EZGO TEXTRON 2 CYCLE ENGINE GASOLINE POWERED VEHICLES OWNER'S OPERATION AND SERVICE MANUAL

2 CYCLE ENGINE GASOLINE POWERED VEHICLES

OWNER..& OPERATION AND SERVICE MANUAL

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MODEL YEAR 1989/1990/1991/1992/1993

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MANUAL NO. 24750-G1

REVISED 4/1/92

FOR YOUR SAFETY Read and understand all labels located on your vehicle. If you don't understand any of the information, contact your E-Z-GO representative for clarification.

Always replace any damaged or missing labels.

On steep hills it is possible for the vehicle 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 governed 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 as abuse and will not be covered under warranty.

If the vehicle is to be used in a commercial environment, we suggest that signs similar to the one illustrated be used to warn of hills that could result in an unsafe coasting condition.

Do not tow a single vehicle at speeds in excess of 12 M.P.H. Towing the vehicle at above the recommended speed, may result in personal injury and/or damage to the vehicle and other property.

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

li&Pat IPPLY-­ TDI.IIDIPdl NOTES, CAUTIONS AND WARNINGS

Throughout this guide you will find Notes, CAUTIONS and WARNINGS.

fn:.WARNING/n:.

Indicates a condition that should be observed.

INDICATES A CONDITION THAT MAY BE HAZARD­ OUS TO PERSONNEL AND MAY RESULT IN DAM­ AGE TO THE VEHICLE.

INDICATES A CONDITION THAT MAY RESULT IN DAMAGE TO THE VEHICLE.

Please observe these Notes, Cautions and Warnings; be aware that servicing a vehicle requires mechanical skill, and a regard for conditions that could be hazard­ ous.

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

OWNER'S OPERATION AND SERVICE MANUAL 2 CYCLE GASOLINE POWERED VEHICLES MODEL YEARS 1989-1993 MANUAL NO. 24750-G1 ISSUED 4/1/92

GOLF CARS GX-440/444 GX-444 GX-444F (FREEDOM) GX-444J (SPIRIT) TRUCKS GXl-300/800 GXT-300/800 GXT-800 PERSONNEL CARRIERS PC4GX PC4GXI PC4GXJ (LIBERTY)

E-2-GO DIVISION OF TEXTRON, INC., P.O. BOX 388, AUGUSTA, GEORGIA 30913-2699

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LIMITED WARRANTY

TO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO YOUR VEHICLE, CALL OR WRITE YOUR LOCAL DISTRIBUTOR, BRANCH, OR E-Z-GO WAR­ RANTY DEPARTMENT.

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The use of NON E-Z-GO parts may void your warranty.

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Tampering with or adjusting of governor to permit vehicle to operate at above factory settings (12-15 M.P.H.) will void your vehicle warranty.

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GENERAL INDEX GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A

1

Operating Controls ................................................

A

1

Before Starting ................••.•..............................•

A

2

Towing .•........................................................

A

4

SeNicing - Initial ..................................................

A

4

Preventative Maintenance ...•.......................................

A

4

Torque Specifications ..............................................

A

9

SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

1

General Precautions ........................•......................

B

1

Battery Removal .........•.....•..................................

B

1

Gas Tank Removal ........•..•......•.............................

B

1

Lifting Procedures ................•...•............................

B

2

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C

1

Tire Repair ....•.................................................

C

1

Tire Mounting ............•.••...•................................

C

1

STEERING ............................................

D

1

Steering Assembly .............•..................................

D

1

Steering Disassembly ............................................. .

D

1

SUSPENSION - BEFORE 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

1

Front Suspension Disassembly ........•....................•.........

E

1

Front Suspension Bearing Maintenance .......•........................

·E

3

Removal of Axle and Hub Assembly .................................•.

E

4

Front Wheel Alignment .................•...........................

E

7

Rear Suspension ..................................................

E

9

SUSPENSION - STARTING 1990 . . . . . . . . . . . . . . . . . . . . . . . . .

E

11

Front Shield Removal ..............................................

E

11

Front Wheel Alignment •.............................•......•.......

E

11

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GENERAL INDEX SECTION

PAGE NO.

SPEED CONTROL AND OIL PUMP ........................

F

1

Accelerator Governor, Carburetor and Oil Pump Linkage ...................

F

Accelerator Pedal Adjustment .•......................................

F

Accelerator Cable Adjustment ........................................

F

Governor Bellcrank, Carburetor, and Oil Pump Bellcrank ..................

F

Linkage Rod Adjustments ....•...................•..................

F

1 2 2 5

SPEED CONTROL AND OIL PUMP-1992 SUPPLEMENT .....

F

9

Carburetor, Air Intake, and Linkage Adjustment ••........................

F

Spark Plug, General Considerations ...................................

F

9

10

BRAKES - 1989 .......................................

G

1

General ............•....••...................•..................

G

Daily Braking Performance Test ........•....................•........

G

6 Month Maintenance .....................................•........

G

1 1

How the Brake Works .....................•...............•........

G

How the Adjuster Works ............................................

G

Disassembly of Brake Pedal .........................................

G

Hill Brake Release Removal .........................................

G

Brake Drum and Shoe Removal ......................................

G

Compensating Brake Linkage Adjustment ..............................

G

Adjustment of Wheel Brake .•......•.......•.........................

G

BRAKES-STARTING 1990 ..............................

G

15

General ........................................................ .

G

Daily Braking Performance Test .............•........................

G

6 Month Maintenance ..............................................

G

How the Brake Works ..............................................

G

How the Adjuster Works ............................................

G

Disassembly of Brake Pedal .........................................

G

Hill Brake Release Removal .........................................

G

Brake Drum and Shoe Removal •.....•...............................

G

Compensating Brake Linkage Adjustment ..............................

G

Adjustment of Wheel Brake ..........................................

G

15 15 15 16 16 19 19 20 23 23

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7

1

2 2 5 5 6 9 9

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I I I I I

GENERAL INDEX ENGINE AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H

1

Engine Specifications ............................................. .

H

1

Engine Mounts ...................................................

H

1

Engine Frame, Removal and Installation ...............................

H

3

Engine Removal ....................••............................

H

3

Muffler and Support Removal .•..••..•....•...........•...•......•...

H

4

Drive Clutch Removal and Installation .••..............................

H

7

Engine Installation ....•..•.....•...•...........................••..

H

9

Engine Cooling System ......•..••...•.............................•

H

9

Engine Repair and Overhaul ......................•..................

H

12

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J

1

Oil Injection, Maintenance .•.•..•...................•................

J

1

Oil Injection Installation ................•...•........................

J

2

Carburetor Operation •.............................................

J

4

Choke System .......•........•...................................

J

4

Carburetor Disassembly ......•.....................................

J

8

Carburetor Adjustment .............................................

J

8

POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K

1

Drive Belt .......•.....•..•................................•..•...

K

2

Driven Clutch ........•............................................

K

2

ELECTRICAL - 1989 AND EARLY PRODUCTION 1990 . . . . . . .

L

1

Circuits and Controls .............................................. .

L

1

Circuit Testing ..........•..••..•..................................

L

3

Starter/Generator ..•.....•..••.•..................................

L

6

Battery Test ......................................................

L

11

Cooling Fan and Flywheel Removal ...................................

L

11

Solid State Ignition .........•......................................

L

13

Specifications

L

19

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GENERAL INDEX SECTION

PAGE NO.

ELECTRICAL - STARTING LATE 1990 .....................

L

21

Electrical System Wiring Diagram .....................................

L

Solid State Ignition System Wiring Diagram .............................

L

22 23

REAR AXLE ...........................................

M

1

Rear Axle Removal ............................................... .

M

1

Rear Axle Shaft Repair .............................................

M

4

HORN AND ACCESSORY WIRING ........................

0

1

Horn Circuit ..................................................... .

0

Head and Taillight Circuit ...........................................

0

Brake Light Circuit .................................................

0

Turn Signals and Flasher ...........................................

0

1 2 3

Hour Meter Circuit ................................................ .

0

State of Charge Meter ............................................. .

0

14 16

BODY AND TRIM ......................................

p

1

PAINT INSTRUCTIONS ..................................

Q

1

TROUBLE-SHOOTING ..................................

R

1

General ........................................................ .

R

By System ...................................................... .

R

1 2

VEHICLE SPECIFICATIONS ..............................

s

Golf Cars (GX-440/444) ...........................................

Spirit ( GX-444J) ..................................................

Freedom (GX-444J} ...............................................

Liberty (PC4GXJ) ................................................ .

Personnel Carrier (PC4GX) .........................................

Industrial Personnel Carrier (PC4GXI) .................................

Turf Truck (GXT-300/800) ..........................................

Industrial Truck (GXl-300/800) .......................................

Carburetor Jetting Altitude Tables .....................................

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s s s s s s s s s

9

1 1 3 5 7 9

11 13 15 17 4/1/92

I I I I I

INTRODUCTION This Operation and Service Manual has been designed to enable you to maintain the vehicle in accordance with procedures developed by E-Z-GO. Adherence to these procedures and trouble-shooting tips will ensure you of the best possible service from the product.

This manual is divided into individually numbered sections.

Certain illustrations and text may describe options or features that your vehicle is not equipped with; disregard these areas.

This manual is designed to cover the 1989 , 1990 and 1991 model years. When service procedures are differ­ ent from one year to the next, it will be noted in the text or immediately following the section it is relevant to.

Throughout this manual you will find NOTES, CAUTIONS, and WARNINGS used. personnel and the vehicle, please observe the following:

For the protection of all

Indicates a condition that should be observed.

INDICATES A CONDITION THAT MAY RESULT IN DAMAGE TO VEHICLE.

&_WARNING 8_

INDICATES A CONDITION THAT MAY BE HAZARDOUS TO PERSONNEL AND MAY RESULT IN DAMAGE TO THE VEHICLE.

To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Only trained personnel should be authorized to service E-Z-GO vehicles.

Proper service, repair and maintenance are important to the safety of the service technician and the safe, reliable operation of all vehicles. If part replacement is necessary, the part should be replaced with the specified replacement part. Note: The use of non E-Z-GO parts may void your warranty. Do not use a replacement part of lesser quality.

The procedures recommended and described in this manual are effective methods of performing service, repair, and maintenance. Some of these procedures require the use of tools specially designed for the purpose.

Accordingly, anyone who intends to use service procedure or tool, which is not recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopard­ ized by the service procedure or tool selected.

It is important to note that this manual contains various NOTES, CAUTIONS, and WARNINGS that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe.

To facilitate ordering parts, an illustrated parts breakdown catalogue is available from your local Distribu­ tor, Branch or the E-Z-GO Service Parts Department.

12/15/90 I I I I I I

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OPERATION AND SERVICE MANUAL SECTION:GENERAL

The model, serial, and manufacturing numbers are stamped on a plate on the right side of the dash housing of the vehicle. (FIG. A-1).

A

CONTROLS The controls of the vehicle consist of a Key Switch, For­ ward-Neutral-Reverse Lever, Choke, Accelerator Pedal and Combination Service Brake and Hill Brake Pedal

KEY SWITCH (FIG. A-2) Located on the seat support panel (FIG. A-2), this switch enables the basic electrical system of the vehicle to be turned off by turning the key to the "OFP' position.

For added security, when the vehicle is left unattended, the key may be removed from the "OFP' position pre­ venting inadvertent operation of the vehicle.

If the vehicle is equipped with E-Z-GO installed custom accessories, some accessories remain operational with the ignition switch in the "OFP' position, e.g., radio, clock, cigarette lighter.

FORWARD-NEUTRAL-REVERSE LEVER (FIG. A-2) Located on the seat support panel adjacent to the Key Switch (FIG. A-2), this lever permits the selection of for­ ward, neutral or reverse.

FIG. A-1 SERIAL NO. PLATE LOCATION Always provide these numbers to the dealer when or­ dering parts for the vehicle.

WHEN SELECTING DIRECTION DESIRED, BOTH THE VEHICLE AND THE ENGINE MUST BE COM­ PLETEL YSTOPPED BEFORE MOVING THE LEVER.

e FIG. A-2 CONTROLS (PANEL MOUNTED) 4/1/92

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GENERAL CHOKE (FIG. A-2) Located on the seat support panel (FIG. A-2), the choke is used to aid cold starting. Pull the choke knob out for the first start of the day or if the vehicle does not start within ten seconds after depressing the accelerator pedal.

Depressing the bottom of the brake pedal is the pre­ ferred method of releasing the parking (hill) brake to as­ sure the longest service life of brake components.

,, BEFORE ENTERING VEHICLE The engine will only start with key in the "ON" position and either forward or reverse selected. As soon as en­ gine starts, push the choke in.

ACCELERATOR PEDAL (FIG.A-3) Depressing the accelerator (FIG. A-3) of the vehicle will release the parking (hill) brake if engaged. This is a fea­ ture to assure that the vehicle is not driven with the park­ ing (hill) brake engaged.

Depressing the vehicle accelerator pedal starts the en­ gine. Each time the pedal is released, the engine will stop.

COMBINATION BRAKE AND HILL BRAKE PEDAL (FIG.A-3) The brake pedal (FIG. A-3) incorporates a parking (hill) brake feature. To engage, push down on the top section of the pedal until it locks in place. The parking (hill) brake will release when the brake pedal is depressed.

Use the BOTTOM section of the brake pedal to operate the regular brake system.

1.

Check for correct tire inflation.

2.

Inspect for fluid leaks.

3.

Be certain that everything is properly stored and secured.

BEFORE STARTING Be sure you are familiar with the vehicle, its equipment and how to use it safely. Although E-Z-GO vehicles have been designed to provide you with a safe and reli­ able vehicle, maintaining its good performance depends to a large extent on the operator.

IMPROPER USE OR OPERATION OF THE VEHICLE OR THE LACK OF PROPER MAINTENANCE MAY RE­ SULT IN DECREASED PERFORMANCE OR DAM­ AGE TO THE VEHICLE. BEFORE INITIAL USE, REMOVE CLEAR PLASTIC SEAT COVERINGS.

FIG. A-3 ACCELERATOR AND BRAKE CONTROLS Pg.A-2

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GENERAL STANDARD VEHICLE IS LIMITED TO 2 OCCU­ PANTS MAXIMUM PER SEAT. Read and understand the following warnings before at­ tempting to operate the vehicle.

&_WARNING&_ WHEN THE VEHICLE IS TO BE LEFT UNATTENDED, TURN THE KEY TO THE "OFF" POSITION, REMOVE KEY AND ENGAGE THE HILL BRAKE. DRIVE THE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CON­ SIDER THE TERRAIN AND EXISTING TRAFFIC CONDITIONS. ALSO CONSIDER THE ENVIRON­ MENTAL FACTORS WHICH EFFECT THE TERRAIN AND YOUR ABILITY TO HANDLE THE VEHICLE. AVOID DRIVING FAST DOWN HILL. SUDDEN STOPS OR CHANGE OF DIRECTION MAY RESULT IN A LOSS OF CONTROL. USE BRAKE TO CON­ TROL SPEED WHEN TRAVELING DOWN AN IN­ CLINE. 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 {HILL) BRAKE WHEN­ EVER THE VEHICLE IS PARKED. KEEP FEET, LEGS, HANDS, AND ARMS INSIDE THE VEHICLE AT ALL TIMES. AVOID EXTREMELY ROUGH TERRAIN. CHECK THE AREA BEHIND THE VEHICLE BEFORE BACKING UP. MAKE SURE THAT THE FORWARD-NEUTRAL-RE­ VERSE LEVER IS IN THE CORRECT POSITION BE­ FORE ATTEMPTING TO START THE VEHICLE. SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING THE VEHICLE TO A COMPLETE STOP BEFORE SHIFTING THE FORWARD-NEU­ TRAL-REVERSE CONTROL.

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ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION.

STARTING THE GASOLINE VEHICLE To start the gasoline vehicle, apply the parking (hill) brake; place the forward-neutral-reverse selector in neutral; place the key in the ignition switch and turn to the "ON" position; move forward-neutral-reverse selec­ tor to the direction desired; release parking (hill) brake by depressing the service brake pedal and depress the accelerator pedal to start the engine (use the choke if re­ quired).

When the lever is in the reverse position, a warning will sound. This is a device to indicate that the vehicle is ready to start and run in reverse.

Depressing the accelerator pedal energizes the starter and ignition circuits which causes the engine to run.

Starting a cold engine may require the use of the choke.

Pull out the choke knob and depress the accelerator un­ til the engine starts. As soon as the engine starts, push in the choke knob.

When the accelerator pedal is released, the ignition cir­ cuit is de-energized and the engine stops. To stop the vehicle more quickly, depress the BOTTOM OF THE BRAKE PEDAL. When leaving the vehicle unattended, engage the hill brake by depressing the TOP of the brake pedal until it locks in place. To release the parking (hill) brake, de­ press the BOTTOM part of the brake pedal.

TO AVOID COMPONENT DAMAGE, THE VEHICLE MUST BE BROUGHT TO A COMPLETE STOP BE­ FORE SHIFTING THE FORWARD-NEUTRAL-RE­ VERSE LEVER. If the vehicle has been running and the engine does not start within 10 seconds, use the choke. To change di­ rection, bring the vehicle to a complete stop before mov­ ing the forward-neutral-reverse shift lever to the direc­ tion desired. Proceed by depressing the accelerator pedal.

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GENERAL TOWING-1989

INITIAL SERVICE CHART Item

A MAXIMUM OF ONE VEHICLE MAY BE TOWED AT A TIME. (Tow bars to fit both 3 and 4 wheel vehicles are available from the E-Z-GO Service Parts Department).

MAXIMUM TOWING SPEED IS 12 M.P.H.

Battery

Check charge condition.

Seats

Remove protective plastic covering.

Brakes

Check operation and adjust if necessary

Fuel

Fill tank with correct fueVoil mixture.

(See Engine Fuel and Lubrication.)

Tires

Check pressure.

TOWING-1990 FOUR WHEEL VEHICLES

A MAXIMUM OF FOUR 4-WHEEL VEHICLES (IN­ CLUDING THE TOW VEHICLE) MAY BE TOWED AT A TIME. (Tow bars to fit 4-wheel vehicles are available from the E-Z-GO Service Parts Department).

THE DRIVE BELT MUST BE REMOVED BEFORE TOWING. SEE CLUTCH SECTION OF THIS MANUAL FOR REMOVAL PROCEDURE. MAXIMUM TOWING SPEED IS 12 M.P.H.

SERVICING A NEW GASOLINE VEHICLE

IT IS IN THE BEST INTEREST OF BOTH THE VEHI­ CLE OWNER AND SERVICING DEALER TO CARE­ FULLY FOLLOW THE PROCEDURES RECOM­ MENDED IN THIS MANUAL. ADEQUATE PREVEN­ TATIVE MAINTENANCE, APPLIED AT REGULAR IN­ TERVALS, IS THE BEST GUARANTEE FOR KEEP­ ING THE E-Z-GO GASOLINE VEHICLE BOTH DE­ PENDABLE AND ECONOMICAL.

Before a new vehicle is put into operation, it is recom­ mended that the owner make a check of the items shown in the INITIAL SERVICE CHART. Service operations are described in pertinent sections of this Service Manual. See Index for location.

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Service Operation

SEATS Preparation of Seats for Service Remove protective plastic coverings from the seats be­ fore placing the vehicle in service. The ONL Yfunction of the plastic coverings is to protect the seat bottoms and back rests during shipping. If the plastic covering is left on the seats and becomes torn, dirt getting under the plastic covering is ground into the cover material. Water getting under the plastic covering is trapped and eventu­ ally will damage the seat assembly.

TIRES Tire condition should be inspected on a daily basis.

Recommended pressure for the standard tire is listed in the Specifications Section. Inflation pressures should be checked on a weekly basis when the tires are cool.

Tire inflation should be governed by the condition of the terrain. For outdoor applications with major use on grassy areas, the following should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure. On a very soft turf, a lower pressure prevents tires from cutting into the turf. All tires should have the same pressure for optimum handling characteristics. Be careful not to overinflate. Due to the low volume of these small tires, overinflation can occur in a matter of sec­ onds. Be sure to replace the valve dust cap after check­ ing or inflating.

PREVENTATIVE MAINTENANCE E-Z-GO suggests that preventative maintenance be performed under the following headings: Daily, Weekly, and Semi-annually.

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GENERAL

fn.WARNING/n.

• Torn seats.

• Damaged or missing equipment.

DO NOT LUBRICATE THE PARKING (HILL) BRAKE LATCH ARM OR CATCH BRACKET NOR ANY CA­ BLE CONTROLS OR CABLES. OIL WILL CAUSE FOREIGN MATTER TO ADHERE TO THESE SUR­ FACES AND ACCELERATE WEAR.

• Mechanical damage.

• Be sure that the engaged parking (hill) brake will hold on a hill and that when disengaged, does not drag or prevent the vehicle from roll­ ing freely.

DAILY CHECK LIST

• Cuts in tires.

After the vehicle has been put into service, it is recom­ mended that the following items be checked daily by the personnel handling the vehicles. Personnel driving ve­ hicles to and from the storage facility can be an asset to a proper maintenance program if trained to look, listen, and feel for an unusual situation. This practice can be a great help in solving many maintenance problems in the minor stages while they can be corrected by simple ad­ justments.

1. Examine the vehicle for damage or anything be­ yond normal wear and tear.

• Perform the Daily Braking Performance Test.

To determine the adequacy of the vehicles brake sys­ tem, the following test should be performed daily:

fn.WARNING/n.

The recommended way of performing the daily brake test and determining any vehicles that have unaccept­ able braking performance is to have personnel handling the vehicles latch the hill brake at a common point on a paved surface while traveling at maximum governed speed. The vehicle stopping location must be observed and vehicles that stop in a significantly greater distance than other acceptable vehicles should immediately be removed from service and inspected by a qualified me­ chanic.

The mechanic should perform a "panic" stop on the sus­ pect vehicle(s) by applying maximum force and travel to the brake pedal while traveling at full speed. He should observe if either of the rear wheels fails to "lock up". If one wheel fails to lock, it is reasonable to expect that a problem exists with the service brake system and the 6 Month Brake Maintenance must be performed in its entirety. If both wheels lock, the parking (hill) brake must be adjusted and the vehicle re-tested per the Daily Brake Test.

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• Ensure that all switches are operating nor­ mally.

• Listen for noises, such as rattles due to loose hardware; scraping sounds such as brakes dragging, etc.; unusual engine noises, and be sensitive to abnormal performance.

2.

• Check the fuel tank and fill if required. (See Fueling Instructions) Clean vehicle.

• Wipe seats.

• Clean floormat.

• Remove trash from dash tray.

ALL DRIVING BRAKE TESTS MUST BE DONE IN A SAFE LOCATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL

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• Check the tires for wear and proper air pres­ sure.

• Visually check the appearance of the vehicle for dents, scratches, loose equipment.

• Wash accumulated dirt from engine compartment and underbody.

FUEL FUEL GAUGE The fuel gauge is a gauge/cap combination. Located under the driver's side seat; it is a direct reading me­ chanical float type.

ENGINE FUEL AND LUBRICATION

/n.WARNING/n.

WHEN REFUELING, INSPECT THE FUEL GAUGE/ CAP FOR LEAKS OR BREAKS IN THE INDICATOR HOUSING THAT COULD RESULT IN FUEL SPILL­ AGE. DO NOT HANDLE FUEL IN AN AREA THAT IS NOT ADEQUATELY VENTILATED. DO NOT PERMIT ANYONE TO SMOKE IN ANY AREA THAT VEHI­ CLES ARE BEING FUELED.

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Pg.A-5

GENERAL Refer to the label attached to the fuel tank which is lo­ cated under the driver's side seat to determine fueling requirements. The vehicle is equipped with oil injection and it will be equipped with a translucent oil container situated on the passenger side below the seat.

The gasoline vehicle should be run on unleaded or regu­ lar grade gasoline. Unleaded gasoline is recommended since it will help prevent spark plug fouling and deposits.

OIL INJECTION Engines equipped with oil injection systems automati· cally mix the gasoline and oil. Fill the fuel tank with gaso­ line and the oil reservoir with E-Z-GO 2 cycle engine oil.

FOR FIRST TANK ONLY, USE 52:1 GASOLINE-OIL MIX RATIO FOR BREAK-IN. THIS, IN CONJUNC­ TION WITH OIL INJECTION, WILL PROVIDE THE 40:1 RATIO REQUIRED FOR THE BREAK-IN PE­ RIOD.

AIR CLEANER ON GASOLINE VEHICLES (FIG. A-4), (FIG. A-5) On gasoline vehicles, the air cleaner requires periodic cleaning for optimum engine life and performance.

Semi-annual (125 hours) is suggested; however, under extremely dusty conditions, more frequent inspections are advisable.

To remove the filter element, unscrew the wing nut on the air cleaner assembly and loosen the screw clamp on the air intake funnel. Rotate the air cleaner assembly counterclockwise separating the assembly from the fun­ nel. REMOVE THE ENTIRE AIR CLEANER AS AN AS­ SEMBLY. Separate the assembly and clean or discard the element. Clean the lower body and dust collector.

DO NOT ALLOW DUST OR FOREIGN MATERIAL TO DROP INTO THE AIR DUCT. Replace the air cleaner as an assembly in reverse order of disassembly. BE CAREFUL TO ALIGN THE AIR CLEANER AND FUNNEL TO PREVENT ANY OB­ STRUCTION IN AIR FLOW. Hand tighten the wing nut.

The air cleaner unit on the vehicle is a dry unit. DO NOT use oil on the filter element or any part of the unit.

Pg.A-6

FIG. A-4 AIR CLEANER REMOVAL

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GENERAL AIR CLEANER ELEMENT CLEANING

&,_WARNING&_ DO NOT USE GASOLINE OR OTHER VOLATILE SOLVENTS TO CLEAN THE ELEMENT.

DO NOT USE COMPRESSED AIR OR LIGHT BULBS TO SPEED THE DRYING PROCESS.

Replace the element after six cleanings or earlier if a leak is suspected.

If the vehicle is NOTto be used immediately after clean­ ing the element, wash the element using a non-sudsing detergent. Rinse until water is clear using a water pres­ sure of 40 psi or below. Allow to air dry or use warm flowing air not to exceed 150_ F.

FIG. A-5 AIR CLEANER ELEMENT STARTER/GENERATOR BELT TIGHTEN­ ING PROCEDURE (FIG. A-6)

DO NOTattempt to clean the element by tapping it on a

Tools Required:

If the vehicle is to be used immediately, do not wash the filter but clean with compressed air at 40 psi or less. Di­ rect air through the filter element from the inside.

Wrench, open end, 9/16", ..................... 1 Wrench, open end, 1/2" ...•...........•...... 2 Tension gauge ............................. 1

hard surface.

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! ! ! !A!9!G!

Qty.

Pg.A-7

GENERAL jam nut (2) on the tensioner (3) and then, tighten the nut (4) on the pivot bolt (5).

Retighten an EX/SITING starter/generator belt (1 ) to 75 - 80 lb. tension when the gauge is applied to the belt at a point midway between the clutches. Secure the jam nut (2) on the tensioner (3) and then, tighten the nut (4) on the pivot bolt (5).

CARE AND CLEANING OF THE VEHICLE

FIG.A-6 STARTER/GENERATOR BELT TIGHTENING

It is important that proper techniques and cleaning ma­ terials be used.

Ordinary 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 the subsequent removal of the material with a damp cloth.

Removal of oil, tar, asphalt, shoe polish, and so forth will require the use of a commercially available vinyVrubber 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 pre­ serving those painted surfaces.

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

Occasional cleaning and polishing with appropriate ma­ terials will enhance the appearance and durability of the painted surfaces.

Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle. These ma­ terials will accelerate corrosion of underbody parts. It is recommended that the underbody be flushed occasion­ ally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to expedite their re­ moval.

WINDSHIELD (IF EQUIPPED) A loose starter/generator belt can create an audible vi­ bration and squeal. New belt tension should be checked after 15-20 hours of use. Check the belt tension after it has run for between 5-15 minutes and readjust the ten­ sion if required.

The use of an automotive 'V' belt tension gauge is es­ sential. The Gates 'Krikit available at most NAPA auto­ motive parts stores has proved to be a reliable and accu­ rate tool.

Tighten a NEW starter/generator belt (1) TO 90 - 11 0 lb. tension when the gauge is applied to the belt at a point midway between the clutches. Secure the

Pg.A-8

Clean with lots of water and ·a clean cloth.

DO NOT USE ANY ABRASIVE OR VOLATILE SOL­ VENTS TO CLEAN PLASTIC PARTS.

TORQUE SPECIFICATIONS FOR UN­ SPECIFIED HARDWARE (FIG.A-8) In general two grades of hardware are used in the vehi­ cle. Grade 5 hardware can be identified by the 3 marks on the hexagonal head. Unmarked hardware is Grade 2.

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GENERAL PACK WHEEL BEARINGS, 2 EACH WHEEL

IFj I

IDo

IFj I

IDo

------------

5 BALL JOINTS

Uj1 nj1

IDo

STEERING IDLER ARM- FITTINGS AT TOP & BOTTOM OF ASSEMBLY

REAR AXLE FILUDRAIN/CHECK

FIG. A-7 LUBRICATION POINTS

ALL TORQUE FIGURES ARE IN FOOT POUNDS

FIG. A-8 TORQUE SPECIFICATIONS

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E�GDii,.:,i,!•J:I

Pg.A-9

GENERAL

· W Check for smooth operation and correct free travel w Check brake performance and adjust if required W Check brake performance and adjust if required . W Check operation when direction selector is in reverse

w

Examine for cuts and excessive wear

Check charge condition and connections to battery Check at each fueling, (use E-Z-GO 2-Cycle Oil) Check for sealing of cap and proper operation of fuel gauge (at each fueling).

