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

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
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
- 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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