EZGO ST 4X4 SERVICE MANUAL (GASOLINE) - PDF DOWNLOAD

600392

TECHNICIAN’S REPAIR AND SERVICE MANUAL

Ref Fcv 19

ST 4X4 GASOLINE POWERED 4 WHEEL DRIVE UTILITY VEHICLE STARTING MODEL YEAR: 2004

SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact a representative for clarification.

Always replace any damaged or missing labels.

On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. (See vehicle specification.) Limit speed by applying the service brake.

Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse and will not be covered under warranty.

If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.

BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

BATTERIES CONTAIN LEAD AND RELATED PARTS

WASH HANDS AFTER HANDLING!

WASH HANDS AFTER HANDLING!

WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm.

Be sure that this manual remains as part of the permanent service record should the vehicle be re-sold.

NOTES, CAUTIONS AND WARNINGS Throughout this guide NOTE, CAUTION and WARNING will be used.

A NOTE indicates a condition that should be observed.

A CAUTION indicates a condition that may result in damage to the vehicle.

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A WARNING indicates a hazardous condition that could result in severe

injury or death.

Please observe these NOTES, CAUTIONS and WARNINGS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.

Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

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The exhaust emissions of this vehicles’ engine is regulated by the Federal EPA. Significant fines could result from modifications or tampering with the engine, fuel, ignition or air intake systems.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations.

Ce système d'allumage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

TECHNICIAN’S REPAIR AND SERVICE MANUAL

GASOLINE POWERED 4 WHEEL DRIVE UTILITY VEHICLE ST 4X4

E-Z-GO Division of Textron Inc., reserves the right to make design changes 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 Inc., is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906-3852

Repair and Service Manual

Page i

NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or Warranty Department with vehicle serial number and manufacturer code.

The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

Overfilling battery may void the warranty.

Tampering with or adjusting the governor to permit vehicle 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 maintain Federal and State emission certification.

BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C).

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TABLE OF CONTENTS TITLE

PAGE

Safety ........................................................................................................................... Inside Covers Notes .................................................................................................................................................ii Safety Information ............................................................................................................................ v

TITLE

SECTION

General Information & Routine Maintenance ...................................................................................A Safety ...............................................................................................................................................B Body and Truckbed ..........................................................................................................................C Brakes ..............................................................................................................................................D Continuously Variable Transmission (CVT)......................................................................................E Direction and Drive Selector............................................................................................................. F Electrical.......................................................................................................................................... G Engine and Transmission .................................................................................................................H Front Suspension and Steering ........................................................................................................ J Fuel System .....................................................................................................................................K Paint ................................................................................................................................................. L Rear Axle and Suspension.............................................................................................................. M Speed Control ..................................................................................................................................N Troubleshooting................................................................................................................................P Wheels and Tires .............................................................................................................................R General Specifications .....................................................................................................................S Limited Warranty .............................................................................................................................. T

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TABLE OF CONTENTS

Notes:

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Repair and Service Manual

SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must be carefully observed:

GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the place of good common sense and prudent driving practices.

Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. The manufacturer strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein.

If you have any questions regarding this vehicle, contact your closest representative or write to the address on the back cover of this publication, Attention: Product Service Department.

The manufacturer reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.

The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

This vehicle conforms to the current applicable standard(s) for safety and performance requirements.

These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specification. Such modifications can cause serious personal injury or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment. Additionally, 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 operating condition.

• Read and observe all warnings and operation instruction labels affixed to the vehicle.

• Follow all safety rules established in the area where the vehicle is being operated.

• Reduce speed to compensate for poor terrain or conditions.

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SAFETY INFORMATION • Apply service brake to control speed on steep grades.

• Maintain adequate distance between vehicles.

• Reduce speed in wet areas.

• Use extreme caution when approaching sharp or blind turns.

• Use extreme caution when driving over loose terrain.

• Use extreme caution in areas where pedestrians are present.

MAINTENANCE Always: • Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.

• Ensure that repairs are performed by those that are trained and qualified to do so.

• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.

• Use specified replacement parts. Never use replacement parts of lesser quality.

• Use recommended tools.

• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle.

• Support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack. Lift the vehicle in accordance with the manufacturer’s instructions.

• Empty the fuel tank or plug fuel hoses to prevent fuel leakage.

• Maintain the vehicle in an area away from exposed flame or persons who are smoking.

• Be aware that a vehicle 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 of both vehicular and pedestrian traffic.

• Replace damaged or missing warning, caution or information labels.

• Keep complete records of the maintenance history of the vehicle.

The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mechanic.

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Repair and Service Manual

SAFETY INFORMATION VENTILATION Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.

Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water heaters and furnaces.

Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

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SAFETY INFORMATION

Notes:

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Repair and Service Manual

GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE

A PAGE NO.

SERIAL AND MANUFACTURING NUMBER LABEL LOCATIONS.................................................A - 1 SERVICING THE VEHICLE .............................................................................................................A - 1 TOWING...........................................................................................................................................A - 2 JUMP STARTING ............................................................................................................................A - 2 ROUTINE MAINTENANCE ..............................................................................................................A - 3 POWERTRAIN MAINTENANCE......................................................................................................A - 3 NEUTRAL POSITION ......................................................................................................................A - 3 BRAKES...........................................................................................................................................A - 4 TIRES...............................................................................................................................................A - 4 CARE AND CLEANING OF THE VEHICLE.....................................................................................A - 4 VEHICLE CARE PRODUCTS..........................................................................................................A - 4 TOP AND WINDSHIELD (IF EQUIPPED)........................................................................................A - 5 TRAILERING....................................................................................................................................A - 5 PROLONGED STORAGE................................................................................................................A - 5 HARDWARE ....................................................................................................................................A - 6 TORQUE SPECIFICATIONS ..........................................................................................................A - 7 CAPACITIES ...................................................................................................................................A - 7 PERIODIC SERVICE SCHEDULE...................................................................................................A - 8

LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7

Serial and Manufacturing Number Label Locations ..............................................................A - 1 Initial Service Chart ...............................................................................................................A - 2 Jump Starting ........................................................................................................................A - 3 Neutral...................................................................................................................................A - 3 Torque Specifications............................................................................................................A - 7 Capacities..............................................................................................................................A - 7 Periodic Service Schedule ....................................................................................................A - 8

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GENERAL INFORMATION & ROUTINE MAINTENANCE

Notes:

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Repair and Service Manual

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

A

Serial No. & Mfg No. (Stamped)

Serial No. & Mfg No. (Label) Supplemental Information label

Serial No. Label

Fig. 1 Serial and Manufacturing Number Label Locations

SERIAL AND MANUFACTURING NUMBER LABEL LOCATIONS Supplemental Information Label Location The supplemental Information label is located on the driver side of the horizontal frame tube below truck bed (Ref Fig. 1 on page A-1).

Serial and Manufacturing No. Label Location The serial and manufacturing number label is located on the passenger side of the horizontal frame tube below the truck bed (Ref Fig. 1 on page A-1).

Serial and Manufacturing No. (Stamped) The serial number and manufacturing number are stamped on the frame below the truck bed (Ref Fig. 1 on page A-1).

Serial No. Sticker Location The serial number is located on the seat support panel below the choke (Ref Fig. 1 on page A-1).

SERVICING THE VEHICLE To prevent severe personal injury or death, resulting from improper servicing techniques, observe the following Warnings: Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with all wheels raised.

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Page A-1

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Wear eye protection when working on the vehicle. In particular, use care when working around batteries, or using solvents or compressed air.

To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the battery before removing any heavy gauge battery wires.

To prevent the possibility of powertrain failure, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a “no load” condition.

ITEM Seats

In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

It is virtually impossible to anticipate all possible component failures or the manner in which each component may fail.

A vehicle requiring repair indicates the vehicle is no longer functioning as designed and should be considered potentially hazardous. Use extreme care when working on a vehicle. When diagnosing, removing or replacing any components that are not operating properly, consider the safety of yourself and those around you, should the component move unexpectedly.

Some components are heavy, spring loaded, highly corrosive, explosive, may produce amperage or 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 the utmost caution. Be careful not to place hands, face, feet or body in a location that could expose them to injury, should an unforeseen dangerous situation occur.

Always use the appropriate tools listed in the tool list and wear approved safety equipment.

Before a new vehicle is put into operation, it is recommended the items shown in the INITIAL SERVICE CHART be performed (Ref Fig. 2 on page A-2).

Page A-2

Remove protective plastic covering

Brakes Check operation and adjust if necessary Check hydraulic brake fluid level Establish new vehicle braking distance Tires

Check pressure

Fuel

Fill tank with correct fuel

Engine Check oil level (Initial change after 5 - 8 hours)

Do not attempt any type of servicing operations before reading and understanding all notes, cautions and warnings in this manual.

It is in the best interest of both vehicle owner and servicing dealer, to carefully follow the procedures recommended in this manual. Adequate preventative maintenance, applied at regular intervals, is the best guarantee for keeping the vehicle both dependable and economical.

SERVICE OPERATION

Battery Charge battery

Fig. 2 Initial Service Chart

TOWING

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This vehicle is not designed to be towed.

It is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable transport.

JUMP STARTING To reduce possibility of severe personal injury or death resulting from a battery explosion, follow jump starting instructions explicitly.

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To reduce possibility of permanent damage to battery, promptly charge a discharged battery.

Turn key switch to OFF. Apply parking brake. Place direction selector in neutral position.

Attach one end of red positive cable to positive post of weak battery and other end to positive post of strong battery (Ref Fig. 3 on page A-3). Attach one end of black negative cable to negative post of strong battery and other end to the front frame receiver of the vehicle to be started.

Start vehicle as usual. Once started, disconnect cables in reverse order and charge the battery as soon as possible.

Repair and Service Manual

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

spark plug wires and disconnect battery at negative terminal before servicing.

Access the powertrain by raising or removing seats. Full access to powertrain may be obtained by raising the load bed. Some service procedures may require the vehicle be lifted (Ref Lifting The Vehicle in SAFETY) for proper lifting procedure and safety information.

+

For maintenance procedures relating to the engine, speed control, fuel system, transmission, and rear axle or suspension, refer to the particular section. See the TABLE OF CONTENTS for section location.

Weak Battery -

Front of Vehicle

NEUTRAL POSITION To prevent the driven clutch from turning the rear axle/front axle during any service operations, move direction selector lever located on the instrument panel to the neutral position indicated. (Ref Fig. 4 on page A-3)

Strong Battery

Forward

+

Fig. 3 Jump Starting

ROUTINE MAINTENANCE Some items must be serviced more frequently on vehicles used under severe driving conditions.

This vehicle will give years of satisfactory service, provided it receives regular maintenance. Refer to the Periodic Service Schedule for appropriate service intervals (Ref Fig. 7 on page A-8). Refer to ‘Lubrication’ in FRONT SUSPENSION AND STEERING section for appropriate lubrication locations.

73777G01

Reverse

Neutral

Fig. 4 Neutral

POWERTRAIN MAINTENANCE To prevent severe personal injury or death, always install a positive stop to prevent load bed from falling.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench ‘shorting out’ a battery, which could result in an explosion.

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To prevent accidental starting, remove and ground Repair and Service Manual

Page A-3

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

BRAKES To prevent severe personal injury or death resulting from operating a vehicle with an improperly operating brake system, the braking system must be properly maintained. All driving brake tests must be done in a safe location with regard for the safety of all personnel.

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After the vehicle has been put into service, it is recommended that the brakes be checked periodically conducting a brake performance test.

Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth.

Removal of oil, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.

The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing with lukewarm or cold water is the best method of preserving the painted surfaces.

Do not use hot water, strong soap or harsh chemical detergents.

For test method and brake service, refer to BRAKES section.

Rubber parts should be cleaned with non-abrasive household cleaner.

TIRES

Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the painted surfaces.

Standard tires for this vehicle are uni-directional and should never be moved from one side of vehicle to the other. driver side tires should always remain on the driver side of the vehicle. passenger side tires should always remain on the passenger side of the vehicle.

Uni-directional tires have an arrow on the sidewall indicating direction of rotation when moving forward.

Tire condition should be inspected and inflation pressures checked per the Periodic Service Schedule when tires are cool. Be sure to install the dust valve cap after checking or inflating tire. For additional information, refer to WHEELS AND TIRES section.

CARE AND CLEANING OF THE VEHICLE To reduce possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

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When pressure washing vehicle, do not use pressure in excess of 700 psi. To prevent cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.

If engine does not start or runs improperly after washing, remove spark plug wires (by pulling the spark plug boots, never the wires). Dry all connections with compressed air. Reinstall wires.

It is important that proper techniques and cleaning materials be used.

Page A-4

Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle. These materials will accelerate corrosion of underbody parts. It is recommended that the underbody be flushed occasionally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to ease its removal, taking care not to chip or otherwise damage paint.

VEHICLE CARE PRODUCTS There are several products, available through a local distributor, an authorized Branch, or the Service Parts Department, to help maintain the vehicle. Among them are: • Touch-up paint specially formulated to match vehicle colors for use on both metal and TPE (plastic) bodies. (P/N 28140-G**, 28432-G** and 75831G01) • Multi-purpose Battery Protectant formulated to form a long-term, flexible, non-tacky, dry coating that will not crack, peel or flake over a wide temperature range. (P/N 75500-G01) • White Lithium Grease designed to provide lubrication protection in areas where staining or discoloring is a problem, or in areas of extreme temperature ranges. (P/N 75502-G01) • Penetrant/Lubricant, a 4-in-1 product that penetrates the most stubborn of frozen parts, lubricates leaving a light lubricating film, prevents corrosion by adhering to wet or dry surfaces and displaces

Repair and Service Manual

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

• •

•

• •

•

moisture, sealing against future moisture return.

(P/N 75503-G01) Multi-purpose Cleaner and Degreaser that contains natural, environmentally safe solvents. (P/N 75504-G01) Multi-purpose Hand Cleaner is an industrial strength cleaner containing no harsh solvents, yet gently lifts grease off hands. May be used with or without water. (P/N 75505-G01) Battery Cleaner that promotes easy, non-violent neutralization of battery acids and battery acid crystals. The resulting sodium salts are water soluble and easily washed away. (P/N 75506-G01) Biodegradable Cleaner that cleans the toughest dirt and heavy soils by breaking down grease to be easily wiped or rinsed away. (P/N 75507-G01) Multi-purpose Value Pack sampler package including 4 ounce (118 ml) aerosol cans of Battery Protector, Penetrant/Lubricant, White Lithium Grease, and Carburetor and Choke Cleaner. (P/N 75508-G01) Plexus plastic cleaner and polish removes minor scratches from windshield. (P/N 28433-G**)

TOP AND WINDSHIELD (IF EQUIPPED) The support structure for the top and windshield provide roll over protection.The top and windshield do not provide protection from falling objects.

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The top and windshield are designed for weather protection only.

TRAILERING To prevent personal injury to occupants of other highway vehicles, be sure that the vehicle and contents are adequately secured to trailer.

Do not ride on vehicle being trailered.

Remove windshield before trailering.

Maximum speed with top is 50 mph (80 kph).

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If the vehicle is to be transported on a trailer at highway speeds, the windshield and top must be removed and the seat bottom secured. Always check that the vehicle and contents are adequately secured before trailering the

vehicle. The rated capacity of the trailer must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load. Engage the parking brake and secure the vehicle to the trailer using ratchet tie downs.

PROLONGED STORAGE

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To prevent severe personal injury or death resulting from a possi-

ble explosion: Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.

Store vehicle in a clean, dry area. Do not store in same area as a stove, furnace, water heater, or other appliance that uses a pilot light or has a device that can create a spark.

Always wear safety glasses to prevent possible eye injury from gasoline or gasoline vapor.

Keep hands, clothing and jewelry away from moving parts. Use care not to contact hot objects.

Raise the rear of the vehicle and support on jack stands before attempting to run the engine.

Preparing the engine for a prolonged storage period (30 days or more) calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corrosion in the engine.

• Add fuel stabilizer to the fuel tank in accordance with the directions provided with the additive shortly before the vehicle is to be stored. If fuel stabilizer is to be added at the time of storage, operate the vehicle for several minutes to circulate the stabilizer throughout the fuel system.

• Raise the rear of the entire vehicle and support on jack stands. Refer to ‘Lifting the Vehicle’ in Section B for proper lifting procedure and safety information.

• Raise the seat bottom and disconnect the fuel hose at the fuel tank. Keep end of hose up near the top of the tank to prevent spilling fuel. With proper ventilation, place the direction selector in NEUTRAL, start the engine and allow to run until it stops due to lack of fuel. Reattach fuel line to tank and replace seat bottom.

• While engine is still warm, change oil to remove contaminants. See ENGINE section.

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Page A-5

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

• Remove spark plugs and pour about 1 oz. (30 ml)

•

of engine oil into each cylinder. Replace spark plugs, ground spark plug wires and use starter to turn engine over a few seconds to distribute oil.

Clean body, chassis and engine of debris, mud, chaff or grass. See ENGINE section.

HARDWARE Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref Fig. 5 on page A-7). Use care when tightening fasteners and refer to the sections in this manual for specific torque values Generally, two grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head. Unmarked hardware is Grade 2.

Page A-6

Repair and Service Manual

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this 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.

BOLT SIZE

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

1"

Grade 2

4 (5)

8 (11)

15 (20)

24 (33)

35 (47)

55 (75)

75 (102)

130 (176)

125 (169)

190 (258)

Grade 5

6 (8)

13 (18)

23 (31)

35 (47)

55 (75)

80 (108)

110 (149)

200 (271)

320 (434)

480 (651)

Grade 8

6 (8)

18 (24)

35 (47)

55 (75)

80 (108)

110 (149)

170 (230)

280 (380)

460 (624)

680 (922)

BOLT SIZE

M4

M5

M6

M8

M10

M12

M14

Class 5.8 (Grade 2)

5.8

1 (2)

2 (3)

4 (6)

10 (14)

20 (27)

35 (47)

55 (76.4)

Class 8.8 (Grade 5)

8.8

2 (3)

4 (6)

7 (10)

18 (24)

35 (47)

61 (83)

97 (131)

Class 10.9 (Grade 8) 10.9

3 (4)

6 (8)

10 (14)

25 (34)

49 (66)

86 (117)

136 (184)

Ref Tsp 1

Fig. 5 Torque Specifications

CAPACITIES Fuel Tank

6.7 gal (25.4 liters) unleaded, 87 octane or higher

Engine Oil

Refer to Engine Manual

Front Differential 15.2 +-1 oz (450 ml) of 80 - 90W GL5 Rear Axle

15.2 +-1 oz (450 ml) of 80 - 90W GL5

Transfer Case

24 oz (700 ml) MOBILFLUID 424

Fig. 6 Capacities

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Page A-7

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

PERIODIC SERVICE SCHEDULE. BEFORE EVERY EVERY EVERY EVERY EVERY EVERY EACH 20 50 100 200 300 500 USE WEEKLY HOURS HOURS HOURS HOURS HOURS HOURS

ITEM Service Brake (Pedal Pressure)

Check

X

(Fluid Level)

Check

X

(Pads & Shoes)

Inspect

X

(Rotors & Drums)

Clean

X

Park Brake

Clean

X

Reverse Warning Buzzer (if equipped)

Check

X

Tires

Check

X

Overall Vehicle Condition

Check

X

Wheels

Check

X

Fuel Gauge

Check

X

Alternator Belt

Check

X

Engine Fan and Cooling Fins

Clean

CVT Enclosure

Clean

Wiring

Check

X

Accelerator

Check

X

Choke

Check

X

Carburetor Linkage

Check

X

Direction Selector

Check

X

Engine Oil

Check Change

Engine Oil Filter

Replace

Air Filter

Check

X

X

X X#

X X **

X X X#

Clean

Spark Plugs

X

Replace

X#

Check

X

Replace

X

Idle Speed

Check

X**

Valve Clearance

Check

X**

Fuel Filter

Check

X

Replace Combustion Chamber

Clean

Steering

Check

X X X

Fig. 7 Periodic Service Schedule

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GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BEFORE EVERY EVERY EVERY EVERY EVERY EVERY EACH 20 50 100 200 300 500 USE WEEKLY HOURS HOURS HOURS HOURS HOURS HOURS

ITEM Tie Rods/Linkages

Check

Rear Axle Lubricant

Check Replace

Front Axle Lubricant

X

X X

X

X**

X

Check Replace

X

X**

Check Replace

Transmission (Transfer Case) Lubricant

X

X

X

X**

X

Muffler/Exhaust

Check

X

Spark Arrester

Clean

Front Knuckles

Check

Front Struts

Check

X

Front Wheel Alignment

Check

X

Rear Shock Absorbers

Check

X

Fuel Tank

Clean

X

Throttle/Governor Linkage

Check

Battery

Clean

X

Drive Belt

Check

X

Front Wheel Bearings

Check

Drive shafts

Lubricate

X

C.V.Joints and Boots

Check

X

X X

X

X

Fig. 7 Periodic Service Schedule ** First occurrence only # More frequently in dusty conditions

Repair and Service Manual

Page A-9

GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page A-10

Repair and Service Manual

SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE

B PAGE NO.

LIST OF ILLUSTRATIONS GENERAL ........................................................................................................................................B - 1 NOTES, CAUTIONS AND WARNINGS ...........................................................................................B - 5 IMPORTANT SAFETY WARNING...................................................................................................B - 5 MODIFICATIONS TO VEHICLE ......................................................................................................B - 5 GENERAL MAINTENANCE .............................................................................................................B - 5 BEFORE SERVICING THE VEHICLE .............................................................................................B - 6 BATTERY REMOVAL AND INSTALLATION ...................................................................................B - 7 Fig. 1 Battery Removal....................................................................................................................B - 7 LIFTING THE VEHICLE ...................................................................................................................B - 8 Fig. 2 Lifting the Vehicle ..................................................................................................................B - 8

Repair and Service Manual

Page B-i

SAFETY

Notes:

Page B-ii

Repair and Service Manual

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

GENERAL The following text is provided as recommended by part II of SAE J2258 DEC 2003. E-Z-GO strongly endorses the contents of this specification.

B.1 PART II FOR THE CONTROLLING PARTY B.1.1 Maintenance and Operations B.1.1.1 Introduction B.1.1.1.1 Like other machines, light utility vehicles can cause injury if improperly used or maintained. Part II contains broad safety practices applicable to vehicle operations. Before operation, the controlling party shall follow such additional specific safety practices as may reasonably be required for safe operation.

B.1.1.1.2 Safety Survey-The controlling party shall perform a safety survey of their premises periodically, and as conditions warrant, identify areas where vehicles should not be operated and to identify possible hazards. (a) Steep Grade-In areas where steep grades exist, vehicle operation should be restricted to the designated vehicle's pathways where possible, and shall be identified with a suitable warning giving the following information: “Warning, steep grade, descend slowly.” (b) Wet Areas-Wet areas could cause a vehicle to lose traction and could affect steering, stability and braking. (c) Sharp Turns, Blind Corners, Bridge ApproachesSharp turns, blind spots, bridge approaches, and other potentially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard. (d) Loose Terrain-Loose terrain could cause a vehicle to lose traction and could affect steering, stability, and braking.

B.1.1.1.3 Utility Vehicle/Pedestrian Interference Areas-Areas where pedestrian and vehicle traffic could interfere should be avoided by rerouting the vehicle or the pedestrian traffic to eliminate the interference. If elimination of the interference is not possible or is highly impractical, signs shall be erected warning pedestrians and vehicle operators of traffic conditions and to use caution.

B

B.1.1.1.4 The controlling party shall train vehicle operators to adhere strictly to the operating instructions stated in vehicle operator's manual and those additional operating instructions provided by controlling party.

B.1.1.1.5 The controlling party shall survey specific operating conditions and environment, establish safety practices, and train vehicle operators to comply with these practices.

B.1.1.2 Operation Experience has shown that vehicles which comply with the provisions stated in 7.8 are stable when properly operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard. Some conditions which could affect stability are failure of the operator to follow safety practices, surface conditions, grade, speed, loading, braking, turning, improper loads, towing, attachments, dynamic forces, and the judgment exercised by the vehicle operator.

B.1.1.3 Nameplates, Markings, Capacity, And Modifications.

B.1.1.3.1 The controlling party shall maintain in a legible condition all nameplates, warnings, and instructions which are supplied by the vehicle manufacturer.

B.1.1.3.2 The controlling party shall not perform any modification or addition which affects capacity or safe operation, or make any change not in accordance with the vehicle manual(s) without the vehicle manufacturer's prior written authorization. Where authorized modifications have been made, the controlling party shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are changed accordingly.

B.1.1.3.3 As required under B.1.1.3.1 or B.1.1.3.2, the vehicle manufacturer shall be contacted to secure new nameplates, warnings, or instructions which shall then be affixed in their proper place on the vehicle.

B.1.1.4

Fuel Handling

B.1.1.4.1 The controlling party shall supervise the handling of liquid fuels (when used) to be certain that it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 30 or as required by local ordinance.

Repair and Service Manual

Page B-1

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

B.1.1.4.2 The controlling party shall supervise the handling of liquefied petroleum gas fuels (when used) to be certain it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 58 or as required by local ordinance.

B.1.1.5

Charging Storage Batteries

B.1.1.5.1 The controlling party shall require batterycharging procedures to be in accordance with appropriate sections of ANSI/NFPA 505, ISO 3691, or local ordinance and meet any other requirements such as OSHA. B.1.1.5.2 The controlling party shall periodically review procedures to be certain that appropriate sections of ANSI/ NFPA 505 or local ordinance and OSHA are strictly complied with, and shall familiarize vehicle operators with it.

B.1.1.6

Lighting For Operating Areas

B.1.1.6.1 The controlling party, in accordance with his responsibility to survey the environment and operating conditions, shall determine if the vehicle requires lights and, if so, shall equip the vehicle with appropriate lights in accordance with the vehicle manufacturer's recommendations.

B.1.1.7

Warning Device(s)

B.1.1.7.1 The controlling party shall make periodic inspections of the vehicle to be certain that the soundproducing and visual device(s), if so equipped, are maintained in good operating conditioning condition.

B.1.1.7.2 The controlling party shall determine if operating conditions require the vehicle to be equipped with additional sound-producing and/or visual devices compatible with the vehicle manufacturer's recommendations, and be responsible for providing and maintaining such devices, in accordance with the vehicle manufacturer's recommendations.

B.1.1.8

B.2.1 Operator Qualifications B.2.1.1 Only persons who are trained in the proper operation of the vehicle shall be authorized to operate the vehicle. Operators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the vehicle according to Section 5 and all other applicable parts of this document and vehicle operator's manual.

B.2.2 Operator’s Training B.2.2.1 The controlling party shall develop and conduct an operator training program.

B.2.2.2 Successful completion of the operator training program by the operator shall be required before operation of the vehicle. The program shall be presented in its entirety to all new operators and not condensed for those claiming previous experience.

B.2.2.3 The controlling party should include, as a minimum, in the operator training program the following: (a) Instructional material provided by the vehicle manufacturer, including vehicle operator's manual. (b) Emphasis on safety of passengers, vehicle operator, and other persons. (c) Safe loading practice, including securing material loads. (d) General safety rules contained within this document and the additional specific rules determined by the controlling party in accordance with this document, and why they were formulated. (e) Introduction of equipment, control locations, and functions, and explanation of how they work when used properly and the consequences of improper use; explanation of surface conditions, grade, and other conditions of the environment which could affect vehicle operation. (f) Operator competency evaluations.

B.2.3 Operator Responsibility B.2.3.1 Read and follow operator's manual.

B.2.3.2 Do not operate vehicle under the influence of drugs or alcohol.

Safety Interlocks

B.1.1.8.1 The controlling party shall make periodic inspections of the vehicle to be certain that the safety interlock system, if so equipped, is operating properly.

Page B-2

B.2 Operating Safety Rules and Practices

B.2.3.3 Safeguard the pedestrians at all times. Do not drive vehicle in a manner that could endanger other persons.

Repair and Service Manual

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

B.2.3.4 Riding on the vehicle by persons other than the operator is authorized only on seat(s) provided by the vehicle manufacturer. All parts of each person's body shall remain within the plan view outline of the vehicle while the vehicle is in motion.

B.2.3.5 When a vehicle is to be left unattended, stop vehicle, apply the parking brake, turn off the control or ignition circuit, and remove the key if provided. Block the wheels if vehicle is on an incline.

B.2.3.6 Maintain a safe distance from potential hazards.

B.2.3.7 Use only approved vehicles in hazardous locations, as defined in the appropriate safety standards.

B.2.3.8 Report all accidents involving personnel, building structures, and equipment.

B.2.3.9 Do not add to, or modify, the vehicle.

B.2.3.10 Slow down or stop, as conditions dictate, and activate a sound-producing warning device, if so equipped, at intersections and when visibility is obstructed at other locations.

B.2.3.11 Ascend or descend grades slowly, avoid turning if possible; normally travel straight up and down.

B.2.3.12 Under all travel conditions, operate vehicle at speeds that will permit it to be brought to a stop in a safe manner.

B.2.3.13 Use caution and slow down when approaching or on wet or slippery surfaces, loose or unfamiliar terrain.

B.2.3.14 Avoid sudden starts, stops, turns, or direction reversals so as not to shift the load, endanger passengers, or lose control of the vehicle.

B.2.3.15 Do not operate vehicle in a dangerous manner, such as stunt driving or horseplay.

B.2.3.16 Avoid running over loose objects, potholes, and bumps.

B.2.4 Loading B.2.4.1 Refer to operator's manual for loading instructions.

B.2.4.2 Transport only stable and safely arranged loads secured to prevent movement. Avoid loads which cannot be centered.

B.2.4.3 Transport only loads within the gross vehicle weight capacity.

B.2.4.4 Avoid material loads exceeding the physical dimensions of the vehicle or as specified by the vehicle manufacturer.

B.2.5 Operator Care of Light Utility Vehicles B.2.5.1 Follow Operator's Manual.

B.2.5.2 At the beginning of each operating period during which the vehicle will be used, the operator shall check the vehicle condition and inspect the tires, warning devices, safety interlocks, lights, battery(s), fuel system, speed and directional controllers, brakes, and steering mechanism. If the vehicle is found to be in need of repair, or in any way unsafe, the matter shall be reported immediately to the controlling party and the vehicle shall not be operated until it has been restored to safe operating condition.

B.2.5.3 If during operation the vehicle becomes unsafe in any way, the matter shall be reported immediately to the controlling party, and the vehicle shall not be operated until it has been restored to safe operating condition.

B.2.5.4 Repairs and adjustments shall only be performed by specifically trained and authorized persons.

B.3 Maintenance Practices B.3.1 Maintenance Procedures B.3.1.1 Maintenance and inspection of all vehicles shall be performed in conformance with the vehicle manufacturer's recommendations and the following practices, if applicable. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect vehicles. (a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed. (b) Before undertaking maintenance or repair, follow the vehicle manufacturer's recommendations for immobilizing the vehicle. (c) Chock wheels and block chassis before working underneath it. (d) Before disconnecting any part of the fuel system of a gasoline-powered vehicle, be sure shutoff valve, if so equipped, is closed, and run engine until fuel system is depleted, engine stops running, and is allowed to cool.

Before disconnecting any part of the engine fuel system of a diesel-powered vehicle, be sure shutoff valve, if so

Repair and Service Manual

Page B-3

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

equipped, is closed, following vehicle manufacturer's recommended practice. (e) Before disconnecting any part of the fuel system of LP/CNG powered vehicles, close the fuel cylinder valve and run the engine until fuel in the system is depleted, the engine stops running, and is allowed to cool (f) Disconnect battery(s). (g) Operation to check performance of the vehicle shall be conducted in an authorized area where suitable conditions exist, free of vehicular and pedestrian traffic.to cool. (h) Before returning the vehicle to service, follow the vehicle manufacturer's recommended procedures. (i) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte, or coolant. (j) Properly ventilate the work area in accordance with applicable regulations or local ordinances. (k) Handle fuel cylinders carefully. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken cylinders and make them unsafe for use.

(r) Hydraulic systems, if so equipped, shall be checked for leaks and condition of parts. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. (s) Modifications and additions which affect capacity and safe machine operation shall not be performed without vehicle manufacturer's prior written authorization.

Where authorized modifications have been made, the controlling party shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, and safety labels are changed accordingly. (t) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a specification at least equal to that provided in the original equipment.

End of SAE J2258 DEC 2003, Part II

(l) Brake mechanisms, steering mechanisms, speed and directional control mechanisms, warning devices, electrical systems, governors, guards, exhaust system, and safety devices shall be inspected regularly and maintained in accordance with the vehicle manufacturer's recommended procedures. (m) Vehicles or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved operating features. (n) Fuel systems shall be checked for leaks and condition of parts. If a leak is found, action shall be taken to prevent the use of the vehicle until the cause of the leak has been repaired. (o) The vehicle manufacturer's capacity, operation, and maintenance instruction plates, tags, and safety labels shall be maintained in legible condition. (p) Batteries, motors, speed and directional controllers, limit switches, protective devices, electrical conductors/insulators, and connections shall be inspected and maintained in accordance with vehicle manufacturer's recommended procedures. (q) Vehicles shall be kept in a clean condition to minimize fire hazards and facilitate the detection of components needing service.

