLEET

  • Page 1 614276 TECHNICIAN’S REPAIR AND SERVICE MANUAL GASOLINE POWERED PERSONNEL CARRIERS ISSUED FEBRUARY 2010...

  • Page 2: Safety

    S AF E T Y For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 TXT VALOR Starting Model Year 2010 E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice.

  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE Safety ........................... Inside Covers General Information...........................ii Safety Information ..........................v TITLE SECTION General Information & Routine Maintenance ...................A Safety ...............................B Body ..............................C 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

    REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z- GO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has rea- son to believe may be operated in personal transportation applications.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specification.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions,Warnings and Dangers • 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.
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers NOTES: Page viii Repair and Service Manual...

  • Page 11: General Information & Routine Maintenance

    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 - 1 FUEL......................... A - 2 TOWING ........................
  • 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, Warnings and Dangers. NOTES: Page A-ii Repair and Service Manual...

  • Page 13: Starting The Vehicle With Adischarged Battery

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. SERIAL NUMBER PLATE AND Observe all instructions provided by the manufacturer of the charger. LOCATION SERVICING THE VEHICLE Two serial number and manufacture date code labels are...

  • Page 14: Fuel

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. the safety of yourself and those around you, should the component move unexpectedly. Some components are heavy, spring loaded, highly corro- FUEL sive, explosive, may produce amperage or reach high...

  • 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, Warnings and Dangers. ward) or ‘R’ (reverse) while being towed, causing possible ROUTINE MAINTENANCE damage to the rear axle. This vehicle will give years of satisfactory service, provid- Use extra caution when towing vehicle.

  • Page 16: Brakes

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BRAKES TOP AND WINDSHIELD After the vehicle has been put into service, it is recom- mended that the brakes be checked by periodically con- ducting a brake performance test.

  • Page 17: Vehicle Care Products

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Removal of oil, tar, asphalt, shoe polish, etc. will require HARDWARE the use of a commercially available vinyl/rubber cleaner. Periodically the vehicle should be inspected for loose The painted surfaces of the vehicle provide attractive fasteners.

  • Page 18: Torque Specifications

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.

  • Page 19: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • 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, Warnings and Dangers. REMARKS Tie Rods - excessive play, bent rods, loose or missing hardware Rear Axle - fluid level, oil leakage, noise, loose or missing hardware Rear Axle - drain &...
  • 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, Warnings and Dangers. 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, Warnings and Dangers. 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 ..............B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE................B - 1 GENERAL MAINTENANCE..................B - 1 BEFORE SERVICING THE VEHICLE............... B - 1 Battery Removal and Installation..............
  • Page 24 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page B-ii Repair and Service Manual...

  • Page 25: General Maintenance

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTICE, CAUTIONS AND WARNINGS Throughout this manual, the following NOTICE, CAUTIONS, WARNINGS and DANGERS are used. For the protection of all personnel and the vehicle, be aware Changes to the weight distribution or the cen- of and observe the following:...
  • Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Set the parking ‘PARK’ brake before per- forming any work on the vehicle. If repairs are to be made that will require welding or cutting, the battery and fuel To prevent illness or death, observe the follow- tank must be removed and the fuel system...

  • 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, Warnings and Dangers. 2). Center the jack under the rear frame crossmember. Raise the vehicle and locate a jack stand under the outer ends of the rear axle.
  • Page 28 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page B-4 Repair and Service Manual...
  • Page 29 BODY TABLE OF CONTENTS FOR SECTION ’C’ SECTION TITLE PAGE NO. BODY ..................................C - 1 General ................................C - 1 BODY COMPONENT REPLACEMENT ........................C - 1 Instrument Panel Replacement ........................C - 4 Cowl Replacement ............................C - 4 Front Shield Replacement ..........................
  • Page 30 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page C-ii Repair and Service Manual...

  • Page 31: Body Component Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BODY NOTICE Drill Out Rivet Pop Rivet Head Only In the following text, there are references to removing/install- ing bolts etc.

  • Page 32: Fig. 2 Body Components (Front)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Frame Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...

