E-Z-GO TXT FLEET, Technician'S Repair And Service Manual

Page 1: ...GASOLINE POWERED PERSONNEL CARRIERS ISSUED FEBRUARY 2010 TECHNICIAN S REPAIR AND SERVICE MANUAL 614276...

Page 2: ...hicle or render it unsafe WASH HANDS AFTER HANDLING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm BATTERY WARNIN...

Page 3: ...e E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCID...

Page 4: ...icle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to...

Page 5: ...General Information Routine Maintenance A 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 Direction...

Page 6: ...Page iv Repair and Service Manual TABLE OF CONTENTS NOTES...

Page 7: ...lf of E Z GO I am directing that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the...

Page 8: ...lly speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always Use the vehicle in a responsible manner and maintain the vehicle in safe operati...

Page 9: ...icle that is not performing as designed is a potential hazard and must not be operated Test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free o...

Page 10: ...age viii Repair and Service Manual NOTES SAFETY INFORMATION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 11: ...RTRAIN MAINTENANCE A 3 BRAKES A 4 TIRES A 4 TRAILERING A 4 TOP AND WINDSHIELD A 4 WINTER OR PROLONGED STORAGE A 4 CARE AND CLEANING OF THE VEHICLE A 4 VEHICLE CARE PRODUCTS A 5 HARDWARE A 6 TORQUE SPE...

Page 12: ...epair and Service Manual NOTES GENERAL INFORMATION ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings...

Page 13: ...p max charger Observe all instructions provided by the manufacturer of the charger SERVICING THE VEHICLE To prevent severe injury or death resulting from improper servicing techniques observe the foll...

Page 14: ...llow adequate space for the expansion of gasoline Leave at least 1 2 5 cm of space below the bottom of the filler neck Fig 3 Fuel Tank When refueling inspect the fuel tank cap for leaks or breaks in t...

Page 15: ...n selector mechanism hold direction selector lever when releasing neutral lock pin handle Fig 4 Neutral Lock To activate the direction selector pull the neutral lock pin handle out and rotate until th...

Page 16: ...he weight of the vehicle see GENERAL SPECIFICATIONS for vehicle weight and load Lock the parking brake and secure the vehicle to the trailer using ratchet tie downs TOP AND WINDSHIELD The top does not...

Page 17: ...wise damage paint If the engine does not start or runs improperly after washing remove the spark plug wire by pulling the spark plug boots never the wires and blow them dry Reinstall the wires Remove...

Page 18: ...is chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners...

Page 19: ...A C A C A Park Brake operation does it hold on a hill C A C A C A C A Accelerator smooth operation Starter Generator Belt tension wear cracks Wiring loose connections broken or missing insula tion Car...

Page 20: ...oose or missing hardware Front Wheel Alignment unusual tire wear C A C A C A Fuel System leaks at tank cap system lines for cracks deterioration filters pump Fuel Filter R Spark Plug R Throttle Govern...

Page 21: ...pair and Service Manual NOTES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers GENERAL INFORMATION ROUTINE M...

Page 22: ...epair and Service Manual NOTES GENERAL INFORMATION ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings...

Page 23: ...nual NOTES CAUTIONS AND WARNINGS B 1 IMPORTANT SAFETY WARNING B 1 MODIFICATIONS TO VEHICLE B 1 GENERAL MAINTENANCE B 1 BEFORE SERVICING THE VEHICLE B 1 Battery Removal and Installation B 2 LIFTING THE...

Page 24: ...Page B ii Repair and Service Manual NOTES SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 25: ...place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the tool list and wear approved safety equi...

Page 26: ...ches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a bat tery which could result in an explosion and severe personal injury or death Aerosol containers of battery te...

Page 27: ...ind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process When lifting the vehicle position jacks and jack stands only on the areas indicated...

Page 28: ...Page B 4 Repair and Service Manual NOTES SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 29: ...1 Instrument Panel Replacement C 4 Cowl Replacement C 4 Front Shield Replacement C 4 Rocker Panel Replacement C 4 Body Replacement C 5 Rear Bumper Replacement C 5 BODY PAINTING C 7 Minor Scratches C 7...

