E-Z-GO 4 CADDY 1999, Technician'S Repair And Service Manual

Page 1: ...a ii f U t mCompany TECHNICIAN S REPAIR AND SERVICE MANUAL GASOLINE POWERED GOLF CARS AND PERSONAL VEHICLES MODEL YEARS 1999 2000 REVISED 12 2000...

Page 2: ...URN SHARP TURN STEEP HILL WASH HANDS AFTER HANDLING APPLY BRAKE APPLY BRAKE APPLY BRAKE WASH HANDS AFTER HANDLING WARNING Battery posts lerminalsandrelated accessoriescontain leadandleadcompounds chem...

Page 3: ...without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice E Z GO Division of Textron is not liable for errors...

Page 4: ...pecifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain Federal and State emissi...

Page 5: ...Safety B Body C Wheels and Tires D Front Suspension and Steering E Speed Control F Engine G Fuel System H Continuously Variable Transmission CVT J Electrical K Accessory Wiring L Mechanical Brakes M...

Page 6: ...TABLE OF CONTENTS Notes __________________________ _ Page iv Repair and Service Manual...

Page 7: ...he material in this manual This vehicle conforms to the current applicable standard for safety and performance requirements These vehicles are designed and manufactured for off road use They do not co...

Page 8: ...ommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Always support the vehicle using wheel chocks and safety stands Never get unde...

Page 9: ...icle in an area that is subject to flame or spark Pay particular attention to natural or propane water heater and furnaces Never work around or operate a vehicle in an environment that does not ventil...

Page 10: ...SAFETY INFORMATION Notes _________________________ _ Page viii Repair and Service Manual...

Page 11: ...7 Adjusting the Belt A 7 AIR INTAKE AND COOLING FINS A 7 SPARK PLUGS A 8 GENERAL PREVENTATIVE MAINTENANCE A 8 BRAKE TEST A 8 TIRES A 8 CARE AND CLEANING OF THE VEHICLE A 8 VEHICLE CARE PRODUCTS A 9 TO...

Page 12: ...5 Fig 13 Air Cleaner A 6 Fig 14 Add Check and Drain Rear Axle Lubricant A 6 Fig 15 Checking Belt Tension with Gauge A 7 Fig 16 Checking Belt Tension with Finger A 7 Fig 17 Adjusting the Belt Tension A...

Page 13: ...starting should not be attempted If the vehicle is equipped with lights and or accessories that are used when the vehicle is not in motion the starter generator may not be adequate to maintain bat ter...

Page 14: ...reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be ca...

Page 15: ...iving conditions POWERTRAIN MAINTENANCE Access the powertrain by raising or removing seat Some service procedures may require the vehicle be lifted Refer to LIFTING THE VEHICLE in section B for proper...

Page 16: ...period of 100 hours Ref Fig 8 on page A 4 The oil should be changed with the engine warm Park the vehicle on a level surface lock the parking PARK brake and remove the key Place a drain pan under the...

Page 17: ...n If nec essary continue to add oil slowly and allow time for oil to flow down into engine Do not overfill O Ring t Jf Fig 12 Adding Engine Oil CAUTION the air filter enclosure Do not overfill engine...

Page 18: ...g liquid automatic dishwasher deter gent and water Rinse in non pressurized clear water Allow to air dry completely before reinstalling Do not force dry the filter CAUTION Do not use pressurized water...

Page 19: ...16 on page A 7 3 8 10 mm New Belt or 1 2 13 mm Existing Belt Maximum Deflection Fig 16 Checking Belt Tension with Finger Re tighten an existing belt to 75 80 lbs 34 36 kg tension using the same techn...

Page 20: ...rake at a common point on a flat dry clean paved surface while traveling at maximum governed speed Observe the vehicle stopping location For vehicles used in fleet applications If the vehicle stops in...

Page 21: ...lubricating film prevents corrosion by adhering to wet or dry surfaces and displaces moisture sealing against future moisture return P N 75503 G01 Multi purpose Cleaner and Degreaser that con tains n...

Page 22: ...attach the fuel line to the tank I NOTE I The vehicle can be stored for the winter with the old oil left in the engine The oil should be TORQUE SPECIFICATIONS changed as part of spring maintenance Thi...

Page 23: ...allons 6 liters BATTERY water solution rinse with clear water Check charge condition and connections to battery WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR...

Page 24: ...etaining nuts Lubricate use wheel bearing grease STEERING ASSEMBLY Lubricate linkage use wheel bearing grease TIE RODS LINKAGES Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and...

