E-Z-GO 625619 2012 Technician Repair Manuals

E-Z-GO 625619 2012 Technician Repair Manuals

Manuals and User Guides for E-Z-GO 625619 2012 Technician Repair. We have 1 E-Z-GO 625619 2012 Technician Repair manual available for free PDF download: Technician's Repair And Service Manual

E-Z-GO 625619 2012 Technician's Repair And Service Manual

E-Z-GO 625619 2012 Technician's Repair And Service Manual (182 pages)

GASOLINE POWERED UTILITY VEHICLE

Brand: E-Z-GO | Category: Utility Vehicle | Size: 16 MB

Table of Contents

Table of Contents

5
- Safety
  2
- General Information
  4
  - Table of Contents
    5
- Safety Information
  7
General Information & Routine Maintenance

11
- Serial Number Location
  13
- Servicing the Vehicle
  13
- Starting the Vehicle with Adischarged Battery
  13
- Fuel
  14
- Neutral Lock
  14
- Towing
  14
- Powertrain Maintenance
  15
- Routine Maintenance
  15
- Brakes
  16
- Care and Cleaning of the Vehicle
  16
- Tires
  16
- Vehicle Care Products
  16
- Sun Top and Windshield
  17
- Trailering
  17
- Winter or Prolonged Storage
  17
- Hardware
  18
- Torque Specifications
  18
- Periodic Service Schedule
  19
- Safety
  27
Safety

31
- Body Component Replacement
  
  33
- Painting
  
  44
Brakes

47
- General
  
  50
  - How the Hydraulic System Works
    50
- Maintenance
  
  50
  - Daily Brake Performance Test
    50
  - Brake System Inspection
    50
  - Wheel Brake
    50
- Master Cylinder
  
  51
  - Brake Fluid
    51
  - Master Cylinder Replacement
    51
- Brake Linkage
  
  52
  - Adjustment
    52
- Brake Drum Removal and Installation
  
  53
- Wheel Brake Service
  
  55
  - Disassembly
    55
  - Cleaning and Inspection
    55
  - Replacing an Adjuster
    56
  - Adjustment
    57
- Bleeding and Flushing
  
  57
  - Bleeding
    57
  - Bleeding Sequence
    57
  - Flushing
    58
- Wheel Brake Assembly Replacement
  
  57
- Brake Pedal Removal and Installation
  
  58
  - Continuously Variable Transmission (Cvt)
    63
  - Direction Selector
    71
Electrical

77
- Circuits and Controls
  79
  - Engine
    79
    
    Starter/Generator
    79
    
    Digital Volt Ohm Meter
    81
    
    Generator Mode
    81
    
    Starter Mode
    81
    
    Testing Ignition Circuit
    81
    
    Testing Charging Circuit
    82
    
    Starter/Generator
    83
    
    Starter/Generator Disassembly
    84
    
    Starter/Generator Removal
    84
    
    Battery Voltage Test
    85
    
    Starter/Generator Inspection
    85
    
    Starter/Generator Repair and Replacement
    85
    
    Power Supply
    86
    
    Storage of Battery
    86
    
    Troubleshooting
    86
    
    Accessory Wiring
    87
    
    Faulty Wire Replacement
    87
    
    Light Bulb Replacement
    87
Engine

95
- Powertrain Maintenance
  
  98
  - Removing Debris
    98
  - Oil Capacity
    98
  - Oil Recommendations
    98
  - Checking the Oil Level
    98
  - Changing the Oil
    99
  - Changing the Oil Filter
    100
- Air Cleaner Maintenance
  
  100
  - Pre-Cleaner Service
    100
  - Cartridge Service
    100
- Starter/Generator Belt Tension
  
  100
  - Adjusting the Belt Tension
    101
- Spark Plugs
  
  101
- Engine Description
  
  102
  - Engine Specifications
    102
- Vehicle Preparation to Test Engine Condition
  
  102
- Engine Removal
  
  103
- Engine Installation
  
  105
- Starter/Generator Replacement
  
  106
  - Starter/Generator Removal
    106
Front Suspension and Steering

109
- Front Axle Replacement
  111
- Front Shock Absorber Replacement
  111
- Front Suspension
  111
- Shock Boot Removal and Replacement
  111
- Front Spring Replacement
  112
- Steering
  
  113
  - Steering Wheel Replacement
    113
  - Tie Rod Replacement
    113
  - Tie Rod, Wheel Bearing and King Pin Inspection
    113
  - Steering Shaft Replacement
    114
  - Steering Housing Assembly Replacement
    115
  - Idler Arm Replacement
    116
  - Rack Ball Joint Installation
    116
  - Rack Ball Joint Removal
    116
  - Rack Replacement
    116
  - Rack Tensioner Replacement
    116
  - Lubrication
    117
- Maintenance
  
  117
  - Steering Pinion and Bearing Replacement
    117
  - Wheel Bearing Inspection/Packing
    117
  - Bearing Adjustment
    118
  - King Pin Bushing Replacement Torque
    118
  - Seal Installation
    118
  - Wheel Alignment
    119
  - Fuel System
    121
  - Rear Axle and Suspension
    129
- General
  
  135
  - Electronic Speed Control
    139
Troubleshooting

147
- Engine
  
  149
- Gasoline Vehicle Performance
  
  149
  - Starter Does Not Turn
    149
  - Starter Turns Slowly
    149
  - Poor Low Speed Performance
    151
  - Poor Midrange or High Speed Performance
    151
  - Engine Overheating
    151
  - Repeated Spark Plug Fouling
    152
  - Carburetor Floods Engine
    152
  - Excessive Smoking
    152
  - Backfiring
    152
  - Erratic, Surging, or Sudden Change in Governed Speed
    153
- Fuel Accumulation in the Crankcase
  
  153
  - Fuel Distribution
    153
  - Mechanical
    153
- Carburator
  
  154
  - Operation and Application
    154
  - Overflow Leak
    154
  - Poor Low Speed Performance
    154
  - Poor Fuel Economy
    154
  - Poor Acceleration
    154
  - Hard Starting
    154
  - Poor High Speed Operation
    155
  - Abnormal Combustion (Fuel Mixture)
    155
  - Loss of Power (Insufficient Fuel)
    155
  - Loss of Power (Insufficient Air)
    155
  - Surging
    155
- Starter/Generator
  
  155
  - Starter Is Noisy
    155
  - Rectification Is Imperfect
    156
  - Generator Does Not Charge
    156
- Suspension and Steering
  
  156
  - Uneven Tire Wear
    156
  - Play in Steering
    156
  - Vibration
    156
  - Steering Pulls to One Side
    157
- Brake System
  
  158
  - Neither Wheel Locks When Park Brake Is Latched
    158
  - Neither Wheel Locks
    158
  - Grabbing Brakes (over Sensitive)
    158
  - Weather Protection
    161
  - Wheels and Tires
    169
  - General Specifications
    175

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