Page 30: ...Page C ii Repair and Service Manual NOTES BODY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 31: ...nted with pop rivets which require that the rivet head be removed in order 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...

Page 32: ...Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers Fig 2 Body Components Front 1 4 5 6 7 8 9 10 11 14 15 16 1...

Page 33: ...nd Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers Fig 3 Body Components Rear 27 32 30 31 33...

Page 34: ...ree spacers 16 under each sill plate for reuse when sill plates are rein stalled Drill out the rivets 17 securing the sides of the cowl to the frame From underneath the cowl remove the ratchet fastene...

Page 35: ...ditional pro tection Remove hardware 28 attaching seat back supports 29 to body At the front of the rear body remove the rivets 30 securing the rear body to the frame and floorboard area Drill out the...

Page 36: ...Page C 6 Repair and Service Manual NOTES BODY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 37: ...ghly clean the surface to be repaired with alco hol and dry 2 Mask the area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint 3 Apply spray touch up pai...

Page 38: ...Page C 8 Repair and Service Manual NOTES BODY PAINT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions Warnings and Dangers...

Page 39: ...S FOR SECTION D SECTION TITLE PAGE NO WHEELS AND TIRES Page D i Repair and Service Manual WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tire I...

Page 40: ...Page D ii Repair and Service Manual NOTES WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 41: ...ould cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor applications with...

Page 42: ...the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tig...

Page 43: ...Page D 3 Repair and Service Manual NOTES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers WHEELS AND TIRES...

Page 44: ...Page D 4 Repair and Service Manual NOTES WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 45: ...d Pinion Unit Clearance E 14 Steering Wheel Replacement E 15 Steering Shaft and Column Replacement E 16 LIST OF ILLUSTRATIONS Fig 1 Steering and Front Suspension E 1 Fig 2 Lubrication Points E 2 Fig 3...

Page 46: ...ii Repair and Service Manual NOTES FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and D...

Page 47: ...ay particular attention to all Notices Cautions Warnings and Dangers Fig 1 Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Sh...

Page 48: ...f this manual Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test the stability of the vehicle on the stands before st...

Page 49: ...ht resistance is felt Rotate the wheel 2 3 more turns to displace excess grease If required tighten castellated nut 3 again until slight resistance is felt If the cotter pin hole in the spin dle 5 ali...

Page 50: ...ut the groove has conventional right hand threads To adjust wheel alignment loosen tie rod jam nuts 1 and turn tie rod 2 until correct alignment is achieved Tighten jam nuts to 36 40 ft lbs 49 54 Nm t...

Page 51: ...er 2 at the front axle 3 Ref Fig 6 Compress shock absorber to clear the mounting bracket Loosen the nut securing the top of the shock absorber to the vehicle frame and then rotate the shock absorber w...

Page 52: ...ing apart intermediate shaft Remove the three 1 3 4 long bolts 18 two 1 1 2 long bolts 28 spring plate 24 and five lock nuts 19 secur ing axle to springs and discard lock nuts At the 3 1 2 long bolt 2...

Page 53: ...27 to secure the rack and pinion unit 16 two short bolts 18 and rear bolts 25 To detach passenger side spring Remove the hardware 18 19 24 28 securing the front of the passenger side leaf spring 17 t...

Page 54: ...heel Bearing and Race Replacement Tool List Qty Required Non ferrous punch 1 Ball peen hammer 1 Bearing driver 1 Remove hub 1 from spindle Ref Fig 10 Hub Replacement on Page E 7 Remove the grease seal...

Page 55: ...t 11 16 1 2 drive 1 To remove rack ball joint 1 loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Ref Fig 11 Remove passenger side front wheel and turn steerin...

Page 56: ...front wheel per WHEELS AND TIRES section and lower vehicle per SAFETY section Check front wheel alignment and adjust if necessary Wheel Alignment on Page E 3 Tie Rod Inspection Replacement Tool List...