Page 25: ...SAFETY WARNING B 8 MODIFICATIONS TO VEHICLE 8 8 GENERAL MAINTENANCE 8 8 BEFORE SERVICING THE VEHICLE 8 8 Battery Removal and lnstallation B 9 LIFTING THE VEHICLE B 10 NEUTRAL LOCK B 10 LIST OF ILLUST...

Page 26: ...SAFETY Notes _ _ ___________________________ _ Page B ii Repair and Service Manual...

Page 27: ...the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruct...

Page 28: ...carrier operator and other employees c general safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were...

Page 29: ...potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arra...

Page 30: ...ders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use I Brakes steering mechanisms speed and direc tional control mechanisms warni...

Page 31: ...s warrant to their premises to identify areas where golf cars should not be operated and to identify possible hazards 5 2 1 Steep Grade In areas where steep grades exist golf car operations should be...

Page 32: ...er and the amount of time the batteries are on charge Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic liters per car per charge Because of the highly volatile nature of...

Page 33: ...truction plates tags or decals are changed accordingly 6 2 8 As required under paragraphs 6 2 6 and 6 2 7 the manufacturer shall be contacted to secure new name plates warnings or instructions which s...

Page 34: ...manner that will change the weight distribution of the vehicle AWARNING A Changes to the weight distribution or the center of gravity may make the vehicle unstable or prone to roll over which could r...

Page 35: ...lines are correctly installed before starting the engine see FUEL SYS TEM section Battery Removal and Installation Tool List Qty Required Insulated wrench 1 2 1 Socket 1 2 3 8 drive 1 Extension 12 3...

Page 36: ...der the rear frame crossmember Raise the vehicle and locate a jack stand under the outer ends of the rear axle Lower the jack and test the stability of the vehicle on the two jack stands Place the jac...

Page 37: ...h the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruc...

Page 38: ...s carrier operator and other employees c general safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were...

Page 39: ...s potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arr...

Page 40: ...ders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use I Brakes steering mechanisms speed and direc tional control mechanisms warni...

Page 41: ...ns warrant to their premises to identify areas where golf cars should not be operated and to identify possible hazards 5 2 1 Steep Grade In areas where steep grades exist golf car operations should be...

Page 42: ...ger and the amount of time the batteries are on charge Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic liters per car per charge Because of the highly volatile nature o...

Page 43: ...struction plates tags or decals are changed accordingly 6 2 8 As required under paragraphs 6 2 6 and 6 2 7 the manufacturer shall be contacted to secure new name plates warnings or instructions which...

Page 44: ...y manner that will change the weight distribution of the vehicle AWARNING A Changes to the weight distribution or the center of gravity may make the vehicle unstable or prone to roll over which could...

Page 45: ...installed before starting the engine see FUEL SYS TEM section Battery Removal and Installation Tool List Qty Required Insulated wrench 1 2 1 Socket 1 2 3 8 drive 1 Extension 12 3 8 drive 1 Ratchet 3 8...

Page 46: ...vehicle and locate a jack stand under the outer ends of the rear axle Lower the jack and test the stability of the vehicle on the two jack stands Place the jack at the center of the front axle Raise t...

Page 47: ...LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Body Components Front C 2 Fig 3 Floor Pan Rocker Panels and Seat Wrap C 3 Fig 4 Rear Body Components for TXT Models C 4 Fig 5 Rear Body Com...

Page 48: ...BODY Notes _ _ ___________________________ _ Page C ii Repair and Service Manual...

Page 49: ...er to push out the shank of the rivet The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightly larger than shank of the rivet Ref Fig 1 on page C 1 Care must...

Page 50: ...tempting anyprocedure Payparticularattention to all Notes Cautions and Warnings Page C 2 kW TYPE KG CE EZGOD1v1s1ana Tntran Inc PO 8ox31111 Augusta Georgia USA30903031111 FRONT SHIELD COMPONENTS Fig 2...

Page 51: ...d this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Seat Wrap for Metal Body Vehicles Floormat Fig 3 Floor Pan Rocker Panels and Seat Wrap Repair...

Page 52: ...on B and this section before attempting anyprocedure Payparticularattention to all Notes Cautions and Warnings 4 Caddy I Shuttle 2 2 Models Only Fig 4 Rear Body Components for TXT Models Page C 4 Repa...

Page 53: ...ll of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 5 Rear Body Components for Metal Body Vehicles Repair and Service Manua...

Page 54: ...before attempting anyprocedure Payparticularattention to all Notes Cautions and Warnings 4 CADDY SHUTTLE 2 2 COMPONENTS FOR TXT MODELS 4 CADDY SHUTTLE 2 2 COMPONENTS FOR METAL BODYVEHICLES Fig 6 4 Ca...