Check that fuel cap vent is free of dirt

r

Clean with baking soda solution

W W r r

Check for smooth movement - Do not lubricate cable Check for smooth movement and adjustment - Do not lubricate cable Check attachment, adjust as required Check attachment, adjust as required Check for build up of foreign matter inside blower housing and cooling fins, clean if required

w

Check for proper starting, unusual noise, vibration, acceleration

w

Check for tension, wear, cracks

W Check for abnormal play, tightness of all hardware W Check for excessive play, bent components or loose connections W Check pressure, see specifications

w

Check all wiring for loose connections and broken/missing insulation W Check filter element see Service Manual (More often in dusty conditions)

w

Check coil / spark plug wires for cracks/loose connections

w

Check for damage to axle and loose or missing hardware

w Check for oil leakage and loose fasteners

w

Check for loose hardware, cracks at attachment points

w

Check if tire wear is unusual, align per Service Manual

W Check for leaks at tank cap, lines, filters, pump, carburetor. Check lines for cracks/deterioration

2-CYCLE VEHICLE PERIODIC SERVICE SCHEDULE

Pg.A-10

E�GDiiHitt•l:I

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GENERAL

w

Check for bent / binding linkage rod and damage or wear to latch arm or catch bracket. r Lubricate bushings, use light oil. Do not lubricate cables or brake latch

w

Check for oil leakage and loose mounting hardware

w

Check operation and governed speed (300 feet in 17 - 18 seconds) Clean body components and wax all painted surfaces Check for wear and smooth movement (lubricate shaft if required) Check for excessive play and tightness of retaining nuts Lubricate, use Shell Alvania EP-2 Clean, lubricate and adjust per Service Manual Lubricate linkage, use Shell Alvania EP-2 Lubricate, use Shell Alvania EP-2 Check for abnormal noise and mounting hardware s Wash filter element Replace if req'd W Check Cylinder head bolt torque, compression Adjust see Service Manual Pack, use Shell Alvania EP-2 multi-purpose grease s Replace ·

w

Check mounting hardware and for leaks at head and muffler pipes

's Gap (replace if req'd) .030 .·.·.··•• w Check lubricant if oil seepage is evident, add rear axle lubricant as required s Replace after 5 years

2-CYCLE VEHICLE PERIODIC SERVICE SCHEDULE (CONTINUED) 4/1/92

! ! ! !A!9!G!

Pg. A-11

GENERAL SISTEMA

DIARIAMENTE

SEMANALMENTE

1 MES 20 HORAS

3 MESES 50 HORAS

SEMIANUALMENTE 125 HORAS

ANUALMENTE 250 HORAS

FRENOS Pedal ..• .• .• .• .• • • .• • Revisar en busca de funcionamiento libre y recorrido correcto.

Freno de servicio . .... • Revisar el funcionamiento y ajustar segun se requiera.

Freno de estacionamiento ... . • Revisar el funcionamiento y ajustar segun se requiera.

DISPOSmYO DE ALARMADE RETROCESO .. .. .... . • Revisar el funcionamiento cuando el selector de sentido de marcha esta en retroceso.

NEUMATICOS ..... ... . • Examinar en busca de cortes y desgaste excesivo.

RUEDAS ............. . • Buscar aros deformados y tuercas faltantes o flojas.

BATERIA ...... ................... • Revisar la carga y las conexiones de la bateria.

ACEITE DEL MOTOR ... ..... • • .. .. • Revisar cuando se abastece de combustible (usar aceite E-Z-GO para motores de 2 tiempos).

MEDIDOR DE COMBUSTIBLE .. .... • Revisar el sello de la tapa y el funcionamiento del medidor (cada vez que se reabastece de combustible). Revisar si la abertura de ventilaci6n de la tapa esta limpia.

BATERIA .• .. .. .. . ........ ..............• .......

+

Limpiar con una soluci6n de bicarbonato de soda.

VARILLAJES DE CONTROL Cable del acelerador • • • • .• • • .• .• .• .• ........... • Revisar en busca de movimiento libre - No lubricar el cable.

Cable del estrangulador ...• ...• .• ....• ..• • .• .• . • Revisar el ajuste y verificar el movimiento libre - No lubricar el cable. varillaje del carburador ...• .....• • • • • • .• .• ...... + Revisar las conexiones, ajustar segun se requiera.

Selector de sentido de marcha • ...• .• .• • • • .• ...• + Revisar las conexiones, ajustar segun se requiera.

VENTILADOR DE ENFRIAMIENTO ...............

+

Buscar acumulaciones de materia extraiia dentro de la caja del ventilador y en las aletas de enfriamiento; limpiar segun se requiera.

MOTOR ..• • ..... ....• . .. ................• .. ..... • Revisar el arranque; buscar ruidos, vibraci6n o aceleraci6n anormales.

CORREA DEL ARRANCADOR/GENERADOR ...... • Revisar la tensi6n, buscar desgaste y grietas.

CONJUNTO DE DIRECCION .. ................... • Buscar juego anormal, revisar el apriete de la tornilleria.

BARRAS DE ACOPLAMIENTONARILLAJE ....... • Buscar juego excesivo, componentes deformados o conexiones flojas.

NEUMATICOS ....... ................ ........... • Medir la presi6n, ver las especificaciones.

ALAMBRADO .................•......, .... .• ... • Buscar conexiones flojas y aislamiento roto o faltante.

FILTRO DE AIRE • ......... . . ... .. .. . .. .. .. .. ....• .• .......... • Revisar el elemento, ver el Manual de servicio (mas a menudo en condiciones polvorientas).

SISTEMA ELECTRICO DEL MOTOR . ... ... .................• ... • Revisar la bobina y los cables de bujias de encendido en busca de grietas y conexiones flojas.

EJE DELANTERO ... .......... .... ........ • ..........• ....... • Buscar daiios y tornilleria floja o faltante.

AMORTIGUADORES DELANTEROS . ...• ..... ..............• .. • Buscar fugas de aceite y sujetadores sueltos.

RESORTES DELANTEROS . .. .. . .. . .. ... . . .. ... .• .. .. ..... ... • Buscar tornilleria floja y grietas en los puntos de fijaci6n.

AUNEAMIENTO DE LAS RUEDAS DELANTERAS ........ ..• .... • Buscar desgaste anormal de los neumaticos. Alinear segun se indica en el Manual de servicio.

SISTEMA DE COMBUSTIBLE . . . .. ........ ........• .... ....... • Buscar fugas en la tapa del tanque y en las lineas, filtros, bomba y carburador. Revisar las lineas en busca de grietas y deterioraci6n.

• Revlsar

A Camblar

+ Umplar, aJustar, etc.

PROGRAMA DE MANTENIMIENTO PERIODICO DEL VEHICULO CON MOTOR DE 2 TIEMPOS Pg.A-12

El!!l:iClii:flist•J:I

4/1/92

j jAjsjGj

GENERAL SISTEMA

DIARIAMENTE

SEMANALMENTE

1 MES 20 HORAS

3 MESES 50 HORAS

SEMIANUALMENTE 125 HORAS

ANUALMENTE 250 HORAS

FRENO DE ESTACIONAMIENTO (PARA PENDIENTES) .......... • Buscar una varilla doblada o atascada; buscar danos o desgaste en el brazo del pestillo o soporte de enganche. + Lubricar los bujes con aceite ligero. No lubrlcar los cables o el pestlllo del freno.

AMORTIGUADORES TRASEROS .. . ..... .....• ....• ........... • Buscar fugas de aceite y tomilleria suelta.

VARILLAJE DEL ACELERADOR/GOSERNADOR ........... .. .... • Revisar el funcionamiento y medir la velocidad gobemada (30 0 pies en 17-18 segundos).

CARROCERIA ................................... ... , ........•.•.... ..•....•.

+

SELECTOR DE SENTIDO DE MARCHA

• Revisar en busca desgaste y movimiento libre (lubricar el eje seg(m se requiera).

Limpiar los componentes y encerar todos los componentes pintados.

PIVOTES DE DIRECCION ..... .. . . ..•.•...•.•....•............ ...... ............ • Buscar juego excesivo y revisar el apriete de las tuercas de retenci6n. + Lubricar con Shell Alvania EP-2.

FRENOS DE SERVICIO .. .... ... .... .. . .. ....... .. ...... .......... .. .............

+

Limpiar, lubricar y ajustar segun se indica en el Manual de servicio.

CONJUNTO DE DIRECCION •.•.• .•......................• .............• .... . .

+

Lubricar el varillaje con Shell Alvania EP-2.

BARRAS DE ACOPLAMIENTONARILLAJE ... .......• .. ......... ......... ...•...

+

Lubricar con Shell Alvania EP-2.

TRANSEJE .. .. ...... ........ .... ............. .. ................... ......... • Buscar ruidos anormales y revisar la tomilleria de montaje.

RLTRO DE AIRE ....................._ •.•.•.•.•...............•........... ........•......... .&. Lavar el elemento. Cambiarlo segun se requiera.

MOTOR .....•..•.•..............•.•••............•.••.·•.• ................•. ...• .....•...... • Revisar el apriete de los pernos de la culata, medir la compresi6n.

COJINETES DE LAS RUEDAS DELANTERAS . .... ... ..... ...• . .. ...•. •..............•.... ...

+ +

Ajustar; ver el Manua1 qe servicio.

Empacar con grasa universal Shell Alvania EP-2.

RLTROS DE COMBUSTIBLE ....._......,•.•......... .. .......•...•.., ..........•.............. .A. Cambiar.

SILENCIADOR/TUBO DE ESCAPE •• • •.• . .........• .• •...••. ... .. ..... ..•.••• ....... . .. .... •.. • Revisar la tornilleria de montaje y buscar fugas en la culata y en los tubos.

BUJIA DE ENCENDIDO .....•..•........•.•..•........•......•.••.•....•. .. ·"· ............... .&. Ajustar la separaci6n ( 0.030 in.) · (cambiar segun se requiera).

TRANSEJE ...............•......•..., • .. .. .• ......... ... ... ... . .• ...... .. .... .... .........• . • -Revisar el lubricante si hay sei'iales de fugas. Agregar lubricante segun se requiera.

Cambiar despues de 5 ai'ios.

.a.

• Revlsar

.&. Camblar

• Umplar, aluatar, etc.

PROGRAMA DE MANTENIMIENTO PERIODICO DEL VEHICULO CON MOTOR DE 2 TIEMPOS (CONTINUACION) 4/1/92

I I I iAl9fGI

Pg. A-13

GENERAL

Pg.A-14

E�GClii=UM•W

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OPERATION AND SERVICE MANUAL SECTION:SAFETY PROCEDURES

GENERAL When any inspection or maintenance is performed on the vehicle it is important that care be exercised to pre­ vent personal injury and damage to the vehicle. Only trained personnel should be authorized to service E-Z­ GO vehicles.

NOTES, CAUTIONS AND WARNINGS

B

NEVER GET UNDER A VEHICLE WHILE IT IS SUP­ PORTED BY A JACK. IF IT IS NECESSARY TO WORK UNDER THE VEHICLE, USE SAFETY STANDS AND TEST THE STABILITY OF THE VEHI­ CLE ON THE STANDS. KEEP SMOKING MATERIALS, FLAME AND SPARKS AWAY FROM GASOLINE AND THE BAT­ TERY.

Throughout this manual you will find NOTE, CAUTION, and WARNING used. For the protection of all personnel and the vehicle, please observe the following:

ALWAYS REMOVE THE KEY FROM THE SWITCH BEFORE CONNECTING OR DISCONNECTING THE BATTERY OR OTHER ELECTRICAL COMPONENT.

Indicates a condition that should be observed.

WHEN CONNECTING BATTERY CABLES, PAY PARTICULAR ATTENTION TO THEIR POLARITIES. NEVER CONFUSE THE POSITIVE CABLE WITH THE NEGATIVE CABLE.

INDICATES A CONDITION THAT MAY RESULT IN

DAMAGE TO THE VEHICLE.

BATTERY REMOVAL AND INSTALLA­ TION

Tools Required:

Qty.

Wrench, open end, insulated, 7/16" ............. 1

&WARNING& INDICATES A CONDITION THAT MAY BE HAZARD­ OUS TO PERSONNEL AND MAY RESULT IN DAM­ AGE TO THE VEHICLE.

BEFORE WORKING ON VEHICLE Before inspecting or working on the vehicle observe the following warnings.

&WARNING& SET THE (HILL) PARKING BRAKE NEVER WORK ON THE ENGINE WHILE IT IS HOT. IF YOU MUST WORK ON THE ENGINE WHILE IT IS RUNNING, ALWAYS REMOVE NECKTIE AND ANY JEWELRY, SUCH AS CHAINS, RINGS, WATCH, ETC. KEEP HANDS, CLOTHING, HAIR AND TOOLS AWAY FROM MOVING PARTS, SUCH AS CLUTCHES AND BELTS.

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! ! ! !B!9!G!

Wrench, open end, insulated, 1/2" .............. 1 Carrier, battery ............................ 1

&WARNING& USE INSULATED WRENCHES AND BE CAREFUL NOT TO ALLOW WRENCHES TO CONTACT ANY METAL PORTIONS OF THE VEHICLE WHILE WORKING ON THE BATTERY TERMINALS. DO NOT CONFUSE BATTERY POLARITY WHEN REIN­ STALLING CABLES.

Remove the two 1/4" flanged nuts that secure the bat­ tery hold down bracket to the 'J' hold down bolts. Re­ move the hold down bracket. Loosen the battery termi­ nal bolts at the positive and negative cables and remove the cables. Lift the battery from the vehicle. Installation is in the reverse order of removal.

FUEL TANK REMOVAL AND INSTALLA­ TION

Tools Required:

Qty.

Wrench, box, 1/2" ........................... 2

Pg. B-1

SAFETY PROCEDURES Wrench, box, 7/16" ......................... 1 Pliers ............................•....... 1

It is not necessary to drain the fuel tank before removing.

At the top of the fuel tank, loosen the hose clamp and slide the fuel line from the tank outlet fitting.Plug the fuel line with a 1/4" bolt to prevent the contents of the fuel fil­ ter and line from being lost. At the underside of the vehi­ cle, remove the 1/4" lock nut that tensions the fuel tank hold down strap. At the rear of the fuel tank, remove the fuel tank mounting hardware. Remove the fuel tank by pushing down on the front of the tank while lifting the rear and remove the tank from the vehicle.

&_WARNING&_ DO NOT STORE THE FUEL TANK IN AN AREA SUB­ JECTED TO HIGH TEMPERATURES, OPEN FLAME OR SPARKS.

IN THE FOLLOWING OPERATION, BE CAREFUL NOT TO POSITION THE JACK IN AN AREA THAT COULD DAMAGE THE BRAKE CABLE OR HANG­ ERS. Raise the inner frame with the jack and place the third jack stand under the rear most suitable portion of the in­ ner frame. Remove the second jack stand (rear of the frame) and lower the vehicle. Move the jack to the oppo­ site side of the vehicle and place the jack under the frame at a point 4"-5" in front of the vertical seat support panel. Raise the side of the vehicle with the jack and place two of the jack stands under the frame. The first stand is placed on the most forward flat area and the second on the rear most flat area of the frame. Lower the jack and test the stability of the vehicle on the four jack stands.

LOWERING THE THREE WHEEL GASO­ LINE POWERED VEHICLE

Installation is in the reverse order of removal.

Lower the vehicle using the reverse procedure to the one used to raise it.

LIFTING THE THREE WHEEL GASOLINE POWERED VEHICLE (FIG. B-1)

LIFTING THE FOUR WHEEL GASOLINE POWERED VEHICLE (FIG. B-1)

Tools Required:

Tools Required:

Qty.

Qty.

Jack, hydraulic, trolley ................ ....... 1

Jack, hydraulic, trolley ....................... 1

Jack stands ... ..........• .. . . ... ...•...... 4

Jack stands ............................... 4

Chocks or wooden blocks ................... . 4

Chocks or wooden blocks .................... 4

&_WARNING&_

&_WARNING&_

BE SURE THAT THE VEHICLE IS ON A FIRM AND LEVEL SURFACE. NEVER GET UNDER A VEHICLE WHILE IT IS SUPPORTED BY A JACK, USE SAFETY STANDS AND TEST THE STABILITY OF THE VEHI­ CLE ON THE STANDS. ALWAYS PLACE CHOCKS IN FRONT AND BEHIND THE WHEELS THAT ARE NOTTO BE RAISED. USE EXTREME CARE SINCE THE VEHICLE IS EXTREMELY UNSTABLE WHILE POSITIONED WITH ONE SIDE RAISED.

BE SURE THAT THE VEHICLE IS ON A FIRM AND LEVEL SURFACE. NEVER GET UNDER A VEHICLE WHILE IT IS SUPPORTED BY A JACK, USE SAFETY STANDS AND TEST THE STABILITY OF THE VEHI­ CLE ON THE STANDS. ALWAYS PLACE CHOCKS IN FRONT AND BEHIND THE WHEELS THAT ARE NOTTO BE RAISED. USE EXTREME CARE SINCE THE VEHICLE IS EXTREMELY UNSTABLE WHILE POSITIONED WITH ONE SIDE RAISED.

Place the jack under the frame at a point 4"-5" in front of the vertical seat support panel. Raise the side of the ve­ hicle with the jack and place two of the jack stands under the frame. The first stand is placed on the most forward flat area and the second on the rear most flat area of the

Place the jack under the frame at a point 4"-5" in front of the vertical seat support panel. Raise the side of the ve­ hicle with the jack and place two of the jack stands under the frame. The first stand is placed on the most forward flat area and the second on the rear most flat area of the

frame.

Pg.B-2

frame.

E�GDii=t:,i1t•l:I

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! !B!9!G!

SAFETY PROCEDURES

IN THE FOLLOWING OPERATION, BE CAREFUL NOT TO POSITION THE JACK IN AN AREA THAT COULD DAMAGE THE BRAKE CABLE OR HANG­ ERS. Raise the inner frame with the jack and place the third jack stand under the rear most suitable portion of the in­ ner frame. Remove the second jack stand (rear of the

frame) and lower the vehicle. Move the jack to the oppo­ site side of the vehicle and place the jack under the frame at a point 4"-5" in front of the vertical seat support panel. Raise the side of the vehicle with the jack and place two of the jack stands under the frame. The first stand is placed on the most forward flat area and the second on the rear most flat area of the frame. Lower :thejac1< and test the stability of the vehicle on the four jack stands.

LOCATIONS FOR JACKING/JACKSTANDS AS INDICATED SHADED AREAS ARE SUITABLE FOR JACKING/LIFTING

FIG. B-1 LIFTING AND JACKING POINTS

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! ! ! !B!9!G!

Pg.B-3

SAFETY PROCEDURES LOWERING THE FOUR WHEEL GASO­ LINE POWERED VEHICLE Lower the vehicle using the reverse procedure to the one used to raise it.

LIFTING PROCEDURE FOR THE FRONT OF THE THREE WHEEL GASOLINE POW­ ERED VEHICLE Tools Required: Qty. Jack, hydraulic, trolley . . . . . . . . . . . . . . . . . . . . . . . 1 Jack stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chocks or wooden blocks . . . . . . . . . . . . . . . . . . . . 4

&WARNING&

BE SURE THAT THE VEHICLE IS ON A FIRM AND LEVEL SURFACE. NEVER GET UNDER A VEHICLE WHILE IT IS SUPPORTED BY A JACK, USE SAFETY STANDS AND TEST THE STABILITY OF THE VEHI­ CLE ON THE STANDS. ALWAYS PLACE CHOCKS IN FRONT AND BEHIND THE WHEELS THAT ARE NOTTO BE RAISED. USE EXTREME CARE SINCE THE VEHICLE IS EXTREMELY UNSTABLE WHILE POSITIONED WITH ONE SIDE RAISED.

Pg.B-4

Place chocks in front of and behind the front and rear tires. Place the jack under the left side of the vehicle frame at a point 4"-5" in front of the vertical seat support panel. Raise the side of the vehicle with the jack and place a jack stand under the frame on the most forward flat area of the frame. Lower the jack and repeat the pro­ cedure on the other side of the vehicle.

LIFTING PROCEDURE FOR THE REAR OF THE THREE WHEEL GASOLINE POW­ ERED VEHICLE

&WARNING& E-Z-GO DOES NOT RECOMMEND OR ENDORSE ANY PROCEDURE THAT LIFTS THE REAR OF THE VEHICLE ALONE. ALWAYS USE THE PROCEDURE FOR LIFTING THE THREE WHEEL GASOLINE POW­ ERED VEHICLE.

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OPERATION AND SERVICE MANUAL SECTION: WHEELS AND TIRES

WHEEL AND TIRE SERVICE Tools Required:

Qty.

Lug wrench ................................ 1 Tire tool .................................. 1 Brush, tire ................................ 1 Mallet, rubber ............................. 1

TIRE REPAIR

C

carefully remove the tire over the outside (valve stem side) of the wheel.

Care must be taken to prevent damage of tire bead.

When the outer bead is free of rim, insert tire tool under inner bead and pry tire off.

MOUNTING TIRE

The vehicle is fitted with low pressure tubeless tires mounted on one piece rims. Should a tire repair be necessary, proceed as follows: If tire is flat, remove wheel and inflate tire to approximately 20 psi. Im­ merse tire in water to locate air leak and mark the location.

Small holes in casing can be plugged with a standard automotive tubeless tire repair kit, available at most automotive supply outlets.

To remove tire from rim, deflate by removing valve core; separate both tire beads from rim and push bead from wide side into rim recess. Using tire tool,

Clean both tire beads and wheel rim bead seats with a tire brush. This is important to prevent loss of air around rim. Install tire on rim (from valve stem side) using a rubber mallet and tire tool. Remove valve core and position bead against narrow flange side. Apply air pressure through stem while press­ ing around center of tread. Pressure will build up and snap beads in place. Remove pressure and in­ stall valve core. Inflate to recommend pressure (see Specifications Section). ADJUST to desired pressure.

WHEEL INSTALLATION. Install wheel on vehicle as shown in FIG. C-1.

TIGHTEN LUG NUTS TO 50-60 FT/LBS TORQUE 4 TAPERED LUG NUTS IN A CRI SS-CROSS PATTERN.

VALVE STEM IS ALWAYS TO OUTSIDE OF WHEEL

FIG. C-1 WHEELS AND TIRES 1/01/89

! ! ! !C!9!A!

Pg. C-1

WHEELS AND TIRES

Pg. C-2

1/01/89

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OPERATION AND SERVICE MANUAL SECTION: STEERING

GENERAL

the mallet will cause the steering wheel to separate from the steering shaft.

The steering unit is a rack and pinion type.

Tools Required:

D

Qty.

Screwdriver, Phillips .•...................... 1 Socket, 1/2" drive, 15/16" .................. 1 Ratchet, 1/2" drive •........................ 1 Hammer, ball pein, 2 lb. .................... 1 Torque wrench, 1/2" drive ................... 1 Ball joint pulling tool ........................ 1 Pliers •.................................... 1 Mallet ...••..•............................ 1

STEERING ASSEMBLY REMOVAL ( FIG. 0-2) Turn the steering wheel full travel to the right to posi­ tion rack end ball joint. (On four wheel vehicles it is · necessary to remove the shield to provide access to the steering arm area. See section E, Suspension.)

Remove cotter pin (1) from slotted nut (2) and back nut off until it protects ball joint stud threads. Using a ball joint pulling tool as a lever, apply pressure to ball joint and tap nut with a hammer to release ball stud. Remove nut and lift stud from arm. Remove three bolts (3) and lock washers (4) securing steer­ ing box to floorboard and lift assembly out of vehi­ cle. (FIG. D-2 ) Reinstall in the reverse order of disassembly.

Tighten ball joint stud slotted nut (2) to 40 ft. lbs. torque. Insert new cotter pin. (FIG. D-2)

FIG. 0-1 STEERING WHEEL AND SCORECARD HOLDER

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DO NOT STRIKE THE STEERING NUT OR THE END OF THE STEERING SHAFT DIRECTLY WITH A HAMMER. Reinstall steering wheel as follows: Slide steering wheel onto steering shaft splines. In­ stall steering nut and tighten to 10-15 ft. lbs. torque.

Reinstall scorecard holder in the reverse order of disassembly.

With the wheels in the straight ahead position, cen­ ter the steering wheel before installing the steering nut and scorecard holder.

DISASSEMBLY STEERING WHEEL REMOVAL (FIG. 0-1) Remove two screws (1) holding the scorecard as­ sembly (2) located on the back of the steering wheel (3). Loosen steering wheel retaining nut (4) two to three turns. Apply upwards pressure to the steering wheel (3). Place a mallet against the steering wheel nut (4) and strike mallet sharply with a hammer.

The combination of upwards pressure and striking

1/01/89

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TIGHTEN SCORECARD ASSEMBLY SCREWS TO 6 IN. LBS. TORQUE MAXIMUM.

STEERING SHAFT REMOVAL (FIG. 0-2) Remove bolts ( 5) and lock washers ( 6) securing the column. Remove column (7) and gasket (14) and slide the shaft (9) out through flanged end of col­ umn.

Pg. 0-1

STEERING

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FIG. D-2 STEERING Pg. D-2

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STEERING GEAR AND RACK REMOVAL (FIG. D-2)

IDLER ARM REMOVAL (FIG. D-3)

Remove steering column (7) from gear box. When removing gears, make note of the position of the spring washers (15), one under the pinion (21) and one under the reduction gear (16). Be sure washers are properly positioned when reassembling gears.

The flat washer (13) is placed on top of the reduc­ tion gear (16).

Loosen clamp (17) securing the bellows (18). Slide rack and rod end assembly (19) out.

Tools Required: .................... Qty.

If ball joint or tie rod end is worn or damaged, the rack and rod end assembly must be replaced as a complete unit.

Clean all parts with solvent and check for wear. Re­ place worn or damaged parts with new parts.

Repack gear box with a high quality gear grease.

(E-Z-GO recommends Shell Alvania EP-2 multi pur­ pose grease.) Apply grease liberally to gear pins, rack, and gears before reassembly.

Pins (20) MUST be lubricated prior to reassembly.

Reassemble all parts in reverse order of disassem­ bly. Be sure all hardware is tightened securely.

IDLER ARM - 4 WHEEL VEHICLES (FIG. D-3) If the idler arm assembly (1) is worn or has exces­ sive play, the idler arm bushings (2) must be re­ placed.

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Pliers .................................... 1 Wrench, open end, 11/16" .................. 1 Socket, 3/8" drive, 15/16" .................. 1 Torque wrench, 3/8" drive .................. 1 To remove the idler arm, disconnect the tie rod ball joint (3) at the bottom of the idler arm and the steer­ ing gear ball joint (4) at the top of the idler arm using the procedure outlined under 'Steering Assembly Removal'.

Lift the front of the vehicle per procedures in 'Safety Procedures' Section B and remove cotter pin (5).

Using a pair of pliers or vice grips, rotate idler shaft (6) back and forth while pulling downwards until the idler arm shaft is removed. After removal of the idler arm shaft, the idler arm assembly may be re­ moved.

Before reinstalling idler arm assembly, repack with Shell Alvania EP-2 multi purpose grease. Reinstall in the reverse order of disassembly. Tighten ball joint nuts to 40 ft. lbs. torque and install new cotter pin.

TIE ROD INSPECTION Lift front of vehicle per procedures in 'Safety Procedures' Section B and check for vertical move­ ment of tie rod which would indicate a worn condi­ tion.

KING PIN INSPECTION Lift front of vehicle per procedures in 'Safety Procedures' Section B. Hold top and bottom of tire and use a rocking motion to check for king pin movement which would indicate a worn condition.

Pg. D-3

STEERING

FIG. 0-3 IDLER ARM REMOVAL Pg. 0-4

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OPERATION AND SERVICE MANUAL SECTION: SUSPENSION

FRONT BUMPER REMOVAL (4 WHEEL VEHICLES) (FIG. E-1) Tools Required:

Qty.

Ratchet, 3/8" drive ......................... 1 Socket, 17/16", 3/8" drive .................. 1 Socket, 9/16", 3/8" drive ................... 1 Wrench, open end, 7/16" ................... 1 Wrench, open end, 9/16" ................... 1

FRONT SHIELD REMOVAL Raise the front of the vehicle as detailed in sec­ tion B. Remove the ·two bolts (1), washers (2), spacers (3) and lock nuts (4) that secure the front shield (5) to the frame.

E

to the frame. Remove the bumper rail. Remove the bolts (20), lock washers (21), and lock nuts (22) that secure the bumper support (16) to the frame.

Remove the bumper support.

Installation is in the reverse order of removal.

FRONT SUSPENSION (FOUR WHEEL VEHI­ CLES) (FIG. E-2) Tools Required:

Qty.

Pliers .................................... 1 Pulling tool ............................... 1 Hammer, ball pein ....................·..... 1 Torque wrench, 1/2" drive .................. 1 Wrench, box end, 15/16" ................... 1

FRONT BUMPER AND SUPPORT REMOVAL

Socket, 15/16", 1/2" drive .................. 1

Remove the bolts (6), lock washers (7), washers (8) and lock nuts (9) that secures the bumper (10) to the bumper rails (11). Remove the bolts (12), lock washers (13), washers (14) and lock nut (15) that secures the. bumper (10) to the bumper supports (16). Remove the bolts (17), lock washers (18), and lock nuts (19) that secures the bumper rail (11)

FRONT SUSPENSION REMOVAL Removal of the front suspension assembly as a unit is not required for most repair work; however, if re­ moval is required, proceed as follows: Lift front of vehicle (see procedures in Section B) and place on jack stands. Remove the front wheels.

FIG. E-1 4 WHEEL FRONT SHIELD AND BUMPER 1/01/89

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Pg. E-1

SUSPENSION

J--

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1•

17

E9

®

26

FIG. E-2 4 WH Pg. E-2

L FRONT SUSPENSION

SUSPENSION Remove the tie rod assembly (7) from the idler arm assembly (1) as follows: Remove the cotter pin ( 8) from the slotted nut (9) and back it off until it pro­ tects the ball joint threads. Using a pulling tool as a lever, apply pressure to the rod end ball joint and TAP the nut with a hammer to loosen the ball stud.

Remove the nut and lower the stud from the idler arm.

Remove the nut (10), washers (11), and bushings (12) from the top of the shock absorber (13). Col­ lapse the shock absorbers. Remove the bolts (14), lock washers (15), nuts (16), and plate (17). Re­ move the front suspension assembly from the vehi­ cle.

Replace all broken or worn parts and reinstall in re­ verse order of disassembly. Tighten slotted nut (9) on the rod end at idler arm to 40 ft. lbs. torque.

Install a new cotter pin.

SPINDLE REPAIR {FIG. E-2) Tools Required:

Qty.

Pliers .•.......................•........... 1 Wrench, box end, 15/16" .................... 1 Reamer, sizing , .875" dia. .................. 1 Torque wrench, 1/2" drive ................... 1 Socket, 15/16", 1/2" drive .................. 1 · To replace the spindles (1 8) and (19), king pin bushings (20), or seal (21), proceed as follows: Remove the wheel and hub (refer to Bearing Service procedures). Disconnect the ball joint (22 or 23) from the steering arm (refer to Front Suspension

Removal). Remove the cotter pin (24) and nut (25).

Remove the king pin (26), taking care to note the position of the thrust bearing (27) and washers (2 8) at top. Remove the spindle (1 8) or (19).

Clean the spindle with a solvent and inspect for dam­ age or worn bushings or seals. If bushings are worn larger than .8 80 inch, press out and replace with new bushings. Press bushings in until flush.

Bushing 1.0. will close slightly when pressed into the housing. If a ream operation is required, use a .875 inch sizing reamer.

Reinstall in the reverse order of disassembly.

Tighten the ball joint nut at the steering arm to 40 ft. lbs. torque; continue tightening to 50 ft. lbs. torque maximum to align cotter pin holes and install a new cotter pin.