Page 57: ...1 Tape measure 1 Wrench 3 4 1 Wire cutters 1 Wire tie 8 long 1 Torque wrench 1 2 drive ft lbs 1 Socket 11 16 1 2 drive 1 To replace bellows 1 Ref Fig 14 first loosen passen ger side front wheel and li...

Page 58: ...fully into bore until it stops and wipe clean of any excess grease Attach rack and pinion unit to front axle Rack and Pin ion Unit Replacement on Page E 14 Spindle Replacement Tool List Qty Required...

Page 59: ...sassemble rack and pinion unit 1 by first removing screw 13 and tensioner 2 to relieve pressure on rack 3 and pinion 4 Ref Fig 17 Loosen jam nut 5 and remove rack ball joint 6 from rack extension 7 Cu...

Page 60: ...he rack and pin ion unit can now be removed from vehicle Retain washers 19 spacers 20 and the two bolts 16 for assembly Replace rack and pinion unit in reverse order of removal Use new lock nuts 18 an...

Page 61: ...placement Tool List Qty Required Socket 15 16 1 2 drive 1 Ratchet 1 2 drive 1 Plastic faced hammer 1 Ball peen hammer 1 Anti seize compound 1 Torque wrench 1 2 drive ft lbs 1 To maintain correct orien...

Page 62: ...stress lines Ref Fig 20 If stress lines are present replace clipboard Install by carefully pressing first the top two then the bottom two retaining tabs into the matching slots in steering wheel Steer...

Page 63: ...ing 12 at top of column and press steering shaft and bearing assem bly into column base Secure with large retaining ring making sure it is fully seated in groove of column Place steering column on veh...

Page 64: ...18 Repair and Service Manual NOTES FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and D...

Page 65: ...rator Cable Adjustment F 3 Throttle Rod Removal F 3 Throttle Rod Adjustment F 3 PEDAL BOX ADJUSTMENTS F 4 Accelerator Pedal Arm Adjustment F 4 Micro Switch Adjustment F 4 Road Test F 4 LIST OF ILLUSTR...

Page 66: ...Page F ii Repair and Service Manual NOTES SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 67: ...lity of the vehicle on the jack stands before starting any repair procedure Never work on a vehicle that is sup ported by a jack alone SYSTEM OPERATION Pedal Box Operation As the accelerator pedal is...

Page 68: ...adjustment of linkage system Other factors may effect the performance characteristics of the vehicle but they should be investigated only after confirming the linkage adjustment SPEED CONTROL Tool Li...

Page 69: ...he accelerator cable position the cable in the accelerator cable bracket at the rear axle so that the throttle is fully closed while allowing 1 travel at the top of the accelerator pedal Once correctl...

Page 70: ...will click when the top of the accelerator pedal moves approximately 1 2 5 8 13 16 mm The accelerator cable as seen at the rear axle should have some slack present and not show any movement until aft...

Page 71: ...ance into this formula to cal culate speed Rate in MPH Distance in feet 5280 Time in seconds 3600 or Rate in KPH Dis tance in meters 1000 Time in seconds 3600 For example 300 ft 5280 13 6 sec 3600 15...

Page 72: ...Page F 6 Repair and Service Manual SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers NOTES...

Page 73: ...8 ENGINE REMOVAL G 9 Controls and Wiring G 10 Removing the Engine from the Vehicle G 10 Engine Installation G 10 DRIVE CLUTCH REMOVAL G 10 LIST OF ILLUSTRATIONS Fig 1 Oil Dipstick G 1 Fig 2 Check Oil...

Page 74: ...Page G ii Repair and Service Manual NOTES ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 75: ...ange as indicated on the dip stick Do not operate vehicle if oil level is below the safe area indicated on the dipstick Oil should be added to bring the level into the safe oper ating range Remember t...

Page 76: ...emove the drain plug 1 allow the oil to drain into the drain pan Fig 5 Oil Drain Plug Before installing the drain plug clean the area around the drain plug mount with a lint free cloth and inspect the...

Page 77: ...cle on level ground Like all liquids oil increases in vol ume when warm The full H mark on the dipstick is calibrated for an engine at operating temperature When the engine is cold the oil will be bel...