Page B-4

Repair and Service Manual

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

NOTES, CAUTIONS AND WARNINGS Throughout this manual, the following NOTES, CAUTIONS and WARNINGS are used. For the protection of all personnel and the vehicle, be aware of and observe the following: A NOTE indicates a condition that should be observed.

A CAUTION indicates a condition that may result in damage to the vehicle or surrounding facilities.

A WARNING indicates a hazardo us cond it ion which could result in

battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders if not treated with utmost caution. Be careful not to 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 equipment.

MODIFICATIONS TO VEHICLE Do not modify the vehicle in any manner that will change the weight distribution of the vehicle.

IMPORTANT SAFETY WARNING

Changes to the weight distribution or the center of gravity may make the vehicle unstable or prone to roll over which could result in injury or death to the operator or passenger(s).

In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

GENERAL MAINTENANCE

!

!

serious injury or death.

It is virtually impossible to anticipate all possible component failures or the manner in which each component may fail.

!

!

To prevent severe personal injury or death resulting from improper servicing techniques, do not attempt any type of servicing operations before reading and understanding all notes, cautions and warnings in this manual.

Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are not operating correctly, take the time to consider the safety ramifications if the component should move unexpectedly.

When any maintenance procedure or inspection is performed, it is important that care be exercised to insure the safety of the technician/mechanic or bystanders and to prevent damage to the vehicle.

Some components are heavy, spring loaded, highly corrosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide,

Always read and understand the entire relevant manual section (chapter) before attempting any inspection or service.

Repair and Service Manual

Page B-5

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

BEFORE SERVICING THE VEHICLE Before attempting to inspect or service a vehicle, be sure to read and understand the following warnings:

To prevent severe personal injury or death, observe the following: Before working on the vehicle, remove all jewelry (rings, watch, necklaces, etc.).

Be sure that no loose clothing or hair can become caught in the moving parts of the powertrain.

Use care not to contact hot objects.

Before attempting to operate or adjust the powertrain, the front and rear of the vehicle must be raised and supported on jack stands.

Wear OSHA approved clothing and eye protection when working on anything that could expose the body or eyes to potential injury. In particular, use care when working with or around batteries, compressed air or solvents.

Always turn the key switch to ‘OFF’ and remove the key before disconnecting a live circuit.

When connecting battery cables, pay particular attention to the polarity of the battery terminals.

Never confuse the positive and negative cables.

The parking brake should always be set, except for cases where the powertrain must be allowed to rotate or service is being performed on the brake system.

If repairs are to be made that will require welding or cutting, the battery and fuel tank must be removed and the fuel system drained.

To prevent serious per! ! sonal injury or death resulting from an explosion, keep all smoking materials, open flame or sparks away from gasoline and batteries.

Never operate the starter with the spark plugs removed unless the ignition system has been disabled and the engine/exhaust are cold. Fuel expelled from the cylinders could be ignited by the ignition system or the hot exhaust system.

Never work on an engine that is hot.

Never test the ignition system without either connecting the spark plug lead to a tester or spare

!

Page B-6

!

grounded spark plug.

If the spark function is to be observed at the spark plug, be sure to install a spare spark plug into the open cylinder before operating the starter.

Never test the function of a fuel pump in the vicinity of a hot engine or other source of flame or combustion.

Never confuse the hoses to and from the fuel pump. Verify that the carburetor and pulse lines are correctly installed before starting the engine (see FUEL SYSTEM section).

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ a battery, which could result in an explosion and severe personal injury or death.

Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to prevent can from contacting battery terminals which could result in an explosion.

To prevent illness or ! ! death, observe the following: Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area.

Exhaust gas (carbon monoxide) is deadly.

Carbon monoxide is an odorless gas that is formed as a natural part of the incomplete combustion of hydrocarbon fuels. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

The following are symptoms of carbon monoxide inhalation: • Dizziness • Vomiting • Intense headache • Muscular twitching • Weakness and sleepiness • Throbbing in temples If experiencing any of these symptoms, get fresh air immediately.

Repair and Service Manual

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

BATTERY REMOVAL AND INSTALLATION

!

!

To prevent severe personal injury or death, resulting from a battery

explosion: Aerosol containers of battery protectant must be used with extreme care. Insulate metal container to prevent can from contacting battery terminals.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ a battery.

Always remove negative (-) cable before removing the positive (+) cable.

Always connect the positive (+) battery cable first and then connect negative (-) battery cable.

8

5 7

1 4

2

In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original position unless otherwise specified. Nonspecified torques are as shown in table contained in Section ‘A’.

Tool List

3

9

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................ 1 Extension, 12", 3/8" drive ............................................ 1 Socket, 1/2", 3/8" drive................................................ 1 Insulated wrench, 1/2"................................................. 1 Battery carrier ............................................................. 1

6

Turn vehicle key ‘OFF’ and remove. Insure all optional electrical accessories are turned OFF. Hold the bolt (item 1) and remove the nut (item 2).

Remove the washer (item 3) (Ref Fig. 1 on page B-7).

Disconnect the negative (-) battery cable (item 4). Always remove negative (-) cable (item 4) before removing the positive (+) cable. Hold the bolt (item 5) and remove the nut (item 6). Remove the washer (item 7). Remove the battery retainer (item 8) and remove the battery (item 9).

Be sure to remove all corrosion from terminals and hardware and wash battery tray. See ‘PERIODIC SERVICE SCHEDULE’ in Section A. Installation of the battery is the reverse of disassembly using new lock nuts.

Fig. 1 Battery Removal After installing battery, coat terminals with commercially available terminal protectant.

Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

2

14 - 18 ft. lbs (19 - 24 Nm)

6

4 - 6 ft. lbs (6 - 8 Nm)

Connect the positive (+) battery cable first and then connect negative (-) battery cable.

Repair and Service Manual

Page B-7

SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

LIFTING THE VEHICLE To prevent possible injury or death resulting from a vehicle falling from a jack, 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. Always place chocks in front and behind the wheels not being raised. Use extreme care since the vehicle is extremely unstable during the lifting process.

!

!

Center of Front Axle

When lifting the vehicle, position jacks and jack stands only on the areas indicated.

Tool List

Qty. Required

Flat Portion of Frame

Floor jack..................................................................... 1 Jack stands ................................................................. 4 Chocks ........................................................................ 4 Some servicing operations may require the front, rear or the entire vehicle to be raised.

To raise the entire vehicle, install chocks in front and behind each front wheel (Ref Fig. 2 on page B-8). Center the jack under the rear axle. 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 jack at the center of the front axle. Raise the vehicle and position jack stands under the frame crossmember as indicated.

Lower the jack and test the stability of the vehicle on all four jack stands.

If only the front or rear of the vehicle is to be raised, place the chocks in front and behind each wheel not being raised in order to stabilize the vehicle.

Lower the vehicle by reversing the lifting sequence.

Page B-8

Repair and Service Manual

Center of Rear Axle View from Underside of Vehicle

Fig. 2 Lifting the Vehicle

Outside End of Rear Axle

BODY AND TRUCKBED TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE

C PAGE NO.

COMPONENT REPLACEMENT ..................................................................................................... C - 1 Seat Bottom Replacement.................................................................................................... C - 1 Seat Back Replacement ....................................................................................................... C - 1 Gas Spring Replacement ..................................................................................................... C - 1 Light Guard Side Replacement ............................................................................................ C - 2 Front Brush Guard Replacement.......................................................................................... C - 3 Front Valance Replacement ................................................................................................. C - 3 Rear Hitch Receiver Replacement ....................................................................................... C - 4 Truck Bed Replacement ....................................................................................................... C - 4 Cowl Replacement ............................................................................................................... C - 5 Instrument Panel Replacement ............................................................................................ C - 6 Rocker Panel Replacement.................................................................................................. C - 8 Floorpan Replacement ......................................................................................................... C - 8 Seat panel (Passenger Side) Replacement ......................................................................... C - 9 Seat panel (Driver Side) Replacement ................................................................................. C - 9 Seat Support Panel Replacement ...................................................................................... C - 10 Rear Fender Replacement ................................................................................................. C - 11 Lower Side Panel Replacement ......................................................................................... C - 12 Front Fender Well Replacement......................................................................................... C - 12

LIST OF ILLUSTRATIONS Fig. 1 Seat Bottom Replacement ................................................................................................... C - 1 Fig. 2 Seat Back Replacement....................................................................................................... C - 1 Fig. 3 Gas Spring Replacement ..................................................................................................... C - 2 Fig. 4 Light Guard Side Replacement ............................................................................................ C - 3 Fig. 5 Front Brush Guard Replacement ......................................................................................... C - 3 Fig. 6 Front Valance Replacement................................................................................................. C - 3 Fig. 7 Rear Hitch Receiver Replacement ....................................................................................... C - 4 Fig. 8 Truck Bed Replacement....................................................................................................... C - 5 Fig. 9 Cowl Replacement ............................................................................................................... C - 6 Fig. 10 Instrument Panel Replacement .......................................................................................... C - 7 Fig. 11 Rivet Removal .................................................................................................................... C - 8 Fig. 12 Rocker Panel Replacement................................................................................................ C - 8 Fig. 13 Floorpan Replacement ....................................................................................................... C - 9 Fig. 14 Seat Panel (Passenger Side) Replacement....................................................................... C - 9 Fig. 15 Seat Panel (Driver Side) Replacement ............................................................................ C - 10 Fig. 16 Rivet Removal .................................................................................................................. C - 10 Fig. 17 Seat Support Panel Replacement .................................................................................... C - 11 Fig. 18 Rear Fender Replacement ............................................................................................... C - 11 Fig. 19 Lower Side Panel Replacement ....................................................................................... C - 12 Fig. 20 Lifting Points..................................................................................................................... C - 13 Fig. 21 Front Fender Well Replacement ...................................................................................... C - 14

Repair and Service Manual

Page C-i

BODY AND TRUCKBED

Notes:

Page C-ii

Repair and Service Manual

C

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

%1/210'06 4'2.#%'/'06 Seat Bottom Replacement Tool List

Qty. Required 1

Phillips screwdriver, large # 3 ..................................... 1

4

3

There is no need to remove the seat bottom frame from hinges (item 2).

Raise the seat bottom (item 1) (Ref Fig. 1 on page C-1).

Remove the screws (item 3) and the washers (item 4) from the back of seat bottom frame (item 5) using Phillips screwdriver. Remove the seat bottom (item 1).

2

Fig. 2 Seat Back Replacement

1

Gas Spring Replacement 6Q RTGXGPV RGTUQPCN KPLW ! ! T[ TGUWNVKPI HTQO C HCNNKPI VTWEM DGF JCXG CP CUUKU VCPV VQ JQNF VTWEM DGF KP TCKUGF RQUKVKQP YJKNG TGRNCE KPI ICU URTKPI

4 3

5

Tool List

Fig. 1 Seat Bottom Replacement Installation of seat bottom is the reverse of disassembly.

Seat Back Replacement Tool List

Qty. Required

Pliers ........................................................................... 1 Ball peen hammer ....................................................... 1

2

Release the truck bed handle (item 1) and raise the bed (item 2) (Ref Fig. 3 on page C-2). Remove the spring pins (item 3) using pliers. Remove the clevis pins (item 4) using ball peen hammer. Remove the gas spring (item 5).

Installation of gas spring is the reverse of disassembly.

Qty. Required

Phillips screwdriver, large # 3 ..................................... 1 Release the truck bed handle and raise the bed (Ref Fig. 2 on page C-1). Remove the screws (item 1) and the washers (item 2) securing the seat back to the cover plate (item 3) using Phillips screwdriver. Remove the seat back (item 4).

Installation of seat back is the reverse of disassembly.

4GRCKT CPF 5GTXKEG /CPWCN

Page C-1

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

1

3

5

4

2

Fig. 3 Gas Spring Replacement

Light Guard Side Replacement Tool List

fully from the vehicle.

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs................................. 1 Socket, 9/16", 3/8" drive .............................................. 1 Wrench, 9/16".............................................................. 1 Park vehicle on a level surface. Engage park brake.

Hold the bolts (item 1) using a 9/16" socket, and remove the nuts (item 2) using a 9/16" wrench, (Ref Fig. 4 on page C-3). Remove the washers (item 3). Use an assistant to help to remove the light guard (items 4, 5) care-

Page C-2

Installation of the light guard is the reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table given below.

ITEM NO 2

4GRCKT CPF 5GTXKEG /CPWCN

TORQUE SPECIFICATION 26 - 31 ft. lbs (35 - 42 Nm)

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

5 3

2

1 4 4

2 3

1

Fig. 5 Front Brush Guard Replacement Fig. 4 Light Guard Side Replacement

Front Valance Replacement

Front Brush Guard Replacement 6JG HTQPV DTWUJ IWCTF KU ! ! JGCX[ 6Q TGFWEG VJG RQUUKDKNKV[ QH RGTUQPCN KPLWT[ KV KU UVTQPIN[ TGEQOOGPFGF VJCV CP CUUKUVCPV JGNR VQ TGOQXG HTQPV DTWUJ IWCTF HTQO VJG XGJKENG

Tool List

Tool List

Park vehicle on a level surface. Engage park brake.

Raise the cowl and latch it (Ref Fig. 6 on page C-3). Hold the nuts (item 1) using 9/16" open end wrench, and remove the bolts (item 2) using Torx bit screwdriver.

Remove the front valance (item 3).

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................ 1 Socket, 5/8", 3/8" drive................................................ 1 Wrench, 5/8" ............................................................... 1

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs................................. 1 Socket, 9/16", 3/8" drive .............................................. 1 Open end wrench, 9/16".............................................. 1 Torx bit screwdriver T- 45............................................ 1

Park vehicle on a level surface. Engage park brake.

Hold the bolts (item 1) using 5/8" socket and remove the nuts (item 2) using 5/8" wrench (Ref Fig. 5 on page C-3).

Remove the washers (item 3). Use additional persons help to remove the front brush guard (item 4) carefully from the vehicle.

Installation of front brush guard is the reverse of disassembly using new lock nuts.

3

Tighten the hardware per torque specification table given below.

1

ITEM NO 2

TORQUE SPECIFICATION 2

35 - 40 ft. lbs (47 - 54 Nm)

Fig. 6 Front Valance Replacement Installation of front valance is the reverse of disassembly using new lock nuts.

4GRCKT CPF 5GTXKEG /CPWCN

Page C-3

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU Tighten the hardware per torque specification table given below.

ITEM NO 2

TORQUE SPECIFICATION 8 - 10 ft. lbs (11 - 13 Nm)

2 4

Rear Hitch Receiver Replacement 6JG TGCT JKVEJ KU JGCX[ 6Q RTGXGPV RQUUKDNG RGT UQPCN KPLWT[ KV KU UVTQPIN[ TGEQOOGPFGF VJCV CP CUUKUVCPV DG WUGF YJGP TGOQX KPI QT KPUVCNNKPI VJG TGCT TGEGKXGT

!

Tool List

!

3 1

Qty. Required

Ratchet, 1/2" drive ....................................................... 1 Torque wrench, 1/2" drive, ft. lbs................................. 1 Socket, 3/4", 1/2" drive ................................................ 1 Impact socket, 9/16", 1/2" drive................................... 1 Wrench, 3/4"................................................................ 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Remove any hitch installed in the receiver. It is necessary to remove the driver side wheel in order to maneuver the receiver above the driver side spring before tilting down and removing below the spring on the passenger side. Loosen the four nuts on the rear driver side wheel half turn.

Lift and support rear of the vehicle per SAFETY section.

Remove the four rear driver side wheel nuts and remove the wheel. With adequate help, support the rear hitch.

Hold the bolt (item 1) using 3/4" socket, and remove the nuts (item 2) using 3/4" wrench (Ref Fig. 7 on page C-4).

Remove washers (item 3). Remove the bolts (item 1) and the backing plates (item 4). Lower the receiver (item 5) and move through the driver side above the spring.

Lower the passenger side below the spring and pull from vehicle.

Installation of rear hitch is the reverse of disassembly using new lock nuts.

5

Fig. 7 Rear Hitch Receiver Replacement Tighten the hardware per torque specification table given below.

ITEM NO 2

TORQUE SPECIFICATION 55 - 60 ft. lbs (75 - 81 Nm)

Truck Bed Replacement 6JG VTWEM DGF KU JGCX[ ! ! CPF CYMYCTF VQ JCPFNG 6Q RTGXGPV RQUUKDNG RGT UQPCN KPLWT[ KV KU UVTQPIN[ TGEQOOGPFGF VJCV CP CUUKUVCPV QT CFGSWCVG NKHVKPI FGXKEG DG WUGF YJGP TGOQXKPI QT KPUVCNNKPI VJG VTWEM DGF HTQO XGJKENG 6Q TGFWEG VJG RQUUKDKNKV[ QH RGTUQPCN KPLWT[ QT FGCVJ TGUWNVKPI HTQO KPEQTTGEV NQCFKPI QH XGJKENG OCMG UWTG EQTTGEV UCHGV[ NCDGN KU KPUVCNNGF CPF OCKPVCKPGF KP IQQF EQPFKVKQP 6Q RTGXGPV RGTUQPCN KPLWT[ TGUWNVKPI HTQO C HCNNKPI VTWEM DGF JCXG CP CUUKUVCPV VQ JQNF VTWEM DGF KP TCKUGF RQUKVKQP YJKNG TGRNCEKPI ICU URTKPI If the truck bed is to be replaced, the label plate must be removed and reinstalled on the new truck bed properly.

Tool List

Qty. Required

Needle nose pliers .......................................................1 Ball peen hammer .......................................................1

Page C-4

4GRCKT CPF 5GTXKEG /CPWCN

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

1 2

4 3

Fig. 8 Truck Bed Replacement Refer to SAFETY section before servicing the vehicle.

Park vehicle on a level surface. Engage park brake.

Remove the gas spring (item 1) (Ref Gas Spring Replacement Section on page C-1). Remove the spring pins (item 2) using needle nose pliers and the clevis pins (item 3) using ball peen hammer connecting truck bed to the main frame (Ref Fig. 8 on page C-5). With adequate support, remove the truck bed (item 4).

Installation of truck bed is the reverse of disassembly.

Cowl Replacement 6Q RTGXGPV UGXGTG RGT UQPCN KPLWT[ QT FGCVJ TGUWNVKPI HTQO GZRNQUKQP ECWUGF D[ CP GNGEVTKECN CTE DG UWTG VJCV VJG MG[ UYKVEJ KU QHH CPF CNN GNGEVTKECN CEEGUUQTKGU CTG VWTPGF

!

!

QHH DGHQTG UVCTVKPI YQTM QP XGJKENG 0GXGT FKUEQPPGEV C EKTEWKV WPFGT NQCF CV VJG DCVVGT[ VGTOKPCN 6JG DCVVGT[ PGICVKXG ECDNG OWUV DG TGOQXGF DGHQTG UVCTVKPI YQTM QP XGJKENG 9TCR YTGPEJGU YKVJ XKP[N VCRG VQ RTGXGPV VJG RQUUKDKNKV[ QH C FTQRRGF YTGPEJ HTQO ŎUJQTVKPI QWVŏ VJG DCVVGT[ YJKEJ EQWNF TGUWNV KP CP GZRNQUKQP CPF UGXGTG RGT UQPCN KPLWT[ QT FGCVJ 9JGP EQPPGEVKPI DCVVGT[ ECDNGU RC[ RCTVKEWNCT CVVGP VKQP VQ VJG RQNCTKV[ QH VJG DCVVGT[ VGTOKPCNU 0GXGT EQP HWUG VJG RQUKVKXG CPF PGICVKXG ECDNG 4GOQXG DCVVGT[ DGHQTG CVVGORVKPI VQ TGOQXG EQYN EQORQPGPVU

4GRCKT CPF 5GTXKEG /CPWCN

Page C-5

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

7 5

4

2

1 3

6

Fig. 9 Cowl Replacement

6Q CXQKF ŎUVTKRRKPIŏ VJTGCFU KP EQYN VCMG ECTG YJGP VKIJVGPKPI DQNVU 7UG NKIJV RTGUUWTG QP PWV FTKXGT Always observe the following warnings when working on or near batteries:

Tool List

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, in. lbs ................................ 1 Extension, 12", 3/8" drive ............................................ 1 Socket, 1/2", 3/8" drive ................................................ 1 Insulated wrench, 1/2" ................................................. 1 Ball peen hammer ....................................................... 1 Needle nose pliers....................................................... 1 Battery carrier.............................................................. 1 Nut driver, 1/4" ............................................................ 1 Park vehicle on a level surface. Engage park brake.

Raise the cowl assembly and engage the latch. Carefully disconnect the battery negative (-) cable first and then the positive (+) cable from the battery using an insulated wrench. Remove the battery (Refer Battery Removal and Installation in SAFETY). Separate the head light plugs and receptacles (Refer ELECTRICAL for head light replacement). Remove all the wiring connected to instrument panel and note the wiring locations. Remove the cotter pins (item 1) using needle nose pliers and clevis

Page C-6

pins (item 2) using ball peen hammer (Ref Fig. 9 on page C-6). Remove the cowl assembly. Remove screws (item 3) and the washers (item 4) on cowl frame (item 5) and front cowl bracket (item 6) using a 1/4" nut driver.

Remove the cowl (item 7) from front cowl frame (item 5) and front cowl bracket (item 6).

Installation of cowl is reverse of disassembly using new cotter pins.

Tighten the hardware per torque specification table given below.

ITEM NO 3

TORQUE SPECIFICATION 30 - 35 in. lbs (3 - 4 Nm)

Instrument Panel Replacement 6Q TGFWEG VJG RQUUKDKNKV[ ! ! QH UGXGTG RGTUQPCN KPLWT[ QT FGCVJ TGUWNVKPI HTQO KPEQTTGEV NQCFKPI QT QRGTCVKQP QH XGJKENG OCMG UWTG EQTTGEV UCHGV[ NCDGN KU KPUVCNNGF CPF OCKPVCKPGF KP IQQF EQPFKVKQP

4GRCKT CPF 5GTXKEG /CPWCN

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

2

1

3

4

5

7

6

Fig. 10 Instrument Panel Replacement

6Q RTGXGPV UGTKQWU RGTUQPCN KPLWT[ QT FGCVJ TGUWNVKPI HTQO GZRNQUKQP ECWUGF D[ CP GNGEVTKECN CTE DG UWTG VJCV VJG MG[ UYKVEJ KU QHH CPF CNN GNGEVTKECN CEEGUUQTKGU CTG VWTPGF QHH DGHQTG UVCTVKPI YQTM QP XGJKENG 0GXGT FKUEQPPGEV C EKTEWKV WPFGT NQCF CV VJG DCVVGT[ VGTOK PCN 9TCR YTGPEJGU YKVJ XKP[N VCRG VQ RTGXGPV VJG RQUUKDKNKV[ QH C FTQRRGF YTGPEJ HTQO ŎUJQTVKPI QWVŏ VJG DCVVGT[ YJKEJ EQWNF TGUWNV KP CP GZRNQUKQP CPF UGXGTG RGT UQPCN KPLWT[ QT FGCVJ 6JG DCVVGT[ PGICVKXG ECDNG OWUV DG TGOQXGF WUKPI KPUWNCVGF YTGPEJ DGHQTG UVCTVKPI YQTM QP XGJKENG

XGJKENG If the instrument panel is to be replaced, the label hand controls plate must be removed and reinstalled on the new instrument panel.

Tool List

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs................................. 1 Rivet Gun .................................................................... 1 Socket, 1/2", 3/8" drive ................................................ 1 Wrench, 1/2"................................................................ 1 Drill .............................................................................. 1 Drill bit ......................................................................... 1

%QXGT DCVVGT[ YKVJ C UJQR TCI DGHQTG UGTXKEKPI VJG 4GRCKT CPF 5GTXKEG /CPWCN

Page C-7

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU Torx bit screwdriver T- 45............................................ 1 Torx bit, 3/8", drive T- 45 ............................................. 1

Installation of rocker panel is reverse of disassembly using new lock nuts.

Park vehicle on a level surface. Engage park brake.

Tighten the hardware per torque specification table given below.

Remove the cowl assembly (Ref Cowl Replacement Section on page C-5). Remove rivets (item 1) using drill and a sharp drill bit (Ref Fig. 11 on page C-8).

ITEM NO 2

Pop Rivet

TORQUE SPECIFICATION 7 - 12 ft. lbs (9 - 16 Nm)

Drill Out Rivet Head Only

Fig. 11 Rivet Removal 3

Remove steering wheel (item 2) (Refer Steering Wheel Replacement section in FRONT SUSPENSION AND STEERING). Hold the nuts (item 3) using 1/2" wrench, and remove the bolts (item 4) using Torx bit screwdriver (Ref Fig. 10 on page C-7). Hold the bolts (item 5) using 1/2" wrench, and remove the nuts (item 6) using 1/2" socket. Pull the instrument panel (item 7) up and over steering column.

Installation of instrument panel is reverse of disassembly using new lock nuts and rivets.

Tighten the hardware per torque specification table given below.

2 1

Fig. 12 Rocker Panel Replacement

Floorpan Replacement Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs .................................1 Socket, 7/16", 3/8" drive ..............................................1 Wrench, 7/16" ..............................................................1 Phillips head screwdriver .............................................1 Park vehicle on a level surface. Engage park brake.

ITEM NO

TORQUE SPECIFICATION

4

15 - 19 ft. lbs (20 - 25 Nm)

6

11 - 15 ft. lbs (15 - 20 Nm)

Rocker Panel Replacement Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs................................. 1 Socket, 7/16", 3/8" drive .............................................. 1 Wrench, 7/16".............................................................. 1 Phillips head screwdriver............................................. 1

Remove rocker panel (Ref Rocker Panel Replacement Section on page C-8). Hold the nut (item 1) using 7/16" wrench and loosen the bolt (item 2) using 7/16" socket and remove the bolts (item 2) using Phillips head screwdriver (Ref Fig. 13 on page C-9). Remove the floorpan (item 3).

Installation of floorpan is reverse of disassembly using new lock nuts.

Replace the old foam pads (item 4) with the new ones if deteriorated or adhered to the old floor pan (item 3).

Park vehicle on a level surface. Engage park brake.

Hold the bolts (item 1) using Phillips head screwdriver and remove the nuts (item 2) using 7/16" wrench, (Ref Fig. 12 on page C-8). Pull the rocker panel (item 3) from the side and remove it.

Page C-8

4GRCKT CPF 5GTXKEG /CPWCN

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU Installation of seat panel (passenger side) is reverse of disassembly.

2

2 3 1

3 1

4

Fig. 13 Floorpan Replacement Tighten the hardware per torque specification table given below.

ITEM NO 2

TORQUE SPECIFICATION 7 - 12 ft. lbs (9 - 16 Nm)

Fig. 14 Seat Panel (Passenger Side) Replacement

Seat panel (Passenger Side) Replacement 6Q RTGXGPV UGXGTG KPLWT[ ! ! QT FGCVJ TGUWNVKPI HTQO GZRNQUKQP QT HKTG FQ PQV UOQMG PGCT VJG HWGN VCPM 9JGP TGOQXKPI VJG UGCV RCPGN KVGO VJG HWGN VCPM ECR OWUV DG TGOQXGF 6Q TGFWEG VJG EJCPEG QH KPJCNCVKQP QH ICU HWOGU YJKEJ CTG JCTOHWN KOOGFKCVGN[ TGRNCEG HWGN ECR KVGO CHVGT TGOQXKPI RCPGN Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs ................................ 1 Phillips head bit, 3/8" drive.......................................... 1 Phillips head screwdriver ............................................ 1 Park vehicle on a level surface. Engage park brake.

Release truck bed handle and lift the bed. Remove the screws (item 2) using Phillips head screwdriver (Ref Fig. 14 on page C-9). Remove the fuel cap (item 1). Remove the seat panel (passenger side) (item 3) from fuel tank neck. Replace the fuel cap (item 1).

Tighten the hardware per torque specification table given below.

ITEM NO 2

TORQUE SPECIFICATION 7 - 12 ft. lbs (9 - 16 Nm)

Seat panel (Driver Side) Replacement Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs................................. 1 Phillips head bit, 3/8" drive .......................................... 1 Phillips head screwdriver............................................. 1 Park vehicle on a level surface. Engage park brake.

Release truck bed handle and lift the bed. Remove the wire tie from parking brake handle. Remove the screws (item 1) using Phillips head screwdriver (Ref Fig. 15 on page C-10). Remove the seat panel (driver side) (item 2) from parking brake handle.

4GRCKT CPF 5GTXKEG /CPWCN

Page C-9

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU Installation of seat panel (driver side) is reverse of disassembly.

Pop Rivet

Drill Out Rivet Head Only

1

Fig. 16 Rivet Removal 2

Remove rocker panel (Ref Rocker Panel Replacement Section on page C-8). Remove the floorpan (Ref Floorpan Replacement Section on page C-8). Remove the rivets (item 1) securing the air intake (item 2), using drill and sharp drill bit (Ref Fig. 16 on page C-10).

Loosen the jam nut (item 3) and remove the choke cable (item 4) from the seat panel (Ref Fig. 17 on page C-11).

Remove the screws (item 5) on the seat frame using Phillips head screwdriver. Do not remove the bolts securing the seat hinge. Remove the seat support panel (item 6).

Fig. 15 Seat Panel (Driver Side) Replacement Tighten the hardware per torque specification table given below.

Installation of seat support panel is reverse of disassembly.

Tighten the hardware per torque specification table given below.

ITEM NO

ITEM NO

4 1

7 - 12 ft. lbs (9 - 16 Nm)

Seat Support Panel Replacement The choke cable does not need to be disconnected from engine. The knob and cover can be removed through the hole in the seat panel.

Do not remove the screws securing the hinges.

Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs................................. 1 Phillips head bit, 3/8" drive .......................................... 1 Phillips head screwdriver............................................. 1 Wrench, 7/16".............................................................. 1 Wrench, 7/8"................................................................ 1 Drill .............................................................................. 1 Drill bit ......................................................................... 1 Rivet gun ..................................................................... 1 Park vehicle on a level surface. Engage park brake.

Page C-10

TORQUE SPECIFICATION

TORQUE SPECIFICATION

4GRCKT CPF 5GTXKEG /CPWCN

7 - 12 ft. lbs (9 - 16 Nm)

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

5

4

1

3

6

To Carburetor 2

Fig. 17 Seat Support Panel Replacement

Rear Fender Replacement

Park vehicle on a level surface. Engage park brake.

Tool List

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................ 1 Socket, 7/16", 3/8" drive.............................................. 1 Wrench, 3/8" ............................................................... 1 Straight blade screwdriver .......................................... 1

Release truck bed handle and lift the bed.

Remove the ratchet fasteners (item 1) from the top of rear fender (Ref Fig. 18 on page C-11). Hold the screws (item 2) using 3/8" wrench, and remove the nut (item 3) using 7/16" socket. Remove the washer (item 4).

Remove the rear fender (item 5) from the lower side panel and frame.

Installation of the rear fender is reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table given below.

1 5

ITEM NO 3

2

TORQUE SPECIFICATION 10 - 15 ft. lbs (13 - 20 Nm)

3 4

Fig. 18 Rear Fender Replacement

4GRCKT CPF 5GTXKEG /CPWCN

Page C-11

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

Lower Side Panel Replacement Tool List

Front Fender Well Replacement Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs................................. 1 Socket, 7/16", 3/8" drive .............................................. 1 Wrench, 3/8"................................................................ 1 Wrench, 7/16".............................................................. 1 Phillips head screwdriver, (18" minimum length)......... 1 Park vehicle on a level surface. Engage park brake.

Remove the seat panel (Driver side) (item 1) (Ref Seat panel (Driver Side) Replacement Section on page C-9) and the seat panel (Passenger side) (item 2) (Ref Seat panel (Passenger Side) Replacement Section on page C-9). Hold the screws (item 3) using 3/8" wrench, and remove the nut (item 4) using 7/16" socket (Ref Fig. 19 on page C-12). Remove the washer (item 5). Remove the lower side panel (item 6) from the frame.

Installation of the lower side panel is reverse of disassembly using new lock nuts.

1 2

3

6JG HTQPV HGPFGT YGNN TGRNCEGOGPV KU CP KPXQNXGF RTQEGUU TGSWKT KPI GZVGPUKXG FKUCUUGODN[ QH VJG XGJKENG 6Q RTGXGPV RGTUQPCN KPLWT[ KV KU UVTQPIN[ TGEQOOGPFGF VJCV CP CUUKUVCPV QT NKHVKPI FGXKEG DG WUGF VQ TGOQXG KPUVCNN HTQPV HGPFGT YGNN HTQO VQ XGJKENG 6Q RTGXGPV UGTKQWU RGTUQPCN KPLWT[ QT FGCVJ TGUWNVKPI HTQO GZRNQUKQP ECWUGF D[ CP GNGEVTKECN CTE DG UWTG VJCV VJG MG[ UYKVEJ KU QHH CPF CNN GNGEVTKECN CEEGUUQTKGU CTG VWTPGF QHH DGHQTG UVCTVKPI YQTM QP XGJKENG 0GXGT FKUEQPPGEV C EKTEWKV WPFGT NQCF CV VJG DCVVGT[ VGTOK PCN 9TCR YTGPEJGU YKVJ XKP[N VCRG VQ RTGXGPV VJG RQUUKDKNKV[ QH C FTQRRGF YTGPEJ HTQO ŎUJQTVKPI QWVŏ VJG DCVVGT[ YJKEJ EQWNF TGUWNV KP CP GZRNQUKQP CPF UGXGTG RGT UQPCN KPLWT[ QT FGCVJ 6JG DCVVGT[ PGICVKXG ECDNG OWUV DG TGOQXGF WUKPI KPUWNCVGF YTGPEJ DGHQTG UVCTVKPI YQTM QP XGJKENG

!