MAINTENANCE ON FRONT WHEEL BEAR­ INGS 4 WHEEL {FIG. E-3) 3 WHEE� {FIG. E-4), {FIG. E-5 ) When maintenance is performed on wheel bearings, they must be repacked with grease to assure proper lubrication during operation. Pack bearings as fol­ lows: Use a grease packing device or use the fol­ lowing manual procedure (see Periodic Service Schedule for grease specification).

Place a dab of grease in the palm of the hand. Us­ ing the other hand, take the bearing and dip the

FIG. E-3 FRONT SPINDLE 1/01/89

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Pg. E-3

SUSPENSION bearing into the grease pushing grease up between the rollers of the bearing.This must be done around the complete bearing until all surfaces are coated with grease. Reinstall the bearings.

FORK REMOVAL AND BEARING SERVICE (FIG. E-4)

Tools Required:

Qty.

Jack stand ................................ 2 Wrench, open end, 11/16" .................. 1 Pliers ..................................... 1 Socket, 2", 1/2" drive ...................... 1 Hammer, ball pein, 2 lb. .................... 1 Puller, slide hammer ........................ 1 Punch, long tapered ........................ 1 Bar, brass ................................ 1 Torque wrench, 1/2" drive ................... 1

b)

The top race is removed using a long ta­ pered punch. Insert the punch through the bottom end of the housing and against the lower edge of the race, strike the punch with a hammer while alternately changing punch position around the edge of the race. Install a new race by tapping it UGHTL Y with a brass bar and hammer.

Reinstall the fork and bearings in the re­ verse order of disassembly.

Tighten the fork stem nut until the fork is snug in the frame, then back off 1/4 turn. Reinstall the dash liner. Reinstall the cowl support and the console (if equipped).

REMOVAL OF FRONT FORK AXLE AND HUB ASSEMBLY (FIG. E-5)

Tools Required:

Qty.

Wrench, open end, 11/16" .................. 1 Wrench, open end, 1 1/8" .................. 2 WHILE REMOVING NUT, SUPPORT FORK SO THAT IT WILL NOT DROP OUT AND DAMAGE THE FORK STEM AND/OR BEARINGS.

Punch, long, tapered ....................... 1

Lift the front of the vehicle (see procedures in Sec­ tion B) and place on jack stands, disconnect the steering rack and ball joint. Remove the cowl center support and remove the console assembly if equipped (see Console Removal Section). Remove the dash tray liner or mat (1). Remove the stem nut (3) and washer (4) from the fork stem (5).

The lower bearing (6) will remain on the fork stem.

To remove this bearing, tap lightly on the bottom surface to separate the bearing from the stem.

Slide the bearing off the stem. With the fork re­ moved from the vehicle, inspect the bearings and grease seals for damage. If the seal is damaged, the bearing and seal assembly must be replaced.

Clean the bearings with solvent and dry thoroughly.

Inspect for damage or wear. Replace with new parts, if necessary. Repack the bearings with grease (see Packing procedure), making sure roll­ ers are completely covered with grease and making sure that there is grease between the rollers and races (see Maintenance on Front Wheel Bearings).

Inspect the outer races (7) and the stem housing for pitting or other damage. If it is necessary to remove and replace the race, proceed as follows:

Torque wrench, 1/2" Drive .................. 1

a)

Pg. E-4

The lower race is removed using a slide hammer puller.

Hammer, ball pein ......................... 1 Socket, 3/4", 1/2" Drive ................... 1

Loosen the shock absorber nut (1) four to five turns. remove the axle nut retainers (2) from the axle nuts on both sides of the fork.

Loosen the axle nut (3) to permit the flat washes (4) to separate from the axle bracket and to permit the axle and hub assembly to drop out of the axle brack­ ets (5 and 6). After the axle and hub assembly has been removed, remove the axle nut (3) and slide the adjuster ring (7) off the end of the axle shaft.

Loosen the jam nut (8) and unscrew jam nut (9) from the axle shaft (ONE END ONLY). After remov­ ing the jam nut from axle shaft, slide the spacers (10) and hub assembly from the end of the axle shaft.

To remove the bearings (11) and grease seals (12) from the hub assembly (13), insert a punch on the opposite side of the bearing to be removed, position it on the bearing cone, tap lightly around the bearing to push the bearing and grease seal out of the hub.

Clean the bearings with a solvent and dry thor­ oughly. Check for wear round the rollers and in the races. Clean the hub assembly with solvent and dry thoroughly; check the outer races in the hub assem­ bly for damage or wear.

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SUSPENSION

FIG. E-4 FRONT FORK REMOVAL 1/01/89

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Pg. E-5

SUSPENSION

FIG. E-5 FRONT FORK ASSEMBLy Pg. E-6

SUSPENSION

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BE SURE THAT THE SEAL RETAINING SURFACE OF THE HUB IS CLEAN AND FREE OF GREASE. REIN­ ST ALL IN THE REVERSE ORDER OF DISASSEMBLY.

When installing grease seals into hubs, insert the grease seals, flange side inward (FIG. E-6), and tap lightly and evenly around the seal until the seal is flush with the outer side of the hub assembly. Lubri­ cate the seal surface with oil.

The hub assembly is reassembled to the axle as­ sembly using the reverse procedure. When rein­ stalling the jam nut (9) on the axle shaft, position the inside jam nut against the spacer, tighten the nut until the hub becomes difficult to turn on the axle shaft and back off the jam nut until the hub turns freely. While holding the inner jam nut, tighten the outside jam nut to 70 - 90 ft. lbs. torque. Reinstall the tire and rim assembly on the hub and tighten the lug nuts to 50 - 60 ft. lb. torque. Install axle in fork assembly using reverse order of disassembly.

Tighten outside lock nuts to 90 - 110 ft. lbs. torque.

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FIG. E-7 VERTICAL ALIGNMENT FRONT WHEEL ALIGNMENT Tools Required:

Qty.

Wrench, open end, 11/16" .................. 1 Square ................................... 1 Wrench, adjustable, 6" .. • ................. • 1

THREE WHEEL VEHICLE (FIG. E-7), (FIG. E-5)

A

A INSTALL THIS SIDE OF SEAL INTO HOUSING. B LUBRICATE SEAL SURFACE.

FIG. E-6 INSTALLING GREASE SEAL

1/01/89 I I I !E(9@1

Should the steering tend to pull to one side, the front wheel should be aligned as follows: Position the ve­ hicle on a flat, level surface and set the wheel in a straight ahead position. Loosen the shock absorber nut (1) four to five turns. Remove the axle retainers (2) from the axle nuts on both sides of the fork.

Loosen the nut (3) at both ends of the axle (FIG. E-5).

&WARNING& WHEN ADJUSTING THE FORK, ENSURE THAT A MINIMUM OF ONE FULL AXLE DIAMETER REMAINS IN THE FORK ARM SLOT.

Using a square, check the vertical alignment of the wheel/tire. Loosen the jam nuts (14) on the axle set screws (15). Adjust the set screws to position the

Pg. E-7

SUSPENSION wheel/tire vertically (90 °) to the floor. Adjust the set screws on both sides of the fork. Lower one side and raise the other to keep the axle firmly within the slot in the axle bracket. Retighten the jam nuts.

Reinstall the axle nut retainers (2) and tighten nuts to 90 - 110 ft. lbs. torque.

Four Wheel Vehicle (FIG. E-8) To check the front end alignment, lift the front of the vehicle (see procedures in Section 8) and rotate each front, tire and scribe or chalk a line around the circumference of each tire at approximately the cen­ ter of the tire. Toe-in dimensions shall be as fol­ lows: (FIG. E-8). Toe-in front dimension is to be 1/4" 1/16" smaller than rear dimension, when measured at points X1, to X1, and X2 to X2. If toe­ in is not within the specified range, an adjustment should be made as follows: Loosen the nuts "8" on the tie rod "C" and rotate tie rod tube as required until the toe-in dimensions are within the acceptable range. Tighten nuts "8".

±

1-4------REAR--------i� X2

X2

FRONT WHEEL BEARINGS (Four Wheel Vehicles (FIG. E-9) Qty.

Tools Required:

X1 �----FRONT

X1

---�•�I

FIG. E-8 WHEEL FRONT END ALIGNMENT

Wrench, box end, 1 1/2" ...................

Jack, hydraulic, trolley ............•........

Jack stands ..... . .....•.....•............

Pliers, needle nose ........................

Pliers, channel lock ........................

1 1 4

1 1 Punch .•...•............................. 1 Hammer, ball pein ......................... 1 Socket, 3/4", 1/2" drive .................... 1 Extension, 6", 1/2" drive ................... 1 Ratchet, 1/2" drive ........................ 1

FIG. E-9 FRONT SPINDLE Pg. E-8

!

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SUSPENSION Loosen the front wheel lug nuts one turn. Lift the front of vehicle (see procedures in Section B) so that wheels are off the floor and install jack stands.

Remove the wheel lug nuts and remove the wheels.

Remove the dust cap (1), remove the cotter pin (2), remove the slotted nut (3), remove the hub (4) and . the outer bearing (5) from the spindle (6). To re­ move the inside bearing and seal, insert a punch from the outside of the hub and lightly tap around the bearing cone (7). Clean the bearings, hub, seal and dust cap with solvent and dry thoroughly. In­ spect for wear or damage.

Worn or damaged parts should be replaced. If the bearings cups (8) are worn or damaged, use a punch to remove them and press in new cups.

Repack the bearings with wheel bearing grease, making sure that grease is forced down between all of the rollers and race. (See Maintenance on Front Wheel Bearings 3 and 4 Wheel).

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BE SURE THAT THE SEAL RETAINING SURFACE OF THE HUB IS CLEAN AND FREE OF GREASE. Install seal (FIG. E-6). Lubricate the seal with oil.

Reassemble using the reverse order of disassembly.

REAR SUSPENSION (3 and 4 Wheel Vehi.­ cles) (FIG. E-10) Tools Required:

Qty.

Socket, 3/4", 1/2" drive .................... 1

springs, two shock absorbers and four rubber bush­ ings in pivot tubes that connect the inner frame to the main frame. To disassemble, proceed as fol­ lows:

COIL SPRING REMOVAL Disconnect the bottom end of the shock absorber (1) by removing the bolt (2), washer (3) and nut (4) from the shock absorber bushing. Lift the rear of vehicle until frame clears the top of the springs.

Remove the springs (5).

BE SURE THAT THE FUEL LINE IS NOT PLACED UNDER TENSION.

SHOCK ABSORBER REMOVAL Remove the nuts (6) and washers (7) from the up­ per shock stud and pull the shock absorbers away from the frame. Reassemble in reverse order of disassembly. Tighten top shock absorber nuts (6) until the bushing (8) expands to the size of the washers (7) .

PIVOT BUSHING REMOVAL Lift the vehicle (see procedures in Section B) and place jack stands under the rear axle. Place a jack under the front center of the power train to remove the load from the connecting pivots. Remove the bolts (9), washers (10) and nuts (11) and lower the front of the frame to provide access to bushings (12).

Socket, 9/16", 1/2" drive ................... 1 Wrench, box end, 9/16" ..................... 1 Extension, 6", 1/2" drive .................... 1 Ratchet, 1/2" .............................. 1 Jack, hydraulic, trolley ...................... 1 Jack stands .............. . ................ 1 Disconnect the ground wire from battery, and engine bolt. The rear suspension consists of two coil

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EXTRA CARE MUST BE TAKEN WHEN LOWERING FRAME OR ELECTRICAL WIRING WILL BE DAMAGED. Remove worn bushings and insert new bushings.

Lubricate with a rubber lube (soap solution) to assist in assembly. Reinstall the bolts (9) and washers (10), and tighten the nuts (11) to 60 - 80 ft. lbs. torque.

Pg. E-9

SUSPENSION

FIG. E-10 REAR SUSPENSION Pg. E-10

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OPERATION AND SERVICE MANUAL

E

SECTION:SUSPENSION -1990 AND LATER SUPPLEMENT

FRONT SHIELD REMOVAL (FIG. E-11) Tools Required:

Qty.

Ratchet, 3/8" drive .......................... 1 Socket, 9/16", 3/8" drive .. ................... 1 Wrench, open end, 7/16" ...............•..... 1 Wrench, open end, 9/16" ......• .....• ........ 1 Raise the front of the vehicle as detailed in section B. Remove the two bolts (3), washers (4) and lock nuts (5) that secure the front shield (1) to the frame.

Pull the lower edge of the front shield (1) forward to re­ lease the spring clip from the support (9). Remove the screws (11), flat washers (12), lock washers (13) and nuts (14). Remove the support (9).

Reassemble using the reverse order of disassembly.

FRONT WHEEL ALIGNMENT, THREE WHEEL VEHICLE - OMITTED FOR 1990.

Four Wheel Vehicle (FIG. E-12) To check the front end alignment, lift the front of the ve­ hicle (see procedures in Section B) and rotate each

�---REAR- --t�

X1

X1

..----FRONT ---1�

FIG. E-12 FRONT WHEEL ALIGNMENT front, tire and scribe or chalk a line around the circumfer­ ence of each tire at approximately the center of the tire.

Toe--in dimensions shall be as follows: (FIG. E-12).

Toe--in front dimension is to be 1/4".:t 1/16" smaller than

FIG. E-11 FRONT SHIELD 4/1/92

I I I !E!o!GI

Pg. E-11

SUSPENSION- SUPPLEMENT rear dimension, when measured at points X1, to X1, and X2 to X2. If toe-in is not within the specified range, an adjustment should be made as follows: Loosen the nuts "B" on the tie rod "C" and rotate tie rod tube as required until the toe-in dimensions are within the acceptable range. On vehicles equipped with tie rod with tow pin, be sure that tow pin "D" is vertical. Tighten nuts "B".

Pg.E-12

4/1/92

! !E!9!G!

OPERATION AND SERVICE MANUAL SECTION:SPEED CONTROL AND OIL PUMP

ACCELERATOR,GOVERNOR,CARBURE­ TOR AND OIL PUMP LINKAGE. (FIG. F-1) Tools Required:

Qty.

F

nor bellcrank moves the carburetor lever, opening the carburetor and activating the oil pump.

GOVERNOR

Pliers, needle nose . . . . . . . . . . . . . . . . . . . . . . . . . 1 Pliers, slip joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Screwdriver, straight blade . . . . . . . . . . . . . . . . . . . 1 Wrench, open end, 9/16" . . . . . . . . . . . . . . . . . . . . 1 Wrench, open end, 1/2" . . . . . . . . . . . . . . . . . . . . . . 1 Wrench, open end, 3/8" . . . . . . . . . . . . . . . . . . . . . 1 The linkages that control the accelerator, governor, car­ buretor and oil injection pump work as a unit, therefore an adjustment to one will have an effect on the other components

SYSTEM COMPONENTS (FIG.F-1) When the accelerator pedal (1) is pressed, the adjust­ able accelerator rod (2) is moved towards the rear of the vehicle which overcomes the resistance of a compres­ sion spring (3). The rear of the accelerator rod is at­ tached to a bellcrank (4) by means of a ball joint (5). The accelerator rod moves the bellcrank energizing the con­ trol circuit of the electrical system by closing the limit switch (6) and then pulls the accelerator cable (7).

The other (engine) end of the accelerator cable pulls against a compression spring (8) that is attached to the rear axle mounted governor bellcrank (9). The bellcrank activates the carburetor throttle lever (10) by means of an adjustable linkage (11) and in tum the carburetor throttle lever operates the oil pump actuator (12) by means of two adjustable linkages (13), (14) and a bellcrank (15).

SYSTEM OPERATION (FIG. F-1) When the accelerator cable pulls against the compres­ sion spring (8) it is compressed until it overcomes the re­ sistance exerted by the governor and its torsion spring, the carburetor and its torsion spring, the friction from the oil pump and friction from all bearings and ball joints. As the accelerator cable compression spring overcomes the combined resistance of the components the gover-

1/01/89

I I I !F!9!Gl

TAMPERING WITH OR ADJUSTING OF GOVERNOR TO PERMIT VEHICLE TO OPERATE AT ABOVE FAC­ TORY SETTING (12-15 MPH) WILL VOID WAR­ RANTY. IN CASES WHERE THE GOVERNOR REQUIRES SERVICE, VEHICLES EQUIPPED WITH A GOVER­ NOR SEAL MUST BE SERVICED AND RESEALED BY AN AUTHORIZED E-Z GO SERVICE BRANCH OR DISTRIBUTOR. Until the vehicle reaches its governed speed (12-15 mph) the vehicle continues to accelerate in a di­ rect relationship to the accelerator pedal position. At governed speed the ground speed sensing governor contained within the rear axle assembly operates against the accelerator compression spring which in tum starts to close the carburetor and reduces the oil pump flow rate.

In effect the accelerator compression spring's flexing in response to throttle cable position, governor bellcrank position and the combined effect of system resistance and dampening, adjusts the position of the carburetor lever and the flow rate of the oil pump. The spring also cushions sudden movements of the linkages to provide smooth power transmission:

SYSTEM PROBLEM SYMPTOMS Erratic acceleration and performance that does NOTin­ clude a noticeable increase in governed speed indicates the need for a linkage adjustment check. (Other factors may contribute to such operation but they should be in­ vestigated only after the linkage adjustments have been checked).

Symptoms that include an increase in governed speed indicates a possible governor failure either within the rear axle or worn bushings on the governor bellcrank shaft.

E�GOii:S:!i1M:I

Pg.F-1

SPEED CONTROL AND OIL PUMP

8.WARNING8

motion. Repeat adjustment procedure if required and in­ spect bushings if smooth operation cannot be achieved.

TO PREVENT INADVERTENT ACCELERATION OF THE VEHICLE AND THE POSSIBLE PERSONAL IN­ JURY THAT MAY RESULT, THE NEGATIVE(-) BAT­ TERY WIRE MUST BE REMOVED FROM THE BAT­ TERY. REFER TO SECTION B OF THIS MANUAL FOR ADDITIONAL CAUTIONS AND WARNINGS.

ACCELERATOR CABLE (FIG. F-2) Check for free motion of the accelerator cable (12) ··· -within its sleeve, and replace if required.

ACCELERATOR PEDAL HEIGHT (FIG. F-2) Measure the height of the accelerator pedal from the floor. A dimension of 5 3/4 to 6 inches is acceptable. Lu­ bricate the pivot with a light oil.

PEDAL HEIGHT ADJUSTMENT (FIG. F-2) Remove the cotter pin (1) from the parking (hill) brake kick off rod (2) and remove the rod from the yoke (3) and the accelerator pedal (4). Loosen the yoke jam nut (5) and rotate the yoke to either shorten or lengthen the ac­ celerator rod (6). Trial fit the yoke, accelerator pedal, and kick off rod until the correct pedal height is estab­ lished. Install the the kick off rod with its associated washers and install a new cotter pin. Lubricate the pivot with a light oil.

ACCELERATOR SWITCH ADJUSTMENT (FIG.F-2) Remove the accelerator bellcrank/switch box cover (7).

With the accelerator pedal in the released (upright) posi­ tion, check that the accelerator bellcrank (8) is contact­ ing the cross member. Loosen the two flanged lock nuts (9) and tum the large headed screw (10) in against the bellcrank. Tum the screw out until it contacts the limit switch actuator and continue turning until a CLICK is heard. Rotate the screw ONE additional full tum.

Tighten both flanged lock nuts firmly. As a rough guide, the top of the accelerator pedal should move no more than 1/2" before the limit switch clicks.

ACCELERATOR BELLCRANK TENSION (FIG.F-2) Tighten the lock nut (11) until it just contacts the bellcrank and then back off ONE full tum. Check for free

Pg.F-2

Do not attempt to lubricate cable, since the lubricant will result in an accumulation of dirt which will cause prema­ ture deterioration of the cable. Ensure that the seals on both ends are in place and keeping the cable clean.

It is not necessary to remove the accelerator bellcrank switch cover to adjust the accelerator cable.

ACCELERATOR CABLE ADJUSTMENT (FIG. F-2) Remove the trunk lid. Slowly depress the accelerator pedal and observe the motion of the governor bellcrank.

The accelerator limit switch should be heard to click be­ fore the governor bellcrank moves. If the switch is acti­ vated AFTER the bellcrank starts to move an adjust­ ment is required and is made at the accelerator switch end of the cable. Slide the boot off the threaded section of the accelerator cable and adjust the position of the cable sleeve by moving the nuts (13) along the sleeve.

The adjustment should be made to ensure that the limit switch is activated before any motion takes place at the governor bellcrank while keeping the slack in the cable to an absolute minimum to reduce excessive motion at the accelerator pedal before the engine starts. Replace the boot.

ACCELERATOR SPRING PIVOT lnspect the spring carrier for free motion about the pivot and lubricate with a light oil if required. Depress the ac­ celerator pedal and check for a smooth action at the spring and governor bellcrank.

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SPEED CONTROL AND OIL PUMP

12

ACCELERATOR CABLE

FIG. F-1 ACCELERATOR, GOVERNOR, CARBURETOR AND OIL PUMP LINKAGE 1/01/89

I I I !F!9!G!

E�GCI ii=>:,it!•]: I

Pg.F-3

- SPEED CONTROL AND OIL PUMP

1/2" MAXIMUM PEDAL TRAVEL �. BEFORE CAUSING LIMIT ,. �7 SWITCH TO CLICK.

ACCELERATOR PEDAL

1/ I

I/ I

I

I

5 3/ 4 TO 6"

I// ;,I /JI '/

ACCELERATOR CABLE

CROSS MEMBER

FIG. F-2 ACCELERATOR LINKAGE REMOVAL AND ADJUSTMENT

Pg.F-4

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I I l lF!9!Gl

SPEED CONTROL AND OIL PUMP GOVERNOR BELLCRANK (FIG.F-3), (FIG.F-4), (FIG.F-5)

WHEN REMOVING/INSTALLING THE LINKAGES TO THE GOVERNOR ARM, USE EXTREME CARE NOT TO DAMAGE OR BEND THE ARM. SUPPORT THE GOVERNOR ARM AND SQUEEZE THE BALL JOINT COMPONENTS TOGETHER (FIG. F-4). FAILURE TO OBSERVE THIS CAUTION MAY RESULT IN SERI­ OUS DAMAGE TO THE GOVERNOR AND RESULT IN THE NEED FOR A COMPLETE REAR AXLE RE­ MOVAL AND DISASSEMBLY. Service tip: To remove the female portion of the ball joint, insert a thin straight blade screwdriver in the slot adjacent to the joint and gently pry apart.

(FIG. F-3)

At the governor ball joint, remove the solid linkage (1).

Move the bellcrank and check for smooth operation against the torsion spring. Any rough motion may indi­ cate poor bearing condition, and they should be re­ placed. (FIG. F-5)

FIG.F-4 BALL JOINT RE-ATTACHMENT CARBURETOR

WHEN REMOVING/INSTALLING THE LINKAGES TO THE CARBURETOR ARM USE EXTREME CARE NOT TO DAMAGE OR BEND THE ARM. SUPPORT THE CARBURETOR ARM AND SQUEEZE THE BALL JOINT COMPONENTS TOGETHER (FIG. F-4). FAIL­ URE TO OBSERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE CARBURETOR AND RE­ SULT IN THE REPLACEMENT OR REBUILDING OF THE CARBURETOR. At the carburetor to oil pump linkage, remove the solid linkage (2) at the carburetor end. Move the throttle lever (3) and check for smooth action and that carburetor tor­ sion spring closes the carburetor.

OIL PUMP BELLCRANK (FIG.F-5)

FIG.F-3 BALL JOINT REMOVAL 1/01/89

I t t tFl9lG!

At the oil pump (5), remove the solid linkage (4). Move the bellcrank and check for smooth motion. If the motion is stiff or rough, loosen the lock nut (6) and tighten until the bellcrank wave washer is compressed; loosen the nut 1 1/2 turns (1-1/16"). If the motion is not satisfactory repeat the adjustment and check the condition of the bearings if smooth motion cannot be achieved.

E�GDii:S:9is!•l:i

Pg.F-5

SPEED CONTROL AND OIL PUMP NOTE: TAMPERING WITH, OR REMOVAL OF GOVERNOR SEAL BY OTHER THAN AUTHORIZED E-Z GO SERVICE OR BRANCH PERSONNEL WILL VOID WARRANTY. ACCELERATOR CABLE WHEN TURNING NUTS TO ADJUST COMPRESSION SPRING ADJUSTER, H OLD THE ADJUSTER ROD HERE WITH PLIERS TO KEEP THE ACCELERATOR CABLE FROM BEING DAMAGED BY TWISTING. -- - PRE-ADJUST GAP TO 7/16" WITH ACCELERATOR RELEASED AND ALL OTHER ADJUSTMENTS MADE BEFORE RUNNING ROAD TEST.

TOP VIEW

6 NOTE: SOLID LINES SHOW FULLY OPEN P OSITIONS. D OTTED LINES SHOW FULLY CLOSED P OSITIONS.

OIL PUMP BELLCRANK

SIDE VIEW

FIG. F-5 OIL PUMP, CARBURETOR AND GOVERNOR LINKAGE ADJUSTMENTS Pg. F-6

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SPEED CONTROL AND OIL PUMP achieved when the governor is held in the wide open position and the carburetor is in the wide open position.

3.

Adjust the accelerator cable such that when the ac­ celerator pedal is fully depressed it opens the car­ buretor lever to the wide open position.

4.

Check that fully depressing and releasing the ac­ celerator pedal results in full motion of travel (76 degrees) at the carburetor lever.

TAMPERING WITH OR ADJUSTING OF GOVERNOR TO PERMIT VEHICLE TO OPERATE AT ABOVE FAC­ TORY SETTING (12-15 MPH) WILL VOID WAR­ RANTY.

FIG. F-6 BALL JOINT ADJUSTMENT

IN CASES WHERE THE GOVERNOR REQUIRES SERVICE, VEHICLES EQUIPPED WITH A GOVER­ NOR SEAL MUST BE SERVICED AND RESEALED BY AN AUTHORIZED E-Z-GO SERVICE BRANCH OR DISTRIBUTOR.

LINKAGE ROD ADJUSTMENTS (FIG. F-5), FIG. F-6)

When making linkage adjustments, follow the sequence indicated.

TO PREVENT BENDING OR DISTORTING THE LEV­ ERS AND BELLCRANKS ALWAYS SUPPORT THE BALL PORTION OF THE JOINT AND SQUEEZE THE JOINT TOGETHER.(FIG. F-4)

1.

2.

Clean all ball joints. Adjust the linkage rods (2), (4) between the carburetor lever and the oil pump (5) by loosening the jam nut (7) and rotating the socket to either lengthen or shorten the rod. The correct length is achieved when the carburetor and the oil pump are both in the wide open position.

Adjust the short linkage rod (1) between the gover­ nor bellcrank and the carburetor by loosening the jam nut (8) and rotating the socket to either lengthen or shorten the rod. The correct length is

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I I I I F!9!G!

HOLD THE COMPRESSION SPRING ADJUSTER ROD WHEN REMOVING THE JAM NUT AND AD­ JUSTING THE COMPRESSION SPRING. FAILURE TO HOLD THIS JOINT WILL RESULT IN THE ACCEL­ ERATOR CABLE TURNING WITHIN ITS HOUSING WHICH WILL RESULT IN THE PREMATURE FAIL­ URE OF THE CABLE.(FIG. F-5) 5.

Remove the jam nut (9).

6.

Pre-adjust the governor compression spring (10) by rotating the adjuster (11) until a dimension of 7/16" is achieved.

7.

Reinstall the jam nut (9).

ROAD TEST Install the negative (-) battery cable. Test drive the vehi­ cle and confirm that the compression spring adjustment results in a speed of 12 to 15 mph when driven at gov­ erned speed (100 yards in 14.0 to17.0 seconds). If the speed is not within the specified limit, stop the vehicle and adjust the spring and repeat the road test until the correct speed is obtained. Tightening the spring results in a speed increase, while loosening it results in a speed reduction.

E�GDii=t:1i1t•J:1

Pg.F-7

SPEED CONTROL AND OIL PUMP

Pg.F-8

E�6Diii:,i1!•l:I

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OPERATION AND SERVICE MANUAL SECTION:SPEED CONTROL AND OIL PUMP 1992 SUPPLEMENT

F

from the threads of the pilot screw and insure that it is fully closed.

Some 1989 and later 2-cycle gasoline powered fleet golf cars encounter spark plug fouling. This is a result of the intermittent engine operation associated with us­ age while golfing, and may NOT apply to range cars, cars subject to extended running, or to GX-800's.

Corrective measures are as follows:

CARBURETOR

Tools Required:

Qty.

14mm Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7mm Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Screwdriver, medium straight blade . . . . . . . . . . . . 1 Confirm that both jets are correct (1989 and later golf cars with BV18 carburetor should have 82.5 main and 80 pilot jets). NOTE: 1989 and 1990 models were shipped from the factory with 90 main and 47.5 pilot jets.

These must be changed. NOTE: Vehicles operated at altitudes other than 0-5000 feet may require alternate jetting.

Use a correctly sized screwdriver and open the pilot screw·1:>ne full turn fr-om the closed position. Hold the screw in place and tighten the locknut. We recommend that you seal the nut and pilot screw with a drop of paint.

Check the adjustment of the 'Throttle Closed" screw.

The throttle plate should be set at 1/8-1/4 turn from fully closed.

Check the condition of the throttle shaft for excessive wear and correct if required.

AIR INTAKE Use a fluted reamer to increase the air horn opening to7/8" diameter, or replace with P/N 23379-G2.

Check the condition of the air intake hose. Make sure that it is tight and has no tears or holes. Check the condi­ tion of the air filter and clean or replace if needed.

LINKAGE ADJUSTMENT Inspect the condition of all ball joint sockets and balls: replace if necessary.

CHANGING MAIN JET

CARBURETOR OPENING

Hold the carburetor bowl in place and carefully, without breaking the bowl seal, remove the bowl retaining bolt and main jet. While holding the bowl in place and the seal intact, replace the main jet and reinstall the retain­ ing nut.

Check the carburetor opening by slowly depressing the accelerator pedal and observing the horizontal rod be­ tween the carburetor and bellcrank. With the accelerator pedal fully depressed, move the horizontal rod towards the front of the car. If the linkage rod moves more than 1 inch, an adjustment is required. (See Pg. F-7 for adjust­ ment procedure.)

ADJUSTMENTS

Use the correct tools to make the pilot screw adjust­ ment. Use a flat blade screwdriver that fits snugly into the slot of the pilot screw. Also, a 7mm box end wrench is preferred to open end type. Correct adjustment of the pilot screw is CRITICAL for proper vehicle performance.

Place the 7mm wrench onto the pilot screw locking nut and hold the pilot screw with the screwdriver. Loosen the locking nut 5-6 turns.