Page 78: ...h not as accurate a new belt may be depressed with a finger A maximum deflection of 3 8 10 mm is acceptable Ref Fig 11 Fig 11 Checking Belt Tension with Finger Re tighten an existing belt to 75 80 lbs...

Page 79: ...nut 12 securing the starter generator adjuster until the starter generator belt can be removed from the drive clutch Remove the starter generator pivot bolts 13 and lift starter genera tor from the ve...

Page 80: ...e properly gapped Ref Fig 17 and replaced in the cylinder head tighten to the specified torque Fig 17 Gapping the Spark Plug Fouled spark plugs are indicated by a wet black appear ance This could be c...

Page 81: ...be ignited by the ignition system or another source resulting in a fire Using the starter motor turn the engine over with the throttle fully open until the compression gauge stops ris ing Cylinder Com...

Page 82: ...0 004 0 006 in Fig 20 Measure Valve Clearance If the valve clearance is incorrect adjust it Valve Clearance Adjustment Turn the crankshaft to the proper direction until the pis ton is at TDC of the c...

Page 83: ...et 7 Remove the Starter Generator See Starter Generator Replacement in this section 8 Remove the two bolts between muffler and Starter Generator bracket using a flat ratchet 9 Remove the ground strap...

Page 84: ...ow the assembly sequence recom mended for mounting hardware With the assistance of a hoist or another person lower the engine into position over the engine support cast ings Install one rear horizonta...

Page 85: ...llation H 3 Carburetor Removal H 4 Carburetor Disassembly H 4 Float Level Alignment H 5 Carburetor Installation H 5 FUEL PUMP H 5 Fuel Pump Replacement H 6 FUEL LINES AND FILTER H 6 FUEL TANK REMOVAL...

Page 86: ...Page H ii Repair and Service Manual NOTES FUEL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 87: ...vehicles it also includes the CARB Canister Ref Fig 1 To prevent serious injury or death resulting from a possible explosion do not smoke near the fuel tank or refuel near open flame or elec trical it...

Page 88: ...he engine during acceleration and heavy load conditions Fuel flow is determined by the main jet size Air is mixed with fuel that passes through the bleed opening in the main nozzle This mixture passes...

Page 89: ...using Installation In the following text there are references to removing install ing bolts etc Additional hardware nuts washers etc that are removed must always be installed in their original positio...

Page 90: ...Socket 12 mm 1 Ratchet 1 Pliers 1 Straight blade screwdriver narrow 1 Before disassembling the carburetor drain the fuel bowl and clean the outside of the carburetor thoroughly with solvent All work...

Page 91: ...Adjustment Carburetor Installation To prevent possible injury from explosion or fire check for clogged or kinked hoses Clogged or kinked carburetor hoses are not only detrimental to the proper operati...

Page 92: ...lace with a hose of the same length and approved material Observe and identify the supply and pulse hoses Remove the hoses plug the fuel lines and remove the fuel pump 1 by removing the two screws tha...

Page 93: ...ine to the CARB canister 5 if the vehicle is so equipped Watch for gasoline leakage from the fuel line always use a drip pan and dispose of spent fuel safely Remove the forward hex nut 6 and bolt Remo...

Page 94: ...Page H 8 Repair and Service Manual NOTES FUEL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 95: ...2 Equilibrium J 2 Removing the Drive Belt J 2 Drive Belt Service J 2 Drive Clutch Removal J 2 Drive Clutch Installation J 4 Driven Clutch Removal J 4 Driven Clutch Repair J 4 Torque Ramp Buttons J 4 D...

Page 96: ...epair and Service Manual NOTES CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings a...

Page 97: ...is depressed the engine speed is increased which causes the cams weights within the centrifugal drive clutch to move outwards and force the moveable sheave inwards The drive belt is engaged by the clu...

Page 98: ...the 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 w...

Page 99: ...bolt 2 from the center of the drive clutch 5 Raise the vehicle frame with the floor jack and allow the powertrain to drop so that the clutch puller bolt clears the spring hanger Remove the front eyebo...