  • Page 33: Fig. 3 Body Components (Rear)

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 3 Body Components (Rear) Repair and Service Manual Page C-3...

  • Page 34: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. From underneath the cowl, remove the ratchet fastener (18) attaching the center of the splash panel (19) to the frame cross member.

  • Page 35: Body Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Body Replacement Remove the rivets (32) that secure the floor of the bag- well area to the frame underneath. Tool List Qty.
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page C-6 Repair and Service Manual...

  • Page 37: Minor Scratches

    BODY-PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers PAINTING hol and dry. 2. Mask the area to be painted (common masking tape is Follow the paint manufacturer’s recommendations for adequate) prior to repair and use aerosol type touch- specific painting procedures and information.
  • Page 38 BODY-PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers NOTES: Page C-8 Repair and Service Manual...

  • Page 39: 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 40 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page D-ii Repair and Service Manual...
  • Page 41 Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has To prevent injury, be sure mount- a recommended inflation pressure less than...
  • Page 42 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten lug nuts as shown. Then, tighten lug nuts to 50 - 85 ft.
  • Page 43 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-3...
  • Page 44 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page D-4 Repair and Service Manual...

  • Page 45: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. MAINTENANCE ......................E - 2 Lubrication ..........................E - 2 Wheel Bearing and King Pin Bushing Inspection ..............E - 2 Wheel Bearing Packing ......................E - 2 Wheel Bearing Adjustment ....................E - 3 Wheel Alignment ........................E - 3 FRONT SUSPENSION ....................
  • Page 46 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page E-ii Repair and Service Manual...
  • Page 47 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...

  • Page 48: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Wheel Bearing and King Pin Bushing MAINTENANCE Inspection NOTICE In the following text, there are references to removing/installing To prevent possible injury or death resulting bolts etc.

  • Page 49: Wheel Bearing Adjustment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. the bearing is removed for inspection. It is recom- If completing a wheel bearing adjustment as part of mended that a bearing packer attached to a grease gun another procedure, tighten front wheels per WHEELS be used;...
  • 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, Warnings and Dangers. Test drive vehicle and confirm steering wheel is cor- rectly centered. If it is not centered, disconnect interme- Rear diate shaft from steering shaft and center steering wheel (Ref.

  • Page 51: Front Suspension

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.

  • Page 52: Front Axle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Front Axle Replacement At the 3 1/2" long bolt (20) securing front of left spring, note location of washer (22) and remove it from end of Tool List Qty.

  • Page 53: Hub Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Loosen front wheels. Lift and support front of vehicle per NOTICE SAFETY section. In addition, support front axle with jack stands.

  • Page 54: Wheel Bearing And Race Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Remove the dust cap (1), cotter pin (2) and castellated Wheel Bearing and Race Replacement nut (3) (Ref.

  • Page 55: Steering

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. STEERING Front of Vehicle Flat Section Fig. 11 Steering Components Rack Ball Joint Replacement To remove rack ball joint (1), loosen passenger side front wheel and lift and support front of vehicle per Tool List...

  • Page 56: Tie Rod Inspection/Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. To install new rack ball joint close to its correct position, Tie Rod Inspection/Replacement measure amount of threads exposed from jam nut (Ref.

  • Page 57: Bellows Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Remove cotter pin (9) and loosen castellated nut (10) until tie rod ball joint (6) threads are protected. Using a ball joint separator as a lever, apply pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm.

  • Page 58: Spindle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Spindle Replacement Tool List Qty. Required Needle nose pliers ............1 Secure rack and pinion unit in vice by the mounting ears Wrench, 11/16".............1 only.

  • Page 59: Rack And Pinion Unit Disassembly And Inspection

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Spindle installation is the reverse order of disassembly. (3) and pinion (4) (Ref. Fig. 17). Loosen jam nut (5) and remove rack ball joint (6) from rack extension (7).

  • Page 60: Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque and continue to tighten as needed to insert new cotter pin.

  • Page 61: Steering Wheel Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTICE Front of Vehicle To maintain correct orientation when replacing steering wheel, first turn wheels straight ahead. To prevent damage to the clipboard, perform the follow- ing removal procedure.