!

9JGP EQPPGEVKPI DCVVGT[ ECDNGU RC[ RCTVKEWNCT CVVGP VKQP VQ VJG RQNCTKV[ QH VJG DCVVGT[ VGTOKPCNU 0GXGT EQP HWUG VJG RQUKVKXG CPF PGICVKXG ECDNG If the front fender is to be replaced, the safety label must not be removed. Install a new label when replacing fender well.

6

Apply petroleum jelly or liquid soap around steering column before installing instrument panel.

Tool List

5 4

Fig. 19 Lower Side Panel Replacement Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

Qty. Required

Ratchet, 3/8" drive .......................................................1 Torque wrench, 3/8" drive, ft. lbs .................................1 Socket, 9/16", 3/8" drive ..............................................1 Socket, 1/2", 3/8" drive ................................................1 Wrench, 9/16" ..............................................................1 Wrench, 1/2" ................................................................1 Wrench, 13mm ............................................................1 Torx bit screwdriver T- 45............................................1 Chain hoist...................................................................1 Refer SAFETY section before you start.

Park vehicle on a level surface. Engage park brake.

4

Page C-12

10 - 15 ft. lbs (13 - 20 Nm)

Remove the rocker panel (Ref Rocker Panel Replacement Section on page C-8). Remove the floorpan (Ref Floorpan Replacement Section on page C-8). Remove

4GRCKT CPF 5GTXKEG /CPWCN

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU the cowl assembly (Ref Cowl Replacement Section on page C-5). Carefully disconnect the battery negative (-) cable first and then the positive (+) cable from the battery using insulated wrench. Remove the battery (Refer Battery Removal and Installation in SAFETY). Remove the direction and drive selector cables (Refer Direction and Drive Selector Cable Adjustment in DIRECTION AND DRIVE SELECTOR). Remove the master cylinder (Refer to Master Cylinder Replacement in BRAKES). Remove all the cables and wires connected to instrument panel and note the wiring locations. Support upper mount frame (item 1) of the instrument panel using lift (Ref Fig. 20 on page C-13).

Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

3

20 - 25 ft. lbs (27 - 34 Nm)

9

11 - 14 ft. lbs (15 - 19 Nm)

13

8 - 13 ft. lbs (11 - 21 Nm)

Lifting Points 1

Fig. 20 Lifting Points Hold the bolt (item 2) connecting upper mount frame to the main frame using 9/16" wrench and remove the nut (item 3) using 9/16" socket (Ref Fig. 21 on page C-14).

Remove the bolt (item 4) using 13mm wrench and washer (item 5). Hold the bolt (item 6) using 1/2" wrench and remove the nut (item 7) using 1/2" socket. Remove the washer (item 8). Raise the whole instrument panel (item 9). Hold the bolt (item 10) using 1/2" wrench and remove the nut (item 11) using 1/2" socket. Remove the washer (item 12). Hold the nut (item 13) using 9/16" wrench and remove the bolt (item 14) using 9/16" socket.

Remove the screw (item 15) connecting front fender well to the cowl and fender support using Torx bit screwdriver. Remove the washer (item 16). Remove the front fender well (item 17).

Installation of the front fender well is reverse of disassembly using new lock nuts.

4GRCKT CPF 5GTXKEG /CPWCN

Page C-13

BODY AND TRUCKBED 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

9

1

3

4 2 6 5

17 8 10 14

12

15 16

7 11 13

Fig. 21 Front Fender Well Replacement

Page C-14

4GRCKT CPF 5GTXKEG /CPWCN

BRAKES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE

D PAGE NO.

GENERAL ....................................................................................................................................... D - 2 How The Hydraulic System Works ....................................................................................... D - 2 Rear Wheel Brake ................................................................................................................ D - 2 Front Disc Brake................................................................................................................... D - 2 MAINTENANCE .............................................................................................................................. D - 2 Daily Brake Performance Test.............................................................................................. D - 2 Brake System Inspection...................................................................................................... D - 3 MASTER CYLINDER ...................................................................................................................... D - 4 Brake Fluid ........................................................................................................................... D - 4 Master Cylinder Replacement .............................................................................................. D - 4 BRAKE DRUM REPLACEMENT .................................................................................................... D - 5 WHEEL BRAKE SERVICE AND REPLACEMENT ......................................................................... D - 6 FRONT DISC BRAKE REPLACEMENT ......................................................................................... D - 9 Caliper Replacement ............................................................................................................ D - 9 Disc Brake Pad Replacement............................................................................................. D - 10 Disc Brake Rotor Replacement .......................................................................................... D - 11 BLEEDING AND FLUSHING ........................................................................................................ D - 11 Bleeding.............................................................................................................................. D - 11 Bleeding Sequence ............................................................................................................ D - 12 Flushing .............................................................................................................................. D - 12 BRAKE PEDAL REPLACEMENT ................................................................................................. D - 13 PARKING BRAKE ......................................................................................................................... D - 13 Lubrication .......................................................................................................................... D - 13 Adjustment.......................................................................................................................... D - 13 Cable Replacement ............................................................................................................ D - 14

LIST OF ILLUSTRATIONS Fig. 1 Hydraulic Brake System Components.................................................................................. D - 1 Fig. 2 Wheel Brake Operation ........................................................................................................ D - 3 Fig. 3 Master Cylinder Replacement .............................................................................................. D - 5 Fig. 4 Brake Drum Replacement .................................................................................................... D - 6 Fig. 5 Wheel Brakes Replacement................................................................................................. D - 7 Fig. 6 Backing Plate Lubrication Points.......................................................................................... D - 8 Fig. 7 Replacing an Adjuster .......................................................................................................... D - 9 Fig. 8 Caliper Replacement.......................................................................................................... D - 10 Fig. 9 Disc Brake Pad Replacement ............................................................................................ D - 10 Fig. 10 Disc Brake Rotor Replacement ........................................................................................ D - 11 Fig. 11 Bleeding And Flushing ..................................................................................................... D - 12 Fig. 12 Brake Pedal Replacement................................................................................................ D - 13 Fig. 13 Parking Brake................................................................................................................... D - 14

Repair and Service Manual

Page D-i

BRAKES

Notes:

Page D-ii

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Master Cylinder

D

Clevis Yoke

Extension Spring

Brake Pedal

Mounts To Frame To Passenger Side Caliper Rotor Mounts To Frame

Rear Brake Line

Front Brake Line

Brake Caliper

Mounts To Frame

Upper Return Spring Wheel Cylinder Brake Shoe

Brake Drum

Lower Return Spring

Fig. 1 Hydraulic Brake System Components

Repair and Service Manual

Page D-1

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

GENERAL How The Hydraulic System Works A hydraulic system actuates the brakes through two separate circuits. The rear master cylinder reservoir operates the front disc brakes, and the front operates the rear drum brakes. The system transmits the power required to activate the friction surfaces (pads front and brake shoes rear) of the braking system from the pedal to the individual brake units at each wheel.

Hydraulic system operation:

Brake adjustment is automatic (Ref Fig. 2 on page D-3).

Adjustment takes place, if needed, whenever the brakes are applied (forward or reverse stop or when the vehicle is stationary). Upon any brake application, the shoes move outward contacting the drum. As the shoes move outward, the automatic adjuster levers (attached to each shoe by a pin) follow the shoe movement. The automatic adjuster pin is smaller than the slot in the brake shoe web; therefore, when the brakes are released, the shoes are allowed to return slightly, providing brake shoe to drum running clearance.

The rear brake includes a parking feature consisting of a lever and strut. The lever is applied by a cable attached to the parking brake lever (hand operated). The parking brake is used to retain the vehicle when stationary.

When at rest, the entire system is full of brake fluid. Upon application of the brake pedal, fluid trapped in front of the master cylinder piston is forced through the brake lines to the wheel cylinders. Here, it forces pistons outwards against the brake pads or shoes. a) The front brake pad contacts the brake disc and continued movement of the piston moves the brake caliper that contains the second brake pad.

The two brake pads apply a clamping force to the disc.

Upon release of the brake pedal, a spring located inside the master cylinder immediately returns the piston to the normal position. The front brake piston retracts slightly as the piston seal retracts. The piston returns the brake fluid to its original position within the rear reservoir of the master cylinder, and the attached brake pads retract from the disc. b) Upon release of the brake pedal, a spring located inside the master cylinder immediately returns the piston to the normal position. The rear brake shoe return springs retract the brake shoes and wheel cylinders which returns the brake fluid to its original position within the front reservoir of the master cylinder.

The disc brake assembly is a single cylinder, one piece housing. The cylinder contains a piston and a piston seal containing a return spring. There are two brake pads, on either side of the disc. The brake pad mounted to the piston will move out and in of the cylinder when the brakes are operated and released. Hydraulic pressure from the brake master cylinder enters the brake cylinder and forces the piston and pad against the rotating disc. As brake pressure continues the piston mounted pad ‘pulls’ the caliper with the second brake pad against the opposite side of the rotating disc. This creates friction to stop the vehicle.The caliper is held in relative position to the mounting bracket with sliding pins secured to the caliper.

Rear Wheel Brake

Daily Brake Performance Test

The 160 x 30mm hydraulic brake is a leading-trailing design. The shoes are held to the backing plate by holddown springs, pins, and spring retainers. The shoes are fitted to the anchor at the bottom and secured by a lower shoe to shoe spring. At the top, the shoe web rests on the wheel cylinder piston.

The shoes are held to the wheel cylinder pistons by the upper shoe to shoe spring. The wheel cylinders are a double piston design, providing even distribution of force to each shoe. There are no links. Shoes rest directly on the piston ends. Wheel cylinders incorporate external boots.

Page D-2

Front Disc Brake

Maintenance of the single disc brake may include lubrication of slide pins, bleeding, performing operational checks, and the checking pad and disc wear.

MAINTENANCE To assure correct braking performance, all periodic maintenance, inspections and procedures must be performed as indicated in the Periodic Service Schedule in Section A of this manual. It is important that a Daily Brake Performance Test be performed and the entire brake system be serviced in accordance with the Periodic Service Schedule.

The brake system must be bled whenever any part of the brake system has been replaced.

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Wheel Cylinder

New Brake Shoes Installed: Adjusters Set to Neutral Position.

Backing Plate Torx Bolt Tube Nut

Brake Shoe Frame Brake Springs

Washer Adjuster

Slot in Brake Shoe Frame Adjuster

Install Belleville Washer With Arch Up As Shown

Brake Drum

Brake Pedal Applied : Wheel Cylinder pushes Brake Shoes Out & OVERCOMES Spring Resistance (BellevilleWasher) of Brake Adjuster.

Slot in Brake Shoe Frame Pulls Adjuster Outwards.

Brake Pedal Released: Wheel Cylinder Retracts & Brake Springs Retract Brake Shoes.

Slot in Brake Shoe Frame Contacts Adjuster but CANNOT OVERCOME Adjuster Spring Resistance (BellevilleWasher).

Brake Shoe Remains In Adjusted Position.

Fig. 2 Wheel Brake Operation Depress brake pedal. The pedal should have some free play and then become hard. A brake pedal that has no free travel, excessive free travel or a spongy feel indicates a brake inspection is required. A brake pedal that falls after it is applied indicates a leak in the master or wheel cylinders. Check brake fluid level. Adjust rear brakes if required and inspect system for fluid leaks.

Brake System Inspection

lic fluid, wipe the friction material and drum or disc until they are dry.

Brake failure usually occurs as either a gradual decrease in braking effect from the friction material being worn away, a loss of braking at one wheel or a sudden and complete failure with no brakes working except the parking brake.

Do not allow brake fluid to contact painted surfaces. Wipe off immediately.

Should the brakes at one wheel become ineffective while the brakes at the other wheel functions properly, remove the wheel and drum. Inspect the brake for evidence of a leaking or inoperative wheel cylinder assembly.

Care should be taken to prevent brake fluid from coming into contact with the brake shoes or pads. If the friction material should become wet with hydrau-

Complete brake failure usually indicates a loss of hydraulic fluid pressure.

Repair and Service Manual

Page D-3

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

The hydraulic system may be checked for leaks by applying pressure to the pedal gradually and steadily. If the pedal sinks very slowly to the floor, the system has a leak. This is not to be confused with a springy or spongy feel due to the compression of air within the lines.

Hydraulic brake systems must be totally flushed if the fluid becomes contaminated with water, dirt or other corrosive chemicals. To flush, bleed the entire system until all brake fluid has been replaced with fresh DOT 3 standard automotive brake fluid.

MASTER CYLINDER

It is important to maintain proper fluid levels in the master cylinder. The fill cap for the cylinder is located under the cowl. To prevent contamination when checking fluid, wipe off any dirt from fill cap before removing it. Reservoir fluid level should be checked per ‘Periodic Service Schedule’ Section in GENERAL INFORMATION AND ROUTINE MAINTENANCE. When required, clean brake fluid should be added to maintain fluid level between the maximum and minimum level indicators of the reservoirs.

Use fresh DOT 3 standard automotive brake fluid.

Just like any other brake part, the master cylinder will eventually require replacement. The usual reason for a master cylinder failure is the cylinder seals (cups) deteriorate. Fluid leaks past the cups and shows as an external leak. A common symptom is a ‘spongy’ brake pedal that goes all the way to the floor when all the other brake components are in good condition. The rubber parts wear with usage or deteriorate with age or fluid contamination.

Corrosion or deposits formed in the cylinder bore due to moisture or dirt in the hydraulic system may result in wear of the cylinder bore or related parts. Do not try to remove corrosion or deposits with a cylinder hone. If corrosion or deposits are present, discard master cylinder and replace with new one.

Master Cylinder Replacement To prevent serious per! ! sonal injury or death resulting from a battery explosion, remove the battery. Always disconnect the negative (-) battery cable first using insulated wrench.

To prevent serious personal injury or death resulting from a brake system containing air, bleed the brake system whenever the brake component is removed, a brake line is disconnected, or the brake fluid in the master cylinder is allowed to fall below the minimum level and it is suspected that air may have entered the system. Ref Bleeding And Flushing section.

Brake Fluid

To prevent serious personal injury or death resulting from a brake failure resulting from contaminated brake fluid, never reuse any excess fluid or return to the original container. Dispose of brake fluid properly.

Check for leaks along all lines and at brake assembly. If no external leaks are apparent, the problem is inside the master cylinder.

After making any repairs to hydraulic lines, wheel cylinders or master cylinder, the brakes must be bled to remove any trapped air. A bleeder valve is located at each wheel cylinder for this purpose.

To prevent serious personal injury or death resulting from a battery explosion, remove the battery. Always disconnect the negative (-) battery cable first using insulated wrench.

To prevent serious personal injury or death resulting from a brake system containing air, bleed the brake system whenever the brake component is removed, a brake line is disconnected, or the brake fluid in the master cylinder is allowed to fall below the minimum level and it is suspected that air may have entered the system. Ref Bleeding And Flushing section.

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During this process, it is likely that brake fluid will leak from the master cylinder. Avoid allowing brake fluid to contact the painted body components of the vehicle. Wipe off immediately.

Page D-4

During this process, it is likely that brake fluid will leak from the master cylinder. Avoid allowing brake fluid to contact the painted body components of the vehicle. Wipe off immediately.

It is recommended that brake fluid be drained when the master cylinder is removed. Open each bleeder valve in turn, and drain fluid into catch pan. Dispose of old fluid properly.

Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs .................................1 Wrench, 3/8" ................................................................1 Insulated wrench, 1/2" .................................................1 Needle nose pliers .......................................................1 Shop towels ............................................................. A/R Catch pan ....................................................................1

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Teflon tape............................................................... A/R

(item 7) is not fastened to master cylinder (item 1).

Remove the master cylinder (item 1) from the vehicle.

Installation of a new master cylinder is the reverse of disassembly using new lock nuts. Reconnect and tighten the brake lines (items 2 & 3) per torque specification table given below.

Be sure that actuating rod attached to the brake pedal clevis is inside master cylinder.

1

At the brake clevis, check that the clevis is free to move easily on the brake pedal indicating that no preload is being applied to the new master cylinder.

Check that there is not excessive pedal free play which would indicate that the master cylinder actuating rod is too loose. Adjust if required to meet both criteria.

4 7 5 3 2

6

Fill reservoir with DOT 3 brake fluid and bleed brake system (Ref BLEEDING AND FLUSHING on page D-11).

After bleeding brake system, check for leaks along all lines and at master cylinder and install the battery.

ITEM NO

Fig. 3 Master Cylinder Replacement The master cylinder is located under the cowl and is connected to the brake pedal by clevis yoke.

It is important to maintain proper fluid levels in the master cylinder. The fill caps for the cylinder are located under the cowl. To prevent contamination when checking fluid, wipe off any dirt from fill cap before removing it. Reservoir fluid level should be checked per ‘Periodic Service Schedule’ Section in GENERAL INFORMATION AND ROUTINE MAINTENANCE. When required, clean fresh DOT 3 standard automotive brake fluid should be added to maintain fluid level between the maximum and minimum level indicators of the reservoirs.

Turn vehicle key to ‘OFF’ and remove. Insure all optional electrical accessories are turned OFF. Remove the battery (Ref Battery Removal And Installation section in SAFETY). Clean the area around the master cylinder (item 1) to prevent dirt and grease from contaminating the hydraulic system (Ref Fig. 3 on page D-5). Remove the front (item 2) and rear brake lines (item 3) using 3/8" wrench where they connect to master cylinder (item 1).

Use a catch pan for the used brake fluid and plug master cylinder (item 1) and brake lines to prevent contamination. Remove the lock nuts (item 4) using 1/2" wrench.

Remove the bolt (item 5). Remove master cylinder (item 1) from clevis yoke vehicle frame (item 6). Clevis yoke

TORQUE SPECIFICATION

2

10 - 15 ft. lbs (14 - 20 Nm)

3

10 - 15 ft. lbs (14 - 20 Nm)

4

12 - 15 ft. lbs (16 - 20 Nm)

BRAKE DRUM REPLACEMENT To prevent severe personal injury or death resulting from a brake failure, never turn a brake drum to ‘true’ a worn friction surface. Turning will make the drum too thin which could result in a brake failure.

To prevent dust inhalation or eye injury, always wear a dust mask and eye protection whenever working on wheel brakes. Do not use pressurized air to blow dust from brake assemblies.

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Inspect the brake drum. Look for a blue coloration or blistered paint that would indicate that it has overheated. Check for evidence of scoring/ gouging. Check for excessive wear indicated by the friction surface being significantly worn and leaving a ledge of unworn drum. If any of these problems are found, the drum must be replaced.

Repair and Service Manual

Page D-5

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Do not apply the brake when removing the wheel lug nuts; the shoes may not fully retract preventing removal of the brake drum.

WHEEL BRAKE SERVICE AND REPLACEMENT

Tool List

To prevent dust inhalation or eye injury, always wear a dust mask and eye protection whenever working on wheel brakes.

Do not use pressurized air to blow dust from brake assemblies.

Replace both brake shoes on both wheels if one or more shoes are worn below .06" (1.5 mm) thickness at any point.

Qty. Required

Torque wrench, 1/2" drive, ft. lbs ................................. 1 Impact wrench, 3/4", 1/2" drive.................................... 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Lug wrench, 3/4" ......................................................... 1 Torx bit screwdriver T - 45 ........................................... 1 Plastic faced hammer.................................................. 1 Hydraulic floor jack ...................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4

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Do not use a commercial brake cleaner unless the entire brake has been disas-

Loosen the four nuts on the rear wheels half turn.

sembled.

Lift and support rear of the vehicle per SAFETY section.

Remove the four rear wheel nuts and remove the wheel (Ref WHEELS AND TIRES). Remove the brake drum (item 1) by grasping it firmly and pulling away from the wheel bolts (Ref Fig. 4 on page D-6). If the drum cannot be removed, tap the drum around the circumference with a plastic faced hammer. If the brake drum still cannot be removed, retract the brake shoes (item 2). Using a Torx driver rotate adjuster Torx head bolts (item 3) on rear side of backing plate (item 4) towards the axle to retract shoes and remove brake drum.

Use care when handling the axles. The spline at the inboard end is subject to damage if not protected. A damaged spline may cause damage to the internal seal when reinstalled.

To install the brake drum slide the brake drum into place.

3

1

2

4

Fig. 4 Brake Drum Replacement

Page D-6

If brake shoes are worn below .06" (1.5 mm) thickness at any point, replace all brake shoes. Brake shoes should be always replaced in pairs and both wheel brake shoes replaced. Be sure that there is no grease, oil, or any other contaminant on brake shoes.

Tool List Qty. Required Ratchet, 1/2" drive .......................................................1 Torque wrench, 3/8" drive, in. lbs.................................1 Torque wrench, 3/8" drive, ft. lbs. ................................1 Extension, 6", 3/8" drive ..............................................1 Socket, 10 mm, 3/8" drive............................................1 Socket, 7/16", 3/8" drive ..............................................1 Socket, 9/16", 3/8" drive ..............................................1 Socket, 3/4", 1/2" drive ................................................1 Wrench, 10 mm ...........................................................1 Wrench, 1/2" ................................................................1 Wrench, 9/16" ..............................................................1 Locking pliers...............................................................1 Pliers............................................................................1 Torx bit screwdriver T - 45 ...........................................1 Dust mask....................................................................1 Safety glasses .............................................................1 Parts brush ..................................................................1 Wheel cylinder clamp ..................................................1 Brake cleaner .......................................................... A/R Shop towels ............................................................. A/R Wire brush ...................................................................1

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

1/2" socket and extension. Pull the brake assembly (item 8) and rear axle shaft (item 9) out from the axle tube (item 7) as an assembly. Remove the axle shaft (item 9) from the brake assembly.

Grease .................................................................... A/R High temperature lubricant...................................... A/R Thread locking compound....................................... A/R Hydraulic floor jack...................................................... 1 Jack stands ................................................................. 2 Wheel chocks.............................................................. 4

Remove excess dust and dirt from the drum (item 1) with a parts brush. Remove any accumulated brake dust from the wheel brake assembly (item 8) with a parts brush.

Unhook upper shoe-to-shoe spring (item 10) and lower shoe-to-shoe spring (item 11). Remove shoe hold-down springs (item 12) and remove shoes (item 13). Remove parking brake strut and lever.

Disassembly Use care not to damage the axle splines.

Loosen the four nuts on the rear wheels a half turn.

Remove the wheel cylinder bolts (item 15) and remove the wheel cylinder (item 14) from the backing plate (item 16).

Lift and support rear of the vehicle per SAFETY section.

Be sure that the parking brake is released. Remove the four rear wheel nuts and remove the wheel. Remove the brake drum (item 1) (Ref Fig. 5 on page D-7).

Cleaning And Inspection

To prevent serious injury or death resulting from a brake failure, never turn a brake drum. The drum must not be turned to ‘true’ a worn friction surface. Turning will make the drum too thin which could result in a brake failure.

Remove the cotter pin (item 2) from the clevis pin (item 3) securing the parking brake cable (item 4) to the parking brake lever. Remove the brake line (item 5) from the rear of the wheel cylinder using 9/16" wrench. Loosen the four brake mounting bolts (item 6) from the rear axle (item 7) flange using a 1/2" wrench and remove it using

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4 5 3 8 14 10 13

18

17

15

12 7 2 1 6 19 16

9 11

Fig. 5 Wheel Brakes Replacement

Repair and Service Manual

Page D-7

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

A backing plate assembly that shows any indication of galling or gouging is not repairable and must be replaced with a new wheel brake assembly. Always replace wheel brake assemblies in pairs.

Inspect the brake drum (item 1) (Ref Fig. 5 on page D-7).

Look for a blue coloration or blistered paint that would indicate that it has overheated. Check for evidence of scoring/gouging. Check for excessive wear indicated by the friction surface being significantly worn and leaving a ledge of unworn drum. If any of these problems are found, the drum must be replaced.

(item 18), and to anchor. Position the adjusters (item 17) so that the pins (item 18) are at the 12 o'clock position.

Adjuster Pin

Adjuster

Wheel Cylinder

Lubricate (3) Bosses Each Side

Lubricate (3) Bosses Each Side

Clean the backing plate (item 16) with a commercially available brake cleaner.

Inspect the backing plate (item 16). Inspect for gouges, galling or other damage, particularly where the backing plate (item 16) is contacted by the brake shoes (item 13).

Be sure shoe ledges are smooth and free of rough edges. Replace both wheel brake assemblies (item 8) if any gouges or galling is found.

It is normal for the shoes to show more wear at the leading and trailing edges. If the brake shoe thickness is approaching .06" (1.5 mm), it is recommended that the shoes be replaced.

Measure the brake shoe (item 13) thickness. Measure at the most worn area. Brake shoes must be replaced when friction material thickness is .06" (1.5 mm) at any point on the shoe. It is recommended that the brake shoe springs (item 10, 11) and brake adjusters (item 17) be replaced when installing new brake shoes.

Check springs for loss of tension and damage. Replace weak springs and any damaged or badly worn parts.

Check adjuster (item 17) operation. Insure that each adjuster will move with approximately 30 - 50 in. lbs (3.4 5.6 Nm) of torque. If adjusters are frozen, badly worn or loose, replace the adjuster assembly.

Replace the wheel cylinder (item 14) if there is any sign of leakage. Insure that the parking lever and strut assembly moves freely. If necessary, this assembly can be serviced as follows: Disassemble by removing the C-clip. Wire brush contact surfaces to remove any corrosion and contaminants.

Lightly grease the pin and contact surfaces before reassembly.

Backing Plate

Fig. 6 Backing Plate Lubrication Points If the wheel cylinder (item 14) was removed, install it to the backing plate (item 16). Insert and tighten the wheel cylinder mounting bolts (item 15). Position shoes (item 13) on backing plate (item 16) and install hold-down springs (item 12). Install parking brake strut with tab on strut engaged in brake shoe web. Place upper end of shoe webs against wheel cylinder, and install upper shoe-to-shoe spring (item 10).

Install lower shoe-to-shoe spring (item 11).

Use great care when installing axle shaft. The shaft must pass through an internal oil seal.

Insert axle shaft (item 9) through brake assembly (item 8). Hold the axle and insert into axle tube (item 7). Keep axle centered in the tube and engage it with the internal spline within the differential. Align the four mounting holes in the pillow block bearing with the brake assembly mounting holes and the holes in the axle tube flange.

Install bolts (item 6) with a 1/2" socket. Connect the brake line (item 5).

Install parking brake cable (item 4) using new cotter pins.

Pre-adjust shoes by rotating adjuster bolt (item 19) away from the axle until shoes contact drum and then back off just enough to eliminate drag.

Reassembly Apply a light coat of high temperature lubricant to shoe support points on the backing plate (item 16), (Ref Fig. 6 on page D-8) and (Ref Fig. 5 on page D-7) to adjuster pin

Page D-8

Fixed Anchor

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tighten the hardware and brake lines per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

6

28 - 31 ft. lbs ( 38 - 42 Nm)

5

10 - 15 ft. lbs (14 - 20 Nm)

15

10 ft. lbs (14 Nm)

19

9 - 10 ft. lbs (12 - 14 Nm)

Adjustment After the brake system has been bled, make 3 to 10 forward and reverse stops by applying firm pressure to the brake pedal on each stop to bring shoes to proper adjustment.

FRONT DISC BRAKE REPLACEMENT To prevent dust inhalation or eye injury, always wear a dust mask and eye protection whenever working on wheel brakes.

Do not use pressurized air to blow dust from brake assemblies.

Caliper Replacement To prevent serious per! ! sonal injury or death resulting from a brake failure resulting from contaminated brake fluid, never reuse any excess fluid or return to the original container. Dispose of brake fluid properly.

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Replacing an Adjuster Replace the adjuster assembly if the adjuster requires more than 50 in. lbs (5.6 Nm) torque to rotate.

Secure the adjuster arm with locking pliers and remove the torx bolt (item 1) on the back side of the backing plate (item 2) with a torx driver (Ref Fig. 7 on page D-9). The bolt may shear off which is acceptable. Remove and discard all adjuster components. Clean the backing plate surfaces that contact with the adjuster (item 3).

Prepare to install the new adjuster by applying a light coat of grease to the belleville washer (item 4). Install the washer (item 5) onto the adjuster arm with arch up as shown in the figure below.

Apply thread locking compound to the bolt.

Insert the nose of the tube nut (item 6) into the backing plate (item 2). Install the bolt (item 1) into the tube nut (item 6) and tighten to 9 - 10 ft. lbs (12 - 14 Nm) torque.

It is recommended to replace both adjusters (item 3), if one is found to require replacement.

2

Tool List

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Qty. Required

Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Torque wrench, 1/2" drive, ft. lbs ................................. 1 Impact wrench, 1/2" drive Extension, 6", 1/2" drive ............................................. 1 Socket, 3/4", 1/2" drive ................................................ 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Allen wrench, 9 mm, 3/8" drive.................................... 1 Wrench, 3/8"................................................................ 1 Catch Pan.................................................................... 1 Park the vehicle on a level surface, engage park brake.

Loosen the four nuts on the front wheels half turn. Lift and support front of the vehicle per SAFETY section.

1

Remove the four front wheel nuts using 3/4" impact socket and remove the wheel. Remove the bolt (item 1) using 3/4" socket and extension (Ref Fig. 8 on page D10). Remove the washer (item 2). Remove the front brake line (item 3) using 3/8" wrench and drain fluid into catch pan for proper disposal. Remove the caliper (item 4).

6 5

4

3

Fig. 7 Replacing an Adjuster

Repair and Service Manual

Page D-9

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Torque wrench, 1/2" drive, 165 ft. lbs capacity ............1 Impact socket, 3/4", 1/2" drive .....................................1 Allen wrench, 9 mm, 3/8" drive ....................................1

3

Needle nose pliers .......................................................1 Park the vehicle on a level surface, engage park brake.

Loosen the four nuts on the front wheels half turn. Lift and support front of the vehicle per SAFETY section.

1 2

4

Remove the four front wheel nuts using 3/4" impact socket and remove the wheel. Do not remove front brake lines (item 1) (Ref Fig. 9 on page D-10). Remove the Cclip (item 3) from the front end of the slide bolts (item 4) and remove the bolts (item 4) using Allen wrench.

Remove the caliper (item 2) (Ref Caliper Replacement on page D-9). Remove the brake pads (item 5) from the caliper (item 2).

Fig. 8 Caliper Replacement Installation of the brake caliper is the reverse of disassembly. Connect and tighten the brake line per torque specification table.

Tighten the hardware per torque specification table below.

Bleed the brakes after installation.

ITEM NO

TORQUE SPECIFICATION

1

42 - 47 ft.lbs (57 - 64 Nm)

3

10 - 15 ft. lbs (14 - 20 Nm) 5

Disc Brake Pad Replacement To prevent severe per! ! sonal injury or death resulting from worn brake pads or loose components, always replace the brake pads on both wheels and in pairs. Be sure to replace C-clips with new ones.

1

4 2 3

Replace both brake pads on wheel, if one or more brake pads are worn below .1" (2.5mm) thickness at any point.

Do not allow caliper to hang from brake line. If caliper is removed, it should be supported by wire ties.

Tool List

Qty. Required

Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Page D-10

Fig. 9 Disc Brake Pad Replacement Installation of the brake pads is the reverse of disassembly using new C-clips. Inspect the Allen bolt (item 4) for corrosion that could cause binding. Clean bolt and apply a light coating of lithium based grease to the shoulder bolt. Replace it with the new one if corrosion or wear is found.

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tighten the hardware per torque specification table below.

ITEM NO 4

TORQUE SPECIFICATION 42 -47 ft. lbs (57 - 64 Nm)

Disc Brake Rotor Replacement To prevent serious personal injury or death resulting from a brake failure, never turn a brake rotor to ‘true’ a worn friction surface. Turning will make the rotor too thin which could result in a brake failure.

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Replace the rotor, if rotor is warped.

Tool List

Qty. Required

Floor jack, 1 1/2 ton .................................................... 1 Jack stands ................................................................. 2 Wheel chocks.............................................................. 4 Torque wrench, 1/2" drive ........................................... 1 Impact socket, 3/4", 1/2" drive..................................... 1 Pulsating front brakes are an indication of a warped rotor.

Inspect for excessive run out, evidence of overheating or deep gouges. If any of these conditions are found, the rotor must be replaced.

Park the vehicle on a level surface, engage park brake.

Loosen the four nuts on the front wheels half turn. Lift and support front of the vehicle per SAFETY section.

Remove the four front wheel nuts using 3/4" impact socket and remove the wheel. Do not remove front brake lines (item 1) (Ref Fig. 10 on page D-11). Remove the caliper (item 2) (Ref Caliper Replacement on page D-9).