Page 55: ...TIRES TABLE OF CONTENTS FOR SECTION D SECTION TITLE D PAGE NO WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 1 LIST OF ILLUSTRATIONS Fig 1 Wheels and Tires D 2 Repair and Service Manu...

Page 56: ...WHEELS AND TIRES Notes __________________________ _ Page D ii Repair and Service Manual...

Page 57: ...pressure tubeless tires mounted on one piece rims Generally the most cost effective way to repair a flat tire resulting from a puncture in the tread portion of the tire is to use a commercial tire pl...

Page 58: ...d all of Section B and this sectionbefore attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings Tire style may vary CROSS SEQUENCE 3 Fig 1 Wheels and Tires Page D 2 Repair...

Page 59: ...ng Pinion and Bearing Replacement E 7 MAINTENANCE E 7 Lubrication E 7 Wheel Bearing Inspection Packing E 7 Seal Installation E 8 Bearing Adjustment E 8 King Pin Bushing Replacement E 9 Wheel Alignment...

Page 60: ...FRONT SUSPENSION AND STEERING Notes ________________________ _ Page E ii Repair and Service Manual...

Page 61: ...er to clear the mounting bracket Front of Vehicle Fig 1 Shock Absorber Replacement On metal body vehicles bend the tabs that secure the flexible grass shield 3 to the cowl down and pull the grass shie...

Page 62: ...must be the same as the distance from the center bolt at rear of right spring to the center bolt at front of left spring Ref Fig 3 on page E 2 Equal Distance Fig 3 Front Axle Alignment Tighten leaf sp...

Page 63: ...Grasp the top and bottom of the wheel and use a rocking motion to check for excessive king pin or wheel bearing movement which indicates a worn or loose condition Tie Rod Replacement Tool List Qty Re...

Page 64: ...E NUT AT THIS TIME Apply upward pressure to the steering wheel Place a plastic faced hammer against the steering wheel nut and strike plastic faced hammer sharply with a ball peen hammer Ref Fig 7 on...

Page 65: ...teering shaft in reverse order of removal Gas ket 8 should be replaced with a new gasket Bolts 9 should be tightened to a light drag between shaft 12 and coupling 11 Do not over tighten Bolts 6 must b...

Page 66: ...E 5 The tensioner can be greased through a right angle grease fitting 29 located on the steering housing directly behind the front shield The ten sioner does need to be removed in order to replace the...

Page 67: ...ing can then be inserted The rack and steer ing pinion must be replaced as a set MAINTENANCE Good routine maintenance of the front suspension and steering consists of routine lubrication See Lubricati...

Page 68: ...and around all of the rollers until the entire bearing is coated in grease Fill the area between the rollers with grease and apply a light coating to the bearing race Install bearing in race Seal Ins...

Page 69: ...the king pin nut 9 to 35 50 ft lbs 50 70 Nm torque Wheel Alignment Tool List Qty Required Floor jack 1 Jack stands 2 Wheel chocks 4 Box end wrench 1 1 4 1 Tape measure 1 Chalk 1 Lift the front of the...

Page 70: ...ts 25 30 ft lbs 34 41 Nm torque Center the steering wheel and adjust the passenger side tie rod 4 until the correct alignment is achieved Lock the tie rod jam nuts 25 30 ft lbs 34 41 Nm torque Check t...

Page 71: ...F 2 SPEED CONTROL LINKAGE ADJUSTMENT F 3 PEDAL BOX ADJUSTMENTS F 4 Accelerator Pedal Arm Adjustment F 4 Micro Switch Adjustment F 4 Control Arm Link F 4 GOVERNOR COMPRESSION SPRING ADJUSTMENT F 6 Road...

Page 72: ...SPEED CONTROL Notes _ _ ________________________ _ Page F ii Repair and Service Manual...

Page 73: ...tance of the accelerator return spring Ref Fig 1 on page F 1 As the accelerator pedal moves the parking brake is released the micro switch closes and activates the igni tion circuit The rear end of th...

Page 74: ...oms that include an increase in governed speed indicate a possible governor failure within the rear axle worn components in the governor system improper adjustment of linkage system I NOTE I Other fac...

Page 75: ...op screw until it just touches the throttle lever when fully closed At the other end of the linkage rod push the arm of the rear bellcrank 6 toward the front of the vehicle until it stops Adjust the b...