Page 100: ...the clutch from the rear axle input shaft Driven Clutch Repair Parts must be reassembled in same position as their original position Mark all components to facilitate accurate reassem bly Some minor f...

Page 101: ...epair and Service Manual NOTES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers CONTINUOUSLY VARIABLE TRANSM...

Page 102: ...epair and Service Manual NOTES CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings a...

Page 103: ...ION SELECTOR Page K i Repair and Service Manual DIRECTION SELECTOR K 2 Removing Direction Selector K 2 Replacing a Micro Switch K 2 Shift Cable Adjustment K 2 Neutral Lock Operation K 2 LIST OF ILLUST...

Page 104: ...age K ii Repair and Service Manual NOTES DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 105: ...vice Manual DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers Fig 1 Direction Selector 1 6...

Page 106: ...emove the attaching hardware Ref Fig 1 Carefully remove the two electri cal wires from the switch Reattach the wires to the new switch Using a DVOM test the switch to ensure it is operational before c...

Page 107: ...d mechanism To prevent possibil ity of fingers becoming pinched in the direction selector mechanism hold direction selector lever when releasing neutral lock pin handle To activate the direction selec...

Page 108: ...Page K 4 Repair and Service Manual NOTES DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 109: ...L 8 BATTERY VOLTAGE TEST L 8 STORAGE OF BATTERY L 9 DVOM DIGITAL VOLT OHM METER L 9 TROUBLESHOOTING L 9 POWER SUPPLY L 9 ACCESSORY WIRING L 10 LIST OF ILLUSTRATIONS Fig 1 Electrical System Wiring Dia...

Page 110: ...Page L ii Repair and Service Manual Notes ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 111: ...starter generator func tions as a generator This is used for charging the bat tery and for the ignition system Generated output is controlled by the voltage regulator at 14 25 14 75 V without regard...

Page 112: ...cal System Wiring Diagram FUEL GAGE OIL LIGHT F E FUEL SENDING UNIT A B TO OIL LIGHT SWITCH ON ENGINE S X REV BUZZER REVERSE MICRO GRND TO ELE PLATE KEY SWITCH CONNECTOR A B PEDAL BOX CONNECTOR ENG MA...

Page 113: ...attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers Fig 2 Electrical System Wiring Diagram F2 F1 A2 A1 DF BLK TO ENGINE STARTER GENERATOR GRN A B 1 2 3 VOLT...

Page 114: ...to the coil or ignitor if the plug is not grounded properly If the engine will not run but the starter will turn the engine proceed as follows 1 Check for loose terminals wires and connections 2 Check...

Page 115: ...easure the resis tance as shown in the following illustrations Fig 4 Resistance Between A B and A C A normal reading with the negative lead on A and the positive lead on B would be 2 18 K A normal rea...

Page 116: ...he solenoid Place the positive probe on terminal B The DVOM should indicate approximately 12 V b Press the accelerator pedal The DVOM will indi cate 0 voltage if the solenoid contacts are closed c If...

Page 117: ...sulators Check the brushes for length approximately 11 16 17 mm or to the line marked on the brush and signs of carbonization 3 Inspect the armature for distortion or broken wires 4 Inspect the field...

Page 118: ...using a DVOM check the field coils for continuity between F1 and F2 and DF and F1 If an open circuit exists replace the field coils Check for continuity between all four terminals and the frame outer...

Page 119: ...ttery should be 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 reaso...

Page 120: ...hat lower than battery voltage A reading of 1 volt below battery voltage is acceptable 3 Check power wire Firmly attach the black probe to the battery post with the black wire attached and the red pro...

Page 121: ...RED SPLICE BUT RED RED RED RED CAP IN LINE FUSE 1 ORANGE 12 VOLTS BATTERY HORN SWITCH YELLOW A B HORN BLACK CONNECT TO MAIN HARNESS IGNITION SWITCH POWER 12V SWITCHED RED FUEL GAUGE OIL LIGHT WHITE BL...