Remove the Rotor (item 3).

Installation of the disc brake rotor is the reverse of disassembly.

Tighten the wheel lug nuts to 50 - 85 ft. lbs (70 - 115 Nm) torque in 20 ft. lbs (30 Nm) increments.

BLEEDING AND FLUSHING Tool List

Qty. Required

Torque wrench, 3/8" drive, in. lbs. ............................... 1 Box end wrench, 1/4" .................................................. 1 Crowfoot wrench, 1/4", 3/8" drive ................................ 1 Shop towels............................................................. A/R Clear hose ............................................................... A/R Clean container ........................................................... 1 Brake fluid, DOT 3................................................... A/R

Bleeding The brake hydraulic system must be free of air to function properly. Any air in the system is compressed when pressure is applied, and the result is a springy, spongy brake pedal.

Air may enter the system if any of the hydraulic parts are disconnected or if the brakes are operated with the master cylinder fluid very low.

1

The process of removing any air that may be trapped in the hydraulic system is known as bleeding the brakes.

3

Bleeding requires the use of the brake pedal and master cylinder as a hydraulic pump to expel air and brake fluid from the system when a bleeder screw is opened.

Bleed the complete hydraulic system at both wheels if: • Primary brake line was disconnected from the master cylinder.

• Air was introduced into the system through low fluid level in master cylinder reservoir.

2

Fig. 10 Disc Brake Rotor Replacement

If a line or hose was disconnected at any fitting located between the master cylinder and the wheel cylinders, then all wheel cylinders served by the disconnected line or hose must be bled.

Repair and Service Manual

Page D-11

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings insure that air cannot enter the system. It is also important that the brake pedal be returned to full ‘up’ position.

Bleeder Valve

Bleed at each wheel cylinder in succession, beginning with the passenger side rear wheel, which is farthest from the master cylinder, the driver side rear wheel and the front wheel brakes.

Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves. Clean each fitting before opening to prevent contaminating the system. Fill master cylinder reservoir to the maximum level with new brake fluid before starting and after bleeding is completed.

Bleeder Hose

Check the master cylinder fluid level frequently during bleeding and keep the reservoirs at least one-half full.

The following steps apply to one bleeder screw and should be repeated at both bleeder points.

1. Attach a bleeder hose to the bleeder screw. Place the other end of the hose in a glass jar partially filled with brake fluid (Ref Fig. 11 on page D-12).

Fig. 11 Bleeding And Flushing

Bleeding Sequence To prevent serious personal injury or death resulting from brake system contamination, never reuse any excess fluid or return to the original container. Dispose of used or old brake fluid properly.

!

!

Do not force brake pedal to floor. The operating rod jam nut could be forced into master cylinder where it could damage internal components.

An assistant will be necessary to perform this procedure.

Be sure that the free end of the hose is submerged in brake fluid. This helps to show air bubbles as they come out of the system, and prevents air from being accidentally drawn into the system through the bleeder screw.

The bleeder valve at the wheel cylinder must be closed at the end of each stroke and before the brake pedal is released to

Page D-12

2. Apply moderate (40 - 50 lbs. [18 – 20 kg]), steady pressure on the brake pedal, and open the bleeder screw.

3. If the brake pedal goes to the floorboard without removing all of the air bubbles, close the bleeder screw and release the brake pedal slowly. Then repeat Steps 2 and 3.

4. When fluid coming from the submerged end of the hose is clear and free of bubbles, close the bleeder screw and release the brake pedal. Tighten bleeder screw to a maximum torque of 38 in. lbs (4.3 Nm).

Flushing The process of removing old brake fluid to rid the system of water, mineral oil or other contaminants is called flushing the hydraulic system.

The flushing procedure is the same as bleeding except that a greater quantity of brake fluid is discharged from each bleeder point to be sure that all of the dirty or contaminated fluid is removed.

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

BRAKE PEDAL REPLACEMENT

!

To prevent severe injury or death resulting from a battery explosion: The battery negative (-) cable must be removed using insulated wrench before removing brake pedal from vehicle.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ a battery, which could result in an explosion and severe personal injury or death.

Cover battery with a shop rag before servicing the vehicle.

When connecting battery cables, pay particular attention to the polarity of the battery terminals.

Never confuse the positive (+) and negative (-) cables.

Tool List

!

Before starting, refer to SAFETY section. Be sure that the parking brake is engaged.

Remove the nut (item 1) using 3/4" wrench and remove bolt (item 2) (Ref Fig. 12 on page D-13). Remove extension spring (item 3) using needle nose pliers. Slide brake pedal (item 4) back so that clevis yoke (item 5) will come out of master cylinder (item 6).

Inspect the shoulder bolt (item 2) for corrosion that could cause binding. This bolt and both bushings (item 7) must be replaced with new ones if corrosion or wear is found.

Installation of brake pedal is the reverse of disassembly using new lock nut.

Tighten the hardware per torque specification table given below.

1

2

1

7

3

5

4

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs. ................................ 1 Deep well socket, 3/4", 3/8" drive................................ 1 Wrench, 3/4" ............................................................... 1 Needle nose pliers ...................................................... 1 Straight blade screwdriver........................................... 1

ITEM NO

6

TORQUE SPECIFICATION 25 - 29 ft. lbs (34 - 39 Nm)

Fig. 12 Brake Pedal Replacement

PARKING BRAKE The rear brake includes a parking brake consisting of a wheel brake lever and strut. The wheel brake lever is activated by a cable attached to the hand operated parking brake lever. The parking brake is used to retain the vehicle when stationary. It may also be used as an emergency brake in the event of hydraulic system failure.

The hand operated parking brake lever is located at the left side of the driver.

Lubrication When lubricating parking brake, be sure to use the recommended dry spray lubricant. Commercial grease can attract dirt and accelerate wear.

Adjustment Before attempting any adjustment, verify that both brake cables are operating smoothly.

With the brake in the fully down position, the brake springs at the rear brakes should be extended. Manually push back the parking brake lever (item 1) to be sure that it is returning correctly (Ref Fig. 13 on page D-14).

Repair and Service Manual

Page D-13

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

1

2

5

4

6 3 7

9

8

Fig. 13 Parking Brake With the parking brake fully released, the clevis pins (item 2) at the parking brake lever should either be loose or only under light spring pressure.

The parking brake adjustment is made at the equalizer bracket (item 3) on the end of the parking brake lever cable (item 4) located under the park brake frame (item 5).

Tighten the spherical nut (item 7) at equalizer bracket (item 3). Tighten nut (item 6) against spherical nut (item 7) per torque specification table and check the tension, see that the cable is straight. Correct tension is when, at the sixth click of the hand operated parking brake lever, the vehicle will not move while under a load on a typical area slope. Readjust if necessary.

Page D-14

Tighten spherical nut (item 7) and nut (item 6) firmly against equalizer bracket to secure

Cable Replacement Equalizer to wheel brake cables must be replaced when they become inoperable. Cable replacement consists of first removing the cotterpin (item 8) and clevis pins (item 9) securing the cable to the park brake lever (item 1) (Ref Fig. 13 on page D-14). Then remove the spherical nut (item 7) and nut (item 6) securing the cable to the equalizer bracket (item 3).

Install new cable in reverse order of removal using new cotter pins and adjust parking brake system per instructions above.

Repair and Service Manual

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

The parking brake to equalizer cable may require replacement if it shows signs of wear. Cable replacement consists of first removing the wire tie securing the rubber boot to the parking brake (item 1). Remove the boot.

Remove the nut (item 6) and spherical nut (item 7).

Remove cotter pin and clevis pin (item 2) and pull cable (item 4) free. Check to see that the pulley rotates freely and lubricate if necessary with a light oil.

Install new cable in reverse order of removal using new cotter pins and adjust parking brake system per instructions above.

Tighten the hardware per torque specification table given below.

ITEM NO 6

TORQUE SPECIFICATION 11 - 14 ft. lbs (15 - 19 Nm)

Repair and Service Manual

Page D-15

BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page D-16

Repair and Service Manual

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE

E PAGE NO.

GENERAL ........................................................................................................................................E - 1 CLUTCHES ......................................................................................................................................E - 1 Drive Clutch ...........................................................................................................................E - 1 Driven Clutch .........................................................................................................................E - 1 Increased Load......................................................................................................................E - 2 Equilibrium.............................................................................................................................E - 2 Drive Clutch Replacement.....................................................................................................E - 2 Driven Clutch Replacement...................................................................................................E - 3 DRIVE BELT ....................................................................................................................................E - 4 Removing the Drive Belt........................................................................................................E - 4 Drive Belt Service ..................................................................................................................E - 4 STORAGE........................................................................................................................................E - 4

LIST OF ILLUSTRATIONS Fig. 1 Continuously Variable Transmission System (CVT) .............................................................E - 1 Fig. 2 CVT Components..................................................................................................................E - 3 Fig. 3 Removing the Drive Belt........................................................................................................E - 4

Repair and Service Manual

Page E-i

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

Notes:

Page E-ii

Repair and Service Manual

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

E

Drive Belt

.

Driven Clutch

Drive Clutch CVT Cover

Fig. 1 Continuously Variable Transmission System (CVT)

GENERAL Power transmission from the engine to the rear axle is by means of a continuously variable transmission (CVT).

The CVT consists of two matched clutch units joined by a drive belt (Ref Fig. 1 on page E-1). The engine mounted drive clutch is a centrifugal unit that responds to engine speed and the rear axle mounted driven clutch is a load sensing unit.

CLUTCHES Drive Clutch

sheaves close, the driven clutch sheaves are forced open by the belt as it rises in the drive clutch. The ratio is greatly decreased and provides maximum speed.

When the accelerator is released, the engine speed is decreased and the cams exert less pressure on the moveable sheave which is forced outwards against the cams by a compression spring. The drive belt disengages from the clutch sheave when engine speed is reduced to the point where the cams exert less force than the spring.

Driven Clutch

When the accelerator 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 clutch sheaves and begins to rotate.

As the engine speed continues 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. As the drive clutch

The driven clutch sheaves are closed at rest which results in the drive belt being held at the outer diameter of the driven clutch. The driven clutch has no weights but is held closed by a torsion spring joined to the moveable sheave and a torque ramp (cam) that is attached to the fixed sheave. The moveable sheave slides against the cam with the three points of contact provided by low friction ‘buttons’.

Repair and Service Manual

Page E-1

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

As the drive belt starts to rotate, the driven clutch starts to rotate. As the speed of the drive clutch increases and the belt starts to climb the drive clutch sheaves, the driven clutch responds by being forced open by the belt which rides lower in the driven clutch sheaves. The sheaves overcome the pressure exerted by the torsion spring and cam.

As the driven clutch slows, the belt rides lower in the drive clutch sheaves. The driven clutch compensates by closing in response to the torsion spring and cam forcing the belt outwards.

Increased Load When a vehicle traveling at governed speed begins to climb a grade or is subjected to other increased load conditions, a change in wheel speed is detected by the clutch system and the drive belt seeks a position where it can achieve adequate friction to overcome the load change. The belt moves outwards on the driven clutch which closes due to the torsion spring moving the moveable sheave against the torque ramps. The movement of the drive belt overcomes some of 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 without an appreciable change to the engine speed since the governor opens the carburetor in direct response to the reduction in ground speed.

Equilibrium The CVT functions because the drive and driven clutches maintain equilibrium. Clutch sets are tuned to the vehicle that they are designed to operate. Changes in vehicle weight or desired performance characteristics require that both clutches be tuned to the needs of the vehicle and remain compatible with each other.

Drive Clutch Replacement To prevent serious per! ! sonal injury or death resulting from inadvertant movement of the vehicle: Disable the electrical system before attempting to remove the drive belt to prevent the engine from inadvertently starting.

Do not allow fingers to become trapped between the belt and clutch sheave.

To prevent burns and other possible injuries, be sure that the engine and exhaust components have cooled before attempting any service.

Page E-2

To prevent serious personal injury or death, use only sockets designed for use with an impact wrench. Never use a socket intended for use with hand tools.

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.

Do not install the bolt with an impact wrench.

In some extreme cases, the clutch may not separate from the crankshaft using the clutch puller. Remove the clutch puller and fill the cavity with grease.

Replace the clutch puller and tighten it with the impact wrench.

The combined mechanical and hydraulic effect will remove the clutch. Remove all excess grease.

Tool List

Qty. Required

Torque wrench, 1/2" drive, ft. lbs. ................................1 Impact wrench, 1/2" drive ............................................1 Impact socket, 1 1/8", 1/2" drive ..................................1 Wrench, 17mm ............................................................1 Plastic faced hammer ..................................................1 Clutch puller (P/N 19779-G2) ......................................1 Thread locking adhesive........................................... AR Remove the bolts (item 1) and remove the CVT cover (item 2). Remove the drive belt (item 3). (Ref Removing the Drive Belt section on page E-4).

Remove the drive clutch bolt (item 4), lock washer (item 5) and pilot washer (item 6) (Ref Fig. 2 on page E-3).

Insert a greased clutch puller and tighten (clockwise) using an impact wrench which will remove the drive clutch (item 7) from the engine crankshaft.

Installation of the drive clutch is the reverse of disassembly. Clean both the engine crankshaft and the drive clutch bore. Slide the clutch onto the engine crankshaft and rotate the clutch while lightly pushing the moveable sheave in and out several times to seat the clutch with the tapered crankshaft.

Apply thread locking adhesive to the threads of the clutch bolt (item 4) before installing (Ref Fig. 2 on page E-3).

Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

1

20 - 30 in. lbs (2 - 3 Nm)

4

40 ft. lbs (55 Nm)

Repair and Service Manual

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

3

11

10

9 8

7

6

5 4

2 1

Fig. 2 CVT Components

Driven Clutch Replacement Inspect the shaft for signs of wear and inspect the bushings for signs of deterioration. If there is wear to the point of causing vibration, the driven clutch must be replaced.

Tool List Qty. Required Ratchet, 1/2" drive....................................................... 1 Torque wrench, 1/2" drive, ft. lbs. ................................ 1 Socket, 1/2", 1/2" drive................................................ 1 External snap ring pliers ............................................. 1 Anti-seize compound ............................................... AR Thread locking adhesive .......................................... AR Remove the bolt (item 1) and remove the CVT cover (item 2). Remove the drive belt (item 3) (Ref Removing the Drive Belt section on page E-4). Remove the driven clutch bolt (item 8) using 1/2" socket, lock washer (item 9) and the retaining washer (item 10) (Ref Fig. 2 on page E-3). Slide the driven clutch (item 11) from the rear axle input shaft.

Installation of the driven clutch is the reverse of disassembly. Coat the rear axle input shaft with a light coating of anti-seize compound and slide the clutch onto the shaft.

Apply thread locking adhesive to the threads of the clutch bolt (item 8) before installing (Ref Fig. 2 on page E-3).

Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

1

20 - 30 in. lbs (2 - 3 Nm)

8

14 - 17 ft. lbs (19 - 23 Nm)

Repair and Service Manual

Page E-3

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

DRIVE BELT

Drive Belt Service

Removing the Drive Belt

The drive belt will require no service unless the vehicle has been operated in an extremely dusty or muddy location in which case it should be washed with plain water during routine CVT Enclosure cleaning (Ref Periodic Service Schedule in GENERAL INFORMATION AND ROUTINE MAINTENANCE). If the belt becomes frayed or badly worn, it must be replaced.

With the vehicle on level ground, remove the drive belt by pulling the belt upwards which will cause the driven clutch sheaves to open and loosen the belt tension (Ref Fig. 3 on page E-4). The belt may then be rolled off the driven clutch.

STORAGE If the vehicle is to be out of service for an extended period of time, the clutches should not be coated with any protecting spray. Both the drive and driven clutches are aluminum and require no treatment.

Fig. 3 Removing the Drive Belt

Page E-4

Repair and Service Manual

DIRECTION AND DRIVE SELECTOR TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE

F PAGE NO.

GENERAL .........................................................................................................................................F- 2 Direction And Drive Selector Cables Adjustment ...................................................................F- 2 DIRECTION SELECTOR .................................................................................................................F - 3 Direction Selector Replacement ............................................................................................F - 3 DRIVE SELECTOR ..........................................................................................................................F - 3 Drive Selector Replacement..................................................................................................F - 3 Proximity Sensor Switch Replacement..................................................................................F - 4

LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7

Direction/Drive Selector Components ...................................................................................F - 1 Direction/Drive Selector Cable Adjustment ...........................................................................F - 2 Removal Of Cable From Ball Joint ........................................................................................F - 3 Direction Selector Replacement............................................................................................F - 3 Drive Selector Replacement..................................................................................................F - 4 Proximity Sensor Switch Testing...........................................................................................F - 4 Rivet Removal .......................................................................................................................F - 4

Repair and Service Manual

Page F-i

DIRECTION AND DRIVE SELECTOR

Notes:

Page F-ii

Repair and Service Manual

DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Direction Selector Handle

F

Knob

Drive Selector Handle

Drive Selector Cable Rivet Direction Selector Cable

Proximity Sensor Switch

Label Hand Control Cover Plate Shifter Housing

Levers On Transmission (Transfer Case)

Fig. 1 Direction/Drive Selector Components

Repair and Service Manual

Page F-1

DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

GENERAL Always observe the following warnings when working on or near batteries:

To prevent serious personal injury or death resulting from explosion caused by an electrical arc, be sure that the key switch is off and all electrical accessories are turned off before starting work on vehicle.

Never disconnect a circuit under load at the battery terminal.

The battery negative (-) cable must be removed before starting work on vehicle.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ the battery, which could result in an explosion and severe personal injury or death.

!

!

The cable length can be adjusted (increased/decreased) at it’s mounting bracket. This is accomplished by moving the cable housing forward or backward at the bracket attachment to increase or decrease the amount of cable available (Ref Fig. 2 on page F-2).

To decrease the amount of cable available, loosen the nuts on either side of the bracket and move the cable away from the lever. Tighten the adjustment nuts after achieving the correct length.

To increase the amount of cable available, loosen the nuts on either side of the bracket and move the cable closer to the lever. Tighten the adjustment nuts after achieving the correct length.

Adjustment Nuts

Mounting Bracket Cable

Cover battery with a shop rag before attempting to remove direction/drive selector components.

Too Long It is not necessary to remove the direction selector assembly to replace the proximity sen-

Ball Joint

sor switch.

Before replacing a suspect direction selector or drive selector or proximity sensor switch, be sure the shift cables are properly adjusted (Ref Fig. 2 on page F-2), the electrical wires are firmly attached and the wire is in good condition. Test suspect component to be sure that it has not failed before replacing.

Too Short

Direction And Drive Selector Cables Adjustment Failure of the transmission to engage correctly indicates that cable adjustment is required.

Tool List

Qty. Required

Open end wrench, 15/16" (Direction selector) ............ 2 Open end wrench, 11/16" (Drive selector)................... 2 Pliers ........................................................................... 1 The direction selector and drive selector are the mechanical linkages that operate cables connected to levers on transmission (transfer case). The cables are sealed and do not require lubrication, but may require occasional adjustment. The only maintenance required is periodic lubrication of the linkage and related moving parts (Refer PERIODIC SERVICE SCHEDULE section).

Page F-2

Correct Lever

Fig. 2 Direction/Drive Selector Cable Adjustment To remove or detach the cable (item 1) from the ball joint (item 2), pull the cable (item 1) from the ball joint (item 2) and remove it (Ref Fig. 3 on page F-3).

Repair and Service Manual

DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

1 2

1

7

5 4

Pull

2

Fig. 3 Removal Of Cable From Ball Joint 3

DIRECTION SELECTOR

6

Direction Selector Replacement To prevent serious per! ! sonal injury or death resulting from explosion caused by an electrical arc, be sure that the battery negative (-) cable is removed before removing the direction selector.

Cover battery with a shop rag before attempting to remove direction/drive selector components.

Direction selector adjustment or replacement should be done in neutral position.

Tool List

Qty. Required

Combination wrench, 9/16" ......................................... 2 Raise the cowl and latch the support. Unscrew and remove the knob (item 1) from the direction selector handle (item 2) (Ref Fig. 4 on page F-3). Remove the lock nut (item 3) and pivot shaft (item 4) attaching the direction selector bracket (item 5) to the shifter housing (item 6) from back side of dash. Remove direction selector cable (item 7) (Ref Direction And Drive Selector Cables Adjustment Section on page F-2). Remove the direction selector from the vehicle.

Installation of direction selector is the reverse of disassembly using new lock nut.

Fig. 4 Direction Selector Replacement Tighten the hardware per torque specification table below.

ITEM NO 3

TORQUE SPECIFICATION 6 - 8 ft. lbs. (8 - 11 Nm)

DRIVE SELECTOR Drive Selector Replacement To prevent serious per! ! sonal injury or death resulting from explosion caused by an electrical arc, be sure that the battery negative (-) cable is removed before removing the drive selector.

Cover battery with a shop rag before attempting to remove direction/drive selector components.

Drive selector adjustment or replacement should be done in 2 wheel drive position.

Tool List

Qty. Required

Combination wrench, 9/16" ......................................... 2

Direction selector knob should be in neutral position during assembly of new components.

Repair and Service Manual

Page F-3

DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Raise the cowl and latch the support. Unscrew and remove the knob (item 1) from the direction selector handle (item 2) (Ref Fig. 5 on page F-4). Remove the lock nut (item 3) and pivot shaft (item 4) attaching the drive selector bracket (item 5) to the shifter housing (item 6) from back side of dash. Remove the drive selector cable (item 7) (Ref Direction And Drive Selector Cables Adjustment Section on page F-2). Remove the drive selector from the vehicle.

7

indicate 00.0 and the audible device will sound, indicating continuity. If the switch is not working properly, no continuity will be indicated. If the 4 wheel drive indicator light stays illuminated in both the 2 wheel & 4 wheel drive positions, the sensor has failed in the closed position and must be replaced.

Set DVOM to audible

1

EP

BE

2 4

5 6 3 Proximity Sensor Switch

Fig. 5 Drive Selector Replacement Installation of drive selector is the reverse of disassembly using new lock nut.

Drive selector handle should be in 2 wheel drive position during assembly of new components.

Tighten the hardware per torque specification table below.

ITEM NO 3

TORQUE SPECIFICATION 6 - 8 ft. lbs (8 - 11 Nm)

Fig. 6 Proximity Sensor Switch Testing Proximity Sensor Switch Replacement To remove the proximity sensor switch requires that two rivets be removed: Remove the rivet head by drilling into the rivet head using a sharp drill bit slightly larger than the shank of the rivet. Apply light pressure to prevent damage to the rivet mounting hole. Remove the rivet and remove the proximity sensor switch (Ref Fig. 7 on page F-4).

Proximity Sensor Switch Replacement Tool List

Qty. Required

Digital Volt Ohm Meter (DVOM) .................................. 1 Drill bit ......................................................................... 1 Drill .............................................................................. 1

Pop Rivet

Drill Out Rivet Head Only

Proximity Sensor Switch Testing Method To test the proximity sensor switch, carefully separate the wire harness at the sensor. Move the drive control to the 4 wheel drive position (Ref Fig. 6 on page F-4). Select the audible continuity setting on the DVOM. Insert the two DVOM test probes into the harness from the sensor.

If the sensor is working properly, the DVOM display will Page F-4

Fig. 7 Rivet Removal Install a new proximity sensor switch using new rivets.

Repair and Service Manual

ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE

G PAGE NO.

CIRCUITS AND CONTROLS.......................................................................................................... G - 2 STARTING ...................................................................................................................................... G - 2 CHARGE COIL/ALTERNATOR ...................................................................................................... G - 2 DIGITAL VOLT OHM METER (DVOM)........................................................................................... G - 2 TESTING IGNITION CIRCUIT ........................................................................................................ G - 3 TESTING THE IGNITION COIL ...................................................................................................... G - 3 TESTING STARTING CIRCUIT ...................................................................................................... G - 4 BATTERY VOLTAGE TEST............................................................................................................ G - 4 TESTING CHARGING CIRCUIT..................................................................................................... G - 5 STORAGE OF BATTERY ............................................................................................................... G - 6 TROUBLESHOOTING .................................................................................................................... G - 6 POWER SUPPLY............................................................................................................................ G - 6 ACCESSORY WIRING ................................................................................................................... G - 7 INSTRUMENT CLUSTER ............................................................................................................... G - 7 DIFFERENTIAL LOCK SOLENOIDS .............................................................................................. G - 7 FUEL CUT SOLENOID ................................................................................................................... G - 8 NEUTRAL SWITCH ........................................................................................................................ G - 8 HEADLIGHTS ................................................................................................................................. G - 8 TAILLIGHT (ACCESSORY) ............................................................................................................ G - 8 BRAKE SWITCH ............................................................................................................................. G - 8 POWER OUTLET............................................................................................................................ G - 8

LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8

Electrical System Circuit....................................................................................................... G - 1 DVOM................................................................................................................................... G - 3 Battery Voltage Test............................................................................................................. G - 5 Fuse Block, Instrument Cluster And Head Light .................................................................. G - 9 Head Light Switch, Key Switch And 12V Outlet ................................................................. G - 10 Neutral Switch And Fuel Sending Unit ............................................................................... G - 11 Differential Lock Solenoids................................................................................................. G - 12 Voltage Regulator, Fuel Cut Solenoid And Starter............................................................. G - 12

Repair and Service Manual

Page G-i

ELECTRICAL

Notes:

Page G-ii

Repair and Service Manual

YEL

WHT

BLK

Repair and Service Manual YEL

WHT

BLK

WHT

BLK/WHT

YEL

GRY

GRY

GRY

20 AMP CHARGE COIL

LEFT IGNITION COIL

GRY

BLU

BLU

RIGHT IGNITION COIL

GRN

GRN

WHT

FUSE BLOCK

RED

BLK

REAR DIFF LOCK SOLENOID

GRN/BLK

ENGINE STOP DIODE

YEL/BLK BLK

REAR DIFF SWITCH FUEL CUT OFF SOLENOID

YEL

GRY

YEL

WHT

BLK

BLK

WHT

LEFT HEADLT

RIGHT HEADLT

BLU/WHT BLK

BLK

BLU/WHT

TAIL LIGHT

BRAKE LIGHT

LIGHT SWITCH

INSTRUMENT CLUSTER

BLU/WHT

BLU/WHT

OIL LIGHT SWITCH

ORN

YEL

BLU

GRY

ORN

GRN/BLK

Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

PWR OUTLET

RED/WHT

ORN

RED

BLU

RED/YEL

BLK

RED/YEL GRN/BLK

BRAKE LIGHT SWITCH

FUEL SENDING SWITCH FRONT DIFF LOCK SOLENOID

ORN

FRONT DIFF SWITCH

PARK BRAKE SWITCH

4 WHL DRIVE IND SWITCH

YEL

RED/YEL

RED/WHT RED/BLK

M2

1

S

REGULATOR RECTIFIER

M1

B

KEY SWITCH

NEUTRAL SWITCH

BLK/WHT

STARTER SOLENOID

WHT

25 AMP IN LINE FUSE

BLK

ELECTRICAL

G

Fig. 1 Electrical System Circuit

Page G-1

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

CIRCUITS AND CONTROLS To prevent severe personal injury or death from inadvertent movement of vehicle, all tests performed requiring starter or engine to rotate must be performed by lifting vehicle (see Section B).

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2) The fuel shut off solenoid opens and permits fuel to flow to the carburetor main jet.

3) The magneto ground is opened, allowing the flywheel mounted magnetic trigger to energize the two spark plug coils (magneto) and fire the two spark plugs.

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Follow the lifting procedure in Section B of this manual. Place wheel chocks in front of and behind the front wheels. Check the stability of the vehicle on the jack stands before starting any repair procedure. Never work on a vehicle that is supported by a jack alone.

The electrical system is a 12 volt negative ground system consisting of: • alternator (optional) • ignition coils (magneto) • starter • starter solenoid • charging coil • battery • voltage regulator • in line fuse • key switch • neutral switch • magnetic trigger These components comprise the starting and charging circuits.

This section will assist in troubleshooting the vehicle electrical system and accessory wiring. Refer to the wiring diagram for wire colors and electrical paths. To troubleshoot the ignition electrical system, refer to the Honda GX 610 Repair Manual for V-Twin Overhead Valve engine.

STARTING The vehicle must be in neutral to start. If not in neutral, the transmission mounted neutral switch will interrupt power to the starter solenoid.

This circuit is controlled by a key switch, fuse, neutral switch and a solenoid.

CHARGE COIL/ALTERNATOR When the engine is running, the charge coil (or the optional high output alternator) starts generating power to charge the battery. Generated output is controlled 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 it is fully charged, current is controlled at 3 to 5 amps.

DIGITAL VOLT OHM METER (DVOM) To prevent severe personal injury or death resulting from a battery explosion, disconnect the battery cables from the battery posts before performing any test of wiring components (see procedure in Section B).

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Electrical tests of the wiring for continuity and voltage tests may be made with a DVOM (Digital Volt Ohm Meter) available through the Service Parts Department (P/N 27481-G01) (Ref Fig. 2 on page G-3). The actual model may vary depending on availability. The DVOM shown is representative only. Any DVOM may be used, however the controls, displays and features may vary depending on the make and model. Always follow the meter manufacturer’s recommendations and instructions for the use and care of meter.

For the purpose of this section, the red probe (+) and black probe (-) are used. Set the meter selector to the ohms scale and check continuity between each circuit component as indicated.

Example: If a switch is open or if there is a break in the wiring, the meter will display OL. To check voltage, select the next DC volts range higher than 12VDC.

When the key switch is turned to the START position three circuits are closed: 1) The circuit to the starter solenoid is closed and will operate the starter, if the neutral switch is in the closed position.

Page G-2

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Repair and Service Manual

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings This section assumes the fuel system is functioning and that the engine is receiving fuel.

Tool List

Qty. Required

DVOM.......................................................................... 1 Spark plug (NGK 2GR5A or DENSO J16CR-U).......... 1 Spark plug tester ......................................................... 1 The engine incorporates a magneto ignition system that fires both plugs simultaneously. There is no distributor required since the valve timing controls the power stroke of each cylinder. The engine can be stopped by turning the key switch to ‘OFF’ position which shorts the magneto interrupting the ignition circuit (Ref Fig. 1 on page G-1).

If the engine will not run, but the starter operates the engine, proceed as follows: 1) Check for loose terminals, wires and connections.

2) Check for an electrical discharge through the spark plug wire as follows: Using a spark plug tester or a spark plug that is known to be good, and with a spark plug installed in each cylinder If using a spark plug, place the known to be good spark plug on a clean grounded engine surface, (cylinder, etc.). Operate the engine with the starter. Look for a strong blue electrical arc between the spark plug electrodes.

3) If there is either a weak arc or no arc, try a new spark plug, then check the condition and the tightness of the spark plug wires. Plug wires can be checked by substituting them with good ones.

Fig. 2 DVOM

4) Replace the spark plugs if necessary. Gap the spark plug .028" - .031" (.71 - .80 mm) using a wire type spark plug gauge.

TESTING IGNITION CIRCUIT To prevent possibility of severe personal injury or death, never operate the starter unless both spark plugs are installed or the ignition system is disabled. Fuel drawn into the cylinders will be expelled through the spark plug opening and could be ignited by the ignition system or another source, resulting in a fire.

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TESTING THE IGNITION COIL Refer to Honda GX610 Repair Manual for V-Twin Overhead Valve engine.

Do not arc spark plug wire to ground.

Connect to a known good spark plug and ground plug to a clean metal surface (cylinder, etc.). Permanent damage may be caused to the ignition system if the plug is not grounded properly.

Repair and Service Manual

Page G-3

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

TESTING STARTING CIRCUIT To prevent the possibility of severe injury or death resulting f rom vehicle inadvertently starting, disconnect battery for steps 2 through 9 (see Section B).

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meter should be “0” Ω with the switch key in the ‘ON’ position and OL with the switch in the ‘OFF’ position.

If the meter does not register, replace the switch.

Reconnect the wires.

9. Turn the key switch to ‘ON’.

• Set the DVOM to the ohms (Ω) scale and place one probe on the black/white (BLK/WHT) at the solenoid. Place the other probe on the key switch terminal (S) with the black/white (BLK/WHT). If continuity is not indicated check for continuity at the neutral switch. If continuity is not indicated, replace neutral switch. If continuity is indicated check wiring between key switch (S) and neutral switch and between neutral switch and starter solenoid. If continuity is indicated, the starter solenoid must be checked.

If any DVOM readings indicate a faulty wire, it is recommended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct components and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

Most DVOM’s can be set to give an audible signal if continuity is present, however readings will generally indicate near Ω.

Readings greater than 1KΩ may indicate a marginal conductor or joint.

Tool List

Qty. Required

10. Check the starting solenoid operation. Turn the key switch to the ‘OFF’ position. a) Place the DVOM (set to appropriate DC volts scale) positive (+) probe on the terminal with the black/white (BLK/WHT) wire solenoid. Place negative (-) probe on to ground. b) The DVOM should indicate reference battery voltage (approximately 12 V). c) Turn the key switch to the ‘OFF’ position.

The DVOM should indicate 0 V. d) Replace solenoid if 12 V is not indicated with the switch turned to ‘ON’.

