Textron EZGO TXT SHUTTLE 2+2 Manuals

Manuals and User Guides for Textron EZGO TXT SHUTTLE 2+2. We have 3 Textron EZGO TXT SHUTTLE 2+2 manuals available for free PDF download: Service Manual, Service & Parts Manual

Textron EZGO TXT SHUTTLE 2+2 Service Manual (202 pages)

Brand: Textron | Category: Golf Cars | Size: 24 MB

Safety
2
General Information
4
Battery Prolonged Storage
4
Battery Disposal
4
Table of Contents
5
Safety Information
7
General Operation
8
General Information & Routine Maintenance
12
Serial Number Label Location
13
Starting the Vehicle with Adischarged Battery
13
Servicing the Vehicle
13
Fig. 1 Serial Number Label
13
Service Operation
14
Fig. 2 Initial Service Chart
14
Early Production Fuel Tank
14
Fig. 3 Fuel Tank
15
Fig. 4 Fuel Tank
15
Fig. 5 Neutral Lock
16
Routine Maintenance
16
Fig. 6 Lubrication Points
16
Powertrain Maintenance
16
Top and Windshield
17
Winter or Prolonged Storage
17
Care and Cleaning of the Vehicle
18
Vehicle Care Products
18
Torque Specifications
19
Fig. 7 Torque Specifications
19
Periodic Service Schedule
20
Fig. 8 Periodic Service Schedule
21
Section Title
23
Battery Removal and Installation
26
Lifting the Vehicle
27
Safety
27
Body
29
Body
31
General
31
Body Component Replacement
31
Instrument Panel Replacement
31
Cowl Replacement
34
Rocker Panel Replacement
34
Front Shield Replacement
34
Body Replacement
34
Rear Bumper Replacement
35
Painting
35
Minor Scratches
35
Larger Scratches
36
Complete Panel Repair
36
Brakes
39
Brakes
40
Brakes System Overview
41
General Description
41
How the Service Brake Works
42
Equalizer Link
42
Automatic Adjuster Mechanism
42
How the Parking Brake Works
42
Compensator Assembly
43
Kick-Off Actuating Linkage
43
Troubleshooting Flowchart
44
Troubleshooting Table
46
Troubleshooting and Inspection
48
New Vehicles
48
Troubleshooting and Inspection Procedures
48
Brake Pedal and Linkage Inspection
48
Periodic Brake Performance Test (PBPT)
50
Aggressive Stop Test
51
Wheel Brake Inspection
52
Maintenance and Repairs
54
Parts Replacement Vs Repair
54
Adjusting Brake Pedal Free Travel
54
Brake Drum Removal and Installation
55
Wheel Brake Service
56
Backing Plate/Entire Wheel Brake Assembly Removal and Installation
57
Brake Shoe Removal
57
Brake Shoe Installation
59
Brake Cable and Equalizer Assembly Removal and Installation
60
Compensator Assembly Removal and Installation
60
Brake Pedal Removal and Installation
60
Parking Brake Catch Bracket Removal and Installation
61
Parking Brake Pedal Removal and Installation
61
Pedal Bumper Adjustment
61
Parking Brake Release Linkage Removal and Replacement
62
Parking Brake Kick-Off Cam Removal, Replacement and Installation
62
Front Suspension and Steering
65
Maintenance
68
Lubrication
68
Wheel Bearing and King Pin Bushing Inspection
68
Wheel Bearing Packing
68
Wheel Bearing Adjustment
69
Wheel Alignment
69
Front Suspension
71
Front Shock Absorber Replacement
71
Front Axle Replacement
72
Front Spring Replacement
72
Hub Replacement
73
Wheel Bearing and Race Replacement
74
Steering
75
Rack Ball Joint Replacement
75
Tie Rod Inspection/Replacement
76
Bellows Replacement
77
Pinion Seal Replacement
77
Spindle Replacement
78
Rack and Pinion Unit Disassembly and Inspection
79
Rack and Pinion Unit Replacement
80
Checking/Adjusting Rack Extension-To-Rack and Pinion Unit Clearance
80
Steering Wheel Replacement
81
Steering Shaft and Column Replacement
82
Speed Control
85
System Operation
87
Pedal Box Operation
87
Pedal Box Adjustments
90
Engine
93
Powertrain Maintenance
95
Checking the Oil Level
95
Changing the Oil
95
Air Filter Inspection/Replacement
97
Starter/Generator Belt Tension
97
Adjusting the Belt
99
Starter/Generator Replacement
99
Cooling System Cleaning
99
Spark Plug
100
Four Cycle Engine
100
Engine Specifications
100
Engine Description
100
Cylinder Head
100
Rocker Cover Removal