  • Page 62: Steering Shaft And Column Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Loosen the steering wheel retaining nut (6) two to three Loosen front wheels. Lift and support front of vehicle per turns (Ref.
  • Page 63 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove Fig. 23 Small Retaining Ring Orientation Slide wave washer into base of steering column.
  • 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, Warnings and Dangers. NOTES: Page E-18 Repair and Service Manual...

  • Page 65: Speed Control

    SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. SYSTEM OPERATION ..................F - 1 Pedal Box Operation ..................F - 1 Governor Operation ..................F - 2 TROUBLESHOOTING ....................F - 2 SPEED CONTROL....................F - 2 Accelerator Cable Removal at Governor ............
  • Page 66 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page F-ii Repair and Service Manual...

  • Page 67: System Operation

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Accelerator Cable Governor Lever - Upper Governor Lever - Lower Governor Spring Accelerator Compression Spring Fig. 1 Accelerator and Speed Control System SYSTEM OPERATION NOTICE Pedal Box Operation...

  • Page 68: Governor Operation

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Governor Operation Drill bit, 3/16"..............1 Rivet gun..............1 Until the vehicle reaches its governed speed, the vehicle will continue to accelerate in relation to the accelerator pedal position.

  • Page 69: Accelerator Cable Removal At Pedal Box

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Accelerator Cable Removal at Pedal Box Accelerator Cable Adjustment (Ref Fig. 3) To adjust the accelerator cable, position the cable in the To access the micro switch, remove the rocker panel (4), accelerator cable bracket at the rear axle so that the lift the floor mat (5) and remove the access cover (6)

  • Page 70: Pedal Box Adjustments

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. PEDAL BOX ADJUSTMENTS rear axle) should have some slack present and not show any movement until after the micro switch clicks. Tool List Qty.
  • Page 71 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. speed specified in the GENERAL SPECIFICATIONS section. Determine speed by measuring the time it takes to travel a known set distance with vehicle at maximum speed.
  • Page 72 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page F-6 Repair and Service Manual...

  • Page 73: Engine

    ENGINE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE ................G - 1 Checking the Oil Level ..................G - 1 Changing the Oil ....................G - 1 AIR FILTER INSPECTION/REPLACEMENT ............G - 3 Cleaning the Air Filter Element................. G - 3 STARTER/GENERATOR BELT TENSION ...............
  • Page 74 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page G-ii Repair and Service Manual...

  • Page 75: Checking The Oil Level

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers For further engine information, see Engine Shop The engine can be operated safely as long as oil is Rebuild and Service Parts Manual.
  • Page 76 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Before installing the drain plug clean the area around NOTICE the drain plug mount with a lint free cloth and inspect the drain plug (1) for damage;...

  • Page 77: Air Filter Inspection/Replacement

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Inspect the new oil filter for any defects, apply engine oil AIR FILTER INSPECTION/REPLACE- to the ’O’ ring seal and install the new oil filter onto the MENT engine until the seal contacts mounting surface of the engine.

  • Page 78: Starter/Generator Belt Tension

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers STARTER/GENERATOR BELT TEN- Re-tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique. A maximum deflec- SION tion of 1/2"...
  • Page 79 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Using a socket and open end wrench, tighten the starter/generator pivot bolts (13) and nuts (14) to the specified torque value.

  • Page 80: Cooling System Cleaning

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers COOLING SYSTEM CLEANING Spark Plug At least once a year, or more often under adverse condi- tions the cooling system should be cleaned. Cleaning will assure an adequate supply of air to the cooling fins.

  • Page 81: Cylinder Head

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers CYLINDER HEAD Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops ris- ing.

  • Page 82: Valve Clearance Inspection

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Valve Clearance Adjustment Turn the crankshaft to the proper direction until the pis- ton is at TDC of the compression stroke. Fig.

  • Page 83: Engine Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers ENGINE REMOVAL 6. Remove the ground strap from the Starter/Generator using a 10 mm socket. Tool List Qty.