The pilot screw should be closed until it stops (do not use excessive force); open the screw 1/2 turn and close again. This operation will remove any distortion or burrs

1/01/89

! ! ! !F!9!G!

To prevent excessive wear to components, you should make sure that the carburetor lever is not forced against the stop when in the fully open position.

OIL PUMP Check the adjustment of the oil pump.The closed pump alignment mark (mark closest to the stop) must align ap­ proximately 1/16" from the mark on the oil pump body (as shown in FIG. F-8) when the carburetor is in the off (closed) position. If the pump alignment marks are not correct, the horizontal control rod (between carburetor and bell crank) must be removed and adjusted .

E.ZGD•i�:, i1!•l:I

Pg.F-9

SPEED CONTROL AND OIL PUMP To adjust oil pump alignment, detach the horizontal con­ trol rod from the bellcrank end only, and loosen the jam nut. Then, with the carburetor in the fully closed position, and the "closed" mark on the oil pump actuator aligned with the mark on the oil pump body (FIG. F-7), adjust the ball joint socket so that it will mate with the ball. From this point, rotate the ball joint socket four (4) complete turns clockwise, which will shorten the rod and offset the alignment marks approximately 1/16". (FIG. F-8).

TO BELLCRANK

------._

FIG. F-7 OIL PUMP ALIGNMENT

SPARK PLUG Install an NGK BP4HS spark plug after carefully gap­ ping it to .030" using a wire spark plug gauge.

NOTE: This gapping operation is essential since the manufacturer sets the plug to .024"-.028".

Check the condition of the spark plug wire and its boots.

Make sure that the wire is securely attached.

GENERAL CONSIDERATIONS Poor fuel quality, old or contaminated fuel can prevent proper operation. If fuel is suspect, drain the fuel tank (remove if necessary) and fill with fresh 89 octane pump gas. Run the vehicle to be sure that the fuel lines, filter, and carburetor fuel bowl have been purged of old fuel .

Make certain that no oil has been added to the fuel tanks of oil injected vehicles. For non oil injected vehicles, confirm that the pre-mixed fuel/oil ratio used is 128:1.

Make sure that the muffler stinger is not bent or broken and that the muffler is not plugged.

Check that the vehicle is correctly governed. (12-15 m.p.h.)

If the preceding procedures have been followed, it will not be necessary to test run each vehicle. However, a test vehicle should be selected at random and operated to confirm that the service covered in this supplement has been implemented correctly. The vehicle should be brought up to operating temperature by running it at full governed speed for at least one-half mile. The spark plug should then be removed and inspected for evi­ dence of excess oil (it should be a brown/black color).

NOTE: The engine will start to burn off excess oil during this period , and the length of time required for a com­ plete clean up will depend on the condition of the en­ gine.

If the engine is excessively oil fouled, plug fouling may continue until the clean-up process is complete. An ex­ cessively fouled engine may also experience carbon fouling that could result from carbon breaking free and bridging the spark plug's electrodes.

APPROX. 1/16"

FIG. F-8 ALIGNMENT ADJUSTMENT

Pg.F-10

Tighten the jam nut and reattach the rod.

If a vehicle exhibits 'pinging' after a week or more of op­ eration, the spark plug should be removed and in­ spected. If some blistering is found, the plug should be replaced with the cooler BP5HS.

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l l !Fl9!Gl

OPERATION AND SERVICE MANUAL SECTION: BRAKES - 1989

To assure proper braking performance, all periodic maintenance inspections and procedures should be performed as indicated in the schedule (Section A) i.e. Daily, Weekly, Monthly, Semi-Annually, and An­ nually.

G

travel to the brake pedal while traveling at full speed.

He should observe if either of the rear wheels fails to "lock up". If one wheel fails to lock, it is reasonable to expect that a problem exists with the service .brake system and the 6 Month Brake Maintenance must be performed in its entirety. If both wheels lock, the parking (hill) brake must be adjusted and the vehicle re-tested per the Daily Brake Test.

GENERAL

6 MONTH BRAKE MAINTENANCE

The overall brake system consists of: (a) self-adjusting wheel brake units which nor­ mally do not require adjustment until inter­ nal components have worn to a point of needing replacement.

Raise the entire vehicle as specified in Safety Proce­ dures Section B of the operation and service man­ ual.

Rotate each rear wheel by hand, and feel for a drag­ ging brake shoe that prevents smooth movement of the wheel and brake drum.

Remove the clevis pin from both cables where they attach to the wheel brake levers.

Again rotate each wheel by hand and feel for a drag­ ging brake shoe that prevents smooth movement of the wheel and brake drum. If the wheel rotates more smoothly than with the brake cables attached, a worn or damaged brake cable is indicated and • MUST be replaced.

Inspect the cables for abrasion to the cable housing.

A kinked cable or a cable housing that has worn to the point of exposing the metal jacket will result in the cable dragging. Any worn or kinked cables MUST be replaced. Operate the brake pedal and observe the movement of the cables. Both should move the same amount and return fully when the brake pedal is released. If the brake pedal does not return to the full up position, excess pedal bushing friction is indicated. The bushing must be removed and lubricated or replaced. Observe the equalizer bar to see if it pivots during operation of the brake pedal. A pivoting equalizer bar, uneven movement or failure of the brake cables to return fully indicates a dragging brake cable which MUST be replaced.

(b) actuating linkages requiring periodic ad­ justment to compensate for normal wear of system components and/or their replace­ ment.

A complete brake system adjustment procedure must be performed whenever any part of the brake system has been replaced. (FIG. G-9)

DAILY BRAKING PERFORMANCE TEST To determine the adequacy of the vehicles brake system, the following test should be performed daily:

AWARNINGA ALL DRIVING BRAKE TESTS MUST BE DONE IN A SAFE LOCATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL The recommended way of performing the daily brake test and determining any vehicles that have unacceptable braking performance is to have per­ sonnel handling the vehicles latch the hill brake at a common point on a paved surface while traveling at maximum governed speed. The vehicle stopping lo­ cation must be observed and vehicles that stop in a significantly greater distance than other acceptable vehicles should immediately be removed from serv­ ice and inspected by a qualified mechanic.

The mechanic should perform a "panic" stop on the suspect vehicle(s) by applying maximum force and

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! ! f !G!9!A!

Gasoline powered vehicles only: When replacing the drivers side cable route the cable through the top rear saddle only.

Remove each brake drum and shoes according to procedures indicated in BRAKE DRUM, SHOE AND BRAKE ASSEMBLY REMOVAL section.

Clean and inspect all brake parts. If there is

Pg. G-1

BRAKES - 1989 evidence of rust or if the adjuster does not move smoothly in the backing plate, the surfaces must be cleaned and smoothed using an emery cloth. The backing plate MUST be replaced if excessive wear such as gouges or galling are in evidence on the backing plate.

INSPECTION OF BRAKE SHOES The pattern of normal brake shoe wear is shown (FIG. G-1) in quadrants A, B, C and D with quadrant 'A' showing the most wear, 'B' will show the second most wear. Quandrants B and D will always be to the rear of the vehicle.

Inspect brake shoes. Brake shoes MUST be re­ placed as a set when either shoe has a lining thick­ ness less than .040 in. thick AT ANY POINT on the shoe.

After lubricating the backing plate and adjuster mechanism at the lubrication points shown in illus­ tration (Fig G-8) , re-assemble and adjust the com­ plete brake system according to the procedures out­ lined in the section later in this chapter.

A complete brake system adjustment procedure must be performed whenever any part of the brake system has been replaced. (FIG. G-9) Retest according to DAILY BRAKING PERFORMANCE TEST.

HOW THE BRAKE SYSTEM WORKS An overall view of the brake system is shown in FIG. G-2.

The brakes are the "servo acting" type.

The wheel brake is a self-adjusting unit and should not require any adjustment until internal components have worn to a point of needing replacement. Also, periodic adjustment to the actuating linkage may be required to compensate for component wear or as a result of a component replacement.

Depressing the brake pedal causes the brake cable to pull the brake actuating lever forward which in turn pushes the rear brake shoe against the brake drum.

Continued movement of the brake actuating lever causes the lever slide mechanism to move which pushes the front shoe against the drum. As the shoes contact the drum "servo action" takes place.

If the vehicle is moving forward the rear brake shoe moves upwards applying pressure against the upper rear portion of the brake drum. The front shoe moves downwards applying pressure against the lower front portion of the brake drum.

The action reverses when the brakes are applied with the vehicle operating in reverse.

HOW THE ADJUSTER WORKS (FIG. G-3) The brake has an automatic adjuster mechanism that compensates for lining wear.

B

FORWARD---

�FORWARD

FIG. G-1 BRAKE WEAR Pg. G-2

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BRAKES - 1989

FIG. G-2 BRAKE LINKAGE

The brake adjuster is activated by movement of the lever attached to the brake cable. Movement of this lever activates the adjuster lever (1) which rotates the 'star' wheel (2). The star wheel's rotation pushes the adjuster screw (3) outwards which in turn moves the brake shoes outward. With the brake correctly adjusted, the adjuster lever does not have enough movement to rotate the star wheel since

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! ! ! !G!9!AI

lever movement is limited to approximately 1 /8".

The 1 /8" of movement limits the adjuster lever's motion to the flat of the tooth that it is sitting on.

As the brake shoe wears, the lever's motion in­ creases which causes the adjuster lever to engage the next tooth of the star wheel. The star wheel is then rotated which expands the brake shoes.

Pg. G-3

BRAKES - 1989

ILLUSTRATIONS SHOW DRIVER'S SIDE BRAKE ONLY. PASSENGER SIDE IS MIRROR IMAGE. 1/8" WHEN IN ADJUST MENT .

r:: DIRECTION OF BRAKE CABLE PULL --��

BRAKE ACTUATOR LEVER ADJUSTER HOUSING

REAR

(2) STAR WHEEL---, (3) ADJUSTER SCREW REAR SHOE

(1) ADJUSTER LEVER NOTE: TEETH ARE NUMBERED IN ILLUSTRATION TO CLARIF Y THEIR POSITIONS. THE DISTANCE OF THE ADJUSTER LEVER TRAVEL IS REGULATED B Y THE AMOUNT OF BRAKE SHOE WEAR.(A)

POSITION OF ADJUSTER LEVER WITH BRAKES DISENGA GED.

WHEN BRAKE SHOE WEAR IS MINIMAL, THE DISTANCE OF ADJUSTER LEVER TRAVEL IS TOO SHORT TO FULLY RE-ADJUST BRAKES.(B)

POSITION OF ADJUSTER LEVER WITH MINIMUM SHOE WEAR AND BRAKES ENGA GED.

AS SHOE WEAR INCREASES, ADJUSTER LEVER TRAVEL INCREASES, THUS TURNING THE STAR WHEEUCl

POSITION OF ADJUSTER LEVER WITH BRAKES ENGA GED AND SH OES WORN TO POINT OF NEEDING SELF-ADJUSTMENT.

WHEN BRAKE SHOES HAVE WORN SUFFICIENTLY TO REQUIRE RE-ADJUSTMENT, THE ADJUSTER LEVER ADVANCES AND RATCHETS TO THE NEXT TOOTH WHEN BRAKES ARE RELEASED.<Dl

POSITION OF ADJUSTER LEVER WITH BRAKES DISENGAGED AND READY TO RESET ADJUSTER SCREW.

WHEN BRAKE IS NEXT ENGAGED, THE ADJUSTER LEVER WILL ROTATE THE STAR WHEEL FAR ENOUGH TO EXTEND THE ADJUSTER SCREW , THUS RE-SETTING THE PROPER SH OE/DRUM CLEARANCE.(El

POSITION OF •ADJUSTER LEVER WITH BRAKES ENGAGED DURING RE­ ADJUSTMENT OF SCREW.

WHEN THE SHOE/DRUM CLEARANCE IS RESET, LESS EFFORT IS REQUIRED TO ENGAGE THE BRAKES, THUS THE ADJUSTER LEVER TRAVEL IS ONCE A GAIN REDUCED.(F,Al

POSITION OF ADJUSTER LEVER WITH BRAKES DISENGAGED AND RE­ ADJUSTMENT COMPLETED. NOTE NEW POSITIONS OF TEETH.

FIG. G-3 HOW THE BRAKE ADJUSTER WORKS

Pg. G-4

9/01/89

I I !G!S!A!

BRAKES - 1989 DISASSEMBLY OF BRAKE PEDAL (FIG. G-4)

Tools Required:

Qty.

Screwdriver, straight blade .................. 1 Pliers .........•.......................... 1 Hammer, ball pein ......................... 1 Unhook the pedal return spring (1). (Insert a thin blade screwdriver between the small hook end and the pedal bracket, move spring back and away from the bracket.)

Remove the lock nut (2) from the pivot bolt (3) and remove the bolt. Remove the spring, disconnect the cable clevis (4) and lift the pedal out through the floorboard.

To remove the parking (hill) brake pedal, note the position of the two springs (5). Remove the "push on" retainer nut (6) (new nut required for assem­ bly), and remove the hinge pin (7). Reassemble in the reverse order of disassembly.

REMOVAL OF PARKING (HILL) BRAKE RELEASE LINKAGE (FIG. G-5)

Tools Required:

Qty.

Pliers .................................... 1 Jack, Hydraulic Trolley ..................... 1 Jack stands .............................. 1 Wrench, open end, 1/4" .•...•.............. 1 To remove the parking (hill) brake release linkage, raise the front of vehicle (see procedure in Section B) to allow access to underside.

To remove the linkage rod (1), remove the cotter pin (2) and washers (3) and (12) from lever arm (4).

Loosen the two setscrews (5) in cam (6), and re­ move the pivot arm shaft (4). The cam (6) and ny­ lon spacer (9) will come out when the pivot arm shaft is removed.

If the spacer (9) or bearings (10 and 11) are worn, replace them with new spacers or bearings.

Reassemble by reverse procedure.

FIG. G-4 BRAKE PEDAL SPRING REMOVAL

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! ! ! !G!9!A!

It may be necessary to remove the indentures on the shaft (4) caused by the setscrews (5).

Pg. G-5

BRAKES - 1989

FIG. G-5 BRAKE "KICK OFF" LINKAGE BRAKE DRUM, SHOE AND BRAKE ASSEMDRUM REMOVAL (FIG. G-7) BLY REMOVAL (FIG. G-6, FIG. G-7 )

Tools Required:

Qty.

Jack, hydraulic trolley ....................... 1 Hammer, plastic tipped ...................... 1 Jack stands .•............................. 4 Screwdriver, flat blade ...................... 2 Socket, 1/2", 1/2" drive .................... 1 Ratchet, 1/2" .............................. 1 Socket, 1 1/16", 1/2" drive .................. 1 Torque wrench, 1/2" drive ..•................ 1 Pliers ..................................... 2 Wrench, open end, 1/2" .................... 1

Pg. G-6

Loosen lug nuts on rear wheels 1/8 to 1/4 turn.

Raise the vehicle (see procedure in Section B). Re­ move the rear wheel (s).

Remove the cotter pin (5) and clevis pin (6) from the brake lever. Remove the cotter pin (8) from the axle nut (9) and remove the nut and washer (10).

TAP the brake drum (11) with a plastic faced ham­ mer to remove the drum. If the drum does not come off, it will be necessary to loosen the brake adjuster mechanism.

Rotate the brake drum until one of the holes is lo­ cated over the star wheel position (11 o'clock for driver's side, 1 o'clock for passenger side).

The hole is aligned with the brake adjuster mecha­ nism when in this position. Insert a flat blade screw­ driver between the adjuster lever and the adjuster screw housing. Insert a second flat blade screw­ driver and push on the bottom portion of the 'star' wheel which will loosen the adjuster screw and re­ tract the shoes to permit the drum to be removed.

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BRAKES - 1989 PASSENGER SIDE

LIGHT SPRING 4

DRIVER'S SIDE

2

1 4

HEAVY SPRING FIG. G-6 WHEEL BRAKES DRIVER'S AND PASSENGER SIDE SE LF-ADJUSTING BRAK E S FRONT OF V E HICLE ·�- .,, +. . ? �

SE LF-ADJUSTING BRAK E S <DRIV E R'S SID E SHOWN)

R E AR OF V EH E � -. -

'-·>-:, �

�

THIS SHOE :r:HIS SHO E ALWAYS ALWAYS FACE S FRONT FACE S R E AR

LIGHT

INSTALL ADJUSTER SPRING WITH LONG END TO WARD RE AR AND CLE AR OF OBSTRUCTIONS

A

ADJUST E R DE TAIL

FIG. G-7 WHEEL BRAKE COMPONENTS 9/01/89 I I I lGl9!At

Pg. G-7

BRAKES - 1989 BACKING PLATE

LUBRICATE BOTH FRONT AND BACK SURFACES AROUND THIS SLOT

LUBRICATE THESE POIN TS

+

ADJUS TER ASSEMBLY

-

LUBRICATE SHADED AREAS

FIG. G-19 BRAKE LUBRICATION AREAS BRAKE SHOE REMOVAL Using a pair of pliers, compress the brake shoe re­ tainer springs (1) at the open end of the spring.

While holding the tension pin (2) with a second set of pliers, turn the retainer spring 1/4 turn to align the slot in the spring retainer with the flats in the tension pin. Remove the brake shoe retainer springs.

Grasp the brake shoes (3) in the center and tilt them outwards and away from the back mounting plate.

This will release the tension in the brake springs (4) .

Remove the brake springs and remove the brake shoes.

Inspect brake shoes. If a brake shoe has less than .040 lining material thickness AT ANY POINT on either shoe then both shoes MUST be replaced.

&WARNING&

WEAR PROTECTIVE GOGGLES AND MASK WHEN CLEANING BRAKE COMPONENTS. LUBRICATE AREAS INDICATED (FIG. G-19) WITH COMMER­ CIALLY AVAILABLE BRAKE COMPONENT LUBRI­ CANT (available from any auto parts outlet).

Check for free lateral (front and back) movement of the adjusting mechanism and for free movement of the 'star' wheel. Remove the boot on the brake lever. Clean any accumulated brake dust from the

Pg. G-8

backing plate and adjuster mechanism using a brush or air hose.

If the brake is being removed for an axle bearing and seal replacement, the four bolts and nuts securing the brake assembly to the rear axle must be re­ moved. When reinstalling the brake mounting bolts, tighten to 23-35 ft. lbs. torque.

REPLACING BRAKE SHOES (FIG. G-17, FIG. G-18)

I �®trre I

The metal portion of the brake shoes differs be­ tween front and rear shoes. The identical ends of the shoes fit against the fixed anchor at the bottom of the brake. The shoe with the straight end en­ gages in the slot in the adjusting screw, while the triangular ended shoe engages in the rear of the ad­ justing mechanism.

The springs must be inserted with the light spring at the top. The long hook is installed down through the rear brake shoe. The heavier bottom spring is in­ stalled with the spring hooks facing up.

Install the brake shoes using the reverse order of disassembly and secure with the brake shoe retainer springs and brake shoe return springs.

9/01/89 f f fG!9!A!

BRAKES - 1989 Clean the axle shaft to remove grease, dirt and all foreign matter. Apply a small amount of lubricant (Neverseize) to the spline.

Insert a straight blade screwdriver between the ad­ justing lever and the adjusting mechanism. Rotate the start wheel counter clockwise until the shoes have retracted sufficiently to permit the brake drum to be installed. Install washer (12), brake drum (11), washer (10), and tighten the axle nut to 70 ft. lbs. torque minimum.

If the slot in the axle nut and the hole in the axle are not in alignment, continue to tighten the axle nut until the alignment is achieved.

3.

Remove the wheel and tire corresponding to the position of the equalizer (Detail 'A').

ADJUSTMENT OF THE WHEEL BRAKE 4.

With the wheel removed, the brake lever is ac­ cessible. Push the brake lever forward and re­ lease (Detail 'B') - repeat as needed until the lever travel is approximately 1/8".

A hammer handle works well as a tool to push the lever.

5.

Reinstall wheel.

6.

Reconnect compensating linkage (2).

Minimum torque is 70 ft. lbs. Torque readings of up to 140 ft. lbs. are satisfactory.

Install new cotter pin (8).

Move the brake lever forward and release fully, re­ peat until the travel of the lever is approximately 1/8". Install brake cables using clevis pin (6) and a new cotter pin (5).

Always use a new cotter pin (3).

ADJUSTING COMPENSATING SPRING 7.

COMPENSATING BRAKE LINKAGE ADJUSTMENT (FIG. G-9)

Tools Required:

Qty.

Ratchet, 1/2" drive ......................... 1

With the parking (hill) brake DISENGAGED, check that the compensating spring length is between 3 7/8" and 3 15/16" (Detail C). If ad­ justment is required it is made at the nut (6) located in front of the spring (7) (Detail 'C').

ADJUSTING FREE PEDAL TRAVEL 8.

Extension, 6", 1/2" drive .................... 1 Socket, 3/4", 1/2 drive ..................... 1 Wrench, open end, 1/2" .................... 1

Measure the free pedal play to determine if it is between 1" - 1 1/2". If an adjustment is re­ quired; release the jam nut (8) from the yoke (9) and adjust at the threaded rod welded nut (10) (Detail 'D').

Pliers ..................................... 1 Hammer, ball pein .......................... 1 Raise the vehicle (see procedure in Section B) 1.

2.

Check the position of the equalizer (1) with parking (hill) brake ENGAGED (Detail 'A'). a)

If dimension exceeds 1/8" proceed to Step 2.

b)

If dimension is within specification proceed to Step 7.

Remove compensating linkage (2) from equalizer (1) by removing cotter pin (3) and clevis pin (4).

9/01/89

! ! ! !G!9!A!

If the nut (6) in front of spring (7) does NOT rotate with the threaded rod, a second 1 /2" wrench will be required. Turn both wrenches simultaneously.

Service Tip: Installing a 5/16-24 jam nut against the nut (6) and locking it in place will eliminate nut movement on the threaded rod and eliminate the need for a second wrench.

ADJUSTING THE WHEEL BRAKE AND SEATING BRAKE COMPONENTS 9.

Engage the parking (hill) brake and then RE­ LEASE. Repeat twenty (20) times.

E�GDiii:,i,t•):t

Pg. G-9

BRAKES - 1989

Be sure to allow the pedal to return fully after each cycle.

1O. ENGAGE the parking {hill) brake and check for a gap of between 3/32" - 5/32" {Detail 'D'). If an adjustment is required, the adjustment is made at the welded rod adjusting nut (10).

Be sure that the adjusting nut (6) rotates with the threaded rod. {See Service Tip).

FINAL SYSTEM CHECK

cycle. Burnish the brakes for 15 cycles. If the brake performance is acceptable after burnishing, the ve­ hicle may be returned to service. If the brake per­ formance is unacceptable the 6 month maintenance MUST be performed again in its entirity.

PARKING (HILL) BRAKE ADJUSTMENT (FIG. G-10) The parking {hill) brake engagement and holding force should be properly adjusted if the brakes have been adjusted per the "recommended brake adjust­ ing procedure."

PARKING (HILL) BRAKE FUNCTION 1.

11. Remeasure the free travel {1"-1 1/2") - if an adjustment is required, the adjustment is made at the welded rod adjusting nut (10) but the gap dimension specified in Detail "D" must be maintained.

12. Tighten jam nut (8).

13. Lower vehicle.

14. Perform the "DAILY BRAKING PERFORMANCE TEST" described at the beginning of this sec­ tion and return to service if the brake perform­ ance is acceptable. If performance is unaccept­ able, the brake shoes must be burnished to conform to the brake drum.

&_WARNING&_ TO TEST FOR THE AUDIBLE "CLICK" OF THE MI­ CRO SWITCH, THE VEHICLE FORWARD-NEU­ TRAL-REVERSE SWITCH MUST BE IN THE NEU­ TRAL POSITION OR HAVE THE REAR WHEELS RAISED TO PREVENT THE POSSIBILITY OF INJURY IF VEHICLE IS ACTIVATED. 2.

Remove the seat, place the forward-neutral-re­ verse switch in the "forward" position, turn the ignition switch to the "on" position, and fully en­ gage the parking {hill) brake.

3.

Slowly depress the accelerator pedal until the "click" of the accelerator switch is detected {the limit switch on the accelerator switch as­ sembly activates the solenoid). If the solenoid is activated {clicked) AFTER the parking {hill) brake is released, the parking {hill) brake is functioning properly.

4.

If the accelerator switch solenoid is activated prior to complete parking {hill) brake disen­ gagement, the cause may be one or a combi­ nation of the following:

BURNISHING NEW BRAKE SHOES

&_WARNING&_ THIS OPERATION MUST BE DONE IN A SAFE LO­ CATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL To burnish the brakes the vehicle must be operated in the forward direction at maximum governed speed and the parking {hill) brake latched. When the vehi­ cle has stopped, the vehicle is operated in the re­ verse direction at maximum governed speed and the parking {hill) brake latched. This braking operation in both directions is considered as one burnishing

Pg. G-10

To check for proper parking {hill) brake func­ tion, lift the rear of the vehicle {see procedures in Section B) so that both rear tires are clear of the ground and there are no objects near the tires.

a)

An improperly adjusted parking {hill) brake kick-off cam.

9/01/89 ! ! !G!9!AI

BRAKES - 1989 ADJUST PASSENGER SIDE BRAKE LEVER

ADJUST DRIVER'S SIDE BRAKE LEVER

FRON T 1/8"

WITH PARKING (HILL) BRAKE DISENGAGED

DETAIL C

:j

3 7/8" 3

l316" t!

ADJUS�IES(�:,�: (71 3/32" TO 5/32" WITH PARKING (HILL) BRAKE ENGAGED

WELDED ROD ADJUSTING NUT (10)

FIG. G-9 BRAKE LINKAGE ADJUSTMENT 9/01/89

! ! ! !G!9!AI

Pg. G-11

BRAKES - 1989 b)

5.

The catch bracket and/or latch arm is worn or damaged.

To check the above items (a, b), lower the rear wheels to the ground. Lift the front of the vehi­ cle (see procedures in Section B). If the vehi­ cle has four wheels, remove the left front wheel (driver's side) for better access to the parking (hill) brake kick-off mechanism, and proceed as follows: a)

b)

c)

3. Using a 7/16" wrench, remove the 1/4" x 3/4" long bolts (3), lock wash­ ers (4), and the nuts (5) which retain the catch bracket (1) to the brake bracket.

4. Remove the catch bracket and install a new catch bracket in the reverse order of disassembly. d)

Check the cam (6) for proper adjustment.

When the latch arm is engaging the catch bracket, there must NOT be any gap be­ tween the top of the cam and the latch arm (FIG. G-10).

e)

If the cam requires adjustment, proceed as follows:

Inspect the catch bracket (1) and latch arm (2) for any damage or wear.

If the parking (hill) brake latch arm needs replacing, see section on "Disassembly of Brake Pedal" .

If the catch bracket needs replacing, pro­ ceed as follows:

1. Engage the parking (hill) brake.

2. Loosen the two cam setscrews (7).

3. Rotate the pivot arm assembly (1, Fig. G-11) upward (clockwise when viewed from the driver's side of the vehicle) to remove the free play in the linkage.

1. Be sure that the parking (hill) brake has been released.

4. Rotate the cam counterclockwise so that the top of the cam is contacting the latch arm.

2. Roll the floormat back from the brake area to provide access to the 1/4" catch bracket mounting nuts (5).

5. While holding the cam and the pivot arm assembly in proper position, tighten the cam setscrews .

.03 MAX GAP AFTER ADJUSTMENT OF CAM-4�,c -----CAM MUST BE AGAINST--+-i,---0#-./ LATCH ARM AT THIS POINT: 0.0" GAP I

' 1/4" MAX GAP AT THIS POINT

FIG. G-10 CATCH BRACKET ADJUSTMENT

Pg. G-12

9/01/89

! ! !G!9!A!

BRAKES - 1989

©

ROTATE CAM COUNTER-CLOCKWISE UNTIL TOP OF CAM CONTACTS L ATCH ARM.

®

WITH PARKING (HILU BRAKE ENG A GED, LOOSEN SE T SCREWS.

®

ROTATE SHAFT CLOCKWISE TO REMOVE LINK A GE FREE-PL AY. HOLD WITH HAND WHILE PROCEEDING.

@

RE-TIGHTEN SE T SCREWS.

FIG. G-11 PIVOT ARM ASSEMBLY

9/01/89

! ! ! !Gl9!A!

E�GClii:£iit{•J:I

Pg. G-13

BRAKES - 1989

Pg. G-14

9/01/89

! ! !G!9!AI

OPERATION AND SERVICE MANUAL SECTION: BRAKES - STARTING 1990

To assure proper braking performance, all periodic maintenance inspections and procedures should be performed as indicated in the schedule (Section A) i.e. Daily, Weekly, Monthly, Semi-Annually, and An­ nually.

G

travel to the brake pedal while traveling at full speed.

He should observe if either of the rear wheels fails to "lock up" . If one wheel fails to lock, it is reasonable to expect that a problem exists with the service ··· brake system and the 6 Month Brake Maintenance must be performed in its entirety. If both wheels lock, the parking (hill) brake must be adjusted and the vehicle re-tested per the Daily Brake Test.

GENERAL

6 MONTH BRAKE MAINTENANCE

The overall brake system consists of: (a) self-adjusting wheel brake units which nor­ mally do not require adjustment until inter­ nal components have worn to a point of needing replacement.

Raise the entire vehicle as specified in Safety Proce­ dures Section B of the operation and service man­ ual.

Rotate each rear wheel by hand, and feel for a drag­ ging brake shoe that prevents smooth movement of the wheel and brake drum.

Remove the clevis pin from both cables where they attach to the wheel brake levers.

Again rotate each wheel by hand and feel for a drag­ ging brake shoe that prevents smooth movement of the wheel and brake drum. If the wheel rotates more smoothly than with the brake cables attached, a worn or damaged brake cable is indicated and MUST be replaced.

Inspect the cables for abrasion to the cable housing.

A kinked cable or a cable housing that has worn to the point of exposing the metal jacket will result in the cable dragging. Any worn or kinked cables MUST be replaced. Operate the brake pedal and observe the movement of the cables. Both should move the same amount and return fully when the brake pedal is released. If the brake pedal does not return to the full up position, excess pedal bushing friction is indicated. The bushing must be removed and lubricated or replaced. Observe the equalizer bar to see if it pivots during operation of the brake pedal. A pivoting equalizer bar, uneven movement or failure of the brake cables to return fully indicates a dragging brake cable which MUST be replaced.

Remove each brake drum and shoes according to procedures indicated in BRAKE DRUM, SHOE AND BRAKE ASSEMBLY REMOVAL section.

Clean and inspect all brake parts. If there is evi­ dence of rust or if the adjuster does not move smoothly in the backing plate, the surfaces must be cleaned and smoothed using an emery cloth. The backing plate MUST be replaced if excessive wear such as gouges or galling are in evidence on the backing plate.

