ENGINE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Controls and Wiring
Unplug the wiring harness from the engine and cut the
wire tie securing the accelerator cable to the engine.
Remove the choke cable from the carburetor. Remove
the push nut at the governor and discard the nut.
Remove the pulse line from the fuel pump. Remove the
ground strap from the engine. Loosen the starter/genera
tor and remove the belt. Remove the short control rod
from the bellcrank and the governor. Remove the short
rod from the bellcrank to the carburetor.
Removing the Engine from the Vehicle
I
NOTE
I
Place suitable blocks under the engine frame
-
- for support. Although the blocks are not
required for engine removal, they will help maintain the align
ment of the frames and simplify engine installation.
Loosen the bolt (3) securing the muffler (4) to the rear
engine frame (5) (Ref Fig. 7 on page G-7).
I
NOTE
I
It is not nece�sary to remove the muffler as
�- ---�- part of the engine removal.
Remove the four bolts (15) that secure the engine to the
engine support castings (13, 17). Lift the engine and
drive clutch vertically through the engine compartment
using a hoist or with the assistance of another person.
Engine Installation
CAUTION
When installing the fuel and pulse lines,
pay particular attention to assure that
the lines are not confused.
Be sure to use a new push nut when installing the accelerator
cable to the governor.
It is important to follow the assembly sequence recommended
for mounting hardware.
With the assistance of a hoist or another person, lower
the engine into position over the engine support castings
(Ref Fig. 8 on page G-9).
Install one rear horizontal and one front bottom engine
bolt (15) through the casting and engine and lightly snug
in place.
Install the remaining horizontal engine bolts and finger
tighten. Remove the front bottom bolt and reinstall the
skid plate (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.
DRIVE CLUTCH REMOVAL
Tool List
Qty. Required
Socket, 5/8", 3/8" drive ................................................ 1
Ratchet, 3/8" drive ....................................................... 1
Impact wrench, 1/2" drive ............................................ 1
Impact socket, 13/16", 1/2" drive ................................ 1
Clutch puller, (E-Z-GO P/N 19779-G2) ........................ 1
Remove the clutch bolt (16). (Ref Fig. 8 on page G-9).
A
WARNING.A.
To
prevent the possibili
ty of personal injury, use
o nly impact s o ckets
when using an impact wrench.
Install a well lubricated clutch puller into the clutch and
hand tighten for several turns. Remove the clutch by driv
ing it off with the impact wrench and the clutch puller.
I
NOTE
I
In some extreme cases, the clutch will be resis
.
- tant to removal. In stubborn cases the clutch
removal tool should be removed and the cavity filled with
grease. Install the clutch puller and use the impact wrench to
drive off the clutch. The combination of hydraulic pressure
(grease) and the impact wrench will remove the most stubborn
clutch. To prevent damage to the clutch, be sure to remove all
grease from the body of the clutch since grease penetrating the
seal may cause premature clutch failure.
It is not necessary to remove the engine to remove the
clutch. Refer to the CONTINUOUSLY VARIABLE
TRANSMISSION (CVT) section for removal and installa
tion with the engine installed in the vehicle.
COOLING SYSTEM CLEANING
At least once a year (or more often under adverse condi
tions) the cooling system should be cleaned. Cleaning
will assure an adequate supply of air to the cooling fins.
Compressed air may be used for routine cooling system
maintenance (Ref Fig. 9 on page G-9).
Operation in wet or damp weather or over freshly cut
grass may result in a variety of debris accumulating and
adhering to the internal shroud and fins of the cooling
system. If this condition exist, proceed as follows:
I
NOTE
I
Avoid spraying water on electrical components.
With the engine cold, direct a strong stream of water at
the cylinder head cooling fins beside the timing belt cover
(Ref Fig. 10 on page G-9).
Page G-8
Repair and Service Manual
Summary of Contents for 4 CADDY 1999
Page 6: ...TABLE OF CONTENTS Notes __________________________ _ Page iv Repair and Service Manual...
Page 10: ...SAFETY INFORMATION Notes _________________________ _ Page viii Repair and Service Manual...
Page 26: ...SAFETY Notes _ _ ___________________________ _ Page B ii Repair and Service Manual...
Page 48: ...BODY Notes _ _ ___________________________ _ Page C ii Repair and Service Manual...
Page 56: ...WHEELS AND TIRES Notes __________________________ _ Page D ii Repair and Service Manual...
Page 72: ...SPEED CONTROL Notes _ _ ________________________ _ Page F ii Repair and Service Manual...
Page 80: ...ENGINE Notes _ _ __________________________ _ Page G ii Repair and Service Manual...
Page 94: ...FUEL SYSTEM Notes _ _ _________________________ _ Page H ii Repair and Service Manual...
Page 110: ...ELECTRICAL Notes _ _ _________________________ _ Page K ii Repair and Service Manual...
Page 120: ...ACCESSORY WIRING Notes __________________________ _ Page L ii Repair and Service Manual...
Page 148: ...REAR SUSPENSION Notes __________________________ _ Page N ii Repair and Service Manual...
Page 154: ...REAR AXLE Notes _ _ ___________________________ _ Page P ii Repair and Service Manual...
Page 158: ...PAINT Notes _ _ ___________________________ _ Page Q ii Repair and Service Manual...
Page 162: ...TROUBLESHOOTING Notes _ _ ________________________ _ Page R ii Repair and Service Manual...
Page 170: ...LIMITED WARRANTY Notes __________________________ _ Page S ii Repair and Service Manual...
Page 176: ...LIMITED WARRANTY Notes __________________________ _ Page S 6 Repair and Service Manual...
Page 178: ...GENERAL SPECIFICATIONS Notes _________________________ _ Page T ii Repair and Service Manual...