  • Page 84: Controls And Wiring

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers 23. Raise the powertrain with the floor jack so that the Tighten the bottom and horizontal mounting bolts to 45 clutch puller bolt clears the spring hanger.

  • Page 85: Fuel System

    FUEL 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 86 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page H-ii Repair and Service Manual...

  • Page 87: General

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CARB Canister Fuel Filter Fuel Line to Fuel Tank Carburetor Fuel Gauge Sending Unit Pulse Line to Crankcase Line Fig.

  • Page 88: Carburetor Operation

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CARBURETOR OPERATION Choke Operation (Ref. Fig. 3) The carburetor consists of four different systems: • float Pull the choke knob (10) out to operate the choke (Ref.

  • Page 89: Fuel System Component Service And Replacement

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. FUEL SYSTEM COMPONENT SER- unless otherwise specified. Non-specified torque specifica- tions are as shown in the table contained in Section ‘A’. VICE AND REPLACEMENT Feed the choke cable assembly (8) through the hole in the bezel (8) (Ref.
  • Page 90 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 5 Carburetor Operation Carburetor Removal Straight blade screwdriver, (narrow) ......1 (Ref. Fig. 5) Tool List Qty.

  • Page 91: Float Level Alignment

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

  • Page 92: Fuel Lines And Filter

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. fuel pump (1) (Ref. Fig. 8). This movement draws fuel the fuel tank on the passenger side of the vehicle from the fuel tank into the fuel pump chamber.

  • Page 93: Fuel Tank Removal

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. have become clogged. The filter should be replaced as CARB CANISTER (Ref. Fig. 11) required. See ‘Periodic Service Schedule’ in Section ‘A’. Tool List Qty.
  • Page 94 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page H-8 Repair and Service Manual...

  • Page 95: 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 96 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers NOTES: Page J-ii Repair and Service Manual...

  • Page 97: General

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Driven Clutch Drive Belt Drive Clutch Fig. 1 Continuously Variable Transmission System (CVT) GENERAL moveable sheave inwards.

  • Page 98: 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, Warnings and Dangers. Driven Clutch The driven clutch sheaves are closed at rest which results in the drive belt being held at the outer diameter of the driven clutch.
  • Page 99 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Use only sockets designed for use with an the spring hanger. Remove the front eyebolt from the impact wrench.

  • Page 100: 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, Warnings and Dangers. Drive Clutch Installation Driven Clutch Repair (Ref. Fig. 3) Clean both the engine crankshaft and the drive clutch NOTICE bore.
  • Page 101 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-5...
  • Page 102 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page J-6 Repair and Service Manual...

  • Page 103: Direction Selector

    DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ..................K - 2 Removing Direction Selector ................K - 2 Replacing a Micro Switch ................. K - 2 Shift Cable Adjustment..................K - 2 Neutral Lock Operation ..................K - 2 LIST OF ILLUSTRATIONS Fig.
  • Page 104 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page K-ii Repair and Service Manual...
  • Page 105 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Fig. 1 Direction Selector Repair and Service Manual Page K-1...
  • Page 106 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers DIRECTION SELECTOR Replacing a Micro Switch To replace a micro switch (5), remove the attaching Before removing a suspected faulty micro switch, hardware (Ref.
  • Page 107 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Spring loaded mechanism. To prevent possibil- ity of fingers becoming pinched in the direction selector mechanism, hold direction selector lever when releasing neutral lock pin handle.
  • Page 108 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers NOTES: Page K-4 Repair and Service Manual...
  • Page 109 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 - 5 TESTING STARTING CIRCUIT ................
  • Page 110 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page L-ii Repair and Service Manual...

  • Page 111: Circuits And Controls

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CIRCUITS AND CONTROLS WIRING The electrical system is a 12 volt negative ground sys- tem (Ref. Fig. 1) (Ref. Fig. 3) consisting of a: •...
  • Page 112 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 1 Electrical System Wiring Diagram Repair and Service Manual Page L-2...
  • Page 113 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 2 Electrical System Wiring Diagram Repair and Service Manual Page L-3...
  • Page 114 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Electrical Controller Voltage Starter/Generator Regulator Reverse Buzzer Solenoid Relay Frame Battery Frame To Magneto Direction Selector Hour Meter Accelerator Pedal...

