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ST SHUTTLE 4/6 2009
E-Z-GO ST SHUTTLE 4/6 2009 Manuals
Manuals and User Guides for E-Z-GO ST SHUTTLE 4/6 2009. We have
1
E-Z-GO ST SHUTTLE 4/6 2009 manual available for free PDF download: Technician's Repair And Service Manual
E-Z-GO ST SHUTTLE 4/6 2009 Technician's Repair And Service Manual (196 pages)
ELECTRIC POWERED PERSONNEL CARRIERS AND GOLF CAR
Brand:
E-Z-GO
| Category:
Golf Cars
| Size: 6 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
General Information & Routine Maintenance
13
Servicing the Electric Vehicle
13
Transporting Vehicle
13
Fig. 1 Initial Service Chart
14
Fig. 2 Lubrication Point
14
Routine Maintenance
14
Vehicle Cleaning and Care
14
Sun Top and Windshield
15
Vehicle Care Products
15
Fig. 3 Torque Specifications
16
Hardware
16
Torque Specifications
16
Periodic Service Schedule
17
Fig. 4 Periodic Service Schedule
18
List of Illustrations
14
Safety
22
Notes, Cautions and Warnings
29
Additional Warnings
30
Battery Removal & Installation
31
Lifting the Vehicle
32
Safety
35
Body
35
Body
37
Body Component Replacement
37
Instrument Panel Replacement
41
Cowl Replacement
41
Front Shield Replacement
41
Rocker Panel End Replacement
41
Rear Body Replacement
42
Foot Rest Replacement
43
Rear Bumper Replacement
43
Front Seat Replacement
44
Front Facing Rear Seat
44
Rear Facing Rear Seat
44
Cargo Bed Replacement
44
Seat/Cargo Bed Latch
44
Minor Scratches
45
Larger Scratches
45
Complete Panel Repair
45
General
37
Wheels and Tires
47
Painting
45
Front Suspension and Steering
51
Maintenance
54
Lubrication
54
Wheel Bearing and King Pin Bushing Inspection
54
Wheel Bearing Packing
54
Wheel Alignment
55
Wheel Bearing Adjustment
55
Front Suspension
57
Front Axle Replacement
58
Axle Linkage Rod Replacement
58
Front Spring Replacement
59
Hub Replacement
60
Wheel Bearing and Race Replacement
60
Steering
62
Rack Ball Joint Replacement
62
Tie Rod Inspection/Replacement
63
Bellows Replacement
64
Pinion Seal Replacement
64
Spindle Replacement
65
Rack and Pinion Unit Disassembly and Inspection
66
Rack and Pinion Unit Replacement
66
Checking/Adjusting Rack Extension-To-Rack and Pinion Unit Clearance
67
Steering Wheel Replacement
68
Steering Shaft and Column Replacement
69
Electronic Speed Control
71
Operation
74
Pedal Box
75
Speed Sensor
75
Controller
75
General Troubleshooting
75
Testing
76
Continuity Check
76
Testing a Switch for Continuity
77
Testing a Solenoid for Continuity
77
Troubleshooting Diagrams
78
Motor
91
Batteries & Charging
97
Battery
99
Battery Maintenance
99
Monthly
100
Cleaning Batteries
101
Safety
99
Battery Replacement
102
Prolonged Storage
102
Battery Charging
103
AC Voltage
103
Troubleshooting
103
Hydrometer
104
Using a Hydrometer
104
Battery Charger
107
Brakes
111
Brake Master Cylinder Fluid
113
Master Cylinder Replacement
113
System Description
113
Bleeding Brakes
115
Brake System Overview
116
Equalizer Link
116
General Description
116
Automatic Adjuster Mechanism
117
How the Parking Brake Works
117
Compensator Assembly
118
Kick-Off Actuating Linkage
118
Troubleshooting and Inspection
123
Brake Pedal and Linkage Inspection
123
New Vehicles
123
Troubleshooting and Inspection Procedures
123
Wheel Brake Inspection
127
Maintenance and Repairs
129
Brake Drum Removal and Installation
130
Wheel Brake Service
131
Backing Plate/Entire Wheel Brake Assembly Removal and Installation
132
Brake Shoe and Adjuster Replacement
132
Brake Cable and Equalizer Assembly Removal and Installation
133
Brake Pedal Removal and Installation
134
Compensator Assembly, Removal and Installation
134
Parking Brake Catch Bracket Removal and Installation
134
Parking Brake Kick-Off Cam Removal, Replacement and Installation
135
Parking Brake Pedal, Removal and Installation
135
Parking Brake Release Linkage Removal and Replacement
135
Pedal Bumper Adjustment
135
Tires
141
Light Bulb Replacement
141
Brakes
141
Rear Suspension
145
Rear Axle
151
Weather Protection
157
Sun Top
159
Top and Windshield
159
Transporting
159
Fold down Windshield
162
Full Front Windshield
163
Rear Windshield
164
Troubleshooting and Diagnostics
165
How to Use the Hand Held Diagnostic Unit
167
Menus
167
Diagnostics Report
167
Error Messages
170
Warning Messages
170
Setting Top Speed and Performance Profiles
170
Troubleshooting
178
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