Page 76: ...rocker panel lift the floor mat and remove the access cover from the floor Ref Fig 6 on page F 4 Remove the screws 15 and cover 16 from the pedal box Ref Fig 7 on page F 5 Loosen the setscrew 17 using...

Page 77: ...Read allof Section Band this section before attempting anyprocedure Payparticular attention to allNotes Cautions and Warnings LO O T T CX T o LO m Fig 7 Accelerator Linkage Repair and Service Manual L...

Page 78: ...spring jam nut 33 Ref Fig 7 on page F 5 Pre adjust the governor compression spring 34 by rotating the adjuster 35 until a dimension of 1 3 4 44 mm is achieved between the inside of the cup washers 36...

Page 79: ...Starter Generator Installation G 1O ENGINE ISOLATION MOUNT REMOVAL G 11 Engine Isolation Mount Installation G 11 MUFFLER REMOVAL G 11 Muffler Installation G 11 LIST OF ILLUSTRATIONS Fig 1 Overhead Val...

Page 80: ...ENGINE Notes _ _ __________________________ _ Page G ii Repair and Service Manual...

Page 81: ...h causes the air fuel mixture to expand The piston has been carried through TDC by centrifugal force and is now forced downwards into the third or power stroke by the expanding gases As the piston rea...

Page 82: ...Screw Type Adjuster Page G 2 VALVE OPEN Timing Belt Pulley Timing Belt Cam Lobe Up VALVE CLOSED VALVE OPERATION Cylinder Piston Cam Lobe Down Valve Cover Camshaft Cam Lobe NOTE This is a simplified d...

Page 83: ...ttention to allNotes Cautions and Warnings Intake 0 0 INTAKE COMPRESSION First Revolution 0 0 POWER EXHAUST Second Revolution NOTE This is a simplified diagram for explanatory use only Rockers guides...

Page 84: ...raight blade screwdriver Slide the feeler gauge back and forth between the rocker and cam until light resis tance is felt Hold the adjuster with the screwdriver and tighten the jam nut with a box wren...

Page 85: ...er to 4 Cycle Engine Shop Rebuild and Service Parts Manual E Z GO P N 27615 G01 COMPRESSION TESTS Tool List Qty Required Compression gauge 1 Spark plug wrench 1 Ratchet 3 8 drive 1 A_WARNING A_ sectio...

Page 86: ...valve sealing problems All readings should be compared with the engine manu factures specification Engine cylinder specifications are usually provided for unseated rings As a general rule the compress...

Page 87: ...tions are as shown in the table contained in Section A This operation will remove the engine through the top of the engine compartment The weight of the engine exceeds normal OSHA limits for one perso...

Page 88: ...e 8 finger tight Tighten the bottom and horizontal mounting bolts to 45 ft lbs 60 Nm torque The remaining installation is in the reverse order of dis assembly using standard torque specifications DRIV...

Page 89: ...s 10 Plastk Washer 12 Fig 8 Engine Mounting Fig 9 Cleaning Cooling System with Air 8 17 5 6 16 Allow the water to flow freely over the cooling fins and through the blower housing After flushing dry wi...

Page 90: ...removal Install the starter generator pivot bolt 7 and hardware loosely in place and install the belt 5 Ref Fig 8 on page G 9 Tighten a new starter generator belt to 90 110 lbs 41 50 kg tension when...

Page 91: ...ch the isolation bracket to the vehicle frame and tighten the flanged nuts 11 to 21 25 ft lbs 28 34 Nm torque Tighten the isolation mount bolt 10 to 21 25 ft lbs 28 34 Nm torque I NOTE I In cas s wher...

Page 92: ...NE Read all of Section B and this sectionbefore attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings Notes _____________________________ _ Page G 12 Repair and Service Ma...

Page 93: ...Carburetor Removal H 2 Carburetor Installation H 3 Carburetor Disassembly H 4 Float Level Adjustment H 4 Throttle Shaft Adjustment H 5 Carburetor Installation H 5 FUEL PUMP H 5 Fuel Pump Replacement...

Page 94: ...FUEL SYSTEM Notes _ _ _________________________ _ Page H ii Repair and Service Manual...

Page 95: ...e buoyancy of the float Fuel Filter Fuel Pump Fuel Line Carburetor exceeds the fuel pressure on the needle valve the float closes the needle valve The float is adjustable to main tain the correct fuel...

Page 96: ...stalling bolts etc Additional hard ware nuts washers etc that are removed must always be installed in their original positions unless otherwise specified Non specified torque specifications are as sho...

Page 97: ...t 15 and slide the carburetor from the engine studs I NOTE I f th carburetor contacts the starter generator it will be necessary to remove the starter belt and tilt the starter generator to permit car...