DVOM.......................................................................... 1 If the engine does not rotate, proceed as follows: 1. Check for a good ground between the battery negative (-), the frame and the engine.

2. Check that vehicle is in neutral (Ref Fig. 1 on page G1).

3. 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.

4. Check for a blown in line fuse and replace if necessary with the recommended amp fuse.

5. Check for loose wires at all terminal connections.

6. Check the complete electrical system for correct circuitry.

7. Inspect for worn insulation or bare wires touching the frame. Bare wires will cause a short circuit.

8. Set the DVOM to the ohms (Ω) scale. A meter reading of “0” Ω indicates continuity. Check for continuity for white (WHT) wire from battery positive terminal (+) to the key switch terminal (B) white (WHT) wire. If continuity is not indicated, there is a fault in the wiring harness. Check for continuity of the key switch.

Remove key switch plate from instrument panel (Ref Instrument Panel Replacement section in BODY AND TRUCKBED). Detach electrical plug from key switch.

Place positive (+) probe on terminal (B) of white (WHT) wire and negative (-) probe on terminal (S) of black/white (BLK/WHT) wire. The reading on the

Page G-4

BATTERY VOLTAGE TEST Hydrogen gas formed during battery charging i s explosive and can cause severe personal injury or death. Avoid any electrical spark or open flame near battery.

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Do not overcharge battery.

If the temperature of the battery or the ambient temperature is below 60° F (15° C), the capacity of the battery will be less. It will require more time to charge.

A cold battery will build up voltage and more rapidly reduce the charging rate.

Batteries that are new or have been stored must be fully charged before being tested or placed in vehicle.

Repair and Service Manual

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Battery voltage can be checked using a voltmeter (Ref Fig. 3 on page G-5). Attach the negative (-) lead of the DVOM to the ground terminal of the battery. The positive (+) lead is then attached to the positive battery terminal.

The voltage reading obtained should be 12 volts or above. If the reading is below 12 volts, the battery requires either charging or replacement.

connected, the accessory alternator is checked in the same way as the charge coil. The starter solenoid must be functional in order to start the vehicle, but is not considered part of the charging circuit.

Tool List

Qty. Required

DVOM.......................................................................... 1 If the battery charge is inadequate (less than 11 VDC), proceed as follows (Ref Fig. 1 on page G-1): a) Check the battery voltage and inspect for loose or corroded terminal posts and connections. Check electrolyte level. b) Check charging circuit component terminals for proper, clean, tight connections.

Check for charging voltage as follows:

DVOM

1) Raise the vehicle (see procedure in Section B) so that both rear wheels are free to rotate and place direction control in neutral.

2) With the engine off, measure the voltage at the battery’s terminals by placing the negative (-) probe on the negative (-) post and the positive (+) probe on the positive (+) post of the battery.

Note the reading (this is battery reference voltage).

3) Attach the DC voltmeter across the regulator’s white ground leads.

4) Start the engine and accelerate to governed speed.

Battery

Fig. 3 Battery Voltage Test

TESTING CHARGING CIRCUIT To prevent serious personal injury or death from inadvertent movement of vehicle, all tests performed requiring starter/ generator or engine to rotate must be performed by lifting vehicle (see Section B).

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The charging circuit consists of a charging coil, voltage regulator and battery. A high output alternator is available as an accessory and is belt driven from the front of the engine. After checking that the accessory wire harness is

5) The meter should read higher than before starting the engine. In a reasonable amount of time, the reading should settle between 14 and 15 volts, indicating the regulator is functioning properly.

6) If no increase over battery voltage is observed, there is a malfunction in the charging circuit.

7) If the reading is above 15 volts, check to assure the wiring harness is not grounded. If it is not, replace the regulator.

8) If the reading is below 14 volts, disconnect the regulator’s white field wire from the system harness. Temporarily connect the white field wire to ground. If the voltage rises above its prior reading, replace the regulator.

9) If the above procedures do not correct the problem, check for faults in the vehicles wiring harness and/or charge coil (Refer to Honda GX610 Repair Manual for V-Twin Overhead Valve engine) or the accessory alternator.

Repair and Service Manual

Page G-5

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

STORAGE OF BATTERY A battery that is removed from service for storage must be cared for as follows:

ing out to the device that is not working. Be sure to check both sides of all switches and fuses.

For battery removal see ‘Battery Removal’ in Section B. Charge fully. Cover terminals with petroleum jelly to prevent oxidation (use commercially available battery protectant when installed in vehicle). Store in a cool place not below 32° F (0° C) or above 80° F (27° C). Battery should be charged every 30 days using a 2 amp trickle charger.

When no battery voltage is found, the problem lies between the point where no voltage is detected and the last place that voltage was detected. In circuits where no voltage is expected, the same procedure may be used except that the DVOM is set to continuity. Place the negative (-) probe on a wire terminal at the beginning of the circuit and work towards the device that is not working with the positive (+) probe. When continuity is no longer indicated, a failed conductor or device is indicated.

TROUBLESHOOTING

POWER SUPPLY

If any DVOM readings indicate a faulty wire, it is recommended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct components and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

Tool List

In order to effectively troubleshoot the circuits that include the lighting, brake and gauges, the technician must be able to use the wiring diagram and a DVOM. The wiring diagram shows the path followed by a voltage or signal from its origination point to its destination. Each wire is indicated by color (Ref Fig. 1 on page G-1).

The technician should use simple logic troubleshooting in order to reduce the number of steps required to isolate the problem.

Example 1: If the vehicle will not start and none of the lights function (or burn dimly) the battery 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 reason to check battery wiring or the fuse since it is obvious that voltage is present. Since bulbs will burn out over time, the obvious place to start is at the headlight that is not functioning. If power is present at the connector and the ground wiring is satisfactory, the only possibilities that exist are a burned out bulb or a poor contact between the connectors and the headlight.

If power is not present but the other headlight functions, a wiring problem is indicated between the two headlights.

DVOM..........................................................................1

Check for loose or bare wires If any DVOM readings indicate a faulty wire, it is recommended that the condition of the terminals and wire junction be examined. A faulty wire should be replaced with one of the same gauge and color and wired between the correct components and wire tied to the harness bundle. The faulty wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

Check for loose wires at each terminal connection and for worn insulation or bare wires touching the frame.

Bare wires may cause a short circuit.

Check battery condition Due to the resistance of the wires involved within the harness, voltage readings may be somewhat lower than battery voltage. A reading of 1 volt below reference battery voltage is acceptable.

Check for adequate battery volts (nominal 12 VDC) by setting DVOM to the next range above 12 VDC and place the red probe (+) on the battery post with the green wire attached. Place the black probe (-) on the battery post with the black wire attached. A reading of 11 VDC or greater indicates adequate battery condition. No reading indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty DVOM. A voltage reading below 11 volts indicates poor battery condition and the vehicle should be recharged before proceeding with the test.

In some cases where battery voltage is expected, the easiest way to test the circuit is to set the DVOM to DC volts and place the negative (-) probe of the DVOM on the negative battery terminal. Move the positive (+) probe to each wire termination starting at the battery and work-

Page G-6

Qty. Required

Repair and Service Manual

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Check power wire The white power wire supplies power to the entire fuse block.

Firmly attach the black probe (-) to the battery post with the black wire attached and the red probe (+) to the white wire terminal at the fuse block. A reading of battery voltage indicates that the power wire is in good condition.

Check fuse Check each fuse for continuity. If a new fuse is required, replace with one of the same amperage.

ACCESSORY WIRING After determining that there is power to the fuse panel, and the fuse is good, continue checking the circuit using the procedures previously used to check the power supply, i.e. loose or rusted connections, bare wires, continuity of the wiring from terminal to terminal, operating condition of switch, etc.

Use the wiring diagram (Ref Fig. 1 on page G-1) to check correct wiring and wire routing. If there is power at the fuse end of the wire, there must also be power at the other end of the wire at the switch or electrical accessory, and eventually at the ground connection. Electricity must flow from the fuse panel through the full length of the circuit to the ground connection. Any interruption of electrical flow must be corrected, whether by repairing or replacing the wire, the switch or accessory.

INSTRUMENT CLUSTER

The Fuel Gauge Sending unit test is described in the ‘FUEL SYSTEM’. If the sending unit and the wiring from the unit to the instrument cluster connector is satisfactory, replace the instrument cluster (Ref Fig. 6 on page G-11).

The Differential Lock indicator and switches can be checked by operating them and observing the solenoids at the differentials. If the solenoid operates but the indicator does not, check for voltage at the instrument cluster connector. If voltage is present but the indicator is not working, replace the instrument cluster. If solenoids do not function, verify that the switches have continuity when closed and replace switch if continuity is not present. If the switch functions correctly, and if battery voltage is not present, check the fuse and that the wire harness does not have an internal break.

Low Oil Pressure Gauge With the engine off, check for continuity between the oil pressure switch’s two terminals. Continuity should be indicated. If not replace the switch. Check that there is adequate oil in the engine and start engine. Shortly after starting, the continuity across the oil pressure switch should be lost as the switch opens in response to oil pressure. If not, replace the switch.

With the switch known to be good, the indicator light should illuminate at the instrument cluster, when the key switch is ON but the engine is not running. If not check the gray wire at the instrument cluster for battery voltage.

If battery voltage is present, replace the instrument cluster. If battery voltage is not present, check that wire harness does not have an internal break.

DIFFERENTIAL LOCK SOLENOIDS

The instrument cluster contains indicator lights for 4 Wheel Drive, Parking Brake, Fuel Gauge, Front and Rear Differential Locks, Low Oil Pressure and a digital hour meter. The cluster is not repairable and must be replaced if there is a malfunction within the unit (Ref Fig. 4 on page G-9).

The Four Wheel Drive Indicator is operated by a proximity switch and the switch can be tested as described in the ‘DIRECTION SELECTOR’ section of this manual.

The switch does not operate the four wheel drive, only the indicator light. Similarly the Parking Brake Indicator uses the same proximity switch that can be tested in the same way. If the switch is good, check for voltage at the instrument cluster connector. If voltage is present but the indicator is not working, replace the instrument cluster. If voltage is not present, verify that the switch is correctly oriented in relation to the operating component and that the wire harness does not have an internal break.

Check operation of switches as described in INSTRUMENT CLUSTER The Differential Lock (Ref Fig. 7 on page G-12). With the switch in the engaged position, check for voltage at the differential lock solenoid connector. If voltage is present, replace solenoid. If battery voltage is not present, check the fuse and that the wire harness does not have an internal break. Replace solenoid.

Repair and Service Manual

Page G-7

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

FUEL CUT SOLENOID The fuel cut solenoid is located in the carburetor and shuts off the flow of fuel to the carburetor main jet when the key switch is OFF (Ref Fig. 8 on page G-12). If the vehicle won’t start, confirm the ignition system is functioning, the air cleaner is not plugged and that there is fuel in the tank and fuel filter. If all of these items are working correctly, raise the seat and turn the key switch ON and OFF. The sound of the solenoid should be heard as it opens when the key is turned to ON. If no sound is heard, the solenoid is suspect. Disconnect the wiring harness and check for voltage when the key switch is ON. If battery voltage is present, replace the solenoid (Refer to Honda GX610 Repair Manual for V-Twin Overhead Valve engine). If battery voltage is not present, check that wire harness does not have an internal break.

NEUTRAL SWITCH To prevent serious personal injury or death from inadvertent movement of vehicle, all tests performed requiring starter/ generator or engine to rotate must be performed by lifting vehicle (see Section B).

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The neutral switch is located on the transmission and prevents the vehicle from being started if the direction selector is in gear (Ref Fig. 6 on page G-11). If the starter will not operate, be sure that the direction selector is in neutral. If the starter still does not operate, check the in line fuse (25 amp) mounted on the driver side under the cowl. If the fuse is good, turn the key switch to ON and remove the wiring harness from the neutral switch.

Check for voltage between the two terminals at the harness. Turn key switch to OFF. If voltage is present, insert a jumper wire between the two wire harness terminals and turn key switch to start. If the starter operates, replace the neutral switch. If battery voltage is not present, check that wire harness does not have an internal break.

page G-10). If the switch is good, check that the wire harness does not have an internal break.

TAILLIGHT (ACCESSORY) The taillight is wired in parallel with the headlights, therefore if the one or both headlights are operating, the problem lies with the bulb, socket or wiring.

BRAKE SWITCH The brake light switch is a hydraulic pressure switch attached to the front reservoir of the master cylinder. If the brake light does not operate, the most likely cause is the fuse, bulb, socket or wiring. Apply the brakes and check for voltage at the bulb socket. If no voltage is present and the fuse and wiring are good, check the brake light switch. With the brake pedal depressed, there should be continuity between the switch terminals. If not replace the switch and refer to BRAKES SECTION for brake bleeding instructions.

POWER OUTLET Check the power outlet by checking for battery voltage at the outlet. If battery voltage is not present, check the fuse and that the wire harness does not have an internal break.

HEADLIGHTS The headlights are wired in parallel to the light switch (Ref Fig. 4 on page G-9). If one light is working, check the other for continuity through the filament. If there is no continuity, the bulb has blown and must be replaced. If both bulbs are out, first check the fuse. If the fuse is good check the switch for continuity and replace the switch if continuity is not present with the switch on (Ref Fig. 5 on

Page G-8

Repair and Service Manual

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

A Packard Connector From Harness To Head light

A

ORN WHT

RED

RED/YEL 25Amp Fuse

INSTRUMENT CLUSTER BLU RED/WHT

#10 GA.WHT

FUSE BLOCK Fig. 4 Fuse Block, Instrument Cluster And Head Light

Repair and Service Manual

Page G-9

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

KEY SWITCH 12V OUTLET BLK To "M1" On Key Switch

WHT To "B" On Key Switch BLK RED/WHT

BLU

OPTIONAL TRUCK BED LIFT SWITCH

BLU/WHT HEAD LIGHT SWITCH

Fig. 5 Head Light Switch, Key Switch And 12V Outlet

Page G-10

Repair and Service Manual

YEL To "I" On Key Switch RED/WHT To "M2" On Key Switch BLK/WHT To "S" On Key Switch

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

2-Pin Connector From Harness To Neutral Switch

A

YEL

BLK

A

Fig. 6 Neutral Switch And Fuel Sending Unit

Repair and Service Manual

Page G-11

ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

3 Pin Connector To Rear Differential DRIVER SIDE FRONT OF VEHICLE

3 Pin Connector To Front Differential

Fig. 7 Differential Lock Solenoids

DRIVER SIDE BEHIND SIDE PANEL

DRIVER SIDE BEHIND SIDE PANEL

BLK/WHT Wire From Harness To Starter

#6 GA. Wire From Harness To Starter

Connector To Voltage Regulator YEL To BLK/YEL From Fuel Cut Solenoid Valve

RED To BLK/RED From Engine Stop Diode

Fig. 8 Voltage Regulator, Fuel Cut Solenoid And Starter

Page G-12

Repair and Service Manual

ENGINE AND TRANSMISSION TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE

H PAGE NO.

POWERTRAIN MAINTENANCE..................................................................................................... H - 2 Removing Debris .................................................................................................................. H - 2 Oil Capacity .......................................................................................................................... H - 2 Oil Recommendations .......................................................................................................... H - 2 Checking the Oil Level.......................................................................................................... H - 2 Changing the Oil................................................................................................................... H - 3 Changing the Oil Filter.......................................................................................................... H - 4 Air Cleaner Maintenance ...................................................................................................... H - 4 Paper Filter Element Service................................................................................................ H - 4 Alternator Belt Tension ......................................................................................................... H - 5 Adjusting Belt Tension.......................................................................................................... H - 5 Spark Plugs .......................................................................................................................... H - 6 ENGINE DESCRIPTION ................................................................................................................. H - 6 Engine Specifications ........................................................................................................... H - 6 Engine Operation.................................................................................................................. H - 6 Vehicle Preparation To Evaluate Engine Condition.............................................................. H - 7 CVT BACK COVER REPLACEMENT............................................................................................. H - 7 ENGINE REMOVAL/INSTALLATION ............................................................................................. H - 7 Engine Removal ................................................................................................................... H - 7 Engine Installation .............................................................................................................. H - 11 STARTER REPLACEMENT.......................................................................................................... H - 11 MUFFLER REPLACEMENT ......................................................................................................... H - 11 EXHAUST MANIFOLD REPLACEMENT...................................................................................... H - 12 TRANSMISSION REPLACEMENT ............................................................................................... H - 13 Checking Transmission (Transfer Case) Lubrication Level................................................ H - 14 SPARK ARRESTER CLEANING .................................................................................................. H - 15 ENGINE SUB FRAME REPLACEMENT....................................................................................... H - 15 ISOLATION MOUNT REPLACEMENT ......................................................................................... H - 16

LIST OF ILLUSTRATIONS Fig. 1 Engine .................................................................................................................................. H - 1 Fig. 2 Cleaning Air Intake ............................................................................................................... H - 2 Fig. 3 Oil Viscosity Chart ................................................................................................................ H - 2 Fig. 4 Cleaning the Top of the Engine............................................................................................ H - 3 Fig. 5 Clean Entire Dipstick ............................................................................................................ H - 3 Fig. 6 Check Oil Level on Dipstick.................................................................................................. H - 3 Fig. 7 Changing The Oil ................................................................................................................. H - 4 Fig. 8 Remove Oil Filter.................................................................................................................. H - 4 Fig. 9 Air Cleaner ........................................................................................................................... H - 5 Fig. 10 Checking Belt Tension with Gauge .................................................................................... H - 5 Fig. 11 Checking Belt Tension with Finger..................................................................................... H - 5 Fig. 12 Adjusting the Belt Tension.................................................................................................. H - 5 Fig. 13 Gapping the Spark Plug ..................................................................................................... H - 6 Fig. 14 CVT Back Cover Removal ................................................................................................. H - 7 Fig. 15 Air Intake System Removal ................................................................................................ H - 9 Fig. 16 Accelerator and Governor Cable Removal......................................................................... H - 9 Fig. 17 Engine Removal ............................................................................................................... H - 10 Fig. 18 Muffler Replacement ........................................................................................................ H - 12 Fig. 19 Exhaust Manifold Replacement........................................................................................ H - 13

Repair and Service Manual

Page H-i

ENGINE AND TRANSMISSION TABLE OF CONTENTS FOR SECTION ‘H’ (CONT.) SECTION TITLE Fig. 20 Fig. 21 Fig. 22 Fig. 23 Fig. 24 Fig. 25

PAGE NO.

Transmission Replacement .............................................................................................. H - 14 Transmission Lubricant Level........................................................................................... H - 14 Spark Arrester Removal ................................................................................................... H - 15 Spark Arrester Cleaning ................................................................................................... H - 15 Engine Sub frame Replacement....................................................................................... H - 16 Isolation Mount Replacement ........................................................................................... H - 17

Page H-ii

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

H

Oil Fill Cap Air Plenum

Air Hose

Exhaust Manifold

Air Cleaner Starter Dip Stick

Fig. 1 Engine

Repair and Service Manual

Page H-1

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

This section describes procedures for performing regular maintenance, preparing vehicle to test engine condition and replacing engine. For engine condition testing and repair procedures, refer Honda Repair Manual, V-Twin engine.

tion. When using a multi-viscosity oil, check oil level more frequently.

SAE 30 oil, if used below 40° F (4° C) will result in hard starting and possible engine bore damage due to inadequate lubrication.

Do not use special additives in recommended oil.

POWERTRAIN MAINTENANCE Access the powertrain by raising or removing seat. Full access to powertrain may be obtained by raising the load bed. Some service procedures may require the vehicle be lifted. Refer to LIFTING THE VEHICLE in section B for proper lifting procedure and safety information.

Removing Debris Engine parts should be ! ! kept clean to reduce risk of overheating and ignition of accumulated debris which could result in severe injury.

Do not mix oil with gasoline.

The oil must be high quality detergent oil classified “For Service SF, SG, SH, SJ” or higher. The selection of oil viscosity is dependent upon the climate in which the vehicle will be used. Most vehicles require 10W-30 oil (Ref Fig. 3 on page H-2).

Synthetic oil meeting ILSAC GF-2, API certification mark and API service symbol with “SJ/CF ENERGY CONSERVING” or higher, is an acceptable oil at all temperatures. Use of synthetic oil does not alter required oil change intervals.

After every off road use, allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins. Dirt and debris may clog the engine’s air cooling system. Clean areas shown to prevent engine damage (Ref Fig. 2 on page H-2). Keep linkages, springs and controls clean. To prevent fire, keep area around muffler free of any combustible material.

Cooling Fins

Air Intake

30

10W-30 5W-30

F0 0

-20

C -30

0 -20

20

40

60

-10 0 20 10 (Air Temperature)

80

100 30

40

Fig. 3 Oil Viscosity Chart

Checking the Oil Level When adding oil between oil changes, do not mix brands and viscosity grades of oil.

Fig. 2 Cleaning Air Intake

Oil Capacity Engine oil capacity is approximately 1.9 quarts (1.8 liters) when changing oil and filter or 1.59 quarts (1.5 liters) crankcase only.

Tool List

Qty. Required

Clean cloth...................................................................2

Oil Recommendations Air cooled engines run hotter than automotive engines. The use of non-synthetic multi-viscosity oils (5W-30, 10W-30, etc.) in temperatures above 40° F (4° C) will result in higher than normal oil consump-

Page H-2

Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will result in oil becoming contaminated and/or oil being discharged into the engine compartment.

Check oil level daily before starting the engine. The vehicle must be on a level surface with the parking brake engaged. Use a cloth to wipe clean the oil dipstick handle and oil fill cap (Ref Fig. 4 on page H-3). This is necessary to prevent debris from falling into the engine.

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Oil Fill Cap

Maximum oil level DO NOT OVERFILL ADD

FULL

Fig. 6 Check Oil Level on Dipstick

Changing the Oil Be aware that engine fluids may be hot and contact to the skin may cause severe burns. Wear rubber gloves to protect skin from exposure to the old oil and degreaser.

!

Do not fill more than 1.59 quarts (1.5 liters) lubrication oil at any one time 1.9 quarts (1.8 liters) with new oil filter). Excess oil may cause oil seals to fail or oil migration into areas that could damage components.

Tool List Qty. Required

Dip Stick

Fig. 4 Cleaning the Top of the Engine Remove the dipstick and wipe off the entire area indicated with a clean cloth (Ref Fig. 5 on page H-3).

ADD

!

Pliers ........................................................................... 1 Oil drain pan ................................................................ 1 Clean cloth .................................................................. 2 For maximum performance and longevity, the engine oil should be replaced after the first twenty (20) hours of operation. After the initial oil change, it should be changed per the Periodic Service Schedule in Section A. Changing the oil filter whenever the oil is changed is highly recommended.

The oil should be changed with the engine warm. Park the vehicle on a level surface, engage the parking brake and remove the key. Place a drain pan under the engine. Wipe the oil fill cap clean with a cloth and remove the cap (Ref Fig. 4 on page H3).

FULL

Fig. 5 Clean Entire Dipstick Insert the dipstick fully into the dipstick tube and remove.

Examine the level of oil on the dipstick. Oil should be at the FULL mark (Ref Fig. 6 on page H-3).

If oil is required, remove oil fill cap and add oil slowly to bring level to the FULL mark. Do not overfill.

Replace dipstick fully into the dipstick tube and firmly replace the oil fill cap.

Clean the area around the oil drain plug (Ref Fig. 7 on page H-4). Remove the drain plug and allow the oil to drain into drain pan. Install drain plug once oil has drained and tighten the drain plug firmly.

Add 1 quart (1 liter) of oil. Start and drive vehicle at a slow speed long enough to warm the oil. Stop and turn off vehicle on a level surface and wait 30 seconds for the oil to settle to the bottom of the engine. Check for leaks.

Slowly add more oil to bring level to the FULL mark on dipstick. Do not overfill.

Repair and Service Manual

Page H-3

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Replace dipstick fully into the dipstick tube and firmly install the oil fill cap.

Front of Vehicle

Oil Filter Oil Drain Plug

Fig. 8 Remove Oil Filter

Air Cleaner Maintenance Drain Plug

The filters must be serviced per the Periodic Service Schedule in Section A for optimum engine life and performance.

Access the filter by unsnapping the spring clip on each side of the air cleaner and removing the air cleaner cover (Ref Fig. 9 on page H-5). If necessary, vacuum or wipe out any loose dirt or trash from the air cleaner base.

Paper Filter Element Service

Fig. 7 Changing The Oil

Changing the Oil Filter Tool List

Qty. Required

Oil filter wrench, to fit 3" (76 mm) oil filter.................... 1 Oil drain pan ................................................................ 1 Clean cloth .................................................................. 2 Clean the area around the oil filter and oil drain. Drain engine oil (Ref Changing the Oil section on page H-3) and remove oil filter (Ref Fig. 8 on page H-4). Make sure the seal comes off with filter and is not stuck to the engine.

Wipe around the sealing surface of filter mount with a clean, lint free cloth. Lightly oil the seal on the new filter with fresh, clean oil. Screw filter on by hand until the seal contacts the filter mount. Tighten 1/2 to 3/4 turn more.

Refill engine with new oil (Ref Changing the Oil section on page H-3).

Page H-4

Do not use petroleum solvents, pressurized water, or compressed air to clean paper filter element. Doing so will damage the filter and will damage the engine.

The paper filter element is a dry unit. Do not use oil on the filter element.

Remove paper filter element and inspect (Ref Fig. 9 on page H-5). Replace if too dirty to clean or at the first sign of filter paper deterioration. Clean paper filter by gently tapping on a flat surface.

Install paper filter element and the air cleaner cover.

Secure end cover with the spring clips.

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Air Cleaner Cover

Air Cleaner Canister

Paper Filter Element

3/8" (1 cm) Max. Deflection for New Belt 1/2" (1.3 cm) Max. Deflection for Existing Belt

Clip

Fig. 11 Checking Belt Tension with Finger Re-tighten an existing belt to 75-80 lbs. (34-36 kg) tension using the same technique. A maximum deflection of 1/2" (1.3 cm) is acceptable.

Fig. 9 Air Cleaner

Alternator Belt Tension

Adjusting Belt Tension

A loose belt can cause audible vibration and squeal.

Tool List

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Socket, 1/2", 3/8" drive................................................ 1 Socket, 3/4", 3/8" drive................................................ 1 Wrench, 1/2" ............................................................... 2 Wrench, 3/4" ............................................................... 1 Belt tension gauge ...................................................... 1 Pry bar ........................................................................ 1

Loosen front and back pivot bolts (item 1) of alternator (Ref Fig. 12 on page H-5).

Loosen adjusting bolt (item 2). Use pry bar to adjust tension on alternator belt. Hold alternator (item 3) in place and tighten adjusting bolt (item 2).

1 3

The alternator belt tension should be checked after the first 15-20 hours of operation and set to 75-80 lbs (34-36 kg).

Tighten a new alternator belt to 90-110 lbs. (41-50 kg) tension when a gauge is applied half way between the two pulleys (Ref Fig. 10 on page H-5).

2

Fig. 12 Adjusting the Belt Tension Tighten pivot bolts (item 1) per torque specification table given below.

Fig. 10 Checking Belt Tension with Gauge Although not as accurate, the belt may be depressed with a finger. A maximum deflection of 3/8" (1 cm) is acceptable for a new belt (Ref Fig. 11 on page H-5).

ITEM NO 1

Repair and Service Manual

TORQUE SPECIFICATION 25 ft. lbs. (35 Nm)

Page H-5

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Spark Plugs

ENGINE DESCRIPTION

Use care not to overtighten the plug.

Overtightening can damage the aluminum cylinder head threads.

The engine is a four cycle air cooled, V block, twin cylinder, overhead valve unit. It incorporates pressure lubrication, and a replaceable oil filter.

Do not sand blast spark plugs. They should be cleaned by scraping or wire brushing by hand and washing in a commercial solvent.

Engine Specifications

Tool List

Qty. Required

Ratchet, 1/2" drive ....................................................... 1 Torque wrench, 1/2" drive, ft. lbs ................................. 1 Spark plug socket, 5/8", 1/2" drive............................... 1 Plug gauge, wire type.................................................. 1 Anti-seize compound................................................ AR Remove and inspect the spark plugs per Periodic Service Schedule in Section A. Fouled spark plugs are indicated by a wet, black appearance. This could be caused by a dirty air filter element or other restrictions in the air intake system. Incorrectly adjusted valves, spark plug wires which are in poor condition or poor quality fuel could also contribute to the problem. Clean and gap to .030" (.76 mm). If a plug has been burned beyond .035" (.89 mm) or the porcelain is cracked, it should be replaced (Ref Fig. 13 on page H-6).

Spark Plug

.030" (.76 mm) Gap

Fig. 13 Gapping the Spark Plug Spark plugs should be properly gapped to .030" (.76 mm) (NGK ZGR5A or DENSO J16CR-U), given a light coat of anti-seize compound and tightened to 15 ft. lbs. (20 Nm) torque.

Page H-6

Engine model .......................................HONDA GX610 Type.................................... Four cycle, overhead valve Number of cylinders......................................2 (V block) Displacement...................................................... 614 cc Rated horsepower ................................. 18hp (13.4 kw) Spark plug type ....... NGK ZGR5A or DENSO J16CR-U Spark plug gap....................................... .030" (.76 mm) Cooling ....................................................................Fan Oil Filter .......................................Replaceable, Spin-off

Engine Operation To understand the operation of a four cycle engine, it is easiest to consider a single cylinder.

The first cycle (stroke) takes place with the piston moving down and the intake valve open. Fuel is drawn into the combustion chamber from the carburetor and through the intake valve and is known as the intake stroke. As the piston reaches the bottom (BDC) of its travel and starts to move upwards, the second cycle begins. The intake valve closes which seals the combustion chamber since the exhaust valve is already closed and causes the fuel air mixture to be compressed as the piston rises. This is known as the compression stroke. Just before the piston reaches TDC (Top Dead Center) the spark plug fires which causes a rapid burning of the air fuel mixture. The temperature rises rapidly which 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 reaches BDC it enters the fourth cycle. The exhaust valve opens and the piston rises forcing burned gases from the combustion chamber in what is known as the exhaust stroke. As the piston moves through TDC and starts down, the first cycle is repeated.

The camshaft is gear driven from the crankshaft. The ignition timing is controlled by an electrical pulse received from a magnet mounted on the crankshaft flywheel. The ignition timing is not adjustable.

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Vehicle Preparation To Evaluate Engine Condition

5

To prevent severe personal injury or death resulting from inadvertent movement of vehicle raise entire vehicle and place in neutral per Section B.

!

4

3

!

To prevent severe injury or death resulting from a fuel fire, never operate without magneto being grounded.

Any fuel drawn into the cylinders will be expelled through the spark plug opening and could be ignited by the ignition system or another source.

Follow procedure to check compression as outlined in the HONDA® Repair Manual for V-Twin Overhead Valve engine.

2 1

Fig. 14 CVT Back Cover Removal

CVT BACK COVER REPLACEMENT Tool List

Qty. Required

Torque wrench, 3/8" drive, ft. lbs ................................. 1 Socket, 7/16", 3/8" drive.............................................. 1 Allen wrench, 3/16", 3/8" drive .................................... 1 Remove the CVT cover, drive belt, driven clutch and drive clutch (Ref CONTINUOUSLY VARIABLE TRANSMISSION).

Remove the bolts (item 1) using a 3/16" Allen wrench and remove the lock washers (item 2) (Ref Fig. 14 on page H-7). Remove the bolts (item 3) using a 7/16" socket, from the driven clutch side and remove the washers (item 4). Remove cover back plate (item 5).

Installation of the CVT back cover is the reverse of disassembly.

Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

1

17 - 20 ft. lbs (23 - 27 Nm)

3

6 - 12 ft. lbs (8 - 16 Nm)

ENGINE REMOVAL/INSTALLATION Engine Removal

!

!

To prevent the possibility of severe personal injury or death resulting

from an explosion: Disconnect the negative (-) battery cable before starting engine removal.

To prevent a possible explosion, do not smoke near the fuel tank or in an area where gasoline is being handled. Do not perform procedures involving the fuel system near open fire or electrical items which could produce a spark.

Do not handle gasoline in an area that is not adequately ventilated.

Always wear safety glasses to prevent possible eye injury from gasoline or gasoline vapor.

The following step involves lifting substantial weight.

Two people are recommended. Use of a personal back support brace and proper lifting technique is required to prevent personal injury.

Repair and Service Manual

Page H-7

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original position unless otherwise specified. Non specified torque figures are as shown in the table contained in Section A. Note the location of wires, wire ties and clamps before removal and always install them in their original location. Use of masking tape to label wires is recommended.

The engine will be lifted out between differential and wide crossmember of frame.