101
Valve Clearance Inspection
101
Valve Clearance Adjustment
102
Engine Removal
102
Controls and Wiring
103
Removing the Engine from the Vehicle
103
Engine Installation
103
Drive Clutch Removal
104
Fuel System
107
Fuel
107
General
110
Early Production Fuel Tank
110
Late Production Fuel Tank
110
Carburetor Operation
111
Float System
111
Pilot Jet System
111
Main Jet System
111
Choke System
111
Carburetor Service
111
Choke Operation
111
Fuel System Component Service and Replacement
112
Choke Cable and Housing Removal
112
Choke Cable and Housing Installation
112
Carburetor Removal
113
Carburetor Disassembly
113
Float Level Alignment
114
Carburetor Installation
114
Fuel Pump
114
Fuel Pump Replacement
115
Fuel Tank Removal
116
Early Production Vehicles
116
Carbon Canister
117
Continuously Variable Transmission (Cvt)
119
General
121
Clutches
121
Fuel Tank
122
Drive Clutch
122
Driven Clutch
122
Increased Load
122
Equilibrium
122
Storage
124
Direction Selector
127
Hardware
130
Electrical
133
Circuits and Controls
135
Testing the Magneto
138
Testing Starting Circuit
139
Testing Charging Circuit
139
Starter/Generator Removal
140
Battery Voltage Test
141
Repair and Replacement
141
Storage of Battery
142
Dvom (Digital Volt Ohm Meter)
142
Rear Suspension
147
Rear Axle Removal
152
Rear Axle Installation
152
Rear Axle
155
Neutral Lock
157
Checking the Lubricant Level
157
Rear Axle Disassembly
158
Axle Shaft Removal and Disassembly
158
Axle Shaft Seal Removal and Replacement
159
Axle Shaft Replacement
159
List of Illustrations
161
Wheels and Tires
161
Wheel and Tire Service
163
Tire Repair
163
Wheel Installation
164
Weather Protection
167
Sun Top and Windshield
169
Front Strut Installation
171
Full Windshield
174
Troubleshooting
177
Gasoline Vehicle Performance
179
Starter Does Not Turn
179
Starter Turns Slowly
179
Engine Runs Rough or Loss of Power
180
Poor Low Speed Performance
181
Poor Midrange or High Speed Performance
181
Engine Overheating
181
Repeated Spark Plug Fouling
182
Carburetor Floods Engine
182
Backfiring
182
Erratic, Surging, or Sudden Change in Governed Speed
183
Fuel Accumulation in the Crankcase
183
Fuel Distribution
183
Mechanical
183
Operation and Application
184
Carburetor
184
Poor Low Speed Performance
184
Poor Fuel Economy
184
Poor Acceleration
184
Hard Starting
184
Poor High Speed Operation
185
Abnormal Combustion (Fuel Mixture)
185
Loss of Power (Insufficient Fuel)
185
Loss of Power (Insufficient Air)
185
Starter Is Noisy
185
Rectification Is Imperfect
186
Generator Does Not Charge
186
Suspension and Steering
186
Uneven Tire Wear
186
Stiff Steering
186
Vibration
186
Steering Pulls to One Side
187
Brake System
187
Fails Brake Performance Test by Stopping in Longer Distance than Normal
187
Neither Wheel Locks When Park Brake Is Latched
188
Unequal Braking (One Wheel Locks Other Rotates)
188
Neither Wheel Locks
188
Grabbing Brakes (over Sensitive)
188
Parking Brake Hard to Latch
188
Parking Brake Will Not Stay Latched
188
General Specifications
191

Textron EZGO TXT SHUTTLE 2+2 Service & Parts Manual (130 pages)

GASOLINE EFI POWERED GOLF CAR

Brand: Textron | Category: Golf Cars | Size: 13 MB

Textron EZGO TXT SHUTTLE 2+2 Service & Parts Manual (120 pages)

48V ELECTRIC POWERED GOLF CARS

Brand: Textron | Category: Golf Cars | Size: 14 MB

Table of Contents
5
How to Use the Service Parts Manual
7
Accelerator
10
Battery Charger
14
Body
18
- Body - Front
  19
- Body - MID Section
  22
- Body - Rear
  24
- Body - Accessories
  28
Brakes
38
Electrical
46
Electronic Speed Control
60
Front Suspension and Steering
64
Motor
74
Rear Axle
76
Rear Suspension
78
Seating
80
- Seating - Convertible Carrier
  81
- Seating and Bag Holder - Golf Car
  90
- Permanent
  98
- Casual
  103
Weather Protection
106
Wheels and Tires
116

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