Page 122: ...Page L 12 Repair and Service Manual Notes ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 123: ...allation M 17 Brake Shoe Removal M 17 Brake Shoe Installation M 17 Brake Cable and Equalizer Assembly Removal and Installation M 18 Compensator Assembly Removal and Installation M 19 Brake Pedal Remov...

Page 124: ...atching Pressure M 15 Fig 21 Brake Assembly M 15 Fig 22 Wheel Brake Lubrication Points M 16 Fig 23 Backing Plate Removal and Installation M 17 Fig 24 Brake Shoe Trailing 17L M 17 Fig 25 Brake Shoe Lea...

Page 125: ...e cables is governed by the brake pedal If the cables can not travel far enough to absorb the slack free travel in the system and still apply the shoes to the drums the braking effort at the wheel bra...

Page 126: ...Doing so will cause permanent damage to the adjuster assem bly and result in a gradual loss of brakes The wheel brakes are equipped with an automatic adjuster mechanism that is designed to compensate...

Page 127: ...top tube within the spring is engaged and the linkage becomes solid Ref Fig 3 on Page K 3 The brake compensator assembly applies a spring load to the parking brake system and insures that the parking...

Page 128: ...ight Providing free travel is correctly adjusted the clevis pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test...

Page 129: ...lling Do this by first verifying that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start d...

Page 130: ...provided that shoes have 06 1 5 mm min material System not adjusted properly Check and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace Start...

Page 131: ...r glazed Check again when shoes are dry Rusted or sticky brake pivot hardware Replace Neither wheel locks Brake system requires complete adjustment Adjust entire system Brake pedal not returning Check...

Page 132: ...eliminate the need for routine brake testing and inspection as shown on the Periodic Service Schedule in Section A Continued proper brake operation depends on periodic mainte nance Brake Pedal and Li...

Page 133: ...ee motion when the pedal is applied and released Inspect the brake cable sup ports to be sure the cables are properly secured If any of these conditions are found replace both cables and equalizer as...

Page 134: ...severe injury or death resulting from operating a vehicle with improperly oper ating brake system the braking system must be properly maintained All driving brake tests must be done in a safe locatio...

Page 135: ...avel Adjusting Brake Pedal Free Travel on page 14 Then repeat the Periodic Brake Performance Tests If vehicle fails remove from service and refer to Wheel Brake Inspection to evalu ate the reason for...

Page 136: ...ficantly worn and leaving a ledge of unworn drum Inspect the splines for galling wear and corrosion If any of these problems are found the drum must be replaced 3 Remove any accumulated brake dust fro...

Page 137: ...es to show more wear at the leading and trailing edges Ref Fig 14 on Page K 12 If the brake shoe thickness is approaching 06 1 5 mm it is recommended that the shoes be replaced It is recommended that...

Page 138: ...e 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 slack from the compensa tor and cables...

Page 139: ...rum Remove washer 4 and spindle cap adapter 7 Slide the brake drum 5 from the axle shaft If required tap the drum with a plastic faced hammer to loosen it from the axle shaft or use drum puller P N 15...

Page 140: ...om brake assembly Do NOT use a commercial brake cleaner unless the entire brake has been disassembled Remove any accumulated brake dust with a brush Remove the brake shoes Brake Shoe Removal on page 1...

Page 141: ...g 1 4 turn to align the slot in the spring retainer with the flats in the tension pin Remove the brake shoe retainer springs Grasp the brake shoes 3 in the center and tilt them outwards and away from...

Page 142: ...e brake drum Brake Drum Removal and Installa tion on page 15 Repeat on other side of vehicle Adjust the brake pedal free travel Adjusting Brake Pedal Free Travel on page 14 Brake Cable and Equalizer A...

Page 143: ...rom the brake pedal by removing the cotter pin 2 and the clevis pin 3 Unplug the wiring harness on models equipped with brake lights Unhook the torsion spring 4 by insert ing a thin blade screwdriver...

Page 144: ...29 Catch Bracket and Latch Arm Parking Brake Pedal Removal and Installa tion Note the location and orientation of the two torsion springs 8 Remove the push nut 9 and pin 10 Ref Fig 28 on Page K 20 and...