Tool List

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Impact wrench, 1/2" drive ............................................ 1 Socket, 12mm, 3/8" drive ............................................ 1 Socket, 1/2", 3/8" drive ................................................ 1 Deep well socket, 17mm, 3/8" drive ............................ 1 Impact socket, 5/8", 1/2" drive ..................................... 1 Impact socket, 13/16", 1/2" drive ................................. 1 Allen wrench, 3/16", 3/8" drive .................................... 1 Wrench, 1/4"................................................................ 1 Wrench, 10mm ............................................................ 1 Wrench, 1/2"................................................................ 2 Wrench, 3/4"................................................................ 1 Insulated wrench, 1/2" ................................................. 1 Straight blade screwdriver ........................................... 1 Needle nose pliers....................................................... 1 Pliers ........................................................................... 1 Masking tape ............................................................ AR Back brace .................................................................. 2 Oil drain pan ................................................................ 1 Utility knife ................................................................... 1 Shop rag, clean ........................................................ AR Plug, for fuel line.......................................................... 1 Cap, for fuel pump....................................................... 1 Release the handle and raise the truck bed. Remove gas spring (Ref Gas Spring Replacement in BODY AND TRUCK BED).

If engine is to be repaired, not replaced, wash engine and chassis to remove dirt build-up.

Disconnect negative (-) cable from battery to prevent electrical shorts that could cause an explosion. Remove seat bottom (Ref Seat bottom Replacement in BODY AND TRUCK BED). Remove seat cross member.

Page H-8

Drain oil from engine.

CVT Back Cover Removal Remove the CVT back cover (Ref CVT BACK COVER REPLACEMENT section on page H-7).

Exhaust Pipe And Exhaust Manifold Removal Note location and disconnect wire from oil pressure switch located above oil filter and free from any wire ties or clamps anchoring it to engine. Remove the spring and remove the exhaust pipe from muffler (Ref MUFFLER REPLACEMENT section on page H-11). Remove the exhaust manifold (Ref EXHAUST MANIFOLD REPLACEMENT section on page H-12) Do not smoke and wear eye protection before opening the fuel system. Provided ventilation is adequate, remove and plug fuel line from fuel pump and cap fuel pump nipple.

Disconnecting Starter Wires Note location of starter wires and remove from starter.

Air Intake System Removal Remove the clamp (item 1) using straight blade screwdriver and disconnect remote air hose (item 2) from air cleaner (item 3) (Ref Fig. 15 on page H-9). Remove air cleaner cover (item 4) and filter (item 5). Remove the bolts (item 6) using 10mm wrench and the washers (item 7). Remove air intake plenum (item 8).

Remove the bolts (item 9) using 1/2" wrench, that mount air filter bracket (item 10) to engine. Hold the bolt (item 11) and remove the nut (item 12). Remove the washers (item 13). Remove bracket.

Accelerator, Governor and Choke Cable Removal To prevent any debris falling into engine, cover carburetor with a clean shop rag and hold in place with a rubber band. Remove accelerator cable (item 1) (Ref Fig. 16 on page H-9). Remove the bolts (item 2) using 12mm wrench and remove governor cable (item 3) and choke bracket (item 4). Remove choke cable connected to the engine (Ref Choke Cable Replacement in FUEL SYSTEM).

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

6 8 Front of Vehicle

7

4 2

5

9 1

3

10 12 13

11

Fig. 15 Air Intake System Removal

1 3

4

2

Fig. 16 Accelerator and Governor Cable Removal

Repair and Service Manual

Page H-9

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

• Remove choke/governor cable bracket from old

Engine Removal Remove the bolts (item 1) using 5/8" impact socket securing engine (item 4) to subframe (item 5) (Ref Fig. 17 on page H-10). Remove the nuts (item 2) and remove the washers (item 3).

engine. Detach governor cable and choke link from carburetor.

Wear a personal back support brace and use proper lifting technique before attempting to lift engine. With a person on each side of vehicle, rotate and lean engine back to position the muffler down, where the driven clutch was, and carefully maneuver engine out of vehicle.

If replacing engine:

4

2

5

3

1

Fig. 17 Engine Removal

Page H-10

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Engine Installation The following step involves lifting substantial weight. Two people are recommended. Use of a personal back support brace and proper lifting technique is required to prevent personal injury.

!

!

A new push nut must be used when installing the accelerator cable to the governor.

Tool List

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Socket, 6mm hex bit, 3/8" drive .................................. 1 Socket, 1/2", 3/8" drive................................................ 1 Socket, 5/8", 3/8" drive................................................ 1 Wrench, 1/2" ............................................................... 2 Crowfoot wrench, 1/4", 3/8" drive................................ 1 If installing a replacement engine: • Attach governor cable and choke link to carburetor and secure choke/governor cable bracket to new engine using existing hardware. Tighten bolts to 21 - 23 ft. lbs. (29 - 32 Nm) torque (Ref Fig. 16 on page H-9).

Wear a personal back support brace and use proper lifting technique before lowering engine into vehicle. With a person on each side of vehicle, install engine in reverse order of removal replacing all lock nuts with new lock nuts.

When installing air intake plenum to carburetor, use ’roof and flashing’ polyurethane sealant to create a tight seal between the plenum and carburetor intake. Use caution not to permit excess sealant to fall into the carburetor.

Tighten engine to subframe mounting hardware to 20 ft. lbs. (30 Nm) torque (Ref Fig. 17 on page H-10).

Connect exhaust pipe to the engine and tighten clamp till no loose play is present.

Check oil level in engine and adjust as needed.

Reconnect negative (-) battery cable and tighten hardware to 5 ft. lbs. (7 Nm).

STARTER REPLACEMENT To prevent the possibility of personal injury, disconnect the negative (-) battery cable before starter removal.

!

!

Disconnect negative (-) cable from battery to prevent electrical shorts that could cause an explosion.

Remove engine (Ref Engine Removal). Follow procedure to remove/install starter as outlined in the HONDA® Repair Manual for V-Twin Overhead Valve engine.

Reconnect negative (-) battery cables and tighten hardware to 5 ft. lbs. (7 Nm).

MUFFLER REPLACEMENT

!

Tool list

!

To prevent burns, check that muffler has cooled before replacing.

Qty. Required

Torque wrench, 3/8" drive, ft. lbs ................................. 1 Ratchet, 3/8" drive ....................................................... 1 Socket, 3/4" ................................................................. 1 Wrench, 3/4"................................................................ 1 Needle nose locking pliers .......................................... 1 Release the handle and raise the truck bed.

Early production models were fitted with a heat shield mounted to the underside of the truck bed. There is no need to remove this heat shield.

Tighten starter terminal nuts to specified torque.

Remove the heat shield. Remove the spring (item 1) using needle nose locking pliers (Ref Fig. 18 on page H12). Hold the bolt (item 2) using 3/4" socket and remove the nut (item 3) using 3/4" wrench. Remove the washer (item 4) and remove the muffler (item 5) from the frame.

If choke cable adjustment is required, adjust per FUEL SYSTEM section.

Installation of muffler is the reverse of disassembly using new lock nut.

Tighten drive clutch bolt to torque specified in CONTINUOUSLY VARIABLE TRANSMISSION section.

Install drive belt and CVT cover.

Attach accelerator cable to governor per FUEL SYSTEM section

Repair and Service Manual

Page H-11

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

3 4 2

1

5

Fig. 18 Muffler Replacement Tighten the hardware per torque specification table given below.

ITEM NO 3

TORQUE SPECIFICATION 20 - 25 ft. lbs. (27 - 34 Nm)

EXHAUST MANIFOLD REPLACEMENT Disconnect negative (-) cable from battery to prevent electrical shorts that could cause an explosion.

!

Tool List

!

tion in CVT). Remove springs (item 1) using needle nose locking pliers (Ref Fig. 19 on page H-13). Remove the nuts (item 2) using 12mm deep well socket, and 3" extension. Loosen clamp (item 3) and remove exhaust manifold (item 4) from exhaust pipe (item 5) and engine.

Installation of exhaust manifold is the reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table given below.

ITEM NO 2

Qty. Required

Extension, 3", 3/8" drive .............................................. 1 Deep well socket, 7/16" ............................................... 1 Deep well socket, 12mm ............................................. 1 Needle nose locking pliers .......................................... 1 Remove seat bottom (Ref Seat Bottom Replacement Section in BODY AND TRUCK BED). Remove the seat back (Ref Seat Back Replacement Section in BODY AND TRUCK BED). Remove seat crossmember.

Remove CVT cover (Ref Drive Clutch Replacement sec-

Page H-12

Repair and Service Manual

TORQUE SPECIFICATION 15 - 17 ft. lbs. (20 - 23 Nm)

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

4

3 2 5

1

Fig. 19 Exhaust Manifold Replacement

TRANSMISSION REPLACEMENT

Wrench, 9/16".............................................................. 2

To prevent the possibili! ! ty of personal injury, disconnect the negative (-) battery cable before starting transmission removal In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original position unless otherwise specified. Non specified torque figures are as shown in the table contained in Section A. Note the location of wires, wire ties and clamps before removal and always install them in their original location. Use of masking tape to label wires is recommended.

If the transmission is to be repaired, and not replaced, wash transmission and chassis to remove dirt build-up.

Tool List

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Deep well socket, 9/16", 3/8" drive.............................. 1 Insulated wrench, 1/2"................................................. 1 Wrench, 1/4" ............................................................... 1

Needle nose pliers....................................................... 1 Pliers ........................................................................... 1 Straight blade screwdriver ........................................... 1 Anti-seize compound................................................... 1 Clean shop towel......................................................... 1 Masking tape ............................................................... 1 Before starting, refer SAFETY section. Park the vehicle on a level surface, engage park brake. Disconnect negative (-) cable from the battery to prevent electrical shorts.

Release the handle and raise the truck bed. Remove the seat bottom (Ref Seat Bottom Replacement section in BODY AND TRUCK BED). Remove seat back assembly and seat crossmember (Ref Seat Back Replacement section in BODY AND TRUCK BED). Remove the direction and drive selector cables (Ref Direction And Drive Selector Cable Adjustment section in DIRECTION AND DRIVE SELECTOR). Remove the accelerator and governor cables (Ref Accelerator, Governor and Choke Cable Removal section on page H-8). Remove CVT cover, drive clutch and driven clutch (Ref CONTINUOUSLY VARIABLE TRANSMISSION). Remove the CVT back cover (Ref CVT BACK COVER REPLACEMENT section

Repair and Service Manual

Page H-13

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

on page H-7). Remove the front drive shaft (Ref Front Drive Shaft Replacement section in FRONT SUSPENSION AND STEERING). Remove rear drive shaft (Ref Rear Drive Shaft Replacement section in REAR AXLE AND SUSPENSION).

Apply anti seize compound on all splines and appropriate commercially available thread lock for bolts before installation.

Tighten the hardware per torque specification table given below.

ITEM NO

8

4

5 10

TORQUE SPECIFICATION

2

26 - 31 ft. lbs (35 - 42 Nm)

7

20 - 25 ft. lbs (27 - 34 Nm)

Checking Transmission (Transfer Case) Lubrication Level The transmission is provided with an oil level check/fill plug (item 1) located on passenger side at rear of case (Ref Fig. 21 on page H-14). Unless leakage is evident, an annual check is sufficient..

6 9

7 1

3

2

Fig. 20 Transmission Replacement 1

Hold the bolts (item 1) using 9/16" wrench and remove the nut (item 2) using 9/16" socket securing the transmission (item 10) to the sub frame (Ref Fig. 20 on page H14). Remove the washer (item 3). Remove the set screw (item 4) using 1/4" wrench and remove the governor lever (item 5). Hold the bolt (item 6) using 9/16" wrench and using a 9/16" socket, remove the nut (item 7) securing the accelerator/governor bracket (item 8) to transmission. Remove the washer (item 9). Remove the transmission (item 10).

Installation of the transmission is the reverse of disassembly using new lock nuts.

Page H-14

2

Fig. 21 Transmission Lubricant Level Clean the fill plug (item 1) and area around it. Remove plug. Correct lubricant level is just below bottom of threaded hole.

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

If lubricant is to be added, use a funnel and add correct type lubricant (Ref Transfer Case in Capacities table in GENERAL INFORMATION & ROUTINE MAINTENANCE) slowly until it starts to seep from hole and install plug.

To replace lubricant, a drain plug (item 2) is provided at bottom of transmission.

Tighten the fill plug to the torque per torque specification table given below.

ITEM NO 1

20 - 25 ft. lbs (27 - 34 Nm)

ENGINE SUB FRAME REPLACEMENT

SPARK ARRESTER CLEANING

The following step involves lifting substantial weight. Two people are recommended. Use of a personal back support brace and proper lifting technique is required to prevent personal injury.

!

To reduce possibility of burns, allow muffler to cool before servicing and never operate vehicle without spark arrester in good condition and in place.

!

Fig. 23 Spark Arrester Cleaning

TORQUE SPECIFICATION

!

Release the handle and raise the truck bed.

Remove screw (item 1) securing spark arrester (item 2) and pull arrester (item 2) from muffler (item 3) (Ref Fig. 22 on page H-15). Brush off carbon deposits from arrester screen without damaging screen (Ref Fig. 23 on page H-15). Screen must be intact.

Replace spark arrester if screen is torn or otherwise damaged. Install arrester on muffler and secure with screw.

!

To prevent serious personal injury or death resulting from a battery explosion, always disconnect the negative (-) battery cable first using insulated wrench before starting engine subframe removal.

In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original position unless otherwise specified. Non specified torque figures are as shown in the table contained in Section A. Note the location of wires, wire ties and clamps before removal and always install them in their original location. Use of masking tape to label wires is recommended.

Tool List

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Socket, 9/16", 3/8" drive .............................................. 1 Wrench, 9/16".............................................................. 1

3

Before starting, refer SAFETY section. Park the vehicle on a level surface, engage park brake. Disconnect negative (-) cable from the battery to prevent electrical shorts.

Release the handle and raise the truck bed. Remove the gas spring (Ref Gas Spring Replacement section in BODY AND TRUCK BED).

2 1

Fig. 22 Spark Arrester Removal

Repair and Service Manual

Page H-15

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

4 2

3 1

Fig. 24 Engine Sub frame Replacement Remove the seat bottom (Ref Seat Bottom Replacement section in BODY AND TRUCK BED). Remove seat back assembly and seat crossmember (Ref Seat Back Replacement section in BODY AND TRUCK BED).

Remove the engine (Ref ENGINE REMOVAL/INSTALLATION section on page H-7). Remove the transmission (Ref TRANSMISSION REPLACEMENT section on page H-13).

Hold the bolts (item 1) using 9/16" socket and remove the nuts (item 2) using 9/16" wrench (Ref Fig. 24 on page H16). Remove the washer (item 3) and remove the engine subframe (item 4).

Installation of the engine sub frame is the reverse of disassembly using new lock nuts.

ISOLATION MOUNT REPLACEMENT Tool List

Ratchet, 3/8" drive .......................................................1 Torque wrench, 3/8" drive, ft. lbs .................................1 Socket, 1/2" .................................................................1 Wrench, 1/2" ................................................................1 Before starting, refer SAFETY section. Park the vehicle on a level surface, engage park brake. Disconnect negative (-) cable from the battery to prevent electrical shorts.

Release the handle and raise the truck bed. Remove the gas spring (Ref Gas Spring Replacement section in BODY AND TRUCK BED).

Tighten the hardware per torque specification table given below.

ITEM NO 2

Page H-16

Qty. Required

TORQUE SPECIFICATION 20 - 25 ft. lbs (27 - 34 Nm)

Repair and Service Manual

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

4

3

1

2

Fig. 25 Isolation Mount Replacement Remove the seat bottom (Ref Seat Bottom Replacement section in BODY AND TRUCK BED). Remove seat back assembly and seat crossmember (Ref Seat Back Replacement section in BODY AND TRUCK BED).

Remove the engine (Ref ENGINE REMOVAL/INSTALLATION section on page H-7). Remove the transmission (Ref TRANSMISSION REPLACEMENT section on page H-13). Remove the engine sub frame (Ref ENGINE SUB FRAME REPLACEMENT section on page H-15).

Hold the bolts (item 1) using 1/2" socket and remove the nuts (item 2) using 1/2" wrench (Ref Fig. 25 on page H17). Remove the isolation mount (item 3) from the main frame (item 4).

Installation of the isolation mount is the reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table given below.

ITEM NO 2

TORQUE SPECIFICATION 12 - 14 ft. lbs (16 - 19 Nm)

Repair and Service Manual

Page H-17

ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page H-18

Repair and Service Manual

FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE

J PAGE NO.

FRONT SUSPENSION .................................................................................................................... J - 2 Front Suspension Disassembly ............................................................................................. J - 2 Control Arm Replacement ..................................................................................................... J - 3 Front Steering Knuckle Replacement.................................................................................... J - 4 Front Strut Replacement ....................................................................................................... J - 4 Bearing Replacement ............................................................................................................ J - 5 Ball Joint Replacement.......................................................................................................... J - 6 Half Shaft Replacement......................................................................................................... J - 7 Front Drive Shaft Removal .................................................................................................... J - 8 Front Differential Guard Replacement................................................................................... J - 9 STEERING ....................................................................................................................................... J - 9 Steering Assembly Replacement .......................................................................................... J - 9 Steering Wheel Replacement.............................................................................................. J - 10 Steering Column Replacement............................................................................................ J - 11 MAINTENANCE ............................................................................................................................. J - 12 Wheel Alignment ................................................................................................................. J - 12

LIST OF ILLUSTRATIONS Fig. 1 Suspension Components ...................................................................................................... J - 1 Fig. 2 Brake Removal...................................................................................................................... J - 2 Fig. 3 Tie Rod End Replacement .................................................................................................... J - 3 Fig. 4 Control Arm Replacement ..................................................................................................... J - 3 Fig. 5 Front Steering Knuckle Replacement.................................................................................... J - 4 Fig. 6 Front Strut Replacement ....................................................................................................... J - 5 Fig. 7 Bearing Replacement............................................................................................................ J - 6 Fig. 8 Ball Joint Replacement.......................................................................................................... J - 7 Fig. 9 Half Shaft Replacement ........................................................................................................ J - 8 Fig. 10 Front Drive Shaft Removal .................................................................................................. J - 8 Fig. 11 Front Differential Guard Replacement................................................................................. J - 9 Fig. 12 Steering Assembly Replacement ...................................................................................... J - 10 Fig. 13 Steering Wheel Replacement............................................................................................ J - 11 Fig. 14 Steering Column Replacement ......................................................................................... J - 11 Fig. 15 Wheel Alignment ............................................................................................................... J - 12

Repair and Service Manual

Page J-i

FRONT SUSPENSION AND STEERING

Notes:

Page J-ii

Repair and Service Manual

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

J

Frame

Steering Assembly

Front Brake Line Strut

Tie Rod End Knuckle Bearing

Ball Joint

Rotor Half Shaft Spindle Cap

Front Differential Hog Ring

Caliper Control Arm Bushings

Control Arm

Fig. 1 Suspension Components

Repair and Service Manual

Page J-1

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

FRONT SUSPENSION In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original positions unless otherwise specified.

Non-specified torque specifications are shown in the table contained in Section A.

To reduce the possibility of personal injury, place wheel chocks in front and behind the rear wheels. Check the stability of the vehicle on the jack stands before starting any repair procedure. Never work on a vehicle that is supported by a jack alone.

!

!

The installation of the wheels and brake is the reverse of disassembly (Refer WHEELS AND TIRES section for wheel lug nuts torque specification).

Tighten the hardware per torque specification table below.

ITEM NO

TORQUE SPECIFICATION

1

42 - 47 ft.lbs (57 - 64 Nm)

Brake Line

To prevent injury caused by a broken socket, use only sockets designed for impact wrench use. Never use a conventional socket.

4

Front Suspension Disassembly Tool List

Qty. Required

Torque wrench, 1/2" drive, 165 ft. lbs capacity ............ 1 Impact wrench, 1/2" drive ............................................ 1 Extension, 6", 1/2" drive ............................................. 1 Socket, 3/4", 1/2" drive ................................................ 1 Socket, 1 1/8", 1/2" drive ............................................. 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Allen wrench, 9mm, 1/2" drive .................................... 1 Wrench, 3/4"................................................................ 1 Wrench, 9/16".............................................................. 1 Wrench, 11/16" ............................................................ 1 Plastic faced hammer.................................................. 1 Straight blade screwdriver ........................................... 1 Needle nose pliers....................................................... 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Wheels and Brake Removal Loosen the four nuts on the front wheels half turn.

Lift and support front of the vehicle per SAFETY section.

Remove the four front wheel nuts and remove the wheel.

Remove the bolt (item 1) using Allen wrench and extension (Ref Fig. 2 on page J-2). Remove the washer (item 2). Remove front brake caliper (item 3) and secure to the frame using wire ties. Remove the rotor (item 4).

Page J-2

2

1

3

Fig. 2 Brake Removal Tie Rod End Removal Never use a ball joint separator (Pickle fork), it will damage the joint.

After replacing the tie rod end, the tie rod is likely to be out of adjustment. The vehicle will require a wheel alignment before being returned to service (Ref Wheel Alignment Section on page J-12).

Jam Nut is LH threaded on passenger side and RH threaded on driver side.

Remove the spindle cap (item 1) using a straight blade screwdriver and plastic faced hammer (Ref Fig. 3 on page J-3). Remove the lock nut (item 2) using a 1 1/8" socket. Remove the outer brake washer (item 3).

Remove the cotter pin (item 4) and castle nut (item 5) using needle nose pliers and 3/4" wrench. Remove the washer (item 6) from tie rod end. Strike knuckle (item 7) with plastic faced hammer to separate tie rod end. Hold tie rod on flat groove using 9/16" wrench and loosen jam nut (item 8) using 11/16" wrench. Remove the tie rod end.

Repair and Service Manual

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

The installation of the tie rod end is the reverse of disassembly using new cotter pin.

Replace the front wheels per WHEELS AND TIRES section and lower vehicle.

Plastic faced hammer.................................................. 1 Straight blade screwdriver ........................................... 1 Needle nose pliers....................................................... 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Lift and support front of the vehicle per SAFETY section.

Tie Rod End

7

6 2 8 5 1

3

4

Fig. 3 Tie Rod End Replacement Tighten the hardware per torque specification table below.

5

ITEM NO

TORQUE SPECIFICATION

2

135 - 165 ft.lbs (183 - 224 Nm)

5

36 - 44 ft.lbs (49 - 60 Nm)

3

Control Arm Replacement 1

A worn control arm bushing (item 6) (Ref Fig. 4 on page J-3) can be identified by checking for excessive play. Lift the vehicle and check the wheel by attempting to rock it back and forth to check for excessive play.

Tool List

Qty. Required

Ratchet, 1/2" drive....................................................... 1 Torque wrench, 1/2" drive, 165 ft. lbs capacity............ 1 Impact wrench, 1/2" .................................................... 1 Extension, 6", 1/2" drive .............................................. 1 Socket, 3/4", 1/2" drive................................................ 1 Socket, 1 1/8", 1/2" drive............................................. 1 Impact socket, 3/4", 1/2" drive..................................... 1 Allen wrench, 5/16", 1/2" drive .................................... 1 Wrench, 9/16" ............................................................. 1 Wrench, 11/16"............................................................ 1 Wrench, 3/4" ............................................................... 1

6

4

2

Fig. 4 Control Arm Replacement Control Arm (Knuckle End Removal) Remove the cotter pin (item 1) and castle nut (item 2) using needle nose pliers and 3/4" wrench from the control arm end ball joint (Ref Fig. 4 on page J-3). Tap off control arm knuckle end (item 3) using a plastic faced hammer.

Control Arm (Frame End Removal) Remove the bolt (item 4) using 3/4" wrench (Ref Fig. 4 on page J-3). Remove the nut (item 5) and remove the control arm (item 3).

The installation of the control arm is the reverse of disassembly using new cotter pin.

Repair and Service Manual

Page J-3

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tighten the hardware per torque specification table below.

ITEM NO

TORQUE SPECIFICATION

2

36 - 44 ft.lbs (49 - 60 Nm)

5

20 - 25 ft.lbs (27 - 34 Nm)

Front Steering Knuckle Replacement Tool List

5

Qty. Required

Ratchet, 1/2" drive ....................................................... 1 Torque wrench, 1/2" drive, 165 ft. lbs capacity ............ 1 Impact wrench, 1/2", 1/2" drive.................................... 1 Extension, 6", 1/2" drive .............................................. 1 Socket, 1 1/8", 1/2" drive ............................................. 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Allen wrench, 5/16", 1/2" drive .................................... 1 Wrench, 9/16".............................................................. 1 Wrench, 11/16" ............................................................ 1 Plastic faced hammer.................................................. 1 Straight blade screwdriver ........................................... 1 Needle nose pliers....................................................... 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Loosen the four nuts on the front wheel half turn.

6

7 2

3 1 4

Fig. 5 Front Steering Knuckle Replacement Tighten the hardware per torque specification table below.

Lift and support front of the vehicle per SAFETY section.

Remove the wheels and brakes (Ref Wheels and Brake Removal Section on page J-2). Remove the spindle cap (item 1) using a straight blade screwdriver and plastic faced hammer (Ref Fig. 5 on page J-4). Remove the lock nut (item 2) using a 1 1/8" socket. Remove the outer brake washer (item 3). Remove the tie rod end (Ref Tie Rod End Removal Section on page J-2). Tap off control arm (item 4) from the steering knuckle (Ref Control Arm (Knuckle End Removal) Section on page J-3). Hold the bolt (item 5) using a 9/16" wrench and remove the nut (item 6) using a 11/16" wrench. Remove the steering knuckle (item 7) using a plastic faced hammer.

The installation of the front steering knuckle is the reverse of disassembly using new cotter pin.

Page J-4

ITEM NO

TORQUE SPECIFICATION

2

135 - 165 ft.lbs (183 - 224 Nm)

6

28 - 34 ft.lbs (38 - 46 Nm)

Replace the front wheels per WHEELS AND TIRES section and lower vehicle.

Front Strut Replacement Ratchet, 1/2" drive .......................................................1 Torque wrench, 1/2" drive, 165 ft. lbs capacity ............1 Extension, 6", 1/2" drive ..............................................1 Socket, 3/4", 1/2" drive ................................................1 Wrench, 9/16" ..............................................................1 Wrench, 11/16" ............................................................1 Plastic faced hammer ..................................................1 Floor jack, 1 1/2 ton .....................................................1

Repair and Service Manual

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Jack stands ................................................................. 2 Wheel chocks.............................................................. 4

The installation of the front strut is the reverse of disassembly using new cotter pins and new lock nuts.

Loosen the four nuts on the front wheel half turn.

Tighten the hardware per torque specification table below.

Lift and support front of the vehicle per SAFETY section.

Remove the wheels and brakes (Ref Wheels and Brake Removal Section on page J-2). Remove tie rod end from steering knuckle (Ref Tie Rod End Removal Section on page J-2). Remove bolt (item 1) using a 9/16" wrench and nut (item 2) using a 11/16" socket (Ref Fig. 6 on page J-5). Remove the steering knuckle (item 4) by tapping steering knuckle (item 4) with a plastic faced hammer. Remove the nut (item 5), strut washer (item 6), and strut bushing (item 7). Remove the front strut (item 8).

Replace the front wheels as per the WHEELS AND TIRES section and lower vehicle.

ITEM NO

TORQUE SPECIFICATIONS

2

135 - 165 ft.lbs (183 - 224 Nm)

5

8 - 12 ft.lbs (11 - 16 Nm)

Bearing Replacement 5 7

6

Worn bearing can be identified by checking for excessive play. Jack up the vehicle and check the wheel by attempting to rock it back and forth to check for excessive play.

Use a commercially available Anti-Seize compound on Shaft and Bearing splines.

Frame

Tool List

Qty. Required

Ratchet, 1/2" drive ....................................................... 1 Torque wrench, 1/2" drive, 165 ft. lbs capacity ............ 1 Impact wrench, 1/2" drive ............................................ 1 Extension, 6", 1/2" drive .............................................. 1 Socket, 3/4", 1/2" drive ................................................ 1 Socket, 1 1/8", 1/2" drive ............................................. 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Allen wrench, 5/16", 1/2" drive .................................... 1 Plastic faced hammer.................................................. 1 Straight blade screwdriver ........................................... 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4

8

1

Tie Rod End 4

Loosen the four nuts on the front wheel half turn.

2

Lift and support front of the vehicle per SAFETY section.

Fig. 6 Front Strut Replacement

Remove the wheels and brakes (Ref Wheels and Brake Removal Section on page J-2). Remove the spindle cap (item 1) using a straight blade screwdriver and plastic faced hammer (Ref Fig. 7 on page J-6). Remove the lock nut (item 2) using 1 1/8" socket. Remove the outer brake washer (item 3). Remove the bolts (item 4) using 3/4" wrench, the lock washer (item 5) and remove the bearing (item 6).

Repair and Service Manual

Page J-5

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Brake line

6

Rotor

4

3 1 2

5

Fig. 7 Bearing Replacement The installation of the bearing is the reverse of disassembly.

Tighten the hardware per torque specification table below.

Replace the front wheels as per the WHEELS AND TIRES section and lower vehicle.

Plastic faced hammer ..................................................1 Straight blade screwdriver ...........................................1 Needle nose pliers .......................................................1 Floor jack, 1 1/2 ton .....................................................1 Jack stands..................................................................2 Wheel chocks ..............................................................4 Loosen the four nuts on the front wheel half turn.

ITEM NO

TORQUE SPECIFICATIONS

2

135 - 165 ft.lbs (183 - 224 Nm)

4

36 - 44 ft.lbs (49 - 60 Nm)

Ball Joint Replacement Never use a ball joint separator (Pickle fork), it will damage the joint.

Tool List

Qty. Required

Ratchet, 1/2" drive ....................................................... 1 Torque wrench, 1/2" drive, 165 ft. lbs capacity ............ 1 Impact wrench, 1/2" drive ............................................ 1 Extension, 6", 1/2" drive .............................................. 1 Socket, 3/4", 1/2" drive ................................................ 1 Socket, 1 1/8" .............................................................. 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Allen wrench, 9mm, 1/2" drive..................................... 1 Wrench, 13mm ............................................................ 1 Wrench, 9/16".............................................................. 1 Wrench, 11/16" ............................................................ 1

Page J-6

Lift and support front of the vehicle per SAFETY section.

Remove the wheels (Ref Wheels and Brake Removal Section on page J-2). Remove the spindle cap (item 1) using a straight blade screwdriver and plastic faced hammer (Ref Fig. 8 on page J-7). Remove the lock nut (item 2) using a 1 1/8" socket. Remove the outer washer (item 3). Remove the tie rod end (Ref Tie Rod End Removal Section on page J-2). Tap off the control arm end from the steering knuckle (Ref Control Arm (Knuckle End Removal) Section on page J-3). Pull the steering knuckle (item 4) slightly outward for more accessibility. Remove the bolts (item 5) using 13mm wrench and the washer (item 6). Remove the ball joint (item 7).

The installation of the ball joint is the reverse of disassembly.

Tighten the hardware per torque specification table below.

Repair and Service Manual

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Wrench, 3/4"................................................................ 1 Wrench, 9/16".............................................................. 1 Plastic faced hammer.................................................. 1 Straight blade screwdriver ........................................... 1 Needle nose pliers....................................................... 1 Pry bar......................................................................... 1 Floor jack..................................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Loosen the four nuts on the front wheel half turn.

Lift and support front of the vehicle per SAFETY section.

Remove the wheels (Ref Wheels and Brake Removal Section on page J-2). Remove the tie rod end (Ref Tie Rod End Removal Section on page J-2). Tap off the control arm end from the steering knuckle (item 4) (Ref Control Arm (Knuckle End Removal) Section on page J-3).

Remove the half shaft (item 2) using pry bar to separate it from the front differential (Ref Fig. 9 on page J-8).

Remove the hog ring (item 3).

4

7 1

3

The installation of the half shaft is the reverse of disassembly using new cotter pins and new hog rings.

Replace the front wheels as per the WHEELS AND TIRES section and lower vehicle.

2

6 5

Fig. 8 Ball Joint Replacement Replace the front wheels as per the WHEELS AND TIRES section and lower vehicle.

ITEM NO

TORQUE SPECIFICATION

2

135 - 165 ft.lbs (183 - 224 Nm)

5

13 - 15 ft.lbs (18 - 20 Nm)

Half Shaft Replacement Use a commercially available Anti-Seize compound on all splines.

Tool List

Qty. Required

Ratchet, 1/2" drive....................................................... 1 Torque wrench, 1/2" drive, 165 ft. lbs capacity............ 1 Extension, 6", 1/2" drive .............................................. 1 Socket, 9/16", 1/2" drive.............................................. 1 Allen wrench, 5/16", 1/2" drive .................................... 1

Repair and Service Manual

Page J-7

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Frame

Strut

To Steering Tie Rod End 1

2 3

Fig. 9 Half Shaft Replacement

Front Drive Shaft Removal Use a commercially available Anti-Seize compound on Shaft and Bearing splines.

Tool List

Qty. Required

Wheel chocks .............................................................. 4 Torque wrench, 1/2" drive, ft. lbs ................................. 1 Impact wrench, 1/2" drive ............................................ 1 Impact socket, 1/2", 1/2" drive ..................................... 1 Ball peen hammer ....................................................... 1 Park the vehicle on a flat surface. Engage park brake.

Install chocks in front and behind each front wheel.

Remove bolts (item 1) using 1/2" impact socket (Ref Fig. 10 on page J-8). Remove the washers (item 2). Compress front drive shaft (item 3) and remove it from underside of the vehicle.