(b) actuating linkages requiring periodic ad­ justment to compensate for normal wear of system components and/or their replace­ ment.

A complete brake system adjustment procedure must be performed whenever any part of the brake system has been replaced. (FIG. G-20)

DAILY BRAKING PERFORMANCE TEST To determine the adequacy of the vehicles brake system, the following test should be performed daily:

&_WARNING&_ ALL DRIVING BRAKE TESTS MUST BE DONE IN A SAFE LOCATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL The recommended way of performing the daily brake test and determining any vehicles that have unacceptable braking performance is to have per­ sonnel handling the vehicles latch the hill brake at a common point on a paved surface while traveling at maximum governed speed. The vehicle stopping lo­ cation must be observed and vehicles that stop in a significantly greater distance than other acceptable vehicles should immediately be removed from serv­ ice and inspected by a qualified mechanic.

The mechanic should perform a "panic" stop on the suspect vehicle(s) by applying maximum force and

10/01/89

I I I !G!O!AI

Pg. G-15

BRAKES INSPECTION OF BRAKE SHOES

The brakes are the "servo acting" type.

The pattern of normal brake shoe wear is shown (FIG. G-12) in quadrants A, B, C and D with quad­ rant 'A' showing the most wear, 'B' will show the second most wear. Quandrants A and C will always be to the rear of the vehicle.

Inspect brake shoes. Brake shoes MUST be re­ placed as a set when either shoe has a lining thick­ ness less than .040 in. thick AT ANY POINT on the shoe.

After lubricating the backing plate and adjuster mechanism at the lubrication points shown in illus­ tration (FIG. G-19), re-assemble and adjust the complete brake system according to the procedures outlined in the section later in this section.

The wheel brake is a self-adjusting unit and should not require any adjustment until internal components have worn to a point of needing replacement. Also, periodic adjustment to the actuating linkage may be required to compensate for component wear or as a result of a component replacement.

A complete brake system adjustment procedure must be performed whenever any part of the brake system has been replaced. (FIG. G-20) Retest according to DAILY BRAKING PERFORMANCE TEST.

Depressing the brake pedal causes the brake cable to pull the brake actuating lever forward which in turn pushes the rear brake shoe against the brake drum.

Continued movement of the brake actuating lever causes the lever slide mechanism to move which pushes the front shoe against the drum. As the shoes contact the drum "servo action" takes place.

If the vehicle is moving forward the rear brake shoe moves upwards applying pressure against the upper rear portion of the brake drum. The front shoe moves downwards applying pressure against the lower front portion of the brake drum.

The action reverses when the brakes are applied with the vehicle operating in reverse.

HOW THE ADJUSTER WORKS (FIG. G-14)

HOW THE BRAKE SYSTEM WORKS An overall view of the brake system is shown in FIG. G-13.

The brake has an automatic adjuster mechanism that compensates for lining wear.

�FORWARD

FORWARD�

FIG. G-12 BRAKE WEAR Pg. G-16

10/01/89 I I !G!O!A!

BRAKES

®

FIG. G-13 BRAKE LINKAGE

The brake adjuster is activated by movement of the lever attached to the brake cable. Movement of this lever activates the adjuster lever (1) which rotates the 'star' wheel (2). The star wheel's rotation pushes the adjuster screw (3) outwards which in turn moves the brake shoes outward. With the brake correctly adjusted, the adjuster lever does not have enough movement to rotate the star wheel since

10/01/89 I I I !G!O!A!

lever movement is limited to approximately 1/8" .

The 1/8" of movement limits the adjuster lever's motion to the flat of the tooth that it is sitting on.

As the brake shoe wears, the lever's motion in­ creases which causes the adjuster lever to engage the next tooth of the star wheel. The star wheel is then rotated which expands the brake shoes.

Pg. G-17

BRAKES

DIRECTION OF BRAKE CABLE PULL ----f..�

..-----BRAKE A CTUATOR LEVER .-----ADJUSTER HOUSING (2) STAR WHEEL

REAR

(1) ADJUSTER LEVER NOTE: TEETH ARE NUMBERED IN ILLUSTRATION TO CLARIFY THEIR POSITIONS. THE DISTANCE OF THE ADJUSTER LEVER TRAVEL IS REGULATED BY THE AMOUNT OF BRAKE SHOE WEAR.(A )

POSITION OF ADJUSTER LEVER WITH BRAKES DISENGA GED.

WHEN BRAKE SHOE WEAR IS MINIMAL, THE DISTANCE OF ADJUSTER LEVER TRAVEL IS TOO SHORT TO FULLY RE-ADJUST BRAKES.(Bl

POSITION OF ADJUSTER LEVER WITH MINIMUM SHOE WEAR AND BRAKES ENGA GED:

AS SHOE WEAR INCREASES, ADJUSTER LEVER TRAVEL INCREASES, THUS TURNING THE STAR WHEEUC)

POSITION OF ADJUSTER LEVER WITH BRAKES ENGA GED AND SHOES WORN TO POINT OF NEEDING SELF-ADJUSTMENT.

WHEN BRAKE SH OES HAVE WORN SUFFICIENTLY TO REQUIRE RE-ADJUSTMENT, THE ADJUSTER LEVER ADVANCES AND RATCHETS TO THE NEXT TOOTH WHEN BRAKES ARE RELEASED.ml

POSITION OF ADJUSTER LEVER WITH BRAKES DISENGA GED AND READY TO RESET ADJUSTER SCREW.

WHEN BRAKE IS NEXT ENGAGED, THE ADJUSTER LEVER WILL ROTATE THE STAR WHEEL FAR ENOUGH TO EXTEND THE ADJUSTER SCREW, THUS RE-SETTING THE PROPER SHOE/DRUM CLEARANCE.(El

POSITION OF ADJUSTER LEVER WITH BRAKES ENGAGED DURING RE­ ADJUSTMENT OF SCREW.

WHEN THE SH OE/DRUM CLEARANCE IS RESET, LESS EFFORT IS REQUIRED TO ENGAGE THE BRAKES, THUS THE ADJUSTER LEVER TRAVEL IS ONCE AGAIN REDUCED.(F ,Al

�' 1"--

(ff'

POSITION OF ADJUSTER LEVER WITH BRAKES DISENGAGED AND RE­ ADJUSTMENT COMPLETED. OTE NEW POSITIONS OF TEETH.

FIG. G-14 HOW THE BRAKE ADJUSTER WORKS Pg. G-18

10/01/89 I I !G!O!A!

BRAKES DISASSEMBLY OF BRAKE PEDAL (FIG. G-15)

Tools Required:

Qty.

Screwdriver, straight blade ... . ........... . .. 1 Pliers .................................... 1 Hammer, ball pein ......................... 1 Unhook the pedal return spring (1}. (Insert a thin blade screwdriver between the small hook end and the pedal bracket, move spring back and away from the bracket.} Remove the lock nut (2) from the pivot bolt (3) and remove the bolt. Remove the spring, disconnect the cable clevis (4) and lift the pedal out through the floorboard.

To remove the parking (hill} brake pedal, note the position of the two springs (5). Remove the "push on" retainer nut (6) (new nut required for assem­ bly}, and remove the hinge pin (7). Reassemble in the reverse order of disassembly.

REMOVAL OF PARKING (HILL) BRAKE RELEASE LINKAGE (FIG. G-16) Tools Required:

Qty.

Pliers .................................... 1 Jack, Hydraulic Trolley ..................... 1 Jack stands .............................. 1 Wrench, open end, 1/4" .................... 1 To remove the parking (hill} brake release linkage, raise the front of vehicle (see procedure in Section B} to allow access to underside.

To remove the linkage rod (1}, remove the cotter pin (2) and washers (3) and (12) from lever arm (4).

Loosen the two setscrews (5) in cam (6), and re­ move the pivot arm shaft (4). The cam (6) and ny­ lon spacer (9) will come out when the pivot arm shaft is removed.

If the spacer (9) or bearings (10 and 11} are worn, replace them with new spacers or bearings.

Reassemble by reverse procedure.

FIG. G-15 BRAKE PEDAL SPRING RE­ MOVAL

10/01/89 I I I !G!O!A!

It may be necessary to remove the indentures on the shaft (4} caused by the setscrews (5}.

Pg. G-19

BRAKES

s-1 '----A _____ _.

FIG. G-16 BRAKE "KICK OFF" LINKAGE BRAKE DRUM, SHOE AND BRAKE ASSEM­ BLY REMOVAL (FIG. G-17, FIG. G-18 ) Tools Required:

Qty.

Jack, hydraulic trolley ....................... 1 Hammer, plastic tipped ..........•........... 1 Jack stands ••..............•.............. 4 Screwdriver, flat blade ..................•... 2 Socket, 1/2", 1/2" drive .................... 1 Ratchet, 1/2" .............................. 1 Socket, 1 1/16", 1/2" drive ......•........... 1 Torque wrench, 1/2" drive ................... 1 Pliers .......•............................. 2 Wrench, open end, 1/2" .................••. 1

DRUM REMOVAL (FIG. G-18) Loosen lug nuts on rear wheels 1/8 to 1/4 turn.

Raise the vehicle (see procedure in Section B). Re­ move the rear wheel (s).

Pg. G-20

Remove the cotter pin (5) and clevis pin (6) from the brake lever. Remove the cotter pin (8) from the axle nut (9) and remove the nut and washer (10).

TAP the brake drum (11) with a plastic faced ham­ mer to remove the drum. If the drum does not come off, it will be necessary to loosen the brake adjuster mechanism.

Rotate the brake drum until one of the holes is lo­ cated over the star wheel position (7 o'clock for driver's side, 5 o'clock for passenger side).

The hole is aligned with the brake adjuster mecha­ nism when in this position. Insert a flat blade screw­ driver between the adjuster lever and the adjuster screw housing. Insert a second flat blade screw­ driver and push on the top portion of the 'star' wheel which will loosen the adjuster screw and retract the shoes to permit the drum to be removed.

10/01/89

I I !G!O!A!

BRAKES

·1�

1·

PASSENGER SIDE

.-

HEAVY SPRING

DRIVER S SIDE

2

2

1

4

LIGHT SPRING

FIG. G-17 WHEEL BRAKES DRIVER'S AND PASSENGER SIDE FIRST USED ON 1990 VEHICLES REAR OF VEHICLE

FRONT OF VEHICLE

SELF-ADJUSTING BRAKES <DRIVER'S SIDE SHOWN)

FRONT OF VEHICLE· 3

THIS SHOE THIS SHOE ALWAYS ALWAYS FACES REAR FACES FRONT INSTALL ADJUSTER SPRING WITH LONG END TOWARD REAR AND CLEAR OF OBSTRUCTIONS 11

REAR OF VEHICLE LIGHT 4

i ADJU,STER DETAIL

FIG. G-18 WHEEL BRAKE COMPONENTS 10/01/89

I I I !G!O!A!

Pg. G-21

BRAKES

BACKING PLATE

LUBRICATE BOTH F RONT AND BACK SURFACES AROUND THIS SLOT

LUBRICATE THESE POINTS

ADJUS TER ASSEMBLY

- LUBRICATE SHADED AREAS

FIG. G-19 BRAKE LUBRICATION AREAS BRAKE SHOE REMOVAL Using a pair of pliers, compress the brake shoe re­ tainer springs (1) at the open end of the spring.

While holding the tension pin (2) with a second set of pliers, turn the retainer spring 1 /4 turn to align the slot in the spring retainer with the flats in the tension pin. Remove the brake shoe retainer springs.

Grasp the brake shoes (3) in the center and tilt them outwards and away from the back mounting plate.

This will release the tension in the brake springs (4).

Remove the brake springs and remove the brake shoes.

Inspect brake shoes. If a brake shoe has less than .040 lining material thickness AT ANY POINT on either shoe then both shoes MUST be replaced.

&_WARNING&_

WEAR PROTECTIVE GOGGLES AND MASK WHEN CLEANING BRAKE COMPONENTS. LUBRICATE AREAS INDICATED (FIG. G-19) WITH COMMER­ CIALLY AVAILABLE BRAKE COMPONENT LUBRI­ CANT (available from any auto parts outlet).

Check for free lateral (front and back) movement of the adjusting mechanism and for free movement of the 'star' wheel. Remove the boot on the brake lever. Clean any accumulated brake dust from the

Pg. G-22

backing plate and adjuster mechanism using a brush or air hose.

If the brake is being removed for an axle bearing and seal replacement, the four bolts and nuts securing the brake assembly to the rear axle must be re­ moved. When reinstalling the brake mounting bolts, tighten to 23-35 ft. lbs. torque.

REPLACING BRAKE SHOES (FIG. G-17, FIG. G-18)

I rnJ(ffiY� I

The metal portion of the brake shoes differs be­ tween front and rear shoes. The identical ends of the shoes fit against the fixed anchor at the top of the brake. The shoe with the straight end engages in the slot in the adjusting screw, while the triangular ended shoe engages in the rear of the adjusting mechanism.

The springs must be inserted with the light spring at the bottom. The long hook is installed down through the rear brake shoe. The heavier top spring is in­ stalled with the spring hooks facing up.

Install the brake shoes using the reverse order of disassembly and secure with the brake shoe retainer springs and brake shoe return springs.

10/01/89 I I !G!O!A!

BRAKES· Clean the axle shaft to remove grease, dirt and all foreign matter. Apply a small amount of lubricant (Neverseize) to the spline.

Insert a straight blade screwdriver between the ad­ justing lever and the adjusting mechanism. Rotate the start wheel counter clockwise until the shoes have retracted sufficiently to permit the brake drum to be installed. Install washer (12), brake drum (11), washer (10), and tighten the axle nut to 70 ft. lbs. torque minimum.

If the slot in the axle nut and the hole in the axle are not in alignment, continue to tighten the axle nut until the alignment is achieved.

3.

Remove the wheel and tire corresponding to the position of the equalizer (Detail 'A').

ADJUSTMENT OF THE WHEEL BRAKE 4.

With the wheel removed, the brake lever is ac­ cessible. Push the brake lever forward and re­ lease (Detail 'B') - repeat as needed until the lever travel is approximately 1/8".

A hammer handle works well as a tool to push the lever.

5.

Reinstall wheel.

6.

Reconnect compensating linkage (2).

Minimum torque is 70 ft. lbs. Torque readings of up to 140 ft. lbs. are satisfactory.

Install new cotter pin (8).

Move the brake lever forward and release fully, re­ peat until the travel of the lever is approximately 1/8". Install brake cables using clevis pin (6) and a new cotter pin (5).

Always use a new cotter pin (3).

ADJUSTING COMPENSATING SPRING 7.

COMPENSATING BRAKE LINKAGE ADJUSTMENT (FIG. G-20) Tools Required:

Qty.

Ratchet, 1/2" drive ......................... 1

With the parking (hill) brake DISENGAGED, check that the compensating spring length is 3 15/16" (Detail C). If adjustment is required it is made at the nut (6) located in front of the spring (7) (Detail 'C').

ADJUSTING FREE PEDAL TRAVEL 8.

Extension, 6", 1/2" drive .................... 1 Socket, 3/4", 1/2 drive ..................... 1 Wrench, open end, 1/2" .................... 1

Measure the free pedal play to determine if it is between 1" - 1 1/2". If an adjustment is re­ quired; release the jam nut (8) from the yoke (9) and adjust at the threaded rod welded nut (10) (Detail 'D').

Pliers ..................................... 1 Hammer, ball pein .......................... 1 Raise the vehicle (see procedure in Section B) 1.

2.

Check the position of the equalizer (1) with parking (hill) brake ENGAGED (Detail 'A'). a)

If dimension exceeds 1/8" proceed to Step 2.

b)

If dimension is within specification proceed to Step 7.

Remove compensating linkage (2) from equalizer (1) by removing cotter pin (3) and clevis pin (4).

10/01/89

I I I !G!O!A!

If the nut (6) in front of spring (7) does NOT rotate with the threaded rod, a second 1/2" wrench will be required. Turn both wrenches simultaneously.

Service Tip: Installing a 5/16-24 jam nut against the nut (6) and locking it in place will eliminate nut movement on the threaded rod and eliminate the need for a second wrench.

ADJUSTING THE WHEEL BRAKE AND SEATING BRAKE COMPONENTS 9.

Engage the parking (hill) brake and then RE­ LEASE. Repeat twenty (20) times.

Pg. G-23

Be sure to allow the pedal to return fully after each cycle.

10. ENGAGE the parking (hill) brake and check for a gap of 3/32" (Detail 'D'). If an adjustment is required, the adjustment is made at the welded rod adjusting nut (10).

I IDJ001Y� I

Be sure that the adjusting nut (6) rotates with the threaded rod. (See Service Tip).

FINAL SYSTEM CHECK

cycle. Burnish the brakes for 15 cycles. If the brake performance is acceptable after burnishing, the ve­ hicle may be returned to service. If the brake per­ formance is unacceptable the 6 month maintenance MUST be performed again in its entirity.

PARKING (HILL) BRAKE ADJUSTMENT (FIG. G-21) The parking (hill} brake engagement and holding force should be properly adjusted if the brakes have been adjusted per the " recommended brake adjust­ ing procedure."

PARKING (HILL) BRAKE FUNCTION 1.

11. Remeasure the free travel (1"-1 1/2") - if an adjustment is required, the adjustment is made at the welded rod adjusting nut (10) but the gap dimension specified in Detail "D" must be maintained.

12. Tighten jam nut (8).

13. Lower vehicle.

14. Perform the "DAILY BRAKING PERFORMANCE TEST" described at the beginning of this sec­ tion and return to service if the brake perform­ ance is acceptable. If performance is unaccept­ able, the brake shoes must be burnished to conform to the brake drum.

&,WARNING&, TO TEST FOR THE AUDIBLE "CLICK" OF THE MI­ CRO SWITCH, THE VEHICLE FORWARD-NEU­ TRAL-REVERSE SWITCH MUST BE IN THE NEU­ TRAL POSITION OR HAVE THE REAR WHEELS RAISED TO PREVENT THE POSSIBILITY OF INJURY IF VEHICLE IS ACTIVATED. 2.

Remove the seat, place the forward-neutral-re­ verse switch in the "forward" position, turn the ignition switch to the "on" position, and fully en­ gage the parking (hill) brake.

3.

Slowly depress the accelerator pedal until the "click" of the accelerator switch is detected (the limit switch on the accelerator switch as­ sembly activates the solenoid). If the solenoid is activated (clicked) AFTER the parking (hill) brake is released, the parking (hill) brake is functioning properly.

4.

If the accelerator switch solenoid is activated prior to complete parking (hill) brake disen­ gagement, the cause may be one or a combi­ nation of the following:

BURNISHING NEW BRAKE SHOES

&,WARNING&, THIS OPERATION MUST BE DONE IN A SAFE LO­ CATION WITH REGARD FOR THE SAFETY OF ALL PERSONNEL To burnish the brakes the vehicle must be operated in the forward direction at maximum governed speed and the parking (hill} brake latched. When the vehi­ cle has stopped, the vehicle is operated in the re­ verse direction at maximum governed speed and the parking (hill} brake latched. This braking operation in both directions is considered as one burnishing

Pg. G-24

To check for proper parking (hill) brake func­ tion, lift the rear of the vehicle (see procedures in Section B) so that both rear tires are clear of the ground and there are no objects near the tires.

a)

An improperly adjusted parking (hill) brake kick-off cam.

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I I !G!O!AI

BRAKES -

·ff1� ·-·

ADJUST DRIVER'S SIDE BRAKE LEVER

ADJUST PA SSENGER SIDE BRAKE LEVER

t 1/8"

r

WITH PARKING (HILL) BRAKE DISENGAGED

DETAIL C =1315/16"

1

ADJUS:,:!S �::: (71 3/32" WITH PARKING (HILL) BRAKE ENGAGED

DETAIL D

FIG. G-20 BRAKE LINKAGE ADJUSTMENT 10/01/89 I I I !G!O!Al

Pg. G-25

BRAKES - 19� ": b)

5.

3. Using a 7/16" wrench, remove the 1/4" x 3/4" long bolts (3), lock wash­ ers (4), and the nuts (5) which retain the catch bracket (1) to the brake bracket.

The catch bracket and/or latch arm is worn or damaged.

To check the above items (a, b), lower the rear wheels to the ground. Lift the front of the vehi­ cle (see procedures in Section B). If the vehi­ cle has four wheels, remove the left front wheel (driver's side) for better access to the parking (hill) brake kick-off mechanism, and proceed as follows: a)

b)

c)

4. Remove the catch bracket and install a new catch bracket in the reverse order of disassembly.

Inspect the catch bracket (1) and latch arm (2) for any damage_ or wear.

If the parking (hill). brake latch arm needs replacing, see section on "Disassembly of Brake Pedal" .

d)

Check the cam (6) for proper adjustment.

When the latch arm is engaging the catch bracket, there must NOT be any gap be­ tween the top of the cam and the latch arm (FIG. G-21).

e)

If the cam requires adjustment, proceed as follows: 1. Engage the parking (hill) brake.

2. Loosen the two cam setscrews (7).

3. Rotate the pivot arm assembly (1, Fig. G-11) upward (clockwise when viewed from the driver's side of the vehicle) to remove the free play in the linkage.

If the catch bracket needs replacing, pro­ ceed as follows:

,_

1. Be sure that the parking (hill) brake has been released.

4. Rotate the cam counterclockwise so that the top of the cam is contacting the latch arm.

2. Roll the floormat back from the brake area to provide access to the 1/4" catch bracket mounting nuts (5).

5. While holding the cam and the pivot arm assembly in proper position, tighten the cam setscrews.

. 03 MAX GAP AFTER ADJUSTMENT OF CAM-J.J'---1-il.----,..

CAM MUST BE AGAINST-,L--,,____ok/ LATCH ARM AT THIS POINT, 0.0" GAP I

6 .....

1/4" MAX GAP AT THIS POINT

FIG. G-21 CATCH BRACKET ADJUSTMENT

Pg. G-26

10/01/89 I I !GIOIA!

BRAKES

©

ROTATE CAM COUNTER-CLOCKWISE UNTIL TOP OF CAM CONTACTS L ATCH ARM.

@

WITH PARKING (HILL) BRAKE ENG A GED, LOOSEN SET SCREWS.

@

ROTATE SHAF T CLOCKWISE TO REMOVE L INKA GE FREE-PLAY. --HOLD WITH HAND WHILE PROCEEDING.

RE-TIGHTEN SET SCREWS.

FIG. G-22 PIVOT ARM ASSEMBLY

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Pg. G-27

BRAKES

Pg. G-28

l ;,·

10/01/89

I I !G!O!AI

OPERATION AND SERVICE MANUAL SECTION:ENGINE AND CONTROLS

&_WARNING&_

ENGINE SPECIFICATIONS Engine model

EC25- 3PG

Bore (72 MM) ...............2.835 0to 2.8357 in.

Stroke (6 0mm) ......................2.3622 in.

Number of cylinders ........................ 1 Piston ring end gap ................008to .016 in.

Compression ratio ......................... 5.8

H

NEVER OPERATE THE STARTER UNLESS THE SPARK PLUG IS INSTALLED OR THE IGNITION · SYSTEM IS DISABLED. FUEL DRAWN INTO THE CYLINDERS WILL BE EXPELLED THROUGH THE SPARK PLUG HOLE AND COULD BE IGNITED BY THE IGNITION SYSTEM, RESULTING IN A FIRE.

ENGINE LUBRICATION

Spark plug gap ...................02 8to .03 0in.

Maximum engine RPM ................... 4 000 Cylinder displacement. .................. 244 cc Piston to bore clearance (Factory engines only) ............0012 to .001 8in.

Piston ring type ......... Upper side keystone type Timing ................ Refer to timing procedure

ENGINE DESCRIPTION The engine is a single cylinder, reed valve, 2-cycle, air cooled engine.

2-CYCLE OPERATION The 2-cycle engine requires two piston strokes or only one revolution for each cycle (intake, compression, igni­ tion and exhaust).

During the upstroke (compression stroke), a vacuum is created in the crankcase drawing a gasoline and air mix­ ture from the carburetor through the cylinder into the crankcase. As the piston moves upward closing the ex­ haust port, compression of gasses takes place above the piston. Firing occurs each time the piston reaches the top of its stroke.

On the downward stroke (power stroke), the exhaust gas is released from the cylinder.At the same time, gas­ ses in the crankcase are compressed and forced up through the cylinder ports into the combustion chamber as the descending piston uncovers the ports.

Ignition timing is produced by the operation of the solid state ignition, ignition coil, and spark plug. The activa­ tion of the solid state ignition is by a rotor on the cooling fan which determines the spark timing.

4/01/92 i i i !H!9!G!

TO PREVENT PREMATURE ENGINE FAILURE, USE ONLY E-2-GO 2-CYCLE OIL. The 2-cycle engine does not require a crankcase oil supply for engine lubrication.Lubrication is achieved by mixing oil with the gasoline. Oil is introduced into the in­ take manifold from a crankshaft driven oil pump.

STORAGE If the vehicle is to be out of service for a period of months, the engine should be prepared according to the following procedure to prevent corrosion of internal parts.

Run a small quantity of 2 0:1 (6.5 ounces per gallon) gasoline-oil mixture through the engine to provide addi­ tional lubrication for the crankcase.

Completely drain the fuel tank and lines. Disconnect the inlet lines at the fuel pump and run the engine until it stops to eliminate any fuel from remaining in the carbu­ retor. Remove the spark plug and apply a small amount of oil (approximately 2 ounces.) in the cylinder to prevent rusting. After applying oil, rotate the crankshaft one revolution to assure that oil coats the cylinder wall. Re­ place the spark plug.

ISOLATION MOUNTS (FIG. H-1), (FIG. H-2) Tools Required:

Qty.

Jack, hydraulic, trolley ....................... 1 Drill, electric

.............................. 1

Drill Bit, 3/16" .............................. 1 Chisel .................................... 1 Socket, long reach, 9/16, 3/8drive .............. 1

E�E:iDiinilM:I

Pg. H-1

ENGINE AND CONTROLS Ratchet, 3/8" ....... .. . .. .................. 1 Wrench, 9/16" box end ............. . . . . .. ... 1 Screwdriver, straight blade . . . . . . .. ... ........ 1

FIG. H-1 FRONT ISOLATION MOUNT

Wrench, 5/16", box end ...................... 1

It is not necessary to remove the engine from the vehicle to replace the isolation mounts.

Four isolation mounts are used.The front pair of mounts use different mounts and attachment hardware from the rear ones. Refer to Service Parts Manual to select the correct color coded mount for your application. Install new mounts with the long side down.If a mount needs to be replaced, proceed as follows: Place an adjustable jack under the engine frame, adjacent to isolation mount to be replaced. Remove the four rivets that attach the isolation mount to the engine frame using a drill or chisel.

To remove a front mount refer to FIG. H-1 Remove the center bolt (1), snubber washer (2), flat washer (3), iso­ lation mount (4), flatwashers (3), (one on the top and one below the slot in the mount bracket of the suspen­ sion frame) lock washer (5) and nut (6). Raise or lower the jack as necessary to allow the mount to be removed from the engine frame.

Replacement mounts are furnished with nuts (7), wash­ ers (8), and bolts (9) for attaching mounts to frame rather than rivets. Install the center bolt (1) and related hardware; tighten securely.

To remove a rear mounts refer to FIG.H-2.Remove the center bolt (1), snubber washer (2), flat washer (3), iso­ lation mount (4) lock washer (5) and nut (6). Raise or lower the jack as necessary to allow the mount to be re­ moved from the engine frame.

Replacement mounts are furnished with nuts (7), wash­ ers (8), and bolts (9) for attaching mounts to frame rather than rivets. Install the center bolt (1) and related hardware; tighten securely.

MUFFLER REMOVAL (FIG. H-3)

FIG. H-2 REAR ISOLATION MOUNT

Pg.H-2

Remove the two bolts (9) and lock nuts (10) that secure the muffler (15) to the exhaust pipe. Remove the two nuts (11), washers (12), and screws (13) that secure the muffler retaining straps (14) to the muffler support. The straps are secured to the support at one end and may be moved to permit the muffler to be removed from the sup­ port. Slide the muffler away from the exhaust pipe and lift the muffler out of the muffler support. Remove the muffler cushion (16) from the muffler support. Remove the bolts (17) from the muffler support.

E�l3Dii�:,i;{•J:I

4/01/92 I I !Hi9!Gl

ENGINE AND CONTROLS ENGINE FRAME INSTALLATION

ENGINE FRAME REMOVAL AND INSTALLATION (FIG.H-4)

Installation is in the reverse order of removal.

Tools Required:

Qty.

ENGINE REMOVAL

Wrench, 7/16" ............................. 1 Wrench, 9/16" .• .• ......................... 1

Tools Required:

ENGINE FRAME REMOVAL

Ratchet, 3/8" ............................... 1

lmJ®TI�I

Qty.

Extension, 6", 3/8 drive ...................... 1 Extension, 2", 3/8 drive ...................... 1

Remove the engine in accordance with the Engine Re­ moval Procedure.

Loosen the four mounting bolts securing the engine frame (1) isolation mounts to the inner frame (2). Re­ move the bolts and lift the engine frame from the vehicle observing the location of the snubber washers (4), flat washers (5) and lock washers (6). In addition to the stated hardware there are an additional two flat washers (7) that are used on either side of each of the slotted mounting bracket.

Socket, 5/8", 3/8 drive ....................... 1 Socket, 1/2", 3/8 drive ....................... 1 Socket, 7/16", 3/8 drive ...................... 1 Socket,12 mm, 3/8" drive ..................... 1 Torque wrench, 3/8" drive .................... 1 Wrench.box, 5/8" ........... . ............... 1 Wrench, box, 9/16" .......................... 1 Wrench, 1/2" open end ................... • ... 1 Wrench, insulated, 1/2" ...................... 1 Screwdriver, straight blade .................... 1 Screwdriver, straight blade, small .............. 1 Screwdriver, Phillips, large .................... 1 Allen wrench, 5/64 .......................... 1 Cutters, diagonal side ....................... 1 Pliers, slip joint ............................. 1 Jack, trolley • • ..............• .............. 1 Jack stands ............................... 2 Chocks or wooden blocks .................... 2

fD,.WARNINGID,.

TO PREVENT THE POSSIBILITY OF PERSONAL IN­ JURY: REMOVE THE (+) BATTERY LEAD AT THE BAT­ TERY AND COVER THE(+) POST WITH A NON CON­ DUCTIVE COVER SUCH AS A SHOP RAG. OBSERVE ALL Of THE WARNINGS AS DESCRIBED IN SECTION B.

FIG. H-3 MUFFLER, ENGINE AND STARTER BELT

4/01/92

! l l lHl9lG!

Remove the four Phillips head screws that secure the trunk lid. Remove the trunk lid.

Remove the center bolt, lock washer,large flat clutch washer and the internal clutch bolt spacer from the drive clutch and clean the old sealant from the threads.