Page 98: ...nal passages with foreign mate rial Do not bend the float pin during removal See Carburetor Troubleshooting elsewhere in this section Remove the float bowl 1 by removing the retaining screw Ref Fig 4...

Page 99: ...longer contacts the tab on the throttle shaft Ref Fig 4 on page H 4 Hold the throttle shaft in the closed position then turn the throttle stop screw clockwise until it con tacts the tab on the thrott...

Page 100: ...nkcase and diluting the oil and possible engine damage FUEL LINES AND FILTER Tool List Qty Required Needle nose pliers 1 Straight blade screwdriver 1 Fuel is supplied to the fuel pump and carburetor t...

Page 101: ...ine to the tank When the vehicle is to be used again the carburetor bowl float drain valve must be closed and the fuel tank filled with fresh 87 minimum octane fuel The addition of fresh fuel mixed wi...

Page 102: ...k or hoses Clean Clogged fuel filter Replace fuel filter Clogged main jet or main jet air passage Clean jets Dirty air filter Clean replace filter element ABNORMAL COMBUSTION Dirty carburetor Clean ca...

Page 103: ...e Clutch Installation J 3 Driven Clutch Removal J 3 Driven Clutch Repair J 3 Torque Ramp Buttons J 3 Driven Clutch Assembly J 3 Driven Clutch Installation J 3 DRIVE BELT J 3 Removing the Drive Belt J...

Page 104: ...CONTINUOUSLY VARIABLE TRANSMISSION CVT Notes _______________________ _ Page J ii Repair and Service Manual...

Page 105: ...es to rise the drive clutch sheave continues to move inwards forcing the drive belt to the outer diameter of the drive clutch sheaves which increases the speed of the belt The ratio is greatly decreas...

Page 106: ...centrifugal force exerted by the cams in the drive clutch This forces the belt lower into the drive clutch which increases the drive ratio This downshifting applies more torque to the rear axle with o...

Page 107: ...uired External snap ring pliers 1 Socket 5 8 1 2 drive 1 Ratchet 1 2 drive 1 Thread locking sealant AR Phillips screwdriver 1 Torque wrench 1 2 drive ft lbs 1 Remove the drive belt 1 Refer to Removing...

Page 108: ...n in which case it should be washed with plain water If the belt becomes frayed or badly worn it must be replaced STORAGE If the vehicle is to be out of service due to off season storage the clutches...

Page 109: ...6 Starter Generator Removal K 6 Starter Generator Disassembly K 6 Starter Generator Inspection K 6 Starter Generator Repair and Replacement K 8 BATTERY VOLTAGE TEST K 8 STORAGE OF BATTERY K 8 LIST OF...

Page 110: ...ELECTRICAL Notes _ _ _________________________ _ Page K ii Repair and Service Manual...

Page 111: ...ion system Generated output is con trolled by the voltage regulator at 14 25 14 75 V without regard to engine speed However the charging current will vary depending on the condition of the battery If...

Page 112: ...HT RED WHT GRN GRN 0 RED Key Ignition Coil Switch RED GRN BLK r 1 A2 I j P lser Co l l Starter generator F2 i I _ _ ____ A1 I I_ _J Engine MS3 GRN Fig 1 Electrical System Wiring Diagram Page K 2 Repai...

Page 113: ...attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings RED WHT 1 l Ignition 0 tarter generator Coil lgnitor To Pos Battery To F2 On Starter Generatpr Fig 2 Electrical Syst...

Page 114: ...n over proceed as following Ref Fig 1 on page K 2 1 Check the battery for a voltage reading which should be between 12 2 and 12 5 volts Inspect for loose or dirty battery post connections 2 Check for...

Page 115: ...Cautions and Warnings 3 l nl To Primary 5 2 nl s n illV 1DJ ill iillJl 11 e t C w N g _Q f A Black Probe Secondary sa _ _ n illV 10Ai ll _ 111 Q jllll g la Q ft Fig 3 Ignition Coil Check Method Fuse...

Page 116: ...above its prior reading replace the regulator 9 If the above procedures do not correct the problem check for faults in the vehicles wir ing harness and or generator STARTER GENERATOR Starter Generato...

Page 117: ...r attention to all Notes Cautions and Warnings Spring Position Brush Spring Fig 5 Starter Generator for Installed Brushes Spring Position for Removing Replacing Brushes Fig 6 Starter Generator Brush R...