The installation of the front drive shaft is the reverse of disassembly. Use new locking bolts.

Page J-8

Repair and Service Manual

Front of the Vehicle

1

2 3

Fig. 10 Front Drive Shaft Removal

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tighten the hardware per torque specification table below.

ITEM NO 1

TORQUE SPECIFICATIONS

Installation of front differential guard is the reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table given below.

21 - 25 ft. lbs (28 - 34 Nm)

Front Differential Guard Replacement Tool List

Fig. 11 on page J-9). Remove the front differential guard (item 3).

ITEM NO

TORQUE SPECIFICATION

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Socket, 9/16", 3/8" drive.............................................. 1 Wrench, 9/16" ............................................................. 1 Wheel chocks.............................................................. 2

Front of Vehicle

1

1

26 - 31 ft. lbs (35 - 42 Nm)

STEERING Steering Assembly Replacement Tool List

Qty. Required

Torque wrench, 1/2" drive, 165 ft. lbs capacity ............ 1 Impact wrench, 1/2" drive ............................................ 1 Impact socket, 11/16", 1/2" drive ................................. 1 Impact socket, 3/4", 1/2" drive ..................................... 1 Wrench, 13mm ............................................................ 1 Wrench, 3/4"................................................................ 1 Needle nose pliers....................................................... 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Loosen the four nuts on the front wheels half turn.

Lift and support front of the vehicle per SAFETY section.

Remove the wheels (Ref Wheels and Brake Removal Section on page J-2). Remove the tie rod end from the steering knuckle (Ref Tie Rod End Removal Section on page J-2). Remove the bolt (item 1) using a 13mm wrench (Ref Fig. 12 on page J-10). Remove washer (item 2). Remove steering shaft (item 3). Remove the bolt (item 4), two washers (item 5), and the nut (item 6).

Remove the bolt (item 7), washer (item 8), and nut (item 9). Remove the steering assembly.

2

The installation of the steering assembly is the reverse of disassembly.

3

Fig. 11 Front Differential Guard Replacement

Tighten the hardware per torque specification table below.

Park the vehicle on a level surface, engage park brakes.

Remove the keys. Place wheel chocks in front of and behind the rear wheels to secure the vehicle. Hold the lock nuts (item 1) using 9/16" wrench and remove the bolts (item 2) using 9/16" socket from the subframe (Ref

Repair and Service Manual

Page J-9

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

3

7

1 2 4 5

8

9

6

Fig. 12 Steering Assembly Replacement Replace the front wheels per WHEELS AND TIRES section and lower vehicle.

ITEM NO

TORQUE SPECIFICATION

1

13 - 18 ft.lbs (18 - 24 Nm)

6

13 - 15 ft.lbs (18 - 20 Nm)

9

13 - 15 ft.lbs (18 - 20 Nm)

Page J-10

Steering Wheel Replacement Do not center punch steering shaft.

Using 1/16" drill bit, drill a small indent in the steering shaft to locate steering wheel puller.

When installing steering wheel, apply commercially available Anti-Seize compound on all splines.

Tool List

Qty. Required

Ratchet, 1/2" drive .......................................................1 Torque wrench, 1/2" drive, 165 ft. lbs capacity ............1 Socket, 3/4", 1/2" drive ................................................1 Adjustable wrench, 10" ................................................1 Drill (electric or air), 3/8" ..............................................1 Drill bit, 1/16" ...............................................................1 Straight blade screwdriver (small) ...............................1 Steering wheel puller ...................................................1

Repair and Service Manual

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Remove the steering wheel cover (item 1) using screw driver (Ref Fig. 13 on page J-11). Remove lock nut (item 2) using 3/4" socket. Remove the washer (item 3). Use steering wheel puller to separate the steering wheel (item 4) from the steering shaft.

Wrench, 13mm ............................................................ 1 Remove the steering wheel (item 1) (Ref Steering Wheel Replacement Section on page J-10) (Ref Fig. 14 on page J-11). Remove the bolt (item 2) using 13mm wrench.

Remove washer (item 3). Hold the bolt head (item 4) and loosen the nut (item 5) using 9/16" wrench. Slide out the steering column (item 6).

2 3 1

4

5

1

4 6

2 3

Fig. 13 Steering Wheel Replacement When installing a new steering wheel, assemble the steering wheel using new lock nut and then replace the cover.

The installation of the steering wheel is the reverse of disassembly.

Fig. 14 Steering Column Replacement

Tighten the hardware per torque specification table below.

The installation of the steering column is the reverse of disassembly.

ITEM NO 2

TORQUE SPECIFICATION 9 - 11 ft.lbs (12 - 15 Nm)

ITEM NO

Steering Column Replacement Tool List

Tighten the hardware per torque specification table below.

Qty. Required

TORQUE SPECIFICATION

2

13 - 18 ft.lbs (18 - 24 Nm)

5

25 - 30 ft.lbs (34 - 41 Nm)

Ratchet, 3/8" drive....................................................... 1 Ratchet, 1/2" drive....................................................... 1 Torque wrench, 1/2" drive, 165 ft. lbs capacity............ 1 Socket, 7/16", 3/8" drive.............................................. 1 Socket, 9/16", 1/2" drive.............................................. 1 Allen wrench, 3/16", 3/8" drive .................................... 1 Wrench, 9/16" ............................................................. 1

Repair and Service Manual

Page J-11

FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

MAINTENANCE Wheel Alignment

Tool List

Attempting to turn the tie-rod with wire tie on the boot, will damage it.

Qty. Required

Wrench, 9/16".............................................................. 1 Wrench, 11/16" ............................................................ 1 Needle nose pliers....................................................... 1 Tape measure.............................................................. 1 Chalk ....................................................................... A/R Diagonal cutter ............................................................ 1 Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4

To adjust the wheel alignment, cut-off wire tie on boot at steering unit using diagonal cutters. Pull boot away from housing and hold tie rod on flat groove using 9/16" wrench. Loosen jam nut using 11/16" wrench. Turn the tie rod so that the wheel moves in or out as desired. Position boot over housing. Use a new wire tie to fasten the boot being sure that the wire tie is located over the groove in the housing.

Test drive the vehicle and confirm that the steering wheel is correctly centered. If not, remove steering wheel and rotate it to correct position.

Lift and support front of vehicle per SAFETY section.

Rotate each wheel and scribe or chalk a line around the circumference of the tire at the center of the thread pattern. Lower the vehicle and roll it forward approximately 5 ft. in order to allow the tires to take their normal running position.

Measure the distance between the chalk lines at both the front and rear of the tires. The measurement taken at the front of the tire should be between 0"- 1/4" (0mm-6mm) more than the rear (TOE OUT) (Ref Fig. 15 on page J12).

Front of Vehicle 0" — 1/4" more than rear

Rear VIEW FROM UNDERSIDE OF VEHICLE

Fig. 15 Wheel Alignment

Page J-12

Repair and Service Manual

FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE

K PAGE NO.

GENERAL ........................................................................................................................................K - 2 FUEL ................................................................................................................................................K - 2 FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT...................................................K - 2 Fuel Lines and Filter ..............................................................................................................K - 2 Fuel Pump .............................................................................................................................K - 3 Fuel Tank...............................................................................................................................K - 3 Choke System .......................................................................................................................K - 4 Choke Operation ...................................................................................................................K - 4 Choke Cable Replacement....................................................................................................K - 4 Carburetor Cleaning ..............................................................................................................K - 5 PROLONGED STORAGE................................................................................................................K - 5

LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4

Fuel System Components .....................................................................................................K - 1 Fuel Lines And Filter Replacement .......................................................................................K - 3 Fuel Tank Replacement ........................................................................................................K - 3 Choke Cable Replacement ...................................................................................................K - 4

Repair and Service Manual

Page K-i

FUEL SYSTEM

Notes:

Page K-ii

Repair and Service Manual

FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

K

(APPROVED

Fuel Line From Tank

Fuel Filter Fuel Level Gauge Fuel Pump

Fuel Hose Pulse Line From Engine

5

To Carburetor

Fuel Line To Fuel Filter Fuel Cap

Vent Line From Carburetor

Fig. 1 Fuel System Components

Repair and Service Manual

Page K-1

FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

GENERAL In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that is removed must always be installed in its original position unless otherwise specified. Nonspecified torque specifications are as shown in the table contained in Section A.

The fuel system consists of a fuel tank, fuel lines, fuel filter, fuel pump, and carburetor. Refer to HONDA® GX610, 18 HP Engine Repair Manual for engine, obtainable from Honda dealer.

FUEL To prevent serious personal injury or death resulting from a possible explosion, do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.

Always wear safety glasses while refueling to prevent possible eye injury from gasoline or gasoline vapor.

!

!

When refueling, inspect the fuel cap for leaks or breaks that could result in fuel spillage.

Do not over fill the fuel tank. Allow adequate space for the expansion of gasoline. Leave at least 1" (2.5 cm) space below bottom of filler neck.

Do not handle fuel in an area that is not adequately ventilated. Do not permit anyone to smoke in an area where vehicles are being fueled.

FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT

!

!

or fire: Check for clogged or kinked hoses. Clogged or kinked carburetor hoses are not only detrimental to the proper operation and performance of the vehicle, but can also be a safety hazard in the case of fuel leaking on a hot engine.

Tests that involve fuel flow should be avoided if at all possible. If a test to determine fuel/vapor presence or flow is required, the ignition system must be disabled. Ground the magneto in order to prevent an ignition spark that could ignite the fuel/ vapor. Never permit smoking or an open flame in an area that contains fuel/vapor. Clean up all fuel spills immediately.

Never attempt to repair a damaged or leaking fuel tank. It must be replaced.

Disconnect the negative (-) battery cable before servicing fuel system.

The fuel filter, tank, hoses and cap should be checked frequently for leaks or signs that the cap vent or filter has become clogged. The filter should be replaced periodically. See ‘Periodic Service Schedule’ in Section A.

Fuel Lines and Filter The filter is marked with a flow direction arrow. Be sure that the arrow points

Shut off the vehicle, when fueling. towards the fuel pump.

Do not use a cell phone while fueling.

Some fuels, called oxygenated or reformulated gasoline, are gasoline blended with alcohols or ethers. Excessive amounts of these blends can damage the fuel system or cause performance problems. If any undesirable operating symptoms occur, use gasoline with a lower percentage of alcohol or ether.

Do not use gasoline which contains more than 5% Methanol.

Do not mix oil with gasoline.

The fuel tank cap is located near the passenger seat. Fill the tank with fresh, clean, automotive grade, unleaded, 87 octane (minimum) gasoline.

Page K-2

To prevent serious personal injury or death resulting from explosion

Orient direction of new fuel filter according to FLOW arrow on side of filter.

Tool List

Qty. Required

Pliers............................................................................1 Hose plug ....................................................................1 Fuel is supplied to the fuel pump and carburetor through flexible fuel hoses. An in-line filter is installed in the hose between the fuel tank and fuel pump.

Move clamps (item 1) from ends of filter (item 2) and raise filter (item 2) above the fuel pump to reduce the amount of gas that will spill (Ref Fig. 2 on page K-3).

Repair and Service Manual

FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Remove the hose (item 3) coming from fuel tank first and plug. Remove filter (item 2) from hose (item 4) going to fuel pump and discard the old filter.

3 2 1

To F

ank u el T 4

To Fuel Pump

Fig. 2 Fuel Lines And Filter Replacement

Pliers ........................................................................... 1 Duct tape ................................................................. A/R Utility knife ................................................................... 1 Raise passenger seat. Release truck bed handle grip and lift the bed. Remove the fuel cap (item 1) and cover opening with duct tape (Ref Fig. 3 on page K-3). Remove the seat panel (passenger side) (item 2) and the lower side panel (item 3) (Refer Seat Panel (Passenger Side) Replacement and Lower Side Panel Replacement in BODY AND TRUCK BED chapter). Remove duct tape from tank filler opening and replace fuel tank cap (item 1). Disconnect the fuel hose (item 4) and vent tube (item 5) from the fuel tank. Disconnect the fuel gauge wires (item 6) from the tank. Remove the bolt (item 7) using 12" extension and 1/2" socket. Remove the lock washer (item 8) and washer (item 9). Remove the tank mounting strap (item 10) and remove the tank (item 11) from the vehicle.

Installation of the new filter is the reverse of disassembly.

Fuel Pump

1

Refer to HONDA® GX610, 18 HP Engine Repair Manual for engine, obtainable from Honda dealer for more details.

2 7

Fuel Tank To prevent serious injury ! ! or death resulting from explosion or fire, disconnect the battery negative (-) cable before starting any operation on fuel tank. An electrical arc from fuel gauge could ignite fuel vapor in the tank.

Do not smoke near the fuel tank. When removing the seat panel (item 2), the fuel tank cap must be removed. To reduce the chance of inhalation of gas fumes which are harmful, cover the tank opening with duct tape before removing panel.

To prevent serious injury or death resulting from explosion or fire, dispose of fuel remaining in old tank correctly. Gasoline vapor left in fuel tank is extremely flammable. Fill tank with water to help eliminate gasoline vapor.

10

8 9

3

4

5

6

11

Fig. 3 Fuel Tank Replacement Installation of the new fuel tank is the reverse of disassembly.

Clean up any fuel leakage from hose.

Tool List

Qty. Required

Ratchet, 3/8" drive....................................................... 1 Extension, 12", 3/8" drive ............................................ 2 Socket, 1/2", 3/8" drive................................................ 2

Repair and Service Manual

Page K-3

FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tighten the hardware per torque specification table given below.

ITEM NO

TORQUE SPECIFICATION

7

entire operating range. If there is any binding or sharp bends, the choke cable assembly and linkage must be inspected and parts replaced as required.

Choke Cable Replacement Tool List

8 - 11 ft. lbs. (11 - 15 Nm)

Choke System Do not attempt to lubricate the choke cable.

Lubricant tends to retain dirt on the moving parts which will cause premature deterioration of the cable.

The choke functions to make initial starting of the engine easier in cold weather conditions. The choke plate restricts the air flow into the carburetor which richens the air/fuel ratio.

Choke Operation Pull choke knob out to operate choke. Check that cable operates smoothly and that cable returns when the knob is released. The motion should be smooth throughout the

Qty. Required

Wrench, 7/16" ..............................................................1 Wrench, 7/8" ................................................................1 Straight blade screwdriver, small .................................1 Raise the seat bottom and support. Remove choke cable (item 1) from ball stud (item 2) of choke pivot plate (item 3) (Ref Fig. 4 on page K-4). Loosen jam nuts (item 4) securing choke cable (item 1) to choke bracket (item 5) using 7/16" wrench. At the driver side of the seat support panel (item 6), loosen the jam nut (item 7) securing to end of the cable and rotate the adapter retainer (item 8).

Remove the choke cable (item 1) from the vehicle.

Installation of the choke cable is the reverse of disassembly.

8

5

7 4

3 2 6

Fig. 4 Choke Cable Replacement

Page K-4

Repair and Service Manual

1

FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Carburetor Cleaning To prevent serious injury or death resulting from explosion or fire, disconnect the battery negative (-) cable.

!

!

Tool List

Qty. Required

Insulated wrench, 1/2"................................................. 1 Pliers ........................................................................... 1 To prepare for carburetor service: a) Disconnect fuel hose at fuel filter and plug ends to prevent contamination. Empty carburetor by running engine until it stops from lack of fuel. b) Disconnect negative (-) cable from battery to prevent electrical short that could ignite fuel vapor. c) Wash engine and chassis to remove dirt build-up. d) Follow carburetor removal and service procedures outlined in HONDA® GX610, 18 HP Engine Repair Manual for engine, obtainable from Honda dealer.

PROLONGED STORAGE For information on preparing vehicle for prolonged storage, refer to the GENERAL INFORMATION AND ROUTINE MAINTENANCE section.

Repair and Service Manual

Page K-5

FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page K-6

Repair and Service Manual

PAINT TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE

L PAGE NO.

PAINTING (EXCEPT FRONT COWL) ............................................................................................. L - 1 Minor Scratches..................................................................................................................... L - 1 Larger Scratches ................................................................................................................... L - 1 Complete Panel Repair ......................................................................................................... L - 1 PAINTING (FRONT COWL ONLY) .................................................................................................. L - 2 Procedure .............................................................................................................................. L - 2

Repair and Service Manual

Page L-i

PAINT

Notes:

Page L-ii

Repair and Service Manual

PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

PAINTING (EXCEPT FRONT COWL) Follow the paint manufacturer’s recommendations for specific painting procedures and information.

L

touch-up paint.

III.

Apply spray touch up paint in light even overlapping strokes. Multiple coats may be applied to provide adequate coverage and finish. Always remember to shake the can for a minimum of one minute to mix the paint and achieve the best color match.

IV.

After painting, allow to dry overnight. Smooth the mask lines using 400 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired. Use a polishing compound (3M Finesse or automotive grade) to renew gloss and to further blend and transition newly painted surface.

Minor Scratches

V.

Clean with alcohol and dry.

For minor scratches, the manufacturer suggests the following steps be taken to repair the Durashield™ body:

VI. (Optional but recommended) Follow this process with clear coat to renew and protect depth of finish.

I.

Thoroughly clean the surface to be repaired with alcohol and dry.

VII. Wax or polish with Carnauba base product, available at any automotive parts distributor.

II.

Touch up damaged area with sequential coats (two coats minimum recommended, allowing 30 - 45 minutes between coats, increasing to 45 - 60 minutes in higher humidity) using brush on touch-up paint, until coating layer is visible, slightly above the surface of the part.

Complete Panel Repair

!

!

All pa inti ng m ust be done in an area with adequate ventilation to safe-

ly disperse harmful vapors.

Wear eye protection and respirator, following manufacturers instructions to protect from overspray and air borne mist.

Provide protection from overspray to vehicle and surrounding area.

III.

Use 400 grit “wet” sand paper to blend touch up area level with the rest of the part being repaired.

Use a polishing compound (3M Finesse or automotive grade) to renew gloss and to further blend and transition newly painted surface.

IV.

Clean with alcohol and dry.

V.

(Optional but recommended) Follow this process with clear coat to renew and protect depth of finish.

VI. Wax or polish with Carnauba base product, available at any automotive parts distributor.

Larger Scratches For larger scratches, the manufacturer suggests the following steps be taken to repair the Durashield™ body: I. II.

Thoroughly clean the surface to be repaired with alcohol and dry.

Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type

In situations where large panels or areas must be painted, touch up paint is not recommended. In such cases professional painting or panel replacement is called for. The manufacturer suggests body panel replacement be considered as a cost effective alternative to painting. If the decision to repaint is taken, the task can be accomplished by any paint and body shop with experience in painting ‘TPE’ panels. TPE is a common material in modern automobile bodies and all body shops should be familiar with the materials and processes required.

The finish will include an application of a primer coat, a base color coat and a clear coat. The manufacturer does not supply these materials due to the variety of paint manufacturers and the preferences of the individual painter.

Most paint manufacturers can perform a computer paint match to assure accurate color matching.

PAINTING (FRONT COWL ONLY) Procedure Inspect the entire part thoroughly for all defects.

Bubbles Or Voids

• Remove bubble or void with carbide burr tool.

• Sand out to one inch beyond the defect with 280 grit sandpaper.

Repair and Service Manual

Page L-1

PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

• Blow off the area to be filled with clean dry com• • •

pressed air.

Fill the defect with Adtech Ultra White filler. a) Mix to manufacturer’s specification. b) Allow to cure (set-up).

Finish sand the filled area to a smooth level finish with 280 grit sandpaper.

Blow off the repaired part with clean dry compressed air.

e) Allow parts to air-dry for approximately 30 minutes, before part removal from the spray booth. f) Allow parts to cure for 24 hours at room temperature before buffing (as needed).

Spot Paint Parts

• Sanding

Gouges Or Deep Scratches

• Sand out to one inch beyond the defect with 280 grit sandpaper.

• Blow off the area to be filled with clean dry compressed air.

•

• Fill the defect with Adtech Ultra White filler.

• •

a) Mix to manufacturer’s specification. b) Allow to dry (set-up).

Finish sand the filled area to a smooth level finish with 280 grit sandpaper.

Blow off the repaired part with clean dry compressed air.

Post Painted Parts (Entire Surface)

•

• Priming

•

• •

a) Prime all repaired areas with Krylon Tough Coat Industrial Primer. b) Apply 3 to 4 medium wet coats. c) Allow the primer to dry for thirty minutes at 70 F. Final sanding a) Finish sand the repaired-primed area, paint peel, light paint, light scratches and/ or heavy paint to a smooth level finish with 400 grit sandpaper. b) Blow off the repaired part with clean dry compressed air. c) Sand the entire surface of the part with 3M brand Red Scotch Brite pad. d) Blow off the repaired part with clean dry compressed air.

Blow off and Tack Rag parts.

Finish paint parts a) Mix Valspar brand product #KPG0064 2component polyurethane paint to manufacturer’s specifications. b) Paint: reactor. c) Paint ratio: 1.5:1 (paint: reactor). d) Apply two medium wet coats of Valspar brand product # KPG0064 in the spray booth to the entire part.

Page L-2

•

•

a) Finish sand the repaired-filled area, paint peel, light paint, light scratches and/or heavy paint to a smooth level finish with 400 grit sandpaper. b) Blow off the repaired part with clean dry compressed air.

Mask part a) Mask off part surface around the repair area. b) Leave approximately 3 to 6 inches in all directions beyond the repaired area unmasked. c) Leave a quarter inch “roll” on the tape edge adjacent to the repair area.

Priming a) Prime all repaired areas with Krylon Tough Coat Industrial Primer. b) Apply 3 to 4 medium wet coats. c) Allow the primer to dry for thirty minutes at 70 ° F. Final Sanding a) Finish sand the repaired-primed area, paint peel, light paint, light scratches and/ or heavy paint to a smooth level finish with 400 grit sandpaper. b) Blow off the repaired part with clean dry compressed air. c) Sand one to three inches beyond the surface sanded in step ‘a’ above with 800 grit sandpaper. d) Blow off the repaired part with clean dry compressed air.

Wash a) Hand wipe repair area with Dupont brand 3901s “Final Clean Prepaint Solvent Wash” on a clean paper towel.

Finish Paint Repair Area

• Mix Valspar brand Product #KPGOO64 2-component polyurethane paint to manufacturer’s specifications. a) Paint: reactor. b) Paint ratio: 1.5:1 (paint: reactor).

Repair and Service Manual

PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

• In the spray booth

•

a) Apply two to four wet mils of Valspar brand product #KPGOO64 to the repaired area. b) Remove all tape around the repaired area immediately after third coat of Valspar brand Product #KPGOO64 is applied. c) Within five minutes of application of Valspar brand product #KPG0064 paint apply one medium-wet coat of Dupont brand #7601 “Chromaclear Blender” if necessary. d) Overlap repair paint and In-mold coating. e) Overlap is 1-2 inches on wet repair and 6-8 inches on the dry (In-mold coating) outer edges of the repair area. f) Let blend flash for 30-60 seconds and then apply a second medium-wet coat, feathering at the extremes of the application area.

Buffing a) If necessary, 24 hours after painting, the entire repair area is buffed with a pneumatic buffing wheel. b) Use a foam pad and 3M brand Perfect-it rubbing #05973 compound. c) Use a new foam pad and 3M brand Perfect-it polishing #05995 compound. d) Finish with 3M #05997 (p/n, 34409) Perfect-it hand glaze.

Repair and Service Manual

Page L-3

PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page L-4

Repair and Service Manual

REAR AXLE AND SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE

M PAGE NO.

REAR AXLE .................................................................................................................................... M - 2 Maintenance ......................................................................................................................... M - 2 Checking Lubrication Level .................................................................................................. M - 2 Solenoid Replacement ......................................................................................................... M - 2 Rear Drive Shaft Removal.................................................................................................... M - 3 Rear Differential Guard Replacement .................................................................................. M - 3 Rear Axle Replacement........................................................................................................ M - 4 REAR SUSPENSION...................................................................................................................... M - 6 General................................................................................................................................. M - 6 Shock Absorber Removal..................................................................................................... M - 6 Rear Spring Removal ........................................................................................................... M - 6

LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8

Rear Axle And Suspension Components ............................................................................. M - 1 Checking Lubrication Level .................................................................................................. M - 2 Solenoid Replacement ......................................................................................................... M - 3 Rear Drive Shaft Removal.................................................................................................... M - 3 Rear Differential Guard Replacement .................................................................................. M - 3 Rear Axle Components ........................................................................................................ M - 5 Shock Absorber Removal..................................................................................................... M - 6 Rear Spring Removal ........................................................................................................... M - 7

Repair and Service Manual

Page M-i

REAR AXLE AND SUSPENSION

Notes:

Page M-ii

Repair and Service Manual

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Shock Absorber

M

Leaf Spring Plate

Rear Shackle

Rear Leaf Spring

Solenoid

Shock Mounting Rear Drive Shaft

Parking Brake Cable

Rear Brake Line

'U' - Bolt Rear Differential Rear Axle

Fig. 1 Rear Axle And Suspension Components

Repair and Service Manual

Page M-1

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

REAR AXLE

Solenoid Replacement

Maintenance The rear axle is provided with a lubricant level fill plug located on the passenger side at rear of housing. Unless leakage is evident, an annual lubricant check is sufficient.

Checking Lubrication Level Tool List

Qty. Required

Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs. ................................ 1 Socket, 7/16", 3/8" drive .............................................. 1 Hose ............................................................................ 1 Funnel ......................................................................... 1 Clean area around fill plug (Ref Fig. 2 on page M-2).

Remove fill plug (The correct lubricant level is just below the bottom of the threaded hole). If lubricant is to be added, remove the fill plug and add lubricant (80 - 90 GEAR LUBE) using a funnel and hose. Add lubricant slowly until lubricant starts to seep from the fill plug.

Install the fill plug. In the event that the lubricant is to be replaced, a drain plug is provided at the bottom of the differential housing. Capacity of axle is 17 oz. (500 - 525 milliliters).

Check solenoid for free actuation after assembly.

Drain hole in the protective boot (solenoid) should be located towards bottom of the vehicle after assembly.

Tool List

Qty. Required

Floor jack, 1 1/2 ton .....................................................1 Jack stands..................................................................2 Wheel chocks ..............................................................4 Ratchet, 3/8" drive .......................................................1 Torque wrench, 3/8" drive, ft. lbs. ................................1 Socket, 10mm, 3/8" drive.............................................1 Socket, 7/16", 3/8" drive ..............................................1 Allen wrench, 1/8"........................................................1 Wrench, 3/8" ................................................................1 Needle nose pliers .......................................................1 Park the vehicle on a flat surface. Engage park brake.

Install chocks in front and behind each rear wheel. Raise passenger seat. Release truck bed handle and lift the bed. The solenoid (item 1) can be accessed from the top.

Disconnect wiring harness from the solenoid (item 1).

Remove the screw (item 2) and the washer (item 3) connecting the solenoid (item 1) to the rear differential (Ref Fig. 3 on page M-3). Hold the shoulder screw (item 5) using Allen wrench 1/8" and remove lock nut (item 4).

Remove the solenoid (item 1). Remove the screw (item 7) and the washer (item 8) which connects differential lock linkage (item 6) and solenoid (item 1).

The installation of the solenoid is the reverse of disassembly using new lock nuts.

Check/Fill Plug Drain Plug

Front of the Vehicle

Drain Plug

Fig. 2 Checking Lubrication Level

Page M-2

Repair and Service Manual

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

2

2

3

1 3

6 4

1

Front of the Vehicle

7 8 5

Front of the Vehicle

Fig. 4 Rear Drive Shaft Removal Tighten the hardware per torque specification table below.

ITEM NO

TORQUE SPECIFICATIONS

1

21 - 25 ft. lbs (24 - 34 Nm)

Fig. 3 Solenoid Replacement Tighten the hardware per torque specification table below.

ITEM NO 2

TORQUE SPECIFICATIONS

Rear Differential Guard Replacement Tool List

Qty. Required

Open end wrench, 9/16".............................................. 1 Torx bit screwdriver T- 45 ............................................ 1

4- 6 ft. lbs (5 - 8 Nm)

Rear Drive Shaft Removal Use a commercially available Anti-Seize compound on Shaft and Bearing splines.

Tool List

Qty. Required

Wheel chocks.............................................................. 4 Torque wrench, 1/2" drive, ft. lbs ................................. 1 Impact wrench, 1/2" drive............................................ 1 Impact Socket, 1/2", 1/2" drive .................................... 1 Ball peen hammer ....................................................... 1

1

Park the vehicle on a flat surface. Engage park brake.

Install chocks in front and behind each rear wheel.

Release truck bed handle and lift the bed. The rear drive shaft (item 3) can be accessed from the top. Remove bolts (item 1) and washers (item 2) using 1/2" impact socket (Ref Fig. 4 on page M-3). Compress rear drive shaft (item 3) and remove it.

The installation of the rear drive shaft is the reverse of disassembly. Use new locking bolts.

2

3

Fig. 5 Rear Differential Guard Replacement

Repair and Service Manual

Page M-3

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Hold the nut (item 1) using open end wrench and remove the screw (item 2) using torx bit screwdriver (Ref Fig. 5 on page M-3). Remove the rear differential guard (item 3).

The installation of the rear differential guard is the reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table below.

ITEM NO 2

TORQUE SPECIFICATIONS 18 - 22 ft. lbs (24 - 30 Nm)

Rear Axle Replacement To reduce the possibility ! ! of severe personal injury or death, follow the lifting procedure in Section B of this manual. Place wheel chocks in front and behind each wheel not being raised and check the stability of the vehicle on the jack stands before starting any repair procedure.

Never work on a vehicle that is supported by a jack alone.

To reduce possibility of personal injury while removing rear axle, be sure to support differential when removing the ‘U’ bolts.

Dispose of used brake fluid properly. Never reuse old fluid.

Allow brake fluid to drain into pan for disposal. Whenever hydraulic brake line is removed, bleed the brake at the end of installation.

Tool List Qty. Required Floor jack, 1 1/2 ton..................................................... 1 Jack stands ................................................................. 2 Wheel chocks .............................................................. 4 Ratchet, 3/8" drive ....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Impact wrench, 1/2" drive ............................................ 1 Socket, 1/2", 3/8" drive ................................................ 1 Deep well socket, 9/16", 1/2" drive.............................. 1 Impact socket, 1/2", 1/2" drive ..................................... 1 Allen wrench, 1/8" ....................................................... 1 Wrench, 9/16".............................................................. 1 Wrench, 3/4"................................................................ 1 Box end wrench, 3/8" .................................................. 1

Page M-4

Ball peen hammer .......................................................1 Straight blade screw driver ..........................................1 Pliers............................................................................1 Needle nose pliers .......................................................1 Drain Pan.....................................................................1 Thread locking sealant ............................................. AR Anti-seize compound ................................................ AR Loosen the four nuts on the rear wheels half turn.

Lift and support the vehicle per SAFETY section.

Remove the four rear wheel nuts and remove the wheel.

Release truck bed handle and lift the bed. Remove the cotter pins (item 1), clevis pins (item 2) and retaining rings (E - rings) (item 3) from the sub frame brackets using needle nose pliers (Ref Fig. 6 on page M-5). Disconnect the park brake cables.

Remove banjo bolts (item 4) and copper gaskets (item 5). Disconnect hydraulic brake lines (item 6) at backing plates. Remove brake lines (item 6).

Hold the bolt (item 7) using 9/16" wrench and remove lock nut (item 8) using 9/16" socket (Ref Fig. 6 on page M-5). Remove bottom end of the shock absorber (item 9). Remove the solenoid (item 10) (Ref Solenoid Replacement Section on page M-2). Remove the locking bolt (item 11) on the rear drive shaft (item 12) using 1/2" impact socket.

Place floor jack under center section of rear axle and raise it just enough to take weight off spring. Support both rear axle and frame properly. Remove lock nuts (item 13) using 9/16" deep well socket, remove washers (item 14) and ‘U’ bolts (item 15). Remove leaf spring plate (item 16) and shock mounting bracket (item 17).

Lower the rear axle (item 18) and pull it out from under side of the vehicle.

The installation of the rear axle is the reverse of disassembly using new locking bolts and new lock nuts.

Apply anti-seize compound to all splines.

Replace the rear wheels per WHEELS AND TIRES section and lower vehicle.

Bleed brake system before installing load bed. See HYDRAULIC BRAKES section.

Repair and Service Manual

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

3 2

1 Park Brakes

6 13 5

16

14

9

4 9

Hydraulic Brakes 7 8

17 10 12

11

15 18

Fig. 6 Rear Axle Components

Repair and Service Manual

Page M-5

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tighten the hardware per torque specification table below.

ITEM NO

TORQUE SPECIFICATIONS

4

11 - 14 ft. lbs (15 - 19 Nm)

8

16 - 20 ft. lbs (22 - 27 Nm)

11

21 - 25 ft. lbs (28 - 34 Nm)

13

16 - 20 ft. lbs (22 - 27 Nm)

2 3

1

REAR SUSPENSION In the following text, there are references to removing/installing bolts, etc. Additional hardware (nuts, washers, etc.) that are removed must always be installed in its original positions unless otherwise specified.