E�GDii:$:sit?•l:I

Pg.H-3

ENGINE AND CONTROLS

&WARNING& TO REMOVE THE DRIVE BELT, PARK ON FLAT SURFACE. WITH F-N-R SWITCH IN NEUTRAL AND THE HILL BRAKE OFF, PUSH VEHICLE BACK­ WARDS WHILE ROLLING THE BELT OVER THE DRIVEN CLUTCH SHEAVE. DO NOT ALLOW FIN­ GERS TO BECOME TRAPPED BETWEEN THE BELT AND THE SHEAVE. Remove the drive belt from the driven clutch sheave by following the instructions in the above warning.

&WARNING& TO PREVENT BURNS, BE SURE THAT THE MUF­ FLER AND EXHAUST COMPONENTS HAVE COOLED BEFORE ATTEMPTING ANY SERVICE.

To remove the engine only, you need to remove only the hardware securing the muffler to the exhaust pipe, the muffler support brace to the generator support bracket, and the starter/generator belt. The following operation is not required for engine removal.

MUFFLER AND MUFFLER SUPPORT RE­ MOVAL {FIG.H-3) Remove the nut (1), lock washers (2), special washers (3), and bolt (4) that secures the muffler support brace (5) to the starter generator bracket (6). Remove the nuts (7), lock washers (8), and bolts that fasten the muffler support to the engine frame.

Remove the two bolts (9) and lock nuts (10) that secure the muffler (15) to the exhaust pipe. Remove the two nuts (11), washers (12), and bolts (13) that secure the muffler retaining straps (14) to the muffler support. The straps are secured to the support at one end and may be

FIG. H-4 ENGINE FRAME Pg.H-4

E�l:iCJ ii =t;,it{•J:I

4/01/92

I I !H!9!G!

ENGINE AND CONTROLS moved to permit the muffler to be removed from the sup­ port. Slide the muffler away from the exhaust pipe and lift the muffler out of the muffler support. Remove the muffler cushion (16) from the muffler support. Remove the bolts (17) from the muffler support.

STARTER/GENERATOR BELT REMOVAL (FIG. H-3) Remove the starter/generator belt (18) by loosening the the lock nut (19), that secures the tension adjuster (20).

Loosen the adjuster and pull up on the belt to pivot the start/generator (21) inwards. Remove the belt.

ELECTRICAL CONNECTIONS (FIG. H-5) Remove the ground strap (1) from the battery by remov­ ing the bolt (2), washer (3), and lock nut (4). Also, dis­ connect the ground strap (1) at the frame by removing the bolt (5) and lock nut (6).

At the passenger side of the vehicle, locate the panel (7) that mounts the voltage regulator and the ignitor unit.

Disconnect the red and the blue solid state ignition wires at the connector(8). Cut wire ties as required. At the coil (9) disconnect the green and the orange wires. (See de­ tails A and B)

LINKAGES (FIG. H-8)

(FIG.

H-6),

(FIG.

FIG. H-6 BALL JOINT REMOVAL

H-7),

USE EXTREME CARE NOT TO BEND THE LEVERS WHEN REMOVING THE LINKAGE. SEPARATE THE THE FEMALE PORTION OF THE BALL JOINT WITH CARE BY INSERTING A THIN STRAIGHT BLADE SCREWDRIVER IN THE SLOT ADJACENT TO THE JOINT AND GENTLY PRY THE JOINT APART. (FIG. H-6) REINSTALL BY SUP­ PORTING THE BALL PORTION OF THE JOINT AND SQUEEZE THE JOINT TOGETHER (FIG. H-7).

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FIG. H-7 BALL JOINT RE-ATTACHMENT Loosen the clamp (1) securing the convoluted hose (2) to the carburetor (3). Remove the hose. (FIG. H-8) Re­ move the solid linkage (4) between the carburetor throt­ tle lever and the rear axle mounted governor arm at the carburetor end. (FIG. H-8)

Pg.H-5

ENGINE AND CONTROLS

A B TO COIL

FIG. H-5 ELECTRICAL CONNECTIONS

Pg.H-6

4/01/92

I I I IHl 91GI

ENGINE AND CONTROLS

To prevent fuel spillage or siphoning, do not allow the fuel line to fall below the level of the fuel in the tank be­ fore plugging the line with a 1/4" bolt. Plug the rubber hose by inserting a 1/4" bolt into the free end, and fas­ tening it to a point above the level of the fuel tank. Se­ cure with a hose clamp.

Remove the oil line from the oil tank and plug with a suit­ able size bolt. To prevent oil loss fasten the hose to a point above the level of the oil tank such as the frame rail.

TO PREVENT SERIOUS ENGINE DAMAGE. ANY TIME THAT THE OIL INJECTION SYSTEM IS DIS­ TURBED THE SYSTEM MUST BE BLED.

ENGINE REMOVAL (FIG. H-10) FIG. H-8 SOLID LINKAGE REMOVAL CHOKE (FIG. H-9) Remove the nut (1) and lock washer(2) that secures the choke cable housing (3) to the intake manifold mounted bracket (4). Remove the bullet (5) that secures the choke cable to the carburetor choke lever swivel and re­ move the cable from the swivel.

Raise the vehicle and support on jack stands per in­ structions in section B.

&_WARNING&_ TO PREVENT INJURY CAUSED BY INADVERTENT MOVEMENT OF THE ENGINE, A SECOND PERSON IS REQUIRED TO SUPPORT AND ASSIST IN RE­ MOVING THE ENGINE.

Remove the four engine mounting bolts (1), lock wash­ ers (2) and flat washers (3) from the underside of the ve­ hicle.

Remove the engine and place on a clean surface that is free from dirt that could enter the carburetor or exhaust.

Support or cushion the engine to prevent damage to the carburetor levers.

It is not necessary to remove the engine to remove or in­ stall the drive clutch.

DRIVE CLUTCH REMOVAL AND INSTAL­ LATION

Tools Required: FIG. H-9 CHOKE CABLE FUEUOIL CONNECTIONS At the fuel pump, disconnect the rubber fue_l line from the gas tank by squeezing the clamp and removing the rub­ ber hose.

4/01/92 l

tt

!H!9!G!

Qty.

Impact wrench, 1/2" drive (air or electric) ......... 1 Socket, impact, 1 1/8, 1/2" drive ................ 1 Screwdriver, flat blade ....................... 1 Clutch removal tool, E-2-GO P/N 19779-G2 ..... 1 Sealant, Locktite 262 ... . . ............• .... AR

E�E:iCli i=>:1 i t{•J: I

Pg.H-7

ENGINE AND CONTROLS

FIG. H-10 ENGINE MOUNTING The clutch mounting bolt should have been removed as detailed in the engine removal section.

&WARNING& TO PREVENT INJURY CAUSED BY A BROKEN SOCKET, USE ONLY SOCKETS DESIGNED FOR IM­ PACT WRENCH USE. NEVER USE A CONVEN­ TIONAL SOCKET.

Pg.H-8

Lightly lubricate the threads on the clutch removal tool.

Insert the clutch removal tool into the the hole in the cen­ ter of the drive clutch.

Use the impact wrench and socket to drive the removal tool into the clutch. Continue until the clutch is sepa­ rated from the engine shaft.

Reverse the impact wrench and remove the tool from the clutch.

E�GDiiHii!•l:I

4/01/92 I I iHi9k3!

ENGINE AND CONTROLS DRIVE CLUTCH INSTALLATION (FIG. H-11) Clean both the engine shaft and clutch bore.

Slide the clutch onto the engine shaft. Rotate it and lightly push the moveable sheave in and out several times to seat the clutch on the tapered engine shaft.

Install the clutch bolt spacer to the clutch.

Position the lock washer (1), and large flat clutch washer (2) onto the clutch bolt (3).

Apply sealant to the threads of the clutch bolt.

Install the clutch bolt and tighten to 55 ft. lbs. torque.

ENGINE INSTALLATION (FIG.H-10) Service tip: To ease the installation of the engine into the frame, it is suggested that two 7/16-14 x 1" long bolts (standard engine mounting hardware) be modified. Cut the heads off both bolts and using a hacksaw cut a screwdriver slot in the cut end of each bolt. Install these bolts finger tight in the di­ agonal engine mounting holes. The engine is be lo­ cated to the engine mounting frame from the engine compartment without the need of a second techni­ cian to line up the engine mounting holes. The fol­ lowing steps are used except that the modified screws are removed after the other two bolts are in­ stalled.

The engine should be positioned over the holes in the engine frame, and the bolts (1), lock washers (2) and flat washers ( 3) installed finger tight through the engine frame and into the engine.

Check the alignment between the starter/generator pul­ ley and the drive clutch starter generator belt pulley.

They should be parallel and aligned to each other. Any SL/GHTinaccuracies may be corrected by adjusting the engine position relative to the mounting holes.

Tighten the engine mounting hardware to 46-49 in. lbs. torque.

Complete the engine installation by following the re­ verse order of disassembly.

Replace wire ties as required.Bleed the oil injection sys­ tem as described in the Fuel system section of this man­ ual.

TO PREVENT SERIOUS ENGINE DAMAGE. ANY TIME THAT THE OIL INJECTION SYSTEM IS DIS­ TURBED THE SYSTEM MUST BE BLED.

4/01/92 I I I !H!9!G!

FIG. H-11 CLUTCHES MUFFLER INSTALLATION (FIG.H-12) Be sure that the muffler insulation/heat barrier (1) is centered in the muffler support (2). Position the muffler (3) in the support. Slide the muffler inlet pipe into the ex­ haust pipe joint and install the bolts (4) through the the two flanges (5). Install the nuts (6) finger tight.

Rotate the two flanges until the top of the flange is paral­ lel with the ground. Tighten the hardware to 100 in. lbs. torque. Position the muffler mounting straps (7), apply thread adhesive to screws (8) and install the washers (9) and lock nuts (10). Tighten to 50 in. lbs torque. Tighten the muffler brace/support hardware to 18 ft. lbs. torque.

ENGINE COOLING SYSTEM (FIG. H-13)

It is not necessary to remove the engine from the vehicle to clean the cooling system. The oil pump may be re­ moved from the blower housing to eliminate the need for bleeding the oil injection system.

Periodically (150 to 200 hours) Inspect and clean the cooling system. Remove build-up of foreign matter such as grass, mud and other deposits from between the fins of the cylinder head. The blower housing should

E�GDii:i:!i,!•l:I

Pg.H-9

ENGINE AND CONTROLS Ratchet, 3/8" drive .......................... 1 Ratchet, 1/4" drive .......................... 1 Extension, 2", 3/8" drive ...................... 1 Socket, 12 mm,1/4" drive ..................... 1 Socket, 12 mm, long reach, 3/8 drive ............ 1 Screwdriver, small, straight blade .............. 1 Screwdriver, Phillips ......................... 1 Brush, parts cleaning ........................ 1

When unplugging the spark plug wire, pull on the con­ nector, never the wire.

Remove the solid linkage (1) between the oil pump lever (2) and the oil injection bellcrank (3) at the oil injection bellcrank.

Remove the oil injection pump by removing the two Phil­ lips head screws (4).

Service tip: To remove the female portion of the ball joint, insert a thin straight blade screwdriver in the slot adjacent to the joint and gently pry apart.

FIG.H-12 MUFFLER COMPONENTS also be removed and both it and the cooling fan be cleaned.

Both the cylinder head and blower housing cleaning should be done together to prevent the foreign matter removed from one entering the other.

&_WARNING&_

Unplug the orange and green coil wires and the spark plug lead.

Remove the solid linkage (5) between the carburetor and the oil injection bellcrank (3) at the carburetor end.

Remove the four bolts(6) that secure the blower housing (7) to the engine and note the location of the ground strap (8).

Pull the blower housing from the engine and clean the fan blades and the interior of the housing.

Remove the eight bolts (9) that attach the cylinder head housing to the cylinder head after noting the location of the spark plug wire support bracket and the choke cable bracket.

Lift the cylinder head housing (10) from the cylinder head and clean the cooling fins.

TO PREVENT BURNS, BE SURE THAT THE MUF­ FLER AND EXHAUST COMPONENTS HAVE COOLED BEFORE ATTEMPTING ANY SERVICE.

CYLINDER HEAD HOUSING/BLOWER HOUSING INSTALLATION (FIG. H-14)

CYLINDER HEAD HOUSING/BLOWER HOUSING REMOVAL (FIG.H-14)

DO NOT FORCE THE BLOWER HOUSING DURING REINSTALLATION

Tools Required:

Qty.

Wrench, 12 mm, open end ................... 1

Pg.H-10

TO PREVENT SERIOUS ENGINE DAMAGE. ANY TIME THAT THE OIL INJECTION SYSTEM IS DIS­ TURBED THE SYSTEM MUST BE BLED.

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I I !H!9!Gl

ENGINE AND CONTROLS

FIG. H-13 COOLING SYSTEM 10

FIG. H-14 COOLING SYSTEM HOUSING

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E�GDii:i:1i1!•l:I

Pg. H-11

ENGINE AND CONTROLS

When reinstalling the oil pump it may be necessary to manually rotate the drive clutch to enable the slot in the crankshaft to align with the oil pump shaft.

When replacing the spark plug wire, adjust the wire in the grommet to prevent the wire from rubbing against the engine.

Installation is in the reverse order of removal.

FIG.H-15 The following section details ALL the steps required to perform a COMPLETEtear down of the engine. Certain steps may be omitted or performed out of sequence de­ pending on the type of repair to be performed. Example: The crankcase separation and oil seal replacement is not required for a top overhaul, that will only require the replacement of piston rings, gaskets and cylinder.

&_WARNING&_ TO PREVENT INJURY CAUSED BY A BROKEN SOCKET, USE ONLY SOCKETS DESIGNED FOR IM­ PACT WRENCH USE. NEVER USE A CONVEN­ TIONAL SOCKET.

Lightly lubricate the threads on the clutch removal tool.

Insert the clutch removal tool into the the hole in the cen­ ter of the drive clutch.

Use the impact wrench and socket to drive the removal tool into the clutch. Continue until the clutch is sepa­ rated from the engine shaft.(FIG.H-16)

ENGINE REPAIR AND OVERHAUL

All internal engine repair work should be done in a clean well lighted environment, therefore, the engine should be cleaned with a commercial grease and oil remover before being removed from the vehicle (see Engine re­ moval section), and set up on a work bench.

DRIVE CLUTCH REMOVAL AND INSTAL­ LATION

Tools Required:

Qty.

Socket, 5/8", 3/8" drive ..........••.......... 1 Ratchet, 3/8" drive ............•............. 1 Impact wrench, 1/2" drive (air or electric) ......•. 1 Socket, impact, 1 1/8, 1/2" drive ............... 1 Clutch removal tool, E-Z-GO P/N 19TT9-G2 ..... 1 Remove the clutch mounting bolt and its related hard­ ware.(FIG.H-15)

Pg.H-12

FIG. H-16 Reverse the impact wrench and remove the tool from the clutch.

EXHAUST PIPE REMOVAL

Tools Required:

Qty.

Socket, 1/2", 3/8" drive ......•................ 1

4/01/92 I I IHI 9!Gt

ENGINE AND CONTROLS Ratchet, 3/8" drive .... .... .. . . .. . . . . . . . . . . . . 1 Extension, 6", 3/8" drive .. . . .. . . . . . .. . . . . . . . . 1 Remove the two nuts and washers that attach the ex­ haust pipe to the cylinder. (FIG. H-17)

Note the location of the spark plug and choke cable sup­ port brackets, before removing the seven screws that at­ tach the cylinder head baffle to the cylinder.

(FIG.H-19)

FIG.H-17

FIG.H-19 SOLID LINKAGE REMOVAL

SPARK PLUG REMOVAL Tools Required:

Qty.

Socket, spark plug,13/16", 3/8" drive .......•... 1 Ratchet, 3/8" drive . ....••. ..•. . .. .........•. 1 Remove the spark plug.(FIG.H-18)

Qty.

Tools Required:

Screwdriver, straight blade, small ......... . .. . . 1 Service tip: To remove the female portion of the ball joint, insert a thin straight blade screwdriver in the slot adjacent to the joint and gently pry the joint apart.

Remove the solid linkage between the carburetor throt­ tle lever and the oil injection pump bellcrank at the bellcrank end. (FIG. H-20)

FIG.H-18 CYLINDER HEAD BAFFLE REMOVAL Tools Required:

Qty.

Socket, 1O mm, 3/8" drive ..... .... .. . .... ..•. 1 Ratchet, 3/8" drive .. .. .. .•..... ........... . . 1

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! ! ! !H!9!G!

E�GCii=t:•it!•):1

FIG.H-20 Pg.H-13

ENGINE AND CONTROLS BLOWER HOUSING REMOVAL Tools Required:

INTAKE MANIFOLD REMOVAL Qty.

Pliers, needle nose ............• ....• ....... 1 Socket, 12 mm, 3/8" drive .• .................. 1

Tools Required:

Qty.

Screwdriver, straight blade .................... 1 Socket, 1O mm, 3/8" drive .................... 1 Ratchet, 3/8" drive .......................... 1

Ratchet, 3/8" drive .......................... 1

Extension, 2", 3/8" drive ...................... 1

Remove the four bolts that secure the blower housing to the crankcase after noting the location of the ground strap.(FIG.H-22), (FIG. H-21)

FUEL LINE

FIG. H-21

Loosen the hose clamp and remove the fuel line from the carburetor. (FIG. H-23)

FIG.H-23 INTAKE MANIFOLD REMOVAL Remove the four bolts that secure the intake manifold and the reed valve assembly to the cylinder, and remove the reed valve assembly and gaskets. (FIG. H-24), (FIG.H-25)

FIG. H-22

Do not remove the oil pump from the blower housing.

Pg.H-14

FIG. H-24 4/01/92 I I !H!9!G!

ENGINE AND CONTROLS

FIG.H-25

FIG. H-27 FAN AND PULSER REMOVAL

FUEL PUMP REMOVAL Tools Required:

Tools Required: Qty.

Socket, 1O mm, 3/8" drive .................... 1

Qty.

Hammer, plastic tipped ... ......... .. .. ...... 1 Screwdriver, straight blade .................... 1 Screwdriver, Phillips ......................... 1

Ratchet, 3/8" drive .......................... 1

Socket, 10 mm, 3/8" drive .................... 1

Extension, 2", 3/8" drive •.................... 1

Ratchet, 3/8" drive .......................... 1

Remove the two bolts securing the fuel pump to the crankcase. (FIG.H-26)

Socket, deep well, 19 mm, 3/8" drive ............ 1 Puller set, flywheel, E-Z-GO #17086-G1 ......•. 1

FAN MOUNTING LOCKING DEVICE Use a straight blade screwdriver and a plastic tipped hammer to straighten the tabs on the fan mounting screw locking device. (FIG.H-28)

FIG. H-26 Be sure to note the location of the gasket and the spac­ er, (FIG.H-27) and the location of the 'O' ring.

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FIG. H-28

Pg.H-15

ENGINE AND CONTROLS FAN MOUNTING NUT REMOVAL Hold the fan and remove the fan retaining nut from the crankshaft. (FIG. H-29)

FIG.H-30

FIG. H-29 FAN MOUNTING SCREWS Remove the screws and the locking device from the fan and remove it and the fan from the flywheel.

(FIG. H-30)

FLYWHEEL REMOVAL Remove the two phillips head screws from the flywheel (FIG. H-31 ), and install the flywheel puller to the crank­ shaft and flywheel using the threaded holes. Remove the flywheel from the crankshaft by turning the threaded center portion in a clockwise direction until the flywheel separates from the crankshaft. (FIG. H-32)

FIG.H-31

FIG. H-32 ROTOR REMOVAL Remove the three screws that attach the rotor to the fly­ wheel. (FIG. H-33)

Pg.H-16

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ENGINE AND CONTROLS

FIG. H-33

FIG. H-35

PULSER ASSEMBLY REMOVAL Remove the two screws securing the pulser assembly to the crankcase. (FIG.H-34)

CYLINDER HEAD AND CYLINDER RE­ MOVAL

Tools Required:

Qty.

Socket, 12 mm, 3/8" drive . ......... .. . ..... .. 1 Ratchet, 3/8" drive .......................... 1 Wrench, 12 mm, box end ..................... 1 Remove the six cylinder head bolts and separate the cylinder head and gasket from the cylinder.

(FIG.H-36), (FIG.H-37)

FIG. H-34 PULSAR COIL REMOVAL Pull the pulser coil wire and grommet from the crank­ case casting and remove the pulser coil from the coil plate. (FIG.H-35)

To replace the pulser coil, or remove the wiring from the crankcase requires that the wiring be de-soldered from the coil.

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E�GDii:i:!i1t•l:I

FIG. H-36

Pg. H-17

ENGINE AND CONTROLS PISTON REMOVAL Tools Required:

Qty.

Pliers, internal snap ring ..............• ....... 1 Remove the piston pin retaining rings from both sides of the piston. (FIG.H-40)

FIG. H-37 Remove the four nuts and lock washers that attach the cylinder to the crankcase. (FIG. H-38)

FIG. H-40 Slide the piston pin out of the piston and remove the pis­ ton from the connecting rod. Separate the connecting rod bearing from the connecting rod. (FIG.H-41)

FIG. H-38 Remove the cylinder and note the orientation of both the piston porting and the cylinder intake port. (FIG.H-39)

FIG. H-41 REMOVING CRANKSHAFT AND BEAR­ INGS Tools Required: Qty.

FIG.H-39 Pg.H-18

Socket, 12 mm, 3/8" drive .................... 1 Ratchet, 3/8" drive .......................... 1 Arbor press ................................ 1 Support, wooden 2"x 4" ...................... 2 Adapter, (suitably sized socket) ................ 1 Seal puller ................................ 1

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ENGINE AND CONTROLS the crankshaft to press the crankshaft from the crank­ case half. (FIG. H-44) BE SURE THAT THE WOODEN SUPPORTS ARE OF AN· EQUAL SIZE. MISMATCHED SUPPORTS WILL RESULT IN THE ARBOR PRESS NOT PRESSING PERPENDICULAR TO THE BASE WHICH MAY RE­ SULT IN DAMAGE TO THE COMPONENTS AND THE CASTING.

SEPARATING THE CRANKCASE Remove the five bolt that join the two sides of the crank­ case. (FIG. H-42)

FIG. H-44 REMOVING THE OIL SEAL Use a seal remover to pull the seals from the crankcase halves.(FIG. H-45)

FIG. H-42 Support the flanged portion of the crankcase on two equal length pieces of wood and use an arbor press to press against the end of the crankshaft. This process will cause the other side of the crankcase to separate from the flanged side. (FIG. H-43)

FIG. H-45

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USE CARE NOT TO DAMAGE THE BORE OF THE CASTING.

REMOVING THE BEARINGS

FIG. H-43 REMOVING THE CRANKSHAFT Support the crankcase on two equal length pieces of wood and use an arbor press to press against the end of

4/01/92 I I I !H!9k3!

BE SURE THAT THE WOODEN SUPPORTS ARE OF AN EQUAL SIZE. MISMATCHED ADAPTERS WILL RESULT IN THE ARBOR PRESS NOT PRESSING COMPONENTS PERPENDICULAR TO THE BASE WHICH MAY RESULT IN DAMAGE TO THE COMPO­ NENTS AND THE CASTING.

Pg.H-19

ENGINE AND CONTROLS Support the crankcase half on two wooden adapters and use an arbor press to press the bearings to the in­ side of the crankcase.

BUT THE RING WOULD TURN, CATCH ON ONE OF THE PORTS AND BREAK. IF THE PINS ARE LOOSE, REPLACE THE PISTON. (FIG. H-47)

CHECKING COMPONENTS FOR WEAR

Tools Required:

Qty. Micrometer, outside, 3" minimum throat . . . . . . . . . 1

Micrometer, inside, 3" (bore gauge) . . . . . . . . . . . . 1 Feeler gauge . • • . . • . . . . • . . . . • . . . . • . • . . . . . . . 1 Gauge block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Clean the cylinder, cylinder head and piston in solvent.

If there is a thick layer of carbon on the head or piston, it should be removed before washing with solvent.

A scored (or grooved) piston or cylinder must be re­ placed.

Inspect the piston and cylinder for cracks, burrs, or burned spots on the piston dome and for scoring on the piston skirt and cylinder wall. Replace with new parts if necessary.

EXTREME CARE MUST BE TAKEN TO AVOID DAM­ AGE TO THE ALUMINUM OF THE PISTON OR HEAD. Break an old ring and use the broken end for removing ring groove carbon and carefully remove the carbon from the piston ring grooves. (FIG. H-46)

FIG. H-47

Both outside and inside micrometers used for piston and cylinder measurements MUST be calibrated to the same gauge block before being used.

The piston pin should fit "finger tighr in the piston, if loose, a new piston is required.

The piston measurement is taken approximately 3/4" from the the skirt, 90 degrees from centerline of the pis­ ton pin holes. (FIG. H-48)

FIG. H-46

FIG. H-48

CHECK THE PISTON RING LOCATING PINS TO MAKE SURE THAT THEY ARE TIGHT IN THE PIS­ TON. A LOOSE PIN COULD POSSIBLY COME OUT DURING ENGINE OPERATION AND WOULD NOT ONLY DAMAGE THE PISTON AND CYLINDER WALL,

Pg. H-20

1001®1r� I

Piston rings are upper side keystone type and must be installed with the bevel towards the top of the piston.

Piston ring end gap must be maintained as specified un­ der Engine Specifications. Thoroughly clean the cylin­ der and install the piston ring approximately 1/2" from

E�GClii�:,i;{•J:I

4/01/92

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ENGINE AND CONTROLS the top. The ring must be parallel to the top surface of the cylinder when measuring the end gap. Check with a feeler gauge as shown. (FIG.H-49) If the ring gap ex­ ceeds .016inch and the cylinder bore is not scored or worn more than .003inch, install new rings.

FIG. H-49 The cylinder and piston must be measured to determine if they are worn to a point where the cylinder must be re­ placed.

The bore measurement is taken at the tightest area of the cylinder. (FIG.H-50) Determine the piston to bore clearance by subtracting the piston measurement from the bore measurement.

Example: If the bore is 2.8366inches and the piston is 2.8291inches, the piston to bore clearance will be .007 5 inch. In this example, the piston is worn and must be re­ placed. If the cylinder bore is scored or is worn more than .003inch over 2.8357 inches or 2.8387, a new cyl­ inder should be installed.

PISTON PIN AND BEARING INSPECTION Inspect the piston pin bearings and spacers for wear. If the bearings show wear, replace the bearings, spacers and pin.

CONNECTING ROD AND CRANKSHAFT INSPECTION

This inspection must be made with the piston removed.

Inspect the connecting rod lower bearings for excessive up and down movement or side play.If the bearings are worn or show heat discoloration, a new crankshaft and rod assembly is required.

4/01/92 ! ! ! !H!9!G!

FIG. H-50 ENGINE ASSEMBLY Tools Required:

Qty.

Arbor press ................................

Support, wooden, 2" x 4" ...................• .

Wrench, torque, 1/2" drive ....................

Adapter, (suitably sized socket ) ................

Socket, 14 mm, 1/2" drive ....................

Socket, 12 mm, 1/2" drive .-...................

Pliers, snap ring ............................

Wrench, 10mm, open end ....................

Wrench, 14 mm, open end ....................

Socket, 12 mm, deep well, 1/2" drive ............

1 2 1 1 1 1 1 1 1 1

CYLINDER AND PISTON ASSEMBLY (FIG. H-51) Install the piston pin bearing and spacers.

Coat the bearings with oil to prevent damage during the first few minutes of operation.

E.ZGDii:i:!i1t•l:I

Pg. H-21

ENGINE AND CONTROLS

FIG. H-51

FIG. H-53

The "F" on the top of the piston is to be positioned to the flywheel (fan) side of the engine.

Install a new cylinder to crankcase gasket and be sure that it is correctly positioned.

Compress the piston rings and slide the cylinder over the piston (FIG. H-54) and secure the crankcase. Be sure the exhaust port faces the correct way. (FIG. H-55)

If piston is being reused, it MUSTbe used with the origi­ nal cylinder.

Install the piston pin into one side of piston.

The two rectangular holes in the side of the piston must be positioned at the intake port (FIG. H-55). Align the piston and pin with the connecting rod and install the pis­ ton pin.

Install the pin snap rings. (FIG. H-52)

FIG. H-54

FIG. H-52

The gap in the retaining rings should be located either at the TOP or the BOTTOM of the ring land.

Assemble the piston rings and position them so that the ring gap is correctly seated around the locating pins.

(FIG. H-53)

Pg.H-22

FIG. H-55 4/01/92

I I iHi9k3i

ENGINE AND CONTROLS Tighten the cylinder attaching nuts to 24 - 28 ft. lbs. torque.

Tighten cylinder securing nuts using a crisscross pat­ tern.

Install a new head gasket with the widest metal edge turned down against the cylinder. Position the head and install head bolts and tighten to 20 - 21 ft. lbs. torque.

Use a crisscross pattern when tightening the head bolts. (FIG. H-56)

FIG. H-57 CRANKSHAFT BEARINGS

liflliiI111PI

FIG. H-56 CRANKSHAFT SEALS

USE AN ADAPTER TO TRANSFER THE LOAD FROM THE ARBOR PRESS TO THE OUTSIDE OF THE BEARING. NEVER PRESS AGAINST THE INNER RACE. Support the crankcase half on the bed of an arbor press and press the bearings into the casting.

CONNECTING ROD BEARINGS BE SURE THAT THE WOODEN SUPPORTS ARE OF AN EQUAL SIZE. MISMATCHED ADAPTERS WILL RESULT IN THE ARBOR PRESS NOT PRESSING COMPONENTS PERPENDICULAR TO THE BASE WHICH MAY RESULT IN DAMAGE TO THE COMPO­ NENTS AND THE CASTING.

Apply a light coat of oil to the seal before installing.

Support the crankcase half on two wooden supports and use the arbor press to press a new seal into place.

(FIG. H-57)

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I I I !H!9!G!

If new connecting rod to crankshaft rod bearings are re­ quired, the complete rod and crankshaft assembly must be replaced.

ASSEMBLING CRANKCASE Clean all parts thoroughly before reassembly. Press new bearings into the case halves. Press new seals into the case halves.

Coat bearings with oil and press the clutch end of the crankshaft into the rear half of the crankcase. Coat the crankcase halves mating surfaces with an appropriate sealer, insert the fan end of the shaft into the crankcase half, and press the case halves together. (FIG. H-58)

Pg.H-23

ENGINE AND CONTROLS Referring to pertinent procedures, reassemble the re­ maining engine parts using the reverse order of disas­ sembly.

ENGINE ASSEMBLY BOLT TORQUE RE­ QUIREMENTS

JR!JiJlnn,,

DO NOT USE AN IMPACT WRENCH TO INSTALL THE CLUTCH DRAWBOLT.