Page 145: ...g 31 Parking Brake Release Linkage and Kick Off Cam Removal and Installation Parking Brake Kick Off Cam Removal Replacement and Installation Disconnect the parking brake release linkage as described a...

Page 146: ...Page M 22 Repair and Service Manual NOTES MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 147: ...e P i Repair and Service Manual REAR SUSPENSION P 1 General P 1 Shock Absorber Removal P 1 Shock Absorber Installation P 1 Rear Spring Removal P 1 Rear Spring Installation P 1 REAR AXLE REMOVAL P 3 Re...

Page 148: ...Page P ii Repair and Service Manual NOTES REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 149: ...the shock absorber Shock Absorber Installation Shock absorber installation is in the reverse order of dis assembly except that the shock absorber nuts 1 3 must be tightened until the shock absorber b...

Page 150: ...e Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers Fig 1 Rear Suspension Front of the Vehicle 1 2 10...

Page 151: ...supporting the differential to the engine frame Remove the U bolts holding axle to engine frame Remove the drive belt and driven clutch see CLUTCHES section Remove the F R shifter bracket nut and loos...

Page 152: ...Page P 4 Repair and Service Manual NOTES REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 153: ...sassembly Q 2 Axle Shaft Seal Removal and Replacement Q 3 Axle Shaft Replacement Q 3 LIST OF ILLUSTRATIONS Fig 1 Neutral Lock Direction Selector Q 1 Fig 2 Add Check and Drain Rear Axle Lubricant Q 1 F...

Page 154: ...Page Q ii Repair and Service Manual Notes REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 155: ...mains locked in the neutral position To activate the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole 3 in the direction se...

Page 156: ...regardless of mileage Always wipe the seals and O rings with a light oil before installing To reduce the possibility of personal injury fol low the lifting procedure in SAFETY section of this manual...

Page 157: ...r surface of axle tube at the sealing area Replace the seal by lightly tapping around the circum ference with a plastic faced hammer Tighten bolts 4 to 26 31 ft lbs 35 42 Nm torque Axle Shaft Replacem...

Page 158: ...Page Q 4 Repair and Service Manual Notes REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 159: ...r Low Speed Performance R 6 Poor Fuel Economy R 6 Poor Acceleration R 6 Hard Starting R 6 Poor High Speed Operation R 7 Abnormal Combustion Fuel Mixture R 7 Loss of Power Insufficient Fuel R 7 Loss of...

Page 160: ...Page R ii Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 161: ...Field coils are open Replace fields Armature coil is open Replace armature STARTER TURNS SLOWLY Terminals are loose or corroded Retighten or clean Weak battery Charge battery Leads are nearly broken o...

Page 162: ...ffler or pipe Repair or replace Low compression in engine Check and repair ENGINE RUNS ROUGH OR LOSS OF POWER Dirty or clogged air filter element Replace as required Incorrect choke adjustment Adjust...

Page 163: ...adjustment Check and adjust Faulty governor adjustment Check and adjust POOR MIDRANGE OR HIGH SPEED PERFORMANCE Spark plug fouled Clean or replace Weak spark Check magneto Carburetor float not level A...

Page 164: ...valve seat dirty Clean or replace Fuel contamination Clean fuel system carburetor Incorrect float level Adjust Clogged air filter element Clean or replace EXCESSIVE SMOKING Wrong oil weight Replace w...

Page 165: ...solvent Carburetor float sticking Disassemble and correct per the service manual Faulty fuel pump Check for correct output Verify fuel is not returning through the pulse line Clean vent screen Faulty...

Page 166: ...VERFLOW LEAK Worn inlet valve or dirty valve seat Replace valve or clean valve seat Worn float mounting tang Replace float Worn float pin Replace pin Damaged float bowl gasket Replace gasket Damaged f...

Page 167: ...or replace Clogged air or fuel filter Replace Poor fuel quality Replace with fresh fuel LOSS OF POWER INSUFFICIENT FUEL Faulty fuel pump Replace fuel pump Dirty carburetor Clean carburetor Dirt in fue...

