Ezgo TERRAIN 500 Manuals

Manuals and User Guides for Ezgo TERRAIN 500. We have 1 Ezgo TERRAIN 500 manual available for free PDF download: Technician's Repair And Service Manual

Ezgo TERRAIN 500 Technician's Repair And Service Manual

Ezgo TERRAIN 500 Technician's Repair And Service Manual (208 pages)

GASOLINE POWERED UTILITY VEHICLE

Brand: Ezgo | Category: Utility Vehicle | Size: 18.8 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
- Towing
  14
- Powertrain Maintenance
  15
- Routine Maintenance
  15
- Brakes
  16
- Tires
  16
- Top and Windshield
  16
- Trailering
  16
- Winter or Prolonged Storage
  16
- Care and Cleaning of the Vehicle
  17
- Hardware
  17
- Vehicle Care Products
  17
- Torque Specifications
  18
- Periodic Service Schedule
  19
- Safety
  26
Safety

31
- Body
  33
  - General
    33
  - Body Componenet Replacement
    33
- Body
  34
  - Minor Scratches
    42
    
    Larger Scratches
    42
    
    Complete Panel Repair
    42
- Wheels and Tires
  47
- Front Suspension and Steering
  51
- Speed Control
  87
- Engine
  96
Fuel System

107
- General
  109
- Carburetor Operation
  110
  - Float System
    110
  - Pilot Jet System
    110
  - Main Jet System
    110
  - Carburetor Service
    110
  - Choke System
    110
  - Choke Operation
    110
- Fuel System Component Service and Replacement
  111
  - Choke Cable and Housing Removal
    111
  - Choke Cable and Housing Installation
    111
  - Carburetor Removal
    112
  - Carburetor Disassembly
    112
  - Float Level Alignment
    113
  - Carburetor Installation
    113
- Fuel Pump
  113
Continuously Variable Transmission (Cvt)

117
- Driven Clutch
  119
- Fig. 1 Continuously Variable Transmission System (CVT)
  119
- Continuously Variable Transmission (Cvt)
  120
  - Clutches
    120
    
    Increased Load
    120
    
    Equilibrium
    120
    
    Removing the Drive Belt
    120
    
    Drive Belt Service
    120
    
    Drive Clutch Removal
    120
  - Fig. 2 Removing the Drive Belt
    120
  - Fig. 3 CVT Components
    121
    
    Drive Clutch Installation
    122
  - Storage
    122
- Direction Selector
  127
Electrical

131
- Circuits and Controls
  133
- Generator
  133
- Starter
  133
- Testing Ignition Circuit
  133
  - Testing the Magneto
    137
- Wiring
  133
- Testing Charging Circuit
  138
- Testing Starting Circuit
  138
- Inspection
  139
- Starter/Generator
  139
  - Disassembly
    139
- Battery Voltage Test
  140
- Dvom (Digital Volt Ohm Meter)
  141
- Power Supply
  141
- Storage of Battery
  141
- Troubleshooting
  141
- Mechanical Brakes
  145
- Rear Suspension
  167
- Rear Axle
  173
Troubleshooting

179
- Gasoline Vehicle Performance
  181
  - Starter Does Not Turn
    181
  - Starter Turns Slowly
    181
  - Engine Runs Rough or Loss of Power
    182
  - Poor Low Speed Performance
    183
  - Poor Midrange or High Speed Performance
    183
  - Engine Overheating
    183
  - Repeated Spark Plug Fouling
    184
  - Carburetor Floods Engine
    184
  - Excessive Smoking
    184
  - Backfiring
    184
  - Erratic, Surging, or Sudden Change in Governed Speed
    185
- Fuel Accumulation in the Crankcase
  185
  - Fuel Distribution
    185
  - Mechanical
    185
  - Operation and Application
    186
- Carburetor
  186
  - Overflow Leak
    186
  - Poor Fuel Economy
    186
  - Poor Acceleration
    186
  - Hard Starting
    186
  - Poor High Speed Operation
    187
  - Abnormal Combustion (Fuel Mixture)
    187
  - Loss of Power (Insufficient Fuel)
    187
  - Loss of Power (Insufficient Air)
    187
  - Surging
    187
- Starter/Generator
  187
  - Starter Is Noisy
    187
  - Rectification Is Imperfect
    188
  - Generator Does Not Charge
    188
- Suspension and Steering
  188
  - Uneven Tire Wear
    188
  - Stiff Steering
    188
  - Play in Steering
    188
  - Vibration
    188
  - Steering Pulls to One Side
    189
- Brake System
  189
  - Neither Wheel Locks When Park Brake Is Latched
    190
  - Neither Wheel Locks
    190
  - Grabbing Brakes (over Sensitive)
    190
  - Parking Brake Hard to Latch
    190
  - Parking Brake will Not Stay Latched
    190
  - General
    193
- General Specifications
  201

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