FIG.H-58 Install the five crankcase bolts and tighten to 18 - 20 ft. lbs. torque using a crisscross tightening pattern.

Pg.H-24

Crankcase . . . . . . . . . . . . . . . . . . . . .

Cylinder . . . . . . . . . . . . . . . . . . . . . . .

Cylinder . . . . . . . . . . . . . . . . . . . . . . .

Cooling Fan . . . . . . . . . . . . . . . . . . . .

Spark Plug . . . . . . . . . . . . . . . . . . . . .

Clutch Drawbolt . . . . . . . . . . . . . . . . .

18 to 20 ft. lbs.

24 to 28 ft. lbs.

17 to 18 ft. lbs.

20 to 24 ft. lbs.

18 to 21 ft. lbs.

54 to 55 ft. lbs.

I

4/01/92 I !H!9!Gl

OPERATION AND SERVICE MANUAL SECTION:FUEL SYSTEM

GENERAL

J

• Condition of oil lines.

The fuel system consists of a fuel tank, fuel lines, pri­ mary filter, fuel pump, secondary filter and carburetor.

The system also includes an oil tank, oil lines, oil filter and a carburetor controlled oil pump that supplies oil to the intake manifold.

• All hardware attaching all oil injection compo­ nents for tightness.

PURPOSE OF OIL INJECTION

• The adjustment of the pump lever.

• Eliminates the pre-mixing of gasoline and oil and lessens maintenance.

• Supplies oil in exact proportion to engine operating demands.

• All hose connections for tightness and leaks

• The oil lines for air bubbles.

If air bubbles are present in the supply lines, inspect the system for leaks and check the oil level in the tank.

• Reduces exhaust smoke and emissions.

• Reduces carbon build-up inside the engine.

• Increases spark plug life.

PUMP OPERATION The oil injection system utilizes a direct drive oil pump that is driven by the crankshaft of the engine. The amount of oil discharged from the pump is controlled by the speed of the engine and by the degree of throttle valve opening of the carburetor.

PUMP ADJUSTMENT The only adjustment of the oil pump is the setting of the pump lever. This adjustment is detailed in the SPEED CONTROL AND OIL PUMP, Section F.

DO NOT OPERATE AN ENGINE WHEN AIR BUB­ BLES ARE PRESENT IN THE OIL LINES. DUE TO RE­ DUCED OIL CONSUMPTION WITH OIL INJECTION, IT TAKES SEVERAL MINUTES FOR A BUBBLE TO PASS THROUGH THE SYSTEM. SERIOUS ENGINE DAMAGE COULD RESULT IN THIS TIME.

MAINTENANCE/ADJUSTMENTS AIR BLEEDING The oil lines and pump must be bled if any of the follow­ ing conditions should occur: • Oil tank is emptied.

PUMP SAFETY

• Oil pump removed from oil lines.

The oil pump has been designed to protect the engine in the event of a failure of the linkage between the oil pump and the carburetor. Should the linkage fail, the pump lever will automatically advance to its fully open (rich) condition. This will result in excessive smoking and pos­ sibly a fouled spark plug but will protect the engine from an inadequate oil supply.

• Oil lines or filter replaced.

INSPECTION Every week inspect the oil injection system for the fol­ lowing: • Tank oil level - fill as required.

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I I I I JI 9!G!

• Oil tank replaced.

BLEEDING PROCEDURE (FIG.J-2)

ALWAYS ADD ONE OUNCE OF OIL PER GALLON OF GASOLINE TO THE FUEL TANK AFTER BLEEDING THE OIL SYSTEM. THIS WILL ASSURE THAT THE OIL INJECTION SYSTEM IS FULLY PRIMED BEFORE RETURNING TO REGULAR GASOLINE.

Pg.J-1

FUEL SYSTEM Tools Required:

OIL TANK AND OIL TANK SUPPORT IN­ STALLATION (FIG. J-2)

Qty.

Pliers, needle nose ......................... 1 Screwdriver, straight blade ................... 1

Tools Required:

Qty.

Wrench, open end, 7/16" ..................... 1

Remove the 1/8" I.D. hose ( 1 ) between the oil pump and the intake manifold at the oil pump (2). Pour oil into the other end of the hose, removing all air bubbles. Attach the hose to the outlet of the oil pump and secure with clamp (3).

Fill the oil tank (4). Loosen the air bleed screw on the oil pump and prime the 1/4" I.D.oil lines and the oil pump.

The inlet line (5) must be free of air bubbles.

Pliers .................................... 1

BEFORE O PERATING, BLEED OIL INJECTION SYS­ TEM PER BLEEDING PROCEDURE. Install the oil tank assembly (4) to the oil tank mounting bracket.

1 m1unr� I

When replacing filter (6), observe the arrow marked on the filter and locate with arrow pointing away from tank and towards the oil pump.

AIR BLEED-- .....

---SHOWS F ULLY CLOSED POSITION --SHOWS F ULLY OPEN POSITION

CLOSE MARK CAUTION: BE SURE TO USE CORRECT PUMP FOR YOUR APPLICATION. SEE SERVICE PARTS MANUAL 23865-G1 IS IDENTIFIED ON PUMP LEVER AS GSA- GOLF CARS {GX440/444, GX-444J, GX444F) 23865-G2 IS IDENTIFIED ON PUMP LEVER AS G6A - ALL OTHER VE HICLES

FIG.J-1 OIL INJECTION PUMP

Pg.J-2

4/1/92 I !J!9!GI

FUEL SYSTEM

EARLY PRODUCTION PRODUCTION

FIG. J-2 OIL INJECTION 4/1/92

I I I IJl9IGI

Pg. J-3

FUEL SYSTEM Install the 1/4" clear tubing onto the inlet valve of the oil pump assembly. Relocate the hose clamp approxi­ mately 1/32" from the end of the hose.

CARBURETOR OPERATION The carburetor is constructed with four different sys­ tems: the float system, the pilot system, the main sys­ tem, and the choke system (FIG.J-3). The carburetor is equipped with fixed jets and requires no adjustment.

FLOAT SYSTEM (FIG. J-10) The float chamber is located directly on the underside of the carburetor, and the fuel is maintained at the stan­ dard level by means of the float and needle valve.

As the fuel flows from the fuel pump to the float chamber through the needle valve and fills the fixed volume chamber, the float rises, and when the buoyancy of the float is equal to the fuel pressure, the needle valve closes to maintain the standard fuel level.

main nozzle increases which draws a larger proportion of fuel to make initial starting easier.(FIG.J-9)

CHOKE OPERATION Operate the choke cable, check that the cable returns when released. The motion should be smooth through­ out the entire range of motion.If there is any binding or sharp bends, the cable must be replaced.

CABLE AND HOUSING REMOVAL

Qty.

Tools Required:

Wrench, open end, 1/2" ...................... 2 Wrench, 7/8" ............................... 1 Wrench, Allen, 5/64" ......................... 1

PILOT SYSTEM The pilot system functions to deliver fuel during low speed operation.The fuel supplied through the main jet is measured by the pilot jet, mixed with the air measured by the pilot air jet (controlled by the pilot screw) and de­ livered to the engine through the pilot outlet and the by­ pass.

MAIN SYSTEM The main system functions to deliver the fuel during ac­ celeration and during heavy load conditions. The fuel is measured by the main nozzle. The air measured by the main air jet is mixed with the fuel through the bleed opening of the main nozzle. This mixture passes through the main bore as atomized air/fuel and is mixed again with intake air to yield the most suitable fuel/air concentration for delivery to the engine.

See the high altitude jetting charts for Carburetor Main Jets. (See "General Specifications", Section S).

CHOKE SYSTEM The choke system functions to make initial starting of the engine easier in cold weather. When the engine turns with the choke closed, the negative pressure of the

Pg. J-4

Do not attempt to lubricate the cable, since the lubricant will tend to retain dirt on the moving parts which will cause premature deterioration of the cable.

CHOKE CABLE REMOVAL (FIG. J-3) Loosen the setscrew attaching the bullet (1) to the cable passing through the choke lever swivel. Remove the nut (2) securing the choke cable housing (3) to its bracket.

At the rear of the vertical seat support remove the nut (4) securing the choke cable to the seat wrap and slide it onto the cable. Pull the cable and grommet (5) from the retaining brackets (6), (7). Pull the cable and grommets through the nut and the vertical seat support.

CHOKE CABLE INSTALLATION Feed the choke cable through the hole in the vertical seat support and install the nut (4) finger tight.Slide the two grommets (5), onto the cable housing and press into place on their retaining brackets.Slide the threaded por­ tion of the housing through the intake manifold mounted bracket and install the nut (2) finger tight.Pass the inner cable through the choke lever swivel.Be sure that both the choke knob and the carburetor choke lever are in the closed position before positioning the bullet (1) with the curved surface to contact the choke lever.Tighten the setscrew securely.

4/1/92

! !J!9!G!

FUEL SYSTEM

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FIG. J-3 CHOKE SYSTEM 4/1/92

I I I IJl9lGI

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Pg. J-5

FUEL SYSTEM

FIG. J-4 FUEL SYSTEM Pg. J-6

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4/1/92 I I I I J!9!GI

FUEL SYSTEM Adjust the position of the curved portion of the cable (at the vertical seat support) to ensure that the cable does not contact any belts or other moving parts. Check that there are no sharp bends before firmly tightening the nuts at both ends of the cable.

CARBURETOR SERVICE Disconnect battery (see procedure in Section B). Be­ fore servicing the carburetor and fuel system, be sure that the ignition circuit and its components are in proper operating condition.

REMOVAL FROM ENGINE (FIG. J-4), (FIG. J-5), (FIG. J-6) Tools Required:

Qty.

Wrench, open end, 1O mm ................... 1 Wrench, open end, 7/16" .................... 1

FIG. J-5 BALL JOINT REMOVAL

Screwdriver, straight blade ................... 1 Disconnect the fuel line (1) from the fuel pump (2) at the carburetor (3). Disconnect the solid linkages from the governor and oil pump bellcrank at the carburetor lever.

WHEN REMOVING/INSTALLING THE LINKAGES TO THE CARBURETOR ARM, USE EXTREME CARE NOT TO DAMAGE OR BEND THE ARM. SUPPORT THE CARBURETOR ARM AND SQUEEZE THE BALL JOINT COMPONENTS TOGETHER (FIG.J-6).FAIL­ URE TO OBSERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE CARBURETOR AND RE­ SULT IN THE REPLACEMENT OR REBUILDING OF THE CARBURETOR. Service tip: To remove the female portion of the ball joint, insert a thin straight blade screwdriver in the slot adjacent to the joint and gently pry apart.

(FIG.J-5)

4/1/92

I I I I Jl91GI

FIG. J-6 BALL JOINT RE-ATTACHMENT Disconnect the air inlet hose by loosening clamp (4).

Remove the nut and washers (5 and 6) and slide the carburetor off the studs.

E�GDli:S;,i,t•J:1

Pg. J-7

FUEL SYSTEM CARBURETOR DISASSEMBLY (FIG. J-7) Tools Required:

Qty.

Wrench, open end, 1O mm ................... 1 Wrench, open end, 1 4 mm ...•..•............ 1

install the float and the float pin. Tum the carburetor on its side to remove the weight of the float from the needle.

This position will allow the float to pivot freely without de­ pressing the spring loaded needle.

Socket, deep well, 1O mm, 3/8" drive ........... 1 Pliers .•..•............................... 1 Ratchet, 3/8" drive •.......•.........•....... 1 Screwdriver, straight blade ...•.•............. 1 Before disassembling the carburetor, clean the outside of the carburetor thoroughly with solvent.

All work should be done on a clean surface. Care should be exercised when disassembling the carburetor or re­ moving the jets. Carburetor malfunctions are mostly due to the wear of parts or clogging by foreign material.

Remove the float bowl (1) and main jet (2).

Inspect the neoprene "O" ring gasket (3) for nicks or cuts. Remove the float pin (4) and float (5).

DO NOT bend the float pin during removal.

Remove the inlet needle (6) and seat (7) and inspect the needle for any wear at its tip.

Remove the main nozzle (8) and inspect holes. Blow clean with compressed air.

Count the number of 1/4 turns required to lightly seat the pilot air screw (9) against its seat, thenremove the pilot screw and the pilot jet (10).

The pilot air screw is factory set and sealed. It MUSTbe reinstalled to the SAME setting. Cleaning the carburetor does not require the removal of the pilot air screw.

Wash all parts in solvent and blow through passages and jets with compressed air. Replace all gaskets and any parts which show wear or damage.

FLOAT LEVEL ADJUSTMENT (FIG. J-8) To adjust the float level, install a new needle and seat or reinstall existing parts if they are in good condition. Re-

Pg. J-8

When adjusting float, NEVER bend the float arm, al­ ways bend the tangs 1 and 2.

The float level should be set to .1 90" to .2 50" from bot­ tom of float to the carburetor body. With the float set to this dimension, tang 1 must JUST TOUCH the needle and tang 2 must not touch the carburetor body or the needle seat.(See detail"A", FREE POSITION, FIG.J-8) After the float level is set in the free position, compress the needle by pushing the float gently toward the carbu­ retor body. In this position than 1 should partially com­ press the needle before tang 2 touches the carburetor body. (See detail "B", COMPRE S SED POSITION, FIG.J-8) After checking the compressed position, check the low fuel position by gently lifting the float away from the carburetor body. In this position, tang 1 must be raised off of needle before tang 2 touches needle seat. (See Detail "C", LOW FUEL POSITION, FIG. J-8) After details "B" and "C" have been checked, return to "A" and recheck before assembling the carburetor.

After adjusting the float level, reassemble the carburetor in the reverse order of disassembly. Assemble the pilot air screw being sure to replace it to its exact original po­ sition.

When reassembling the air intake adapter to the choke side of the carburetor, reinstall washers under the head of the screws to prevent the screws from restricting the choke shaft movement. Check for free movement of the choke shaft and butterfly after the air cleaner adapter is installed and before the carburetor is installed on the en­ gine.

THROTTLE SHAFT ADJUSTMENT (FIG. J-7) To adjust throttle shaft (1 2) and throttle valve (1 3), tum the stop screw counterclockwise until it no longer con­ tacts the tab on the throttle shaft. Hold the throttle shaft in the closed position, then tum the stop screw (1 1) clockwise until it contacts the tab on the throttle shaft; tum the screw clockwise one quarter tum maximum.

4/1/92

! !J!9!G!

FUEL SYSTEM

CARBURETOR B V 18 SHOWN BV-21 IS SIMILAR

FIG. J-7 CARBURETOR 4/1/92

I I I tJ!9!GI

E�GD ii�:, it\•l:I

Pg.J-9

FUEL SYSTEM

When reinstalling the carburetor to the engine, installa­ tion of a new gasket is recommended to assure an air tight seal. Ensure that fuel lines and air intake hose con­ nections are air tight. Inspect the air intake hose for damage and replace if required.

&WARNING& THE ABOVE MALFUNCTIONS ARE NOT ONLY DET­ RIMENTAL TO THE PROPER OPERATION AND PERFORMANCE OF THE CAR, BUT CAN ALSO BE A SAFETY HAZARD IN THE CASE OF FUEL LEAK­ ING ON A HOT ENGINE.

SERIOUS ENGINE DAMAGE MAY RESULT FROM IN­ CORRECTLY CONNECTING THE PULSE AND FUEL LINES.

FUEL PUMP (FIG. J-11)(FIG. J-12) Tools Required:

operated by crankcase pressure through the pulse line.

As the pistion moves up away from the crankcase, a negative pressure draws the diaphragm (1) in the fuel pump toward the engine. This action draws gasoline from the tank into the pump chamber (2) through the in­ let valve (3). This same suction causes the outlet valve (4) to the carburetor to close so that fuel will not return from the carburetor. As the piston moves downward to­ ward the crankcase, a positive pressure in the crank­ case causes the diaphragm (1) to move in the opposite direction away from the engine. This action forces the inlet valve to close and the outlet valve (4) to the carbu­ retor to open, filling the carburetor bowl.

Qty.

Socket, 1O mm, 3/8" drive . • . . . . . . . . . . . . . . . . . . 1 Ratchet, 3/8" drive . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1989 AND EARLY 1990 The fuel pump is mounted directly onto the crankcase and is operated by crankcase pressure impulses. As the piston moves up away from the crankcase, a negative pressure draws the diaphragm (1) in the fuel pump to­ ward the engine. This action draws gasoline from the tank into the pump chamber (2) through the inlet valve (3). This same suction causes the outlet valve (4) to the carburetor to close so fuel will not return from the carbu­ retor. As the piston moves downward toward the crank­ case, a positive pressure in the crankcase causes the diaphragm (1) to move in the opposite direction away from the engine. This action forces the inlet valve to close and the outlet valve (4) to the carburetor to open, filling the bowl in the carburetor.

The pump is removed by first removing its two mounting bolts, then removing it along with its spacer gasket and "O" ring. Assembly is in the reverse order of dis-assem­ bly.

STARTING MID 1990 Differences exist in the mounting of fuel pumps on vehi­ cles produced during the 1990 model year. Early 1990 vehicles share the same fuel pump as the 1989 model.

The fuel pump is mounted directly onto the crankcase and is operated by crankcase pressure impulses. Start­ ing late production 1990, the fuel pump is remotely mounted on the fuel tank heat shield, and is connected to the engine crankcase by a pulse line. The fuel pump is

Pg.J-10

Do not change the length of the pulse line. It is 'tuned' to the pump's operation.

&WARNING& TESTS THAT INVOLVE FUEL FLOW SHOULD BE AVOIDED IF AT ALL POSSIBLE. IF A TEST TO DE­ TERMINE FUEL/VAPOR PRESENCE OR FLOW IS REQUIRED, THE IGNITION SYSTEM MUST BE DIS­ ABLED IN ORDER TO PREVENT IGNITION SPARK THAT COULD IGNITE THE FUEL/VAPOR. NEVER PERMIT SMOKING OR OPEN FLAME IN AN AREA THAT CONTAINS FUEL. CLEAN UP ALL FUEL SPILLS IMMEDIATELY.

FUEL LINES AND FILTERS (FIG. J-4) (FIG. J-13) Tools Required:

Qty.

Screwdriver, straight blade . . . . . . . . . . . . . . . . . . . . 1 Pliers, needle nose . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fuel is supplied to the fuel pump and carburetor through flexible fuel hoses. An in-line type filter is installed in the line between the fuel tank and fuel pump, and a second in-line type filter is installed in the line between the fuel pump and the carburetor. Fuel filters, fuel lines and the fuel tank cap vent should be inspected on a periodic ba­ sis for leaks, a clogged tank vent or clogged filters, etc.

Filters should be replaced when necessary, but under no circumstances should the period of time between fil­ ter changes exceed one year. (200 hours).

4/1/92

! !J!9!G!

FUEL SYSTEM

THE FILTERS ARE MARKED WITH FLOW DIREC­ TION ARROWS. BE SURE ARROW POINTS TO­ WARD THE FUEL PUMP ON THE FILTER BETWEEN TANKANDPUMP,ANDTHEARROWPOINTSAWAY FROM THE PUMP ON THE FILTER BETWEEN THE PUMP AND CARBURETOR. The fuel tank should be drained and any foreign matter removed after the vehicle has been stored for a lengthy period.

8WARNING8 DO NOT ATTEMPT TO REPAIR A DAMAGED OR LEAKING FUEL TANK, IT MUST BE REPLACED. (SEE THE PROCEDURE IN SECTION B).

temperature at which the vehicle is to be operated. The jet size chart (see Specifications) is intended for use as a guide for re-jetting the carburetor as necessary for op­ timum performance of the vehicle.

The main jet selection should be based on the coldest temperature and the lowest altitude at which the vehicle will be operated. tlse one jet size larger than recommended for extremely hilly terrain or when hauling heavy loads, or long sus­ tained runs. 90 is larger than 87.5.

The pilot (low speed) jet has been sized for use in most altitude and temperature combinations and normally will not require changing. If it should become necessary to change the pilot jet, care must be taken to ensure that vehicle driveability and performance are not adversely affected.

CARBURETOR MAIN JETS (See table in SPECIFICATIONS, Section S)

FUEL TANK REMOVAL/INSTALLATION

The size of the main jet used in the vehicle's carburetor is dependent to a large degree on the altitude and the

See the proper safety procedure for tank removal in Section B.

4/1/92

I I I IJl9@

Pg. J-11

FUEL SYSTEM

TANG 1

FLO AT

BV-18 .119 .040 BV-21

.250 .190

"A" FREE POSIT ION TANG 2

NEEDLE & SEA T

"B" COMPRESSED POSIT ION

NEEDLE & SEA T

FLOAT

TANG 1

·c·

LOW FUEL POSITION NEEDLE & SEAT

FIG. J-8 FLOAT ADJUSTMENT Pg.J-12

4/1/92 I I J!9IGI

FUEL SYSTEM

PILOT JET

MAIN NOZZLE

r�==� -

MAIN AIR JET

I 1 11 I I I I 11 LL----- ---- JJ

MAIN JET

PILOT SCREW

NOTE: CHOKE ORIENTATION MAY VARY.

FIG. J-9 AIR AND FUEL FLOW

NEEDLE

FIG. J-10 FUEL LEVEL CONTROL

4/1/92 I I I I Jl9!Gl

Pg.J-13

FUEL SYSTEM

FROM FUEL TANK

FIG. J-11 NON REMOTE FUEL PUMP

TO CARBURETOR

PULSE LINE

FROM FUEL TANK

FIG. J-12 REMOTE FUEL PUMP

Pg.J-14

4/1/92

I IJl9IGI

FUEL SYSTEM

FUEL PUMP PULSE LINE

FROM FUEL PUMP TO FUEL PUMP

1

FIG.J-13 REMOTE FUEL PUMP

4/1/92

I I I I JI g@

Pg.J-15

FUEL SYSTEM

Pg. J-16

E.ZE:iDii:S:si1t•l:I

4/1/92

! ! ! !J!9!GI

OPERATION AND SERVICE MANUAL SECTION: POWER TRANSMISSION

GENERAL (FIG. K-1) The two clutch assemblies perform as a continu­ ously variable transmission (CVT). This drive sys­ tem consists of a centrifugal member (drive clutch), a load sensing member (driven clutch), and a drive belt. When the throttle is advanced and the engine speed is increased, the movable sheave of the cen­ trifugal member (mounted on engine crankshaft) is moved inward to engage the drive belt. Centrifugal force is supplied by the cams (weights) operating in the movable sheave housing. When the throttle is closed, the engine slows down, reducing the force on the cams, allowing the sheaves to separate due to the spring pressure on the movable sheaves.

At idle speed, the belt rides at the bottom of the sheaves on the clutch shaft such that the drive is disengaged. As the engine speed is increased, the

K

movable sheave will move inward against the belt, thus engaging the belt between the two clutch sheaves. At this point, the drive is at maximum ratio of almost 4 to 1 • With increasing engine speeds, the moveable sheave is forced toward the stationary sheave which increases the belt pitch diameter.

This decreases the ratio, shifting the drive for higher speeds.

The load sensing member (driven clutch) is a torque-responsive variable pitch sheave which maintains an equilibrium condition with the centrifu­ gal member at all speeds. Sheave pressure varies directly with load input so that the drive "down shifts" its ratio with increased load without apprecia­ ble change of engine speed. The moveable sheave spiral ramp and followers are activated by belt fric­ tion. The spring is used to ensure constant belt con­ tact under all operating conditions.

DRIVE CLUTCH DRIVEN CLUTCH

1

FIG. K-1 CLUTCHES AND BELTS

1/01/89 ! ! ! !K!9k3!

Pg. K-1

POWER TRANSMISSION DRIVE CLUTCH REMOVAL (FIG. K-1)

DRIVE BELT

&WARNING&

REMOVING BELT

&WARNING& DISCONNECT BATTERY TO PREVENT THE POSSI­ BILITY OF THE ENGINE INADVERTENTLY START­ ING DURING THE BELT REMOVAL PROCEDURE. TO PREVENT BURNS, BE SURE THAT THE MUF­ FLER AND EXHAUST COMPONENTS HAVE COOLED BEFORE ATTEMPTING ANY SERVICE. DO NOT ALLOW FINGERS TO BECOME TRAPPED BETWEEN THE BELT AND THE SHEAVE. To remove the drive belt, park on a flat surface.

With the F-N-R switch in neutral and the parking (hill} brake off, pull up on the drive belt to spread the driven cluitch sheaves. Push the vehicle back­ wards and roll the belt off the driven clutch.

DRIVE BELT SERVICE The drive belt should not require any service except when the vehicle has been operated in an extremely dusty or muddy area. In such case, it should be washed with plain water.

If the belt is frayed or badly worn, it should be re­ placed.

DRIVE CLUTCH Tools Required:

Qty.

Hammer, plastic tipped ...................... 1 Socket, 3/8", 3/8" drive .................... 1 Ratchet, 3/8" drive

........................ 1

Clutch puller, E-Z-GO, PIN 19778-G2 ......... 1 Socket, impact, 1 1 /8", 1/2" drive ............ 1 Impact wrench, 1/2" drive (air or electric} ..... 1 Sealant, Loctite 262 ...................... AR Torque wrench, 1/2" drive ................... 1

Pg. K-2

TO PREVENT INJURY CAUSED BY A BROKEN SOCKET, USE ONLY SOCKETS DESIGNED FOR IM­ PACT WRENCH USE. NEVER USE A CONVEN­ TIONAL SOCKET. Remove the drive belt (5) (refer to 'Removing Belt' procedure}. Remove the drawbolt (4) and washers (2, 3} from shaft end. Install a lubricated clutch puller (part number 19779-G2} and use an impact wrench turning clockwise to remove the clutch.

DRIVE CLUTCH INSTALLATION (FIG. K-1, FIG. K-2 )

DO NOT INSTALL THE BOLT WITH AN IMPACT TOOL. 6.

Clean both the engine shaft and clutch bore.

7.

Slide the clutch onto the engine shaft. Rotate it and lightly push the moveable sheave in and out several times to seat the clutch on the tapered engine shaft.

8.

Position the lock washer (3) and large clutch pilot washer (2) onto the clutch bolt (4).

9.

Apply sealant to the threads of the clutch bolt (4)

10. Install the clutch bolt and tighten to 55 ft. lbs. torque.

DRIVEN CLUTCH (FIG. K-2) Tools Required

Qty.

Pliers, external snap ring .................... 1 Screwdriver, Phillips ........................ 1 Sealant, Loctite 262 ....................... AR Socket, 3/8", 1/2" drive .................... 1 Torque wrench, 1/2" drive .................. 1 The driven clutch may be disassembled for minor field repairs.

DRIVEN CLUTCH REMOVAL (FIG. K-2) Remove the drive belt (refer to 'Removing Belt' pro­ cedure}. Remove the bolt (1}, lock washer (2) and retaining washer (3) and slide the clutch off.

E�GDii$:1it(•]:I

1/01/89 ! ! !K!9k$I

POWER TRANSMISSION DRIVEN CLUTCH DISASSEMBLY (FIG. K-2) Remove the external retaining ring (14) and sepa­ rate the ramp and dust seal (13) as an assembly.

Remove the spring (12) and moveable sheave (9).

REPLACING (FIG. K-2)

BROKEN

RAMP

BUTTONS

The ramp buttons (10) may be replaced by remov­ ing screw (11) and substituting a new ramp button ancf replacing the screw.

REASSEMBLY Check that the clutch shaft is smooth and shows no signs of wear. Check that the inner bore of the bushings are free from burrs. If bushings are worn to point of causing excessive vibration or shaft wear,

the clutch must be replaced. Clutch reassembly is the reverse order of disassembly.

INSTALLATION Coat the rear axle input shaft with "Neverseize" and slide clutch onto the shaft. Assemble the drawbolt, lock washer and pilot bushing before coating the drawbolt threads with Loctite 262 and installing the bolt. Tighten the drawbolt to 16-20 ft. lbs. torque.

STORAGE If the vehicle is to be out of service due to "off season" storage, the clutches should be protected from corrosion. Remove the drive belt (see 'Drive Belt Removal' procedure) and spray all external sur­ faces of both clutches with WD-40 or equiva­ lent.

5

FIG. K-2 DRIVEN CLUTCH 1/01/89

! ! ! !K!9!G!

Pg. K-3

POWER TRANSMISSION

Pg. K-4

EeGDii:£tid•J:I

1/01/89

! ! ! !K!9!G!

OPERATION AND SERVICE MANUAL SECTION:ELECTRICAL - 1989 / EARLY 1990

IDENTIFYING ELECTRICAL SYSTEMS (FIG. L-1) Differences exist in the wiring of the electrical systems of vehicles produced during the 1990 model year. Early Production 1990 vehicles share the same electrical sys­ tem as the 1989 models, while later 1990and1991 vehi­ cles have a different wiring harness and different wiring connections resulting in a different electrical system.

Before proceeding in this chapter, examine the wiring connections on the voltage regulator (located on a panel near the rear of the engine compartment) to identify which system was incorporated into the vehicle, then proceed according to the information in the appropriate ELECTRICAL section (1989 / EARLY 1990 p. L-1 thru L-20 or LATE PRODUCTION 1990/1991 p. L-21 through L-23).

! LATER 1990 / 1991

L

a motor. This circuit is controlled by a key switch, a fuse, an accelerator switch, a solenoid switch and a forward­ neutral-reverse switch. With the key switch in the "ON" position and with either "forward or reverse" selected, battery current is available to the accelerator limit switch which remains open until the accelerator pedal is de­ pressed. When the pedal is depressed, the plunger on the switch is released, the contacts close and the igni­ tion circuit is energized. Battery current then energizes the starter solenoid which closes the contacts. Battery current then flows through the forward-neutral-reverse switch and through the neutral limit switch to the starter/ generator. The starter/generator now functions as a motor to start the engine.

The engine can be stopped either by releasing the ac­ celerator pedal to the full up position or by turning the key switch to the "OFF"position. When the accelerator pedal is released, the plunger on the accelerator limit switch is depressed, the contacts open, and the ignition circuit is de-energized.

GENERATOR (FIG. L-2) When the engine is running, the starter/generator func­ tions as a generator and current is generated. This cur­ rent is used for charging the battery and for the ignition system. Generated output is controlled by the voltage regulator at 14.5 to 15.5 V, without regard to engine R.P.M. However, the charging current will vary depend­ ing on the condition of the battery. If the battery is fully charged, current is controlled at 3 to 5 amps.

FIG. L-1 IDENTIFYING ELECTRICAL SYSTEMS CIRCUITS AND CONTROLS The electrical system is a negative grounded 12 volt system and contains a starter/generator, voltage regu­ lator, starter solenoid, forward-neutral-reverse switch, igniter, pulser coil, accelerator limit switch, "Neutral" limit switch, key switch, and ignition coil. The limit switches are devices to ensure that the electrical con­ tacts are in a fully engaged position before becoming energized.