Page 118: ...que to 33 40 ft lbs 450 550 kg cm Tighten terminal nuts to the following torques F1 F2 torque to 43 52 in lbs 50 60 kg cm DF torque to 26 35 in lbs 30 40 kg cm BATTERY VOLTAGE TEST Battery voltage can...

Page 119: ...FOR SECTION L SECTION TITLE PAGE NO DVOM DIGITAL VOLT OHM METER L 1 TROUBLESHOOTING L 1 POWER SUPPLY L 3 ACCESSORY WIRING L 3 LIST OF ILLUSTRATIONS Fig 1 DVOM L 1 Fig 2 Accessory Wiring Diagram L 2 R...

Page 120: ...ACCESSORY WIRING Notes __________________________ _ Page L ii Repair and Service Manual...

Page 121: ...e tested before trying to troubleshoot the lighting circuit Example 2 If a problem occurs in the lighting circuit that results in only one of the headlights not working there is no reason to check bat...

Page 122: ...BLU WHT BLK BRN BLKbJYEL YEL BRN WHT YEL BRN BLJk IRED REJ rvJ1BLK Hour Meter Taillight Turn Signal Turn Signal Taillight Driver Side Passenger Side For Vehicles Without Turn Signals Remove WHT Wire F...

Page 123: ...the test I NOTE I D e to the resistance of the w res involved within the harness voltage readings may be somewhat lower than battery voltage A reading of 1 volt below battery voltage is acceptable 3 C...

Page 124: ...WIRING Read all of Section B and this sectionbefore attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings Notes _____________________________ _ Page L 4 Repair and Servic...

Page 125: ...Removal and Installation M 18 Brake Pedal Removal and Installation M 19 Parking Brake Catch Bracket Removal and Installation M 19 Parking Brake Pedal Removal and Installation M 20 Pedal Bumper Adjustm...

Page 126: ...stallation M 17 Fig 24 Brake Shoes and Springs M 17 Fig 25 Setting Adjuster Screw M 18 Fig 26 Brake Cable Equalizer and Compensator M 18 Fig 27 Brake Pedal Removal and Installation M 19 Fig 28 Catch B...

Page 127: ...ystem consists of a service brake and parking brake pedal parking brake release linkage compensator assembly equalizer link brake cables and self adjusting wheel brake assemblies See Mechanical Brake...

Page 128: ...er assembly and result in a gradual loss of brakes The wheel brakes are equipped with an automatic adjuster mechanism that is designed to compensate for brake shoe wear and eliminate the need for manu...

Page 129: ...acket This is the preferred method which minimizes wear on components 2 Pressing the accelerator pedal rotates the kick off cam which forces the pedal latch arm to move away from the catch bracket The...

Page 130: ...ch Arm Kick Off Cam Adjustment Pedal Pad Pedal Bumper Condition Secured Adjustment Page M 4 Good Pedal Free Travel Correct Yes Perform the Periodic Brake Performance Test PBPT 3 Times Fails GU 2 out o...

Page 131: ...sive Brake Test 10 times Return to Service Go to Imfirst If tight after second time go to 111 Dynamic Adjust means to fully apply and release the brakes on a vehicle while it is rolling Do this by fir...

Page 132: ...adjusted properly Check and adjust per manual End of brake cable loose from anchor Check and repair brackets Cracked brake drum Replace Starting 2001 Model Year In excess of Low pedal force at parkin...

Page 133: ...urn at equal rate Indication of dragging cable Cracked brake drum Replace Brake shoes wet or glazed Check again when shoes are dry Rusted or sticky brake pivot hardware Replace Brake system requires c...

Page 134: ...ued proper brake operation depends on periodic maintenance Brake Pedal and Linkage Inspection 1 Inspect brake pedal return bumper Be sure that the brake pedal is contacting the pedal return bumper whe...

Page 135: ...replace both cables and equalizer as a set 5 Check the clevis pins Check clevis pins attaching the brake cables to the brake lever They must be loose when the brake pedal has been released Ref Fig 19...

Page 136: ...ROUTINE MAIN TENANCE section of this manual as an evaluation of braking system performance It is useful as a method of identifying subtle loss of performance over time and as part of troubleshooting a...

Page 137: ...the Periodic Brake Performance Tests If vehicle fails remove from service and refer to Wheel Brake Inspec tion on page M 12 to evaluate the reason for failure Aggressive Stop Test AwARNINGA of all pe...

Page 138: ...re when handling the adjuster arm Too much force will damage the adjuster and require that both wheel brake assemblies be replaced 6 Visually check the condition and operation of the adjuster mechanis...

Page 139: ...Shoe Wear 10 Inspect the brake shoe springs Be sure that they are not broken or damaged and are correctly installed The hooked end of the adjuster spring is inserted through the front of the front sh...