  • Page 115: Testing The Magneto

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. cylinder, etc.). Turn over the engine with the starter. Look for a blue electrical arc at the spark plug elec- trode.

  • Page 116: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 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 117: Inspection

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. prior reading, replace the regulator. 2. Inspect the brush assembly for wear and damage to the brush holder insulators. Check the brushes for 9) If the above procedures do not correct the length, approximately 11/16"...

  • Page 118: Battery Voltage Test

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 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 119: Storage Of Battery

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. STORAGE OF BATTERY The wiring diagram shows the path followed by a volt- age or signal from its origination point to its destination. Each wire is indicated by color and is divided into the A battery that is removed from service for storage must main harness and the dash harness (Ref.
  • Page 120 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. battery voltage indicates that the power wire is in good NOTICE condition. If any DVOM readings indicate a faulty wire, it is recommended NOTICE that the condition of the terminals and wire junction be exam- ined.
  • Page 121 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. WHITE BROWN GRAY GRAY BLACK BLACK GRAY BLACK BLACK BLACK BLUE BLUE/WHITE BLACK BLACK WHITE Fig. 11 Accessory Wiring Diagram Repair and Service Manual Page L-11...
  • Page 122 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page L-12 Repair and Service Manual...

  • Page 123: Mechanical Brakes

    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 - 2 Equalizer Link ..............................M - 2 Automatic Adjuster Mechanism ........................M - 2 How the Parking Brake Works ........................M - 2 Compensator Assembly ..........................M - 3 Kick-Off Actuating Linkage ..........................M - 3...
  • Page 124 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ’M’ SECTION TITLE PAGE NO. Fig. 15 Adjuster Mechanism ............................M - 12 Fig. 16 Brake Shoe Wear ............................M - 13 Fig. 17 Orientation of Brake Shoe Springs ......................M - 13 Fig. 18 Free Travel Adjustment ..........................M - 14 Fig.
  • Page 125 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Identification Hole Hinge Pin Pedal Latch Service Brake Pedal Kick Off Spacer Catch Bracket...
  • Page 126 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. How the Service Brake Works Depressing the service brake pedal pulls the compensa- tor assembly and equalizer link, which are connected to the brake cables (Ref.
  • Page 127 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Compensator Assembly The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.
  • Page 128 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of:...
  • Page 129 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • Page 130 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING TABLE Test (PBPT), and Aggressive Stop Test is performed (Ref. Fig. 6 on Page K-6). Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Condition...
  • Page 131 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification ment is latched.
  • Page 132 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPEC- TION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes.
  • Page 133 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. cables and linkages or initial break-in of components. brake lever. They must be loose when the brake pedal Not enough pedal free travel may indicate improper has been released (Ref.
  • Page 134 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0" Gap Push (0.0 mm) Catch...
  • Page 135 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. ping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should stop within the “normal”...
  • Page 136 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. found, the drum must be replaced. NOTICE 3. Remove any accumulated brake dust from the wheel The brake adjuster mechanism must expand and release fully brake assembly with a brush.
  • Page 137 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 7. Check the condition and operation of the moving The pattern of normal brake shoe wear is anchor assembly (Ref.
  • Page 138 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. MAINTENANCE AND REPAIRS travel will limit braking capability. Too little pedal free travel may cause the brakes to drag (not fully released). Tool List Qty.
  • Page 139 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Check to see that the clevis pins attaching the brake cables to the brake levers are loose (Ref. Fig. 19 on Page K-15).
  • Page 140 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. one additional inner brake drum washer (total of 2) to shoes or the friction surface of the brake drum. Use only obtain required spacing.
  • Page 141 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Backing Plate/Entire Wheel Brake Assembly accumulated brake dust from the backing plate and adjuster mechanism using a brush or air hose. Removal and Installation If the brake is being removed for an axle bearing and Remove the four bolts (1) and lock nuts (2) securing the...
  • Page 142 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. The brake shoe end is squared off and engages the the hole in the axle. Maximum torque 140 ft. lbs. (190 screw end of the adjuster.
  • Page 143 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. TOP PULL ADJUSTER ASSEMBLY Fig. 27 Brake shoes and Springs Compensator Assembly, Removal and with brake lights. Unhook the torsion spring (4) by insert- ing a thin blade screwdriver between the small hook and Installation the bracket.
  • Page 144 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Remove the two bolts (1) and nuts (2) which secure the catch bracket. Replace the catch bracket with a new one, replace and tighten the hardware to 85 - 95 in.
  • Page 145 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. setscrew heads in the kick-off cam should be approxi- Parking Brake Kick-Off Cam Removal, mately 1/4" - 3/8” (6 - 9.5 mm). Replacement and Installation.
  • Page 146 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page M-22 Repair and Service Manual...