Page 168: ...e regulator ground connection Repair Open or short circuit Repair or replace Faulty starter generator Repair starter generator Condition Possible Cause Correction Condition Possible Cause Correction U...

Page 169: ...heck brake cable and replace if sticky or damaged Brake shoes severely worn Replace Brake shoes glazed Sand shoes with emery cloth provided that shoes have 06 1 5 mm min material System not adjusted p...

Page 170: ...on of wheel that is not locking Sticky dragging cable Check for brake lever return Check that brake levers return at equal rate Indication of dragging cable Cracked brake drum Replace Brake shoes wet...

Page 171: ...Page R 11 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers TROUBLESHOOTING...

Page 172: ...Page R 12 Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 173: ...TENTS FOR SECTION S SECTION TITLE PAGE NO Page S i Repair and Service Manual LIMITED WARRANTY EMISSIONS Federal Emission Component Defect Warranty 2004 S 1 California Emission Control Warranty Stateme...

Page 174: ...Page S ii Owner s Guide NOTES LIMITED WARRANTY EMISSIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers...

Page 175: ...Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 M...

Page 176: ...ed however solely because of the lack of required maintenance or failure to keep maintenance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY R...

Page 177: ...urchased LENGTH OF COVERAGE This warranty shall be for a period of two 2 years from the initial date of purchase WHAT IS COVERED REPAIR OR REPLACEMENT OF PARTS Repair or replacement of warranted part...

Page 178: ...Page S 4 Repair and Service Manual VEHICLE WARRANTIES CALIFORNIA 2009 NOTES...

Page 179: ...L SPECIFICATIONS Page T i Repair and Service Manual TXT FLEET GASOLINE POWERED GOLF CAR T 1 TXT FREEDOM GASOLINE POWERED GOLF CAR T 2 TXT VALOR GASOLINE POWERED GOLF CAR T 3 LIST OF ILLUSTRATIONS Fig...

Page 180: ...e T ii Repair and Service Manual GENERAL SPECIFICATIONS NOTES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dang...

Page 181: ...B w o T t n e n a m r e P d e v o r p p A h t i w s r a C f l o G 3 y t i c a p a C g n i w o T m c 8 0 1 n i 5 2 4 l a i t n e r e f f i D e c n a r a e l C d n G n o i s n e p s u S g n i r e e t S...

Page 182: ...r a B w o T t n e n a m r e P d e v o r p p A h t i w s r a C f l o G 3 y t i c a p a C g n i w o T m c 8 0 1 n i 5 2 4 l a i t n e r e f f i D e c n a r a e l C d n G n o i s n e p s u S g n i r e e...

Page 183: ...o T t n e n a m r e P d e v o r p p A h t i w s r a C f l o G 3 y t i c a p a C g n i w o T m c 8 0 1 n i 5 2 4 l a i t n e r e f f i D e c n a r a e l C d n G n o i s n e p s u S g n i r e e t S r e...

Page 184: ...r and Service Manual GENERAL SPECIFICATIONS Fig 1 Vehicle Dimensions 47 0 in 119 cm Front 34 0 in 86 cm Rear 38 5 in 97 cm 46 5 in 118 cm 68 in 173 cm 66 0 in 168 cm 91 0 in 231 cm 4 25 in 11 0 cm Gro...

Page 185: ...anual GENERAL SPECIFICATIONS Fig 2 Vehicle Turning Clearance TURNING CLEARANCE DIAMETER 19 ft 5 8 m RECOMMENDED MAX RAMP 25 GRADE or 14oMAX RECOMMENDED MAX SIDE TILT 25 GRADE or 14oMAX FREEDOM 19 ft 5...

Page 186: ...e T 6 Repair and Service Manual NOTES GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dange...

Page 187: ...nsidered potentially hazardous Use extreme care when working on any vehicle When diagnosing removing or replac ing any components that are not operating correctly take time to consider the safety of y...

Page 188: ...l may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road...