Page 140: ...from rest to the point at which the brake cables start to move the brake levers This should not be confused with the light resistance that is felt as the brake pedal is depressed enough to remove slac...

Page 141: ...parking brake pedal until it latches The parking brake should latch between 65 and 75 lbs 29 34 kg indicated on the scale Ref Fig 20 on page M 15 Perform the Periodic Brake Performance Test as descri...

Page 142: ...re assembly of the wheel brake Worn or damaged components must be replaced Wheel brake service is required periodically as a preven tive maintenance measure see Periodic Service Sched ule in Section A...

Page 143: ...our bolts 1 and lock nuts 2 securing the wheel brake backing plate to the flange on the axle tube Ref Fig 23 on page M 17 Fig 23 Backing Plate Removal and Installation Remove the clevis pin securing t...

Page 144: ...ngs must be installed with the light spring closest to the adjuster mechanism with the hook installed down through the rear brake shoe and up through the front brake shoe The heavy top spring is insta...

Page 145: ...and both bushings 7 must be replaced with new ones if corrosion or wear is found Brake pedal installation is in the reverse order of disas sembly Tighten the nut 5 to 25 29 ft lbs 34 39 Nm torque and...

Page 146: ...Pedal Bumper Fig 29 Pedal Bumper Adjustment Parking Brake Release Linkage Removal and Replacement Remove the cotter pin 2 washers 3 and bushings 4 from linkage rod 1 Remove the linkage rod Ref Fig 30...

Page 147: ...REARSUSPENSION N 1 GENERAL N 1 Shock Absorber Removal N 1 Shock Absorber Installation N 1 RearSpring Removal N 1 Rear Spring Installation N 1 REAR AXLE REMOVAL N 1 Rear Axle Installation N 3 LIST OF I...

Page 148: ...REAR SUSPENSION Notes __________________________ _ Page N ii Repair and Service Manual...

Page 149: ...dance with the instructions provided in Section B of this manual and support the rear of the vehicle on the outer ends of the rear bumper Remove the bottom shock absorber nut 1 Ref Fig 1 on page N 2 C...

Page 150: ...REAR SUSPENSION Read all of Section B and this sectionbefore attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings Fig 1 Rear Suspension Page N 2 Repair and Service Manual...

Page 151: ...e belt and driven clutch see CLUTCHES section Remove the F R shifter bracket nut with a 12 mm wrench and loosen the cable nuts with a 1 2 wrench then remove the cable and bracket from the differential...

Page 152: ...ENSION Read all of Section B and this sectionbefore attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings Notes ______________________________ _ Page N 4 Repair and Servic...

Page 153: ...haft Seal Removal and Replacement P 2 Axle Shaft Replacement P 2 LIST OF ILLUSTRATIONS Fig 1 Removing Installing Outer Snap Ring P 1 Fig 2 Removing Installing Axle Shaft P 1 Fig 3 Pressing Bearing fro...

Page 154: ...REAR AXLE Notes _ _ ___________________________ _ Page P ii Repair and Service Manual...

Page 155: ...new one regardless of mileage Always wipe the seals and O rings with a light oil before installing AwARNINGA To reduce the possibility of personal injury follow the lifting procedure in SAFETY section...

Page 156: ...uds Using a seal puller remove the axle shaft seal 5 from the casing CAUTION area Use care to prevent damage to the inner surface of the axle tube at the sealing Replace the seal by lightly tapping ar...

Page 157: ...PAINT TABLE OF CONTENTS FOR SECTION Q SECTION TITLE PAGE NO PAINTING Q 1 Minor Scratches Q 1 Larger Scratches Q 1 Complete Panel Repair Q 1 Repair and Service Manual Page Q i...

Page 158: ...PAINT Notes _ _ ___________________________ _ Page Q ii Repair and Service Manual...

Page 159: ...with alcohol and dry II Mask the area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint Ill Apply spray touch up paint in light even overlapping strokes...

Page 160: ...NT Read all of Section B and this sectionbefore attempting anyprocedure Payparticular attention to all Notes Cautions and Warnings Notes _____________________________ _ Page Q 2 Repair and Service Man...

Page 161: ...TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION R SECTION TITLE PAGE NO GASOLINE VEHICLE PERFORMANCE R 1 STARTER GENERATOR R 5 SUSPENSION AND STEERING R 6 Repair and Service Manual Page R i...

Page 162: ...TROUBLESHOOTING Notes _ _ ________________________ _ Page R ii Repair and Service Manual...