  • Page 147: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................P - 1 General ......................P - 1 Shock Absorber Removal................. P - 1 Shock Absorber Installation ................P - 1 Rear Spring Removal ..................P - 1 Rear Spring Installation..................
  • Page 148 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page P-ii Repair and Service Manual...

  • Page 149: General

    REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Shock Absorber Installation Shock absorber installation is in the reverse order of dis- NOTICE assembly except that the shock absorber nuts (1,3) must be tightened until the shock absorber bushings (4) In the following text, there are references to removing/installing...
  • Page 150 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Vinyl Cap Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual Page P-2...
  • Page 151 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REAR AXLE REMOVAL Remove the accelerator cable from the accelerator bracket and take off the push nut holding the cable on Tool List Qty.
  • Page 152 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page P-4 Repair and Service Manual...

  • Page 153: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ’Q’ SECTION TITLE PAGE NO. NEUTRAL LOCK ............................... Q - 1 REAR AXLE ................................Q - 1 Checking the Lubricant Level ........................Q - 1 REAR AXLE DISASSEMBLY ............................ Q - 2 Axle Shaft Removal and Disassembly ......................Q - 2 Axle Shaft Seal Removal and Replacement ....................Q - 3 Axle Shaft Replacement ..........................
  • Page 154 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page Q-ii Repair and Service Manual...

  • Page 155: Neutral Lock

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers For further axle information, see Four Cycle Transaxle REAR AXLE 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 156 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers REAR AXLE DISASSEMBLY The rear axle is a precision assembly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment.
  • Page 157 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Axle Shaft Seal Removal and Replacement Tools List Qty. Internal Snap Ring Pliers ..........1 Seal Puller ..............1 Plastic Faced Hammer ..........1 Ratchet ................1 Torque Wrench, ft.
  • Page 158 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Notes: Page Q-4 Repair and Service Manual...

  • Page 159: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. TROUBLESHOOTING ....................R - 1 Gasoline Vehicle Performance ................R - 1 Starter Does Not Turn ..................R - 1 Starter Turns Slowly..................R - 1 Starter Rotates but Vehicle Doesn’t Start or Hard to Start ....... R - 1 Engine Runs Rough or Loss of Power .............
  • Page 160 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page R-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, Warnings and Dangers GASOLINE VEHICLE PERFORMANCE Condition Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and retighten Poor wiring connections...
  • Page 162 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction Fuel pump faulty Repair or replace Fuel line clogged or clamp loose Clean or replace if required Cracked or broken fuel line Replace with new hose Main jet blocked...
  • Page 163 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction POOR LOW SPEED Plugged gas tank vent Clean or repair PERFORMANCE Choke on Push choke in Carburetor float level incorrect Check/Replace float...
  • Page 164 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction REPEATED SPARK PLUG Wrong spark plug type Replace with correct spark plug FOULING Wrong spark plug gap Check and adjust if required Faulty magneto...
  • Page 165 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction ERRATIC, SURGING, OR SUDDEN Damaged governor spring Replace CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm...
  • Page 166 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction OPERATION AND APPLICATION Engine not reaching full temperature Increase run time intervals to build higher cylinder temperature Continuous use at 1/4 throttle or less at low Instruct operator...
  • Page 167 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction POOR HIGH SPEED OPERATION Fuel pump faulty Replace fuel pump Loose main jet Tighten main jet Incorrect fuel level in float bowl Adjust float...