Non-specified torque specifications are shown in the table contained in Section A.

General The rear suspension is the connecting member between rear axle and main frame. It consists of the rear axle, rear springs, shock absorbers and shock/stop mounts mounted on to the main frame.

Change the shock absorbers one at a time.

Qty. Required

Wheel chocks .............................................................. 4 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Deep well socket, 9/16", 3/8" drive.............................. 1 Wrench, 9/16".............................................................. 1 Ball peen hammer ....................................................... 1 Park the vehicle on a flat surface. Engage park brake.

Install chocks in front and behind each rear wheel.

Release truck bed handle and lift the bed. The shock absorber (item 3) can be accessed from the top. Hold the bolt (item 1) using 9/16" wrench and remove lock nut (item 2) using 9/16" socket (Ref Fig. 7 on page M-6).

Remove the shock absorber (item 3).

The installation of the shock absorber is the reverse of disassembly using new lock nuts.

Page M-6

Tighten the hardware per torque specification table below.

ITEM NO

Shock Absorber Removal

Tool List

Fig. 7 Shock Absorber Removal

2

TORQUE SPECIFICATIONS 16 - 20 ft. lbs (22 - 27 Nm)

Rear Spring Removal To reduce the possibility of personal injury or death, follow the lifting procedure in section B of this manual. Place wheel chocks in front and behind the front wheels and check the stability of the vehicle on the jack stands before starting any repair procedure. Never work on a vehicle that is supported by a jack alone.

!

!

To prevent injury caused by the broken socket, use only socket designed for impact wrench use. Never use a conventional socket.

When lifting the rear axle with the jack, be sure to lift on the axle tube flanges.

NEVER lift with jack against the aluminum housing.

Repair and Service Manual

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings If both springs are to be replaced and the rear axle is not to be removed, it is important to remove and replace one spring at a time. Springs must be replaced in sets. Never replace just one.

Tool List

Qty. Required

ITEM NO

TORQUE SPECIFICATIONS

2

8 -10 ft. lbs (11 - 15 Nm)

3

16 - 20 ft. lbs (22 - 27 Nm)

Floor jack, 1 1/2 ton .................................................... 1 Jack stands ................................................................. 4 Wheel chocks.............................................................. 4 Ratchet, 1/2" drive....................................................... 1 Torque wrench, 3/8" drive, ft. lbs ................................. 1 Impact wrench, 1/2" drive............................................ 1 Deep well socket, 9/16", 3/8" drive.............................. 1 Deep well socket, 3/4", 1/2" drive................................ 1 Impact socket, 9/16", 1/2" drive................................... 1 Wrench, 9/16" ............................................................. 1 Wrench, 3/4" ............................................................... 1 Needle nose pliers ...................................................... 1

1

7

3 46

2

Loosen the four nuts on the rear wheels half turn.

Install wheel chocks in front and behind each front wheel.

Lift the rear of the vehicle until the tires clear the ground.

Place jack stands under the rear of the frame as shown in the LIFTING PROCEDURE in Section B of this manual. Put the floor jack at the center of rear differential being careful to locate the jack on the axle tube flanges, lift it and place the two jack stands just inboard of the spring pads and slightly below the rear axle tubes. The jack stands are to prevent the rear axle from falling when the rear axle is lowered from the rear springs. Lower the floor jack. Ensure stability of the vehicle. Remove wheel lug nuts using 3/4" impact socket (Refer WHEELS AND TIRES section for wheel lug nuts torque specification).

Remove the rear wheels.

5

Fig. 8 Rear Spring Removal

Hold the rear lower shackle and front spring bolts (item 1) using 3/4" deep well socket and remove the lock nuts (item 2) using 3/4" wrench (do not remove bolts at this time) (Ref Fig. 8 on page M-7). Remove the nuts (item 3) using 9/16" deep well socket, 3/8" drive, the washers (item 4) and the ‘U’ bolts (item 5). Remove the leaf spring plate (item 6) and allow the rear axle tube to rest on the jack stand. Remove the bolts (item 1) and the rear spring (item 7).

The installation of the rear spring is the reverse of disassembly using new lock nuts.

Tighten the hardware per torque specification table below.

Replace the rear wheels per WHEELS AND TIRES section and lower vehicle.

Repair and Service Manual

Page M-7

REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page M-8

Repair and Service Manual

SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE

N PAGE NO.

ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE ................................................... N - 2 System Operation................................................................................................................. N - 2 Governor Operation.............................................................................................................. N - 2 General Cable Adjustment Procedure.................................................................................. N - 2 Governor Compression Spring Adjustment .......................................................................... N - 3 Accelerator/governor Cable Adjustment............................................................................... N - 3 Accelerator Pedal Replacement ........................................................................................... N - 4 ROAD TEST.................................................................................................................................... N - 5 TROUBLESHOOTING .................................................................................................................... N - 5

LIST OF ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5

Accelerator and Governor System ....................................................................................... N - 1 Cable Adjustment ................................................................................................................. N - 2 Governor Compression Spring Adjustment.......................................................................... N - 3 Accelerator/Governor Cable Adjustment.............................................................................. N - 4 Accelerator Pedal Replacement........................................................................................... N - 4

Repair and Service Manual

Page N-i

SPEED CONTROL

Notes:

Page N-ii

Repair and Service Manual

SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

N

Accelerator Pedal Return Spring

Accelerator Pedal

Accelerator Cable Accelerator Cable/ Governor Spring Governor Extension Spring Governor Cable

Governor Bellcrank

Carburetor Throttle Lever

Transfer Case

Fig. 1 Accelerator and Governor System

Repair and Service Manual

Page N-1

SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE System Operation The linkages that control the accelerator mechanism, governor and carburetor are designed to operate as an integrated assembly. Any adjustment to one portion of the system will have an effect on the other components within the system.

When the accelerator pedal is depressed, the accelerator cable moves upwards, overcoming the resistance of the accelerator return spring (Ref Fig. 1 on page N-1).

The rear of the accelerator cable is connected to the governor lever. The other side of the governor lever is connected to the governor cable. The other end of the governor cable is attached to carburetor.

nor lever position which controls the position of the carburetor throttle plate. The compression spring provides cushioning of sudden changes in throttle linkage position to provide smooth power transmission.

General Cable Adjustment Procedure If any accelerator/governor cable adjustment is made, it is necessary to go back and perform the governor/accelerator cable adjustment again. This must be done because any adjustment made in the accelerator/governor cable will affect the governor performance.

Adjustment Nuts

Mounting Bracket

As the accelerator pedal is depressed, the accelerator cable pulls the governor lever which rotates and pulls the governor cable attached to the carburetor throttle lever.

Cable Too Long

When the accelerator cable pulls against the accelerator cable/governor spring, the spring compresses until it overcomes the resistance exerted by the governor mechanism and its extension spring. As the accelerator cable/ governor spring overcomes these forces, the governor lever moves and the motion is transferred through the governor cable to the throttle lever on the carburetor.

Ball Joint

Governor Operation

Too Short

To reduce the possibility of serious personal injury or death resulting from a loss of control by the vehicle operating above the factory specified speed, never tamper with the governor. Tampering with the governor may void the warranty.

!

!

If the governor requires service, the service must be performed by an authorized service branch or distributor.

Until the vehicle reaches its governed speed, the vehicle will continue to accelerate in direct relation to the accelerator pedal position. When the governed speed is reached, the ground speed governor contained within the transmission operates against the accelerator cable/governor spring. The accelerator cable remains in the fully open position while the governor compresses the spring as it rotates and moves the governor cable to retard the carburetor throttle lever.

Correct Lever

Fig. 2 Cable Adjustment Properly adjusted, the cable should be short enough to be slightly loose but not too short to be pulling on the lever when at rest (Ref Fig. 2 on page N-2).

It is the force of the accelerator cable/governor compression spring in response to accelerator pedal and gover-

Page N-2

Repair and Service Manual

SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

To permit proper cable adjustment, the cable length may be increased/decreased at its mounting bracket. This is accomplished by moving the cable housing forward/ backward at the bracket attachment to increase/ decrease the amount of available cable.

To decrease amount of available cable, loosen the nuts on either side of the bracket and move the cable away from the lever. Once correct length is achieved, tighten the nuts.

Pre-adjust governor compression spring (item 4) by holding governor rod (item 5) and rotating governor adjuster (item 2) until a dimension of 1 3/8" (35 mm) is achieved between the inside of the cup washers. This dimension is a starting point and may be further adjusted after a road test.

Tighten the jam nut and perform road test (Ref ROAD TEST section on page N-5).

To increase amount of available cable, loosen the nuts on either side of the bracket and allow the cable to move closer to the lever. Once correct length is achieved, tighten the nuts.

4

Governor Compression Spring Adjustment To reduce the possibility ! ! of serious personal injury or death r esulting from a loss of control by the vehicle operating above the factory specified speed, never tamper with the governor. Tampering with the governor may void the warranty.

Remove the negative (-) battery cable using an insulated wrench before adjusting governor system of the vehicle.

When connecting battery cable, pay particular attention to the polarity of the battery terminals.

Never confuse the positive and negative cables.

If the governor requires service, the service must be performed by an authorized service branch or distributor who will reseal the governor after calibration.

Hold the governor compression spring adjuster rod when turning the governor adjuster. Failure to hold the rod will cause the accelerator cable to twist which may cause premature failure.

Tool List

Qty. Required

Wrench, 3/8" ............................................................... 1 Wrench, 9/16" ............................................................. 1 Wire cutter................................................................... 1 Pliers ........................................................................... 1 Safety seal ............................................................... AR Remove negative (-) battery cable. Raise the bed and seat bottom. Cut and remove safety seal (item 1). Hold governor adjuster (item 2) and loosen the jam nut (item 3) (Ref Fig. 3 on page N-3).

5

8" 1 3/mm) (35 adjust Pre 2

1

3

Fig. 3 Governor Compression Spring Adjustment

Accelerator/governor Cable Adjustment The function of the carburetor and governor system may be impaired if no movement is evident.

Tool List

Qty. Required

Wrench, 1/2"................................................................ 2 Needle nose pliers....................................................... 1 Check to see that the accelerator cable/governor spring is preadjusted to 1 3/8" (35 mm) (Ref Fig. 3 on page N3).

Correct adjustment of the accelerator linkage will be achieved when the carburetor throttle lever is fully closed when the accelerator pedal is released and fully open when the pedal is fully depressed.

Adjust the accelerator cable (item 1) by adjusting the two nuts securing the cable to governor bracket (item 2) until the governor cable (item 3) shows slight slack at the connection to the governor lever (item 4) (Ref Fig. 4 on page N-4).

Repair and Service Manual

Page N-3

SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Never confuse the positive and negative cables.

Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from ‘shorting out’ a battery, which could result in an explosion and severe personal injury or death.

The negative (-) battery cable must be removed using insulated wrench before removing the accelerator pedal from the vehicle.

Cover the battery with a shop rag before servicing the vehicle.

1

If any adjustments or replacement are made in the accelerator pedal area, it is necessary to go back and perform the accelerator/governor cable adjustment again. This must be done because any adjustment made in the accelerator pedal area may affect the cable adjustment.

2

3

Tool List 4 5

Qty. Required

Ratchet, 3/8" drive .......................................................1 Torque wrench, 3/8" drive, ft. lbs .................................1 Deep well socket, 3/4", 3/8" drive ................................1 Wrench, 3/4" ................................................................1 Ball peen hammer .......................................................1 Needle nose pliers .......................................................1 Straight blade screwdriver ...........................................1

4

1 5

Fig. 4 Accelerator/Governor Cable Adjustment

7 2

Fully depress the accelerator pedal and check that the throttle lever (item 5) at the carburetor is opening fully.

Accelerator Pedal Replacement To prevent serious injury ! ! or death resulting from a battery explosion: When connecting battery cables, pay particular attention to the polarity of the battery terminals.

9 8 6 3

Fig. 5 Accelerator Pedal Replacement

Page N-4

Repair and Service Manual

SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Refer to SAFETY section before you start.

Park the vehicle on a level surface, engage park brake.

Remove cotter pin (item 1) using needle nose pliers and clevis pin (item 2) using ball peen hammer (Ref Fig. 5 on page N-4). Detach the accelerator cable (item 3).

Remove the extension spring (item 4) using needle nose pliers. Hold the bolt (item 5) using 3/4" wrench and remove the nut (item 6) using 3/4" deep well socket.

Remove the washer (item 7). Remove the accelerator pedal (item 8).

Installation of the accelerator pedal is the reverse of disassembly using new cotter pin and new locknut.

Inspect the bolt (item 5) for corrosion that could cause binding. Both bushings (item 9) and bolt (item 5) must be replaced with new ones if corrosion or wear is found.

Tighten the hardware per torque specification table given below.

ITEM NO 6

TORQUE SPECIFICATION 20 - 25 ft. lbs. (27 - 34 Nm)

ROAD TEST

test and adjustment procedure until the factory recommended governed speed is achieved.

Install new safety seal on governor after calibrating the vehicle.

TROUBLESHOOTING Erratic acceleration and performance that does not include a notable increase in governed speed, may indicate the need for a linkage adjustment.

Symptoms that include an increase in governed speed indicate: • Worn components in the governor system • Improper adjustment of linkage system • Loose adjustment of accelerator cable and governor cable.

Symptoms that include a decrease in governed speed indicate: • Compression spring has lost its temper and needs replacement with correct compression spring • Improper adjustment of linkage system • Loose adjustment of accelerator cable and governor cable • Worn components in the governor system.

Install the negative (-) battery cable.

Test drive the vehicle and confirm that the compression spring adjustment results in the maximum governed speed specified in the GENERAL SPECIFICATIONS section. Determine speed by measuring the time it takes to travel a known set distance with vehicle at maximum speed. Enter time and distance into this formula to calculate speed: Rate (in MPH) = (Distance in feet ÷ 5280) ÷ (Time in seconds ÷ 3600) or Rate (in KPH) = (Distance in meters ÷ 1000) ÷ (Time in seconds ÷ 3600) For example: (300 ft. ÷ 5280) ÷ (8.18 sec. ÷ 3600) = 25 MPH or (100 m ÷ 1000) ÷ (9 sec. ÷ 3600) = 40 KPH If the speed is not within the specified speed range, stop the vehicle and adjust the governor compression spring.

Tightening the spring results in a speed increase while loosening it will result in a speed decrease. Repeat road

Repair and Service Manual

Page N-5

SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page N-6

Repair and Service Manual

TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE

P PAGE NO.

ENGINE............................................................................................................................................P - 1 GASOLINE VEHICLE PERFORMANCE..........................................................................................P - 1 STARTER / GENERATOR...............................................................................................................P - 5 SUSPENSION AND STEERING......................................................................................................P - 6

Repair and Service Manual

Page P-i

TROUBLESHOOTING

Notes:

Page P-ii

Repair and Service Manual

TROUBLESHOOTING 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

'0)+0'

P

For engine troubleshooting, diagnostic and repair procedures, refer to Honda Engines Owner’s Manual 6 X 610 shipped with vehicle or 4 X 610 / 620 Engine Shop Manual.

)#51.+0' 8'*+%.' 2'4(14/#0%' Condition STARTER DOES NOT TURN

STARTER TURNS SLOWLY

Possible Cause

Correction

Weak or bad battery

Recharge or replace as necessary

Terminals are loose or corroded

Clean and retighten

Poor wiring connections

Repair or replace wire and/or connections

Faulty Ignition Switch

Repair or replace wire and/or connections

Solenoid faulty

If no audible ‘click’ is heard, check power and ground. Replace solenoid if power and ground is good

Starter terminals are loose or corroded

Tighten or clean

Leads are broken or faulty ground

Check for breaks at bend or joint.

Replace or repair leads

Field coils are open

Repair or replace

Armature coil is open

Repair or replace

Terminals are loose or corroded

Retighten or clean

Weak battery

Charge battery

Crankcase over filled with oil

Drain and fill to recommended level with approved oil

Leads are nearly broken or connections Check for any defect of leads at bend or joint. are faulty Replace leads or repair connections Mechanical problem inside starter

Check

Internal engine damage

Inspect and repair

Crankcase over filled with oil

4GRCKT CPF 5GTXKEG /CPWCN

Page P-1

TROUBLESHOOTING 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

Condition

Possible Cause

STARTER ROTATES BUT VEHICLE Weak Battery WILL NOT START OR HARD TO Corroded or loose battery connections START

POOR LOW SPEED PERFORMANCE

POOR MIDRANGE OR HIGH SPEED PERFORMANCE

Correction Recharge or replace as necessary Clean and tighten battery connections.

Apply a coat of battery protectorate to terminals

Check for adequate fuel level

Fill with correct grade gasoline to 1" (2.5 cm) below bottom of filler neck

No spark at spark plugs. Broken or disconnected spark plug wiring

Check and replace if required

Spark plugs fouled

Clean or replace

Incorrect spark plug gap/type

Set gap correctly

Fuel pump faulty

Repair or replace

Fuel line clogged or clamp loose

Clean or replace if required

Cracked or broken fuel line

Replace with new hose

Main jet blocked

Clean or replace jet

Throttle lever motion restricted

Check all linkages and repair

Dirt or water in fuel line or carburetor

Clean lines and carburetor. Replace filter

Clogged fuel filter

Check and replace if required

Engine flooded

Push choke in. Clean/or replace spark plugs

Engine fuel starved

Use choke and push in as soon as engine runs smoothly

Air intake tube is blocked

Repair or clean

Clogged air filter

Wash or replace as required

Plugged muffler or pipe

Repair or replace

Bad / Stale fuel

Drain tank and carburetor. Fill with good fuel.

Plugged gas tank vent

Clean or repair

Choke on

Push choke in

Carburetor dirty

Clean or replace

Fuel pump faulty

Repair or replace

Insufficient fuel level

Add fuel

Spark plug fouled

Clean or replace

Spark plug fouled

Clean or replace

Dirty air filter

Clean or replace

Brake(s) dragging

Perform brake maintenance

Fuel filter clogged. Carburetor malfunc- Repair or replace tion Ignition, valve malfunction

Page P-2

4GRCKT CPF 5GTXKEG /CPWCN

Repair or replace

TROUBLESHOOTING 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

Condition ENGINE OVERHEATING

REPEATED SPARK PLUG FOULING

Possible Cause

Correction

Foreign matter in cylinder fins and blow- Clean er housing Damaged blower housing or fins

Repair or replace

Damaged or plugged muffler

Repair or replace

Inadequate oil supply

Check oil system, inspect oil pump, change oil, fill to correct level

Wrong spark plug type

Replace with correct spark plug

Wrong spark plug gap

Check and adjust if required

Faulty ignition system

Check and repair if required

Poor quality gasoline

Use correct fuel, check bulk storage tank for proper storage and handling

Air leak allowing dirt to enter system

Repair

Choke sticking closed

Repair

Wrong main jet for conditions (high alti- Replace with correct altitude jet for tude operations) conditions

CARBURETOR FLOODS ENGINE

EXCESSIVE SMOKING

Inlet valve/seat dirty

Clean or replace

Fuel contamination

Clean fuel system/carburetor

Clogged air filter element

Clean or replace

Wrong oil weight

Replace with recommended oil

Dirty oil

Change

Crankcase overfilled with oil

Drain and fill to recommended level

Piston rings worn or broken

Replace

Valve adjustment

Adjust

Valves worn

Replace

Valve seals or valve guides worn

Replace

4GRCKT CPF 5GTXKEG /CPWCN

Page P-3

TROUBLESHOOTING 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

Condition BACKFIRING

Possible Cause

Correction

Loose muffler or leaking gasket

Repair

Clogged spark arrestor

Clean

Dirty Carburetor

Clean

Carburetor throttle lever motion restrict- Repair ed Carburetor throttle lever not closing fully Adjust Throttle stop preventing throttle from closing fully

Adjust

Carburetor throttle valve spring weak or Replace broken Incorrect adjustment of accelerator, governor and carburetor linkages

Adjust

Carburetor throttle lever shaft bent

Replace or rebuild carburetor

Governor torsion spring weak or broken Replace Faulty plug wires

Replace

Faulty ignition system

Check and repair if required

Clean and/or oil ERRATIC, SURGING, OR SUDDEN Governor bracket spring dragging CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm

Repair or replace

Bent governor shaft

Replace

Governor failure within the transmission Repair

Page P-4

4GRCKT CPF 5GTXKEG /CPWCN

TROUBLESHOOTING 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

56#46'4 )'0'4#614 Condition STARTER IS NOISY

BATTERY HAS TO BE RECHARGED REGULARLY

Possible Cause

Correction

Bolts are loose

Tighten to correct torque

Starter has foreign matter inside

Clean starter/generator interior

Bearings are faulty

Replace

Bearings contain foreign matter

Replace

Load (i.e. number of accessories operating Reduce load to meet generator output at one time) exceeds generator output Armature bent

Repair 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 required

Commutator is dirty with oil or dust

Clean with a cleaner and dry cloth

GENERATOR DOES NOT CHARGE Corroded or loose battery connections

Clean and tighten battery connections

Incorrect voltage regulator output

Replace

Poor voltage regulator ground connection

Repair

Open or short circuit

Repair or replace

Faulty generator

Repair generator

Field coil is shorted or broken

Repair or replace

4GRCKT CPF 5GTXKEG /CPWCN

Page P-5

TROUBLESHOOTING 4GCF CNN QH 5GEVKQP $ CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP[ RTQEGFWTG 2C[ RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU %CWVKQPU CPF 9CTPKPIU

5752'05+10 #0& 56''4+0) Condition UNEVEN TIRE WEAR

Possible Cause

Correction

Incorrect tire pressure

Inflate to recommended pressure

Improper alignment (Incorrect toe out)

Align front tires

STIFF STEERING

Damaged steering assembly

Replace

PLAY IN STEERING

Steering wheel loose

Inspect splines - replace steering wheel if required; Tighten steering wheel nut

Steering components worn

Replace

Loose wheel bearings

Replace

Steering components worn

Replace

Loose wheel bearings

Replace

Out of round tires, wheels, or brake drums

Inspect and replace if out of round

Incorrect tire pressure

Inflate to recommended pressure

Dragging wheel brakes

Service brake system

Suspension component failure

Repair

Alignment incorrect

Align

VIBRATION

STEERING PULLS TO ONE SIDE

Page P-6

4GRCKT CPF 5GTXKEG /CPWCN

WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE

R PAGE NO.

WHEEL AND TIRE SERVICE ......................................................................................................... R - 1 Tire Replacement / Repair.................................................................................................... R - 1 Wheel Installation ................................................................................................................. R - 2

LIST OF ILLUSTRATIONS Fig. 1 Wheels and Tires ................................................................................................................. R - 3

Repair and Service Manual

Page R-i

WHEELS AND TIRES

Notes:

Page R-ii

Repair and Service Manual

WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

WHEEL AND TIRE SERVICE To prevent serious personal injury caused by a broken socket, use only sockets designed for impact wrench use. Never use a conventional socket.

To prevent serious injury or death resulting from a tire explosion, never exceed inflation pressure rating on tire sidewall.

To prevent tire explosion, pressurize tire with small amount of air applied intermittently to seat beads. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing valve core.

Use caution when inflating tires. Due to the low volume of these small tires, overinflation can occur in a matter of seconds. Overinflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause personal injury or death.

!

!

Standard tires for this vehicle are uni-directional and should never be moved from one side of vehicle to the other. Driver side tires should always remain on the driver side of the vehicle. Passenger side tires should always remain on the passenger side of the vehicle.

Uni-directional tires have an arrow on the sidewall indicating direction of rotation when moving forward.

Tool List

Qty. Required

Torque wrench, 1/2" drive, ft. lbs. ................................ 1 Lug wrench, 3/4" ......................................................... 1 Impact wrench, 1/2" drive............................................ 1 Impact socket, 3/4", 1/2" drive..................................... 1 This vehicle comes standard with uni-directional tires.

Tire condition should be inspected and inflation pressures checked per Periodic Service Schedule when the tires are cool. Be sure to install the valve dust cap after checking or inflating. When removing wheels with an impact wrench, use only impact sockets. Regular sockets are not designed for impact pressures exerted by power tools.

R

Tire inflation will depend on the type of tires fitted but under no condition should inflation pressure be higher than recommended on the tire sidewall. Standard and optional tires should be inflated to pressure designated in GENERAL SPECIFICATIONS section. If pressure is not designated in GENERAL SPECIFICATIONS, inflate to pressure designated on tire sidewall. All four tires should have the same pressure for optimum handling characteristics. Do not overinflate. Due to the low volume of these small tires, overinflation can occur in a matter of seconds. Be sure to install the valve dust cap after checking or inflating.

Tire Replacement / Repair To prevent injury, be ! ! sure mounting/demounting machine is anchored to floor. Wear OSHA approved safety equipment when mounting/demounting tires.

Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.

Tires should be replaced when the center lugs of the tire have worn to 1/16” (0.1cm).

The vehicle is fitted with low 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 plug.

If the tire is flat, raise vehicle and remove wheel. Refer to ‘Lifting the Vehicle’ in Section B for proper lifting procedure and safety information. Inflate tire to maximum recommended pressure. Immerse tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufacturer’s specifications.

If the tire is to be removed or mounted, the tire changing machine manufacturer’s recommendations must be followed in order to minimize the possibility of personal injury. Be sure to position tire on wheel correctly. Arrow on tire indicates rotation when moving forward.

Position the rim to suit the side that the tire will be installed on the vehicle.

Follow all instructions and safety warnings provided by the mounting/demounting machine manufacturer.

Repair and Service Manual

Page R-1

WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Wheel Installation Do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.

It is important to follow 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. Be sure to position the wheel on hub correctly with arrow indicating direction of rotation when moving forward. Finger tighten lug nuts in a ‘cross sequence’ pattern (Ref Fig. 1 on page R-3). Then, tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in 20 ft. lbs. (30 Nm) increments following the same ‘cross sequence’ pattern.

Page R-2

Repair and Service Manual

WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Tire style may vary

Front of Vehicle

Rotat io n Valve stem is always to outside of wheel Always replace dust cap

'CROSS SEQUENCE'

1

3

4

2

Fig. 1 Wheels and Tires

Repair and Service Manual

Page R-3

WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings

Notes:

Page R-4

Repair and Service Manual

GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE

S PAGE NO.

Gasoline Powered ST 4X4 Utility Vehicle ........................................................................................S - 1

LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions...............................................................................................................S - 2 Fig. 2 Vehicle Incline Specifications ................................................................................................S - 3 Fig. 3 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance................................S - 4

Repair and Service Manual

Page S-i

GENERAL SPECIFICATIONS

Notes:

Page S-ii

Repair and Service Manual

GENERAL SPECIFICATIONS Gasoline Powered ST 4X4 Utility Vehicle

S

STANDARD EQUIPMENT: CHASSIS BODY (Front) BODY (Rear) BATTERY ENGINE

TRANSFER CASE TRANSMISSION FUEL TANK BRAKES (FRONT) BRAKES (REAR) PARK BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED STANDARD COLOR DASH PANEL TIRE TIRE PRESSURE WEIGHT (Without fuel) BED OPERATING CONTROLS & INSTRUMENTATION

Welded steel, hot-dip galvanized, front hitch receiver Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer) with Base Coat/Clear Coat Lightweight, replaceable steel panels, plastic rear fenders One 12 Volt Maintenance Free (340 CCA, 38 Minute Reserve) 18 H.P. (13.4 kW) 37.5 ci (614 cc) Twin Cylinder, Air Cooled, Overhead Valve, Replaceable Oil Filter, Replaceable Dry Cartridge Air Filter with Remote Air Intake, Transistorized Magneto, Fixed Jet Bowl Carburetor, Pulse Fuel Pump Helical geared with Forward, Reverse and Ground Speed Governor Automatic Continuously Variable Transmission (CVT) 6.7 Gallon (25.4 Liters) Tank Dual Front Wheel, Hydraulic 8" (20 cm) Disc Brakes Dual Rear Wheel, Hydraulic 6.3" (16 cm) Drum Brakes Hand Operated Lever with Indicator Light Independent with Hydraulic Struts Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack & Pinion Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold Operator & 1 Passenger 1500 lbs. (680 kg) Including Operator, Passenger, Accessories & Cargo 25 mph (40 kph) Recon Green Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 2 Drink Holders Carlisle AT489, 25 x 11 - 12 (Uni-directional) 16 - 20 psi (110 - 138 kPa) 1250 lbs. (570 kg) Rotomolded Load Bed, 40" L X 50" W X 13" H (102 X 127 X 33 cm)

Removable Key, Direction Selector, Electric Fuel Gauge, 4WD/2WD Selector with Indicator Lights, Electric Front & Rear Differential Locks with Indicator Lights, Hour Meter, Volt Meter MAXIMUM TRAILER WEIGHT 1500 lbs. (680 kg)

Specifications subject to change without notice

Repair and Service Manual

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GENERAL SPECIFICATIONS

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40" (102 cm)

50" (127 cm)

107" (272 cm)

18 in.

11.5 in.(46 cm) (29 cm) 50" (127 cm) 31.5" (80 cm) 16" (40.6 cm) Front 43 3/8" (110 cm) Rear 43 3/4" (111 cm)

9 1/2" (24 cm) Clearance At Lowest Point On Frame

76" (193 cm)

Fig. 1 Vehicle Dimensions

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Repair and Service Manual

8 3/8" (21.3 cm) Clearance At Lowest Point Of Vehicle (On Rear Axle) (No Skid Plate)

GENERAL SPECIFICATIONS

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Maximum Recommended Ramp Grade 25% or 14° Max.

Maximum Recommended Side Tilt 25% or 14° Max.

Fig. 2 Vehicle Incline Specifications

Repair and Service Manual

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GENERAL SPECIFICATIONS

TURNING CLEARANCE DIAMETER Approx. 25 ft (7.6 m)

Fig. 3 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance

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Repair and Service Manual

LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE

T PAGE NO.

EMISSION CONTROL SYSTEM WARRANTY STATEMENT .........................................................T - 1 ENGINE OWNER WARRANTY POLICY .........................................................................................T - 1

Repair and Service Manual

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LIMITED WARRANTY

Notes:

Page T-ii

Repair and Service Manual

T

LIMITED WARRANTY EMISSION CONTROL SYSTEM WARRANTY STATEMENT (Owner’s Defect Warranty Rights and Oblications)

Refer to the HONDA® Operating & Maintenance Instructions, provided with vehicle, for Emission Control System Warranty information.

ENGINE OWNER WARRANTY POLICY Refer to the HONDA® Operating & Maintenance Instructions, provided with vehicle, for Engine Warranty information.

Repair and Service Manual

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LIMITED WARRANTY

Notes:

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Repair and Service Manual

Read and understand the following warnings before attempting to operate the vehicle:

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To prevent personal injury or death, observe the following: When vehicle is to be left unattended, engage parking brake, move direction selector to ‘F’ (forward) position, turn key to ‘OFF’ position and remove key.

Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic conditions. Consider environmental factors which effect the terrain and the ability to control the vehicle.

Avoid driving fast down hill. Sudden stops or change of direction may result in a loss of control.

Use service brake to control speed when traveling down an incline.

Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.

All travel should be directly up or down hills.

Use extra care when driving the vehicle across an incline.

Stay in designated areas and avoid steep slopes.

Use the parking brake whenever the vehicle is parked.

Keep feet, legs, hands and arms inside vehicle at all times.

Avoid extremely rough terrain.

Check area behind the vehicle before operating in reverse.

Make sure the direction selector is in correct position before attempting to start the vehicle.

Slow down before and during turns. All turns should be executed at reduced speed.

Always bring vehicle to a complete stop before shifting the direction selector.

See GENERAL SPECIFICATIONS for vehicle load and seating capacity.

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Read and understand the following text and warnings before attempting to service vehicle:

In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

It is virtually impossible to anticipate all possible component failures or the manner in which each component may fail.

Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are

not operating correctly, take time to consider the safety of yourself and others around you should the component move unexpectedly.

Some components are heavy, spring loaded, highly corrosive, explosive or may produce high amperage or reach high temperatures. Battery acid and hydrogen gas could result in serious bodily injury to the technician/ mechanic and bystanders if not treated with the utmost caution. Be careful not to 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 equipment.

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To prevent personal injury or death, observe the following: Before working on the vehicle, remove all jewelry (rings, watches, necklaces, etc.)

Be sure that no loose clothing or hair can contact moving parts.

Use care not to touch hot objects.

Raise rear of vehicle and support on jack stands before attempting to run or adjust powertrain.

Wear eye protection when working on or around vehicle. In particular, use care when working around batteries, using solvents or compressed air.

Hydrogen gas is formed when charging batteries.

Do not charge batteries without adequate ventilation.

Do not permit open flame or anyone to smoke in an area that is being used for charging batteries.

A concentration of 4% hydrogen gas or more is explosive.

Engine exhaust gas (carbon monoxide) is deadly.

Carbon monoxide is an odorless, colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

The following are symptoms of carbon monoxide inhalation: Dizziness Vomiting Intense Headache Muscular Twitching Weakness and Sleepiness Throbbing in Temples If any of these symptoms are experienced, get fresh air immediately. Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area.

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E-Z-GO Division of Textron, Inc. 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 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. Technical Communications Department