Page 163: ...tment does not work Tighten or clean Check for breaks at bend or joint Replace or repair leads Repair or replace Repair or replace Retighten or clean Charge battery Check for any defect of leads at be...

Page 164: ...xhaust valves Incorrect carburetor float setting Dirt or water in fuel line carburetor Plugged fuel tank vent Muffler damaged or plugged Fuel pump vent dirty Fuel pump has a ruptured diaphragm Low com...

Page 165: ...Adjust Incorrect or plugged main jet Check size for appropriate altitude Clean Dirty air filter Clean or replace Brake dragging Perform brake maintenance Low compression Check engine Governor misadju...

Page 166: ...e Valve seals or valve guides worn Replace Accelerator limit switch out of adjustment Adjust Loose muffler or leaking gasket Repair Carburetor throttle lever motion restricted Repair Carburetor thrott...

Page 167: ...air or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough Smooth with emery cloth Incorrect voltage output Check and replace any components if re quired Commut...

Page 168: ...ing grease Inspect gasket for good seal Raise the vehicle and observe the rack bellows while moving the steering from lock to lock Any distortion of the bellows may indicate that an excess of grease h...

Page 169: ...ANTY TABLE OF CONTENTS FOR SECTION S SECTION TITLE PAGE NO FEDERAL EMISSION COMPONENT DEFECT WARRANTY S 1 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT S 3 LIMITED WARRANTY S 3 Repair and Service Man...

Page 170: ...LIMITED WARRANTY Notes __________________________ _ Page S ii Repair and Service Manual...

Page 171: ...lser Coil 4 Exhaust Manifold 5 Miscellaneous Items Used in Above Systems i Fuel Hoses clamps and sealing gaskets OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest a...

Page 172: ...ICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHEMNT OF INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DEALER OR SERVICE CENTER AUTHORIZED BY E Z GO THE USE OF PARTS THAT ARE NOT...

Page 173: ...E Z GO to which FUJI supplies the en gine as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding...

Page 174: ...he event that any emission related part is found to be defective during the warranty period you should notify E Z GO Warranty Department at 1 800 241 5855 and you will be given the appropriate warrant...

Page 175: ...engine operating schedule PROCEDURE INTERVAL a Check for sealing of fuel cap and proper operation of WEEKLY fuel gauge at each fueling Check that fuel cap vent is free of dirt b Check engine for unus...

Page 176: ...LIMITED WARRANTY Notes __________________________ _ Page S 6 Repair and Service Manual...

Page 177: ...TXT GASOLINE FREEDOM AND FREEDOM HP T 3 TXT GASOLINE 4 CADDY I SHUTTLE 2 2 T 4 METAL BODY GASOLINE FREEDOM AND FREEDOM HP T 5 METAL BODY GASOLINE SHUTTLE 2 2 4 CADDY T 6 LIST OF ILLUSTRATIONS Fig 1 Ve...

Page 178: ...GENERAL SPECIFICATIONS Notes _________________________ _ Page T ii Repair and Service Manual...

Page 179: ...sorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant tee ball and four drink holders SEATING Formed fabric backed vinyl covers over cushion foam Seating for o...

Page 180: ...k absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant tee ball and four drink holders SEATING F...

Page 181: ...absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant tee ball and four drink holders SEATING Formed fabric backed vinyl covers over cushion foam Seating fo...

Page 182: ...absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant tee ball and four drink holders SEATING Fo...

Page 183: ...RING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant tee ball and four drink holders SEATING Formed fabric backed vinyl covers over cushion foam Seating for operator and...

Page 184: ...REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Self compensating single reduction rack and pinion DASH PANEL Scuff resistant tee ball and four drink holders SEATING Formed fabric...

Page 185: ...TXTMODEL GENERAL SPECIFICATIONS METAL BODYMODEL NOTE Shaded Area Indicates 4 CADDY SHUTTLE 2 2 Outline 46 5 in 118cm Fig 1 Vehicle Dimensions Repair and Service Manual Page T 7...

Page 186: ...7 cm 47 in 119 cm RECOMMENDED MAX SIDE TILT 25 GRADE or 14i MAX NOTE TXT FREEDOM MODEL SHOWN RECOMMENDED MAX RAMP 25 GRADE or 14i MAX TURNING CLEARANCE DIAMETER 19 ft 5 8 m Fig 2 Vehicle Dimensions In...

Page 187: ...ng as designed and there fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating corre...

Page 188: ...of Textron Inc P O Box 388 Augusta Georgia 30903 0388 USA Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Te...