  • Page 168: Suspension And Steering

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction RECTIFICATION IS IMPERFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough...

  • Page 169: Brake System

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure Dragging wheel brakes Service brake system Suspension component failure Repair...
  • Page 170 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction NEITHER WHEEL LOCKS WHEN Incorrect cable adjustment Return to factory specification PARK BRAKE IS LATCHED. (NOTE: Excessive brake pedal free travel Adjust per manual AT FULL SPEED THE WHEELS MAY...
  • Page 171 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Notes: Repair and Service Manual Page R-11...
  • Page 172 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Notes: Page R-12 Repair and Service Manual...

  • Page 173: Limited Warranty

    LIMITED WARRANTY - EMISSIONS TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. Federal Emission Component Defect Warranty (2004) ........S - 1 California Emission Control Warranty Statement (2004) .........S - 3 Repair and Service Manual Page S-i...
  • Page 174 LIMITED WARRANTY - EMISSIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page S-ii Owner’s Guide...
  • Page 175 (ii) Hoses, belts, connectors, and assemblies. OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized E-Z-GO distributor, dealer, or service provid- er. Bring your sales receipts indicating date of purchase for this engine. The distributor, dealer, or service provider authorized by E-Z-GO will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order.
  • Page 176 VEHICLE WARRANTIES - CALIFORNIA (2009) As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by E-Z-GO when a problem exists.
  • Page 177 E-Z-GO recommends that you retain all receipts covering maintenance on your vehicle, but E-Z-GO cannot deny warranty solely for the lack of receipts. As the vehicle owner, you should be aware that E-Z-GO may deny you warranty coverage if your vehicle or a covered part has failed due to abuse, neglect, or improper maintenance, unapproved modifications, or the use of parts not made or approved by E-Z-GO.
  • Page 178 VEHICLE WARRANTIES - CALIFORNIA (2009) NOTES: Repair and Service Manual Page S-4...

  • Page 179: General Specifications

    TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. TXT FLEET GASOLINE POWERED GOLF CAR ............. T - 1 TXT FREEDOM GASOLINE POWERED GOLF CAR..........T - 2 TXT VALOR GASOLINE POWERED GOLF CAR ............ T - 3 LIST OF ILLUSTRATIONS Fig.
  • Page 180 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page T-ii...
  • Page 181 11.42:1 (Forward) 15.78:1 (Reverse) Specifications are subject to change without notice * Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has a recommended inflation pressure less than the inflation pressure recommended in Owner’s Manual...
  • Page 182 11.42:1 (Forward) 15.78:1 (Reverse) Specifications are subject to change without notice * Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has a recommended inflation pressure less than the inflation pressure recommended in Owner’s Manual...
  • Page 183 11.42:1 (Forward) 15.78:1 (Reverse) Specifications are subject to change without notice * Do not use low inflation pressure tires on any E-Z-GO vehicle. Do not use any tire which has a recommended inflation pressure less than the inflation pressure recommended in Owner’s Manual...
  • Page 184 GENERAL SPECIFICATIONS 68 in. (173 cm) 46.5 in. (118 cm) Front 4.25 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance 38.5 in. (97 cm) 66.0 in. (168 cm) 91.0 in. (231 cm) 47.0 in. (119 cm) Fig. 1 Vehicle Dimensions Repair and Service Manual Page T-4...
  • Page 185 GENERAL SPECIFICATIONS RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% GRADE or 14 o MAX 25% GRADE or 14 o MAX TURNING CLEARANCE DIAMETER FREEDOM 19 ft. (5.8 m) FLEET 19 ft. (5.8 m) VALOR 19 ft. (5.8 m) Fig. 2 Vehicle Turning Clearance Repair and Service Manual Page T-5...
  • Page 186 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page T-6 Repair and Service Manual...
  • Page 187 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 188 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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