STARTER (FIG. L-2) When starting the engine, the field coils are in series with the armature and the starter/generator operates as

4/1/92

I I I ILl9!GI

WIRING

£WARNING£ BEFORE MAKING ANY TEST OF WIRING COMPO­ NENTS, DISCONNECT THE BATTERY CABLES FROM THE BATTERY POSTS (SEE PROCEDURE IN SECTION B).

Electrical tests of the wiring for continuity may be made with a "multi-tester'' meter, available through E-Z-GO Service Parts or the nearest E-Z-GO distributor. Set the meter selector knob to the ohms scale and check continuity between each circuit component as indicated.

Example: If the cut out switch is open or if there is a hid­ den break in the wiring, the meter will read infinity.

Pg.L-1

ELECTRICAL - 1989 / EARLY 1990

.¢

' <==:::> I

RED

FORWARD REVERSE

(-)

12 VDC

RED

A

C>•

RED

A1

F-N-R SWITCH

D

•<>

,--I

i

II

1

I

GRN

REVERSE WARNING DEVICE

BU<

IGNITION SWITCH

r--

BLK

sTr� __ J

BLK D

SOLENOID

RED

NEUTRAL RED LIMIT SWITCH

ACCELERATOR LIMIT SWITCH

�7

I J

REo� i

BU<

,-7

ID- �---+---+--o

I OF

VOLTAGE REGULATOR

RED

GRN

C

BU<

L��

YEL/RED

IGNITION COIL

ORN

A�B

D

F2

B I A

FUSE

BU<

DF

A2

allli_._______.._.._ll!!!l��•C> ,/ED• --

REVERSE WARNING SWITCH

STARTER!' GENERATOR

SPARK PLUG

ORN

IGNITOR BLU

RED

tkd

r

PULSER COIL

FIG.L-2 ELECTRICAL SYSTEM WIRING DIAGRAM - 1989/ EARLY 1990 Pg.L-2

4/1/92

I I I ILl9IGI

ELECTRICAL - 1989 / EARLY 1990 TESTING IGNITION CIRCUIT Tools Required:

Qty.

V.O.M. ................................... 1 If the engine will NOTrun but the starter will turn the en­ gine.

1. Check for loose wires at the terminals and connec­ tions.

&_WARNING&_ NEVER OPERATE THE STARTER UNLESS THE SPARK PLUG IS INSTALLED OR THE IGNITION SYSTEM IS DISABLED. FUEL DRAWN INTO THE CYLINDER WILL BE EXPELLED THROUGH THE SPARK PLUG HOLE AND COULD BE IGNITED BY THE IGNITION SYSTEM, RESULTING IN A FIRE.

DO NOT ARC SPARK PLUG WIRE TO GROUND. CONNECT TO A KNOWN-TO-BE-GOOD SPARK PLUG AND GROUND PLUG TO A METAL SURFACE (MUFFLER, CYLINDER, ETC.). PERMANENT IR­ REPARABLE DAMAGE MAY BE CAUSED TO THE IGNITOR IF PLUG IS NOT GROUNDED. 2.

Check for an electrical discharge through the spark plug ignition wire as follows: Using a spark plug that is known to be good, place on a metal surface (muffler, cylinder, etc.), connect the spark plug wire and turn over the engine with the starter. Look for a blue electrical arc at the spark plug electrodes.

3. Replace the plug if necessary. Gap the spark plug .028" to .03 0".

4. If there is either a weak arc or no arc in Step 2, try a new spark plug, then check the spark plug ignition wire for loose terminals. Check the ignition wire by substituting it on another engine or using one that is known to be good.

5. Check the ignition coil by temporarily attaching an­ other one that is known to be good.

It is not necessary to place the coil in the mounting bracket; just attach the wires. If the engine then oper­ ates, replace the old coil.

6.

Check the ignitor by temporarily attaching another one that is known to be good.

4/1/92

l l l l Ll9!G!

It is not necessary to mount the ignitor; just attach the wires.

If the engine then operates, replace the old ignitor.

7. Check the engine timing per the Timing Procedure.

'-:!fESTING STARTING CIRCUIT

&_WARNING&_ DISCONNECT BATTERY FOR STEPS 1 THROUGH 8 (SEE PROCEDURE IN SECTION B).

If the engine will not turn over in either forward or re­ verse, check the following: 1. Check the battery for a voltage reading which should be between 12.4 and 1 4.0 volts. Inspect for loose or dirty battery post connections.

2. Check for a blown fuse and replace if necessary with a Buss AGC 25 amp fuse.

3. Check for loose wires at all terminal connections.

4. Check the complete electrical system for correct circuitry(FIG.L-2).

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

6. Check for continuity through the key switch. Set volt-ohm meter on XI scale, place positive (+) probe on the terminal with the blue wire attached and negative (-) probe to the terminal with the black wire. The reading on the meter should be "O" ohms with the switch key in the "ON"position. If the meter does not register, replace the switch.

7. Check continuity through the 'neutral' limit switch.

Place a probe on terminal "E" of the ignition switch and the solenoid terminal with the red wires at­ tached. Place the forward-neutral-reverse switch in forward. If the ohmmeter shows "O" ohms, the switch is good. If the meter does not register, check the wires from the key switch to the limit switch. If wires and connections are good, the for­ ward-neutral-reverse switch should be removed to check the engagement of the limit switch's actu­ ating lever with the cam. If all checks are good, re­ place the neutral limit switch.

8. Check for continuity through the accelerator limit switch. Place a probe on terminal "E"(FIG.L-2) of key switch and the other probe on the positive(+) terminal of the coil and depress the accelerator pedal. If the ohm meter shows "O" ohms, the switch is good. If the meter does not register, check the wires from the ignition switch to the accelerator

E�GDii:S:!itt•J:I

Pg.L-3

ELECTRICAL - 1989 / EARLV 1990

9.

limit switch, accelerator limit switch to the solenoid and from the solenoid to the coil. If wires and con­ nections are good, install a jumper wire across the neutral limit switch that is activated by the forward­ neutral-reverse switch arm. Repeat Step 7. If the meter does not register, replace the accelerator limit switch, if the meter registers, replace the neu­ tral limit switch attached to the forward-neutral-re­ verse switch.

Check the electrical contacts in the forward-neu­ tral-reverse switch for continuity. Set the volt-ohm meter on XI scale. a) With the forward-neutral-reverse indicator in the forward position, place positive(+) probe on terminal "A" and the negative(-) probe on terminal "B"; the meter reading should be "O". b)

Place positive(+) probe on terminal "C"; the meter reading should be "O".

c)

With forward-neutral-reverse indicator in the reverse position, place positive(+) probe on terminal "A" and the negative(-) probe on ter­ minal "D"; the meter reading should be "O".

d)

Place positive(+) probe on terminal "C" and the negative(-) probe on terminal "B"; the me­ ter reading should be "O".

e)

If O reading is not obtained in a-d, replace for­ ward-neutral-reverse switch.

TESTING CHARGING CIRCUIT 1.

If the battery charge is insufficient, check the fol­ lowing: a) Check the battery voltage and inspect for loose or corroded terminal posts. b)

Check all terminals for proper and tight con­ nections.

c)

Check for charging voltage by the following method.

10. Check the starting solenoid operation. Turn the key switch to the "ON" position and the forward­ neutral-reverse switch to the neutral position.

Connect the battery. a) Place the voltmeter positive(+) probe on ter­ minal "A" of the solenoid (FIG. L-2). Place the negative(-) probe on terminal "B". The voltmeter should indicate approximately 12 V. b)

Depress and hold the brake while depressing the accelerator pedal. The voltmeter will re­ turn to "O" voltage if the solenoid contacts are closed.

c)

If "O" voltage is not indicated while the accel­ erator pedal is depressed, replace the sole­ noid.

Pg. L-4

E�GDii=>:, i1!•l:I

1.

Raise the vehicle(see procedures in Sec­ tion B) such that both rear wheels are free to rotate.

2. Set the voltmeter on 50 V.D.C. Place the negative(-) probe on negative(-) post on the battery and the positive(+) probe on positive post on the battery. Observe the battery voltage.

3.

Start the engine and accelerate to gov­ erned speed.

4.

Observe the meter for a reading between 14.5 V to 15.5 V.

5.

If the voltage is above 15.5 volts, replace the regulator.

6. If no increase over battery voltage is ob­ served, there is a malfunction in the charging circuit. If a low voltage is ob­ served, check the following: a) Check the voltage regulator for malfunction. b) Start the engine and accelerate to governed spe�d. c)

A reading of 14.5 V to 15.5 V should be observed.

d) With the engine off, check be­ tween the ground strap and D-, D+, and OF terminals; the reading should be "O" ohms.

4/1/92

! !U9!G!

ELECTRICAL - 1989 / EARLY 1990

CD IGNITION SWITCH (D REVERSE WARNING SWITCH 0 IGNITION COIL 0 REVERSE WARNING DEVICE

(D A CCELERATOR LIMIT SWITCH (D VOLTAGE REGULATOR Q) SOLEN OID IGNITOR UNIT

CD

(D 12 VOLT BATTERY @ STARTER/GENERATOR @ENGINE @F-N-R SWITCH @ IN-LINE FUSE @ PULSOR COIL CONNECTOR @ NEUTRAL LIMIT SWITCH

1989/EARLY 1990

LATER 1990

0

FIG. L-3 ELECTRICAL SYSTEM (PHYSICAL LOCATIONS) 4/1/92

I I I ILl91GI

Pg.L-5

ELECTRICAL - 1989 / EARLY 1990 2.

Do not remove the cover from the voltage regulator.

This unit is set and sealed by the manufacturer and is not adjustable. If a charging problem is traced to the regulator, it must be replaced with a new unit.

Remove the drive belt from the driven clutch sheave by following the instructions in the above warning.

TO PREVENT BURNS, BE SURE THAT THE MUF­ FLER AND EXHAUST COMPONENTS HAVE COOLED BEFORE ATTEMPTING ANY SERVICE.

MUFFLER SUPPORT REMOVAL (FIG. L-4) STARTER/GENERATOR

Tools Required:

3.

Qty.

Ratchet, 3/8" drive ......................... 1 Ratchet, 1/4" drive ........................ .. 1 Extension, 6", 3/8" drive ..................... 1 Extension, 2", 1/4" drive .................. . .. 1 Socket, 3/4", 3/8" drive ...................... 1 Socket, 1/2", 3/8" drive ...................... 1 Socket, 7/16", deep well ..................... 1 Socket, 10 mm, 1/4" drive .................... 1 Socket, 8 mm, 1/4" drive ..................... 1 Wrench, 9/16", open end ..................... 1 Wrench, !/2", Insulated, open end .............. 1 Wrench, 1/2", open end ...................... 1

MUFFLER REMOVAL (FIG. L-4) 4.

Remove the two bolts (10) and lock nuts (11) that secure the muffler (12) to the exhaust pipe. Re­ move the two nuts (13) washers (14), and bolts (15) that secure the muffler retaining straps (16) to the muffler support.The straps are secured to the sup­ port at one end and may be moved to permit the muffler (12) to be removed from the support. Slide the muffler away from the exhaust pipe and lift the muffler out of the muffler support. Remove the muffler insulation/heat barrier (17) from the muffler support (18). Remove the bolts (19) from the muf­ fler support.

5.

Remove the muffler support and brace.

6.

Remove the starter/generator belt (20) by loosen­ ing the nut (21) that secures the pivot bolt (22).

Loosen the adjuster by loosening the jam nut (23) near the engine, and then turn the adjuster to loosen it. Pull up on the belt to pivot the starter/ generator (23) inwards. Remove the belt.

7.

Remove the hardware securing the starter/genera­ tor pivot bolt.

Screwdriver, large, straight blade ..... . ........ 1

STARTER/GENERATOR REMOVAL 1.

Raise the vehicle as described in section B.

&WARNING& TO PREVENT THE POSSIBILITY OF PERSONAL IN­ JURY: OBSERVE ALL OF THE WARNINGS AS DESCRIBED IN SECTION B. REMOVE THE (+) BATTERY LEAD AT THE BAT­ TERY AND COVER THE(+) POST WITH A NON CON­ DUCTIVE COVER SUCH AS A SHOP RAG. TO REMOVE THE DRIVE BELT, PARK ON FLAT SURFACE. WITH F-N-R SWITCH IN NEUTRAL AND THE HILL BRAKE OFF, PUSH VEHICLE BACK­ WARDS WHILE ROLLING THE BELT OVER THE DRIVEN CLUTCH SHEAVE. DO NOT ALLOW FIN­ GERS TO BECOME TRAPPED BETWEEN THE BELT AND THE SHEAVE.

Pg.L-6

Remove the lock nut (1), washer ( 2), special washers (3), and bolt (4) that secures the muffler support brace (5) to the starter generator bracket (6). Remove the lock nut (7), and washer (8), that fasten the muffler support to the engine frame (9).

Some starter/generator pivot bolts have a stop attached to it that prevents its rotation; requiring no use of a back up wrench.

8.

Use a large screwdriver hooked under the head of the pivot bolt to slide the pivot bolt out of the starter/ generator.

9.

Carefully lift the starter/generator out of the the en­ gine compartment and remove the wires attached to it.

4/1/92

! ! L!9!G!

ELECTRICAL - 1989 / EARLY 1990

NOTE: WHEN INSTALLING MUFFLER SUPPORT BAR, APPLY THREAD ADHESIVE (E-Z GO PART # 18659-G1) TO BOLTS. INSTALL AS SHOWN. TORQUE HARDWARE TO 26 - 28 FT. LBS.---------

FIG. L-4 STARTER/GENERATOR AND MUFFLER REMOVAL 4/1/92

I I I ILl91GI

E�GDii:i:,i,t•l:I

Pg.L-7

ELECTRICAL - 1989 / EARLY 1990 STARTER/GENERATOR INSTALLATION 1.

2.

Installation is in the reverse order of removal.

Tighten nuts securing wires to 45 in. lb. torque.

A loose starter/generator belt can create an audible vi­ bration and squeal. New belt tension should be checked after 15 to 20 hours of use. Check the belt tension after it has run for between 5 to 15 minutes and readjust the tension if required.

The use of an automotive 'V' belt tension gauge is es­ sential. The Gates 'Krikit' is available at most NAPA automotive parts stores has proved to be a reliable and accurate tool.

3.

4.

Tighten a NEWstarter/generator belt to 90-110 lb tension when the gauge is applied to the belt at a point midway between the clutches. Secure the jam nut on the tensioner, and then tighten the nut on the pivot bolt.

Tighten an EXISTING starter/generator belt to 75 - 80 lb tension when the gauge is applied to the belt at a point midway between the clutches. Se­ cure the jam nut on the tensioner, and then tighten the nut on the pivot bolt •

MUFFLER INSTALLATION (FIG.L-4) 5.

Be sure that the muffler insulation/heat barrier is centered in the muffler support. Position the muf­ fler (12) in the support. Slide the muffler inlet pipe into the exhaust pipe joint and install the bolts (10) through the the two flanges (25).

Install the nuts(11) finger tight. Rotate the two flanges until the top of the flange is parallel with the ground.

Tighten the hardware to 100 in. lbs. torque. Posi­ tion the muffler mounting straps and install the lock nuts (13) washers, bolts (15). Tighten to 50 in. lbs torque.

STARTER/GENERATOR DISASSEMBLY (FIG. L-5), (FIG. L-6) To disassemble the starter/generator, proceed as fol­ lows. Remove the brush covers (1) by prying out with a screwdriver. Pull up on the brush springs and move to the side of brushes, slide the brushes out approximately 1/4" (FIG. L-6). Remove the through bolts (2) and the rear cover (3). Remove the frame and the field coils (4).

Pg.L-8

Remove the 5 mm screws from the brush holder and 6 mm nuts from A1, A2 terminals. Remove the brush holder. Hold the pulley and remove the pulley nut (5).

After the pulley is removed, remove the screws (6) and remove the front cover. Remove the woodruff key (7) and spacer (8). Install a bearing adapter at the rear side of the bearing as shown in (FIG. L-8). Using an auto­ motive type 2 jaw puller, apply pressure to the armature shaft and pull the bearing off.

STARTER/GENERATOR INSPECTION AND REPAIR INSPECTION Visually inspect the following: 1.

lnspect the outside face of the commutator for wear or damage.

2.

Inspect the brush assembly for wear and damage to the brush holder insulators. Check the brushes for length and signs of carbonization.

3.

Inspect the armature for distortion, broken wires, or carbonization.

4.

Inspect the field coil insulators and lead wire.

5.

Check the bearings for free rotation and lack of end play.

REPAIR 1.

2.

Commutator - Clean with a soft, clean cloth.

3.

Test the insulation between the core and the com­ mutator segments and between the commutator segments and shaft with a circuit tester. If continu­ ity is indicated, the insulation is defective and the armature must be replaced.

4.

Using a circuit tester, ch.eek the field coils for conti­ nuity between "F1" and "F2" and "DF" and "F1". If an open circuit exists, replace the field coils. Check for continuity between all four terminals and the frame (outer shell). If continuity is indicated, the field coils are grounding against the frame and the field coils must be replaced .

5.

Clean all parts to be reinstalled and reassembling reverse order of disassembly. Tighten bolts and nuts to the following torques:

Replace any damaged or cracked brush holders or brushes worn to less than 11/16" in length.

4 mm

15-21 in. lbs. 17-24 kg-cm

4 mm

30-43 in. lbs. 35-50 kg-cm

6 mm

52-74 in. lbs. 60-85 kg-cm

14 mm

33-40 ft. lbs. 450-550 kg-cm

4/1/92

! !U9!Gl

ELECTRICAL - 1989 / EARLV 1990

FIG. L-5 STARTER/GENERATOR 4/1/92

I I I ILl91GI

E�GCI ii�:,it{•J:I

Pg.L-9

- ELECTRICAL - 1989 / EARLY 1990 BRUSH SPRING

BRUSH

"- COMMUTATOR /

FIG.L-6 STARTER/GENERATOR BRUSH REMOVAL

A1

CLOCKWISE ROTATION

COUNTER CLOCKWISE ROTATION

STARTER/GENERATOR VIEWED FROM PULLEY END

FIG. L-7 CIRCUIT DIAGRAM, STARTER/GENERATOR DIRECTION- 1989/ EARLY 1990 Pg.L-10

E�l3Dii=>:1it{•J:I

4/1/92 I I I ILl91GI

ELECTRICAL - 1989 / EARLY 1990 PULLER BEARING ADAPTER (SPLITTER)

FIG. L-8 BEARING REMOVAL Tighten terminal nuts to the following torques: 43-52 in.lbs.· 50-60 kg-cm F1-F2 DF 26-35 in.lbs. 3Q-40 kg cm

BATTERY REMOVAL See procedures in Section B.

BATTERY TEST The only test for a maintenance free battery is a voltage test which can be made using a voltmeter.The negative lead of the voltmeter is attached to the ground terminal of the battery. The positive lead of the voltmeter is at­ tached to the positive terminal. Voltage reading should be 12 volts or above. If voltage reading is below 12 volts, then the battery requires charging or replacement.

&,_WARNING&_ THE HYDROGEN GAS FORMED DURING BATTERY CHARGING IS EXPLOSIVE. AVOID ANY ELECTRI­ CAL SPARK OR OPEN FLAME NEAR BATTERIES.

If the temperature of the battery or the ambient tempera­ ture is below 60_F, the capacity of the battery will be less. It will require more hours of charge if below 60_F, since a cold battery will build up voltage and more rap­ idly reduce the charging rate.

DO NOT OVERCHARGE BATTERY. 4/1/92

I I I ILl9!GI

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

STORAGE Batteries that are removed from service for storage must be cared for as follows: Fully charge. Store in a cool place not below 32_F or above 80_F. Batteries should be charged every 30 days.

If trouble is encountered in bringing batteries to full charge, line voltage may be below 115 volts. Contact the power company or an electrician and have the line voltage checked.

COOLING FAN/FLY WHEEL REMOVAL (FIG. L-9)

Tools Required:

Qty.

Wrench, 12mm, box end ..................... 1 Wrench, 19mm, box end ..................... 1 Puller, flywheel E-2-GO (17086-G1) ........... 1 Socket, 10mm, 3/8 drive ..................... 1 Ratchet, 3/8 drive ...... • .................... 1 Remove the cooling fan shroud.(See Engine and Con­ trols Section).

Hold the cooling fan/flywheel and use a 19mm open end wrench. Loosen the nut retainer (4) and remove the nut (2) and washer (3) from the crankshaft (FIG. L-9).

Using an E-2-GO cooling fan/flywheel puller, part num­ ber 17086-G1, remove the cooling fan from the crank­ shaft. Installation is in the reverse order of removal.

Pg. L-11

ELECTRICAL - 1989 / EARLY 1990 SPARK PLUG

DO NOT ARC SPARK PLUG WIRE TO GROUND. CONNECT TO A KNOWN-TO-BE-GOOD SPARK PLUG AND GROUND PLUG TO A METAL SURFACE (MUFFLER, CYLINDER, ETC.). PERMANENT IR­ REPARABLE DAMAGE MAY BE CAUSED TO THE IGNITOR IF PLUG IS NOT GROUNDED. Before removing the spark plug, all dust and foreign ma­ terial should be removed from the cylinder head. See Trouble-Shooting section for causes of plug fouling.

FIG. L-9 FLYWHEEL REMOVAL

IGNITOR.

YELLOW/RED

RED

GREEN ACCELERATOR MICRO SWITCH BLK

BLK

BLACK

SPARK PLUG

E

...._____s E _t_u _ D-1

;fiL

I

�c�� - - -IBE

�b,i I

ENGINE L ____________ J

<ENGINE HOUSING TO FRAME)

FIG. L-10 SOLID STATE IGNITION SYSTEM WIRING DIAGRAM - 1989/ EARLY 1990 Pg.L-12

4/1/92

I lU9!G!

ELECTRICAL - 1989 / EARLY 1990 Clean a fouled plug and regap to .028-.030 inch. Use a wire type gauge for checking the electrode gap. Install and tighten to 18 - 21 ft. lbs. torque.

If new plug is required, use either an NGK-BP5HS or a Champion L92-YC.

Forward: 18_ 3_11,500 R.P.M. (B.T.D.C)

SOLID STATE IGNITION (FIG.L-11), (FIG. L-12), (FIG.L-13 )

Fasten the pulser mounting plate with the center of the screws in alignment with the timing mark line at the plate.

Remove the cooling fan/flywheel using the procedure noted under Cooling Fan/Flywheel Removal.

Remove the two ignition mounting screws (5). Pull the wiring grommet through the existing hole and remove the pulser. Installation is in the reverse order of re­ moval. Adjust using the procedure listed under Solid State Ignition or Timing.

REASSEMBLY PROCEDURE (FIG.L-12), (FIG.L-13) 1.

2.

Reverse: 21

Reassembly procedures for the pulser assembly:

2.

Ignition Timing Check (forward rotation only).

Due to the function of the S.S.I. system, the timing checks may be made only when engine is running.

If the ignition timing in the forward rotation is correct, the timing in reverse rotation will also be correct. Therefore, timing checks are only required in the forward rotation.

Install the pulser coil with the terminal on the left side.

Fasten the coil tightening screws (M4 x 0.7 P).

(Fastening should be in accordance with (FIG. L-12) to maintain an air-gap of .016-.022 in. between the coil and the rotor.)

a)

Remove the dust plate from the cooling fan shroud.

b)

Set the engine R.P.M. at 1,500 R.P.M. 200 in forward rotation.

c)

Illuminate the slit line on the cooling fan shroud using a timing light and check if the slit line and the embossed mark on the cooling fan (FIG. L-14) are in alignment.

d)

The timing is correct when the marks are in alignment. (FIG. L-16).

(Fastening torque: 5.2-13 lb.-in.)

3.

4.

Solder the blue wire to the A terminal and the red wire to the B terminal.

Use continuity tests as shown in "Trouble-Shoot­ ing".

1.

Assure that the connections of the blue and red wires are correct; a misconnection will permit the coil to func­ tion but will cause the timing to have a 40_ error.

Ignition Timing Adjustment (Forward rotation) If the ignition timing is incorrect, adjust it in accor­ dance with the following procedures. a)

Remove the cooling fan shroud and cooling fan, and loosen the plate mounting screws.

b)

Adjust the timing by rotating the plate - left or right.

(Fasten screws to 52 in. lb.)

(FIG. L�16).

c)

Check the timing in accordance with the igni­ tion timing check 1 and 2.

USE ONLY AN INDUCTION TYPE TIMING LIGHT. 1.

Ignition Timing (FIG. L-17)

4/1/92

! ! ! !U9!G!

(Standard)

(FIG.

L-14),

3_11,500 R.P.M. (B.T.D.C)

E�GDiiHit!•l:I

Pg.L-13

ELECTRICAL - 1989 / EARLY 1990

z

Lt

z

(!)

::i 0

0 (.)

..J

w w ::c � � LL

I­ LL <C ::c en � z <C a:

(.)

FIG.L-11 SOLID STATE IGNITION SYSTEM Pg.L-14

4/1/92 I I I ILl9!GI

ELECTRICAL - 1989 / EARLY 1990

FIG.L-12 PULSER COIL INSTALLATION

BLUE

RED

PULSER COIL

I

FIG.L-13 PULSER COIL WIRING 4/1/92

I I I ILl91GI

E�GDiiHi1\•l:I

Pg.L-15

ELECTRICAL - 1989 / EARLV 1990 FASTENING TORQUE: 50-55 IN./LBS.

TIMING MARK BLOWER HOUSING

TIMING MARKS

FIG. L-14 TIMING MARK LOCATIONS Pg.L-16

E�GDii=ni1M:I

4/1/92 I I I ILl91GI

ELECTRICAL - 1989 / EARLY 1990

ACCEPTABLE TIMING TOLERANCE

0° REF I

\

ll�NG MARKS� � / ?NO

A-

.....,-9�

\\ ij

FIG. L-15 TIMING MARK ALIGNMENT

�

VANCE IN TIMING

FIG. L-16 TIMING ADJUSTMENT 4/1/92

I I I IU9IGI

E�GCii:i:,i,!•l:I

Pg.L-17

ELECTRICAL - 1989 / EARLY 1990

z

0

i==

z

S2 w

0

a: � a: 0 u.

I-

w >

Cl)

::>

�

(.)

0

z

CJ

a..

C\I

I

Lt)

C\I (.)

w

� a.. a: Cl

w w

a:

Cl Cl)

C\I

a..

Cl)

w z

CJ

a z

� i==

w

z

0

i==

z

....

S2

ci5

w w a:

CJ

w

Cl

C\I C\I

....

C\I

0 C\I

....

0)

....

co

I'....

....

CD

'

f

0 0 0

....

X

-�raTS 8Nll/\lll NOl11N81

FIG. L-17 SOLID STATE IGNITION TIMING CURVE Pg.L-18

4/1/92

I ILl9!GI

ELECTRICAL - 1989 / EARLY 1990 SPECIFICATIONS STARTER/GENERATOR

Brush

Length

Standard

(23 mm) 29/32"

Minimum

(16 mm) 5/8"

Brush Tension

(0.8 -0.1 kg) 1.764 lbs. @ 29/32" at brush length 23 mm

Commutator

Standard outer diameter

(41 mm) 1.614

Limit outer diameter

(39 mm) 1.535"

Out of round repair limit

(0.03 mm) .0015"

Repair standard of depth of mica

(0.2 mm) .0078" .019" -.031"

Shaft

Coil Resistance

Pulley Side

Shaft diameter

(20) .18r

Rear side

Shaft diameter

(15) .590"

Armature Coil Field Coil

Pulley

0.0134 ohm at 20 C F1 -F2

0.0056 ohm at 20 C

F1 -DF

5 ohm at 20 C

Belt

A type, single groove

Outer diameter

(87.6 mm) 3.448"

FIG.L-18 SPECIFICATIONS STARTER/GENERATOR 4/1/92

I I I I U9!G!

Pg.L-19

ELECTRICAL - 1989 / EARLY 1990

REGULATOR SPECIFICATIONS Model

T10722D

BatteryVoltage

12V

Weight

0.3 kg

Polarity

Negative Ground

Regulated voltage

(-6.6 C)

20 F

15.5V

(25 C)

TTF

15V

0.5V

(60 C)

140 F

14.5V

0.5V

0.5V

At 6,000 R.P.M. (starter/generator) between D+ and 0-, 3.5 Amps (adjusted by full battery and resistance)

FIG. L-19 REGULATOR SPECIFICATIONS

IYOFF, C

L

V

locm�

BATT.

I C

V

0

J +©

l -©

RED BLACK·

FIG. L-20 VOM SETUP Pg.L-20

4/1/92

I ILl91GI

OPERATION AND SERVICE MANUAL

SECTION:ELECTRICAL - STARTING LATE 1990

IDENTIFYING ELECTRICAL SYSTEMS (FIG. L-1)

Differences exist in the wiring of the electrical systems of vehicles produced during the 1990 model year. Early Production 1990 vehicles share the same electrical sys­ tem as the 1989 models, while later 1990 vehicles have a different wiring harness and different wiring connec­ tions resulting in a different electrical system. Before proceeding in this chapter, examine the wiring connec­ tions on the voltage regulator (located on a panel near the rear of the engine compartment) to identify which system was incorporated into the vehicle, then proceed according to the information in the appropriate ELEC­ TRICAL section (1989 / EARLY 1990 p. L-1 thru L-20 or LATE PRODUCTION 1990 p. L-21 through L-23).

L

a motor. This circuit is controlled by a key switch, a fuse, an accelerator switch, a solenoid switch and a forward­ neutral-reverse switch. With the key switch in the "ON" position and with either "forward or reverse" selected, battery current is available to the accelerator limit switch which remains open until the accelerator pedal is de­ pressed. When the pedal is depressed, the plunger on the switch is released, the contacts close and the igni­ tion circuit is energized. Battery current then energizes the starter solenoid which closes the contacts. Battery current then flows through the forward-neutral-reverse switch and through the neutral limit switch to the starter/ generator. The starter/generator now functions as a motor to start the engine.

The engine can be stopped either by releasing the ac­ celerator pedal to the full up position or by turning the key switch to the "OFF" position. When the accelerator pedal is released, the plunger on the accelerator limit switch is depressed, the contacts open, and the ignition circuit is de-energized.

GENERATOR (FIG. L-2) When the engine is running, the starter/generator func­ tions as a generator and current is generated. This cur­ rent is used for charging the battery and for the ignition system. Generated output is controlled by the voltage regulator at 14.5 to 15.5 V, without regard to engine R.P.M. However, the charging current will vary depend­ ing on the condition of the battery. If the battery is fully charged, current is controlled at 3 to 5 amps.

FIG.L-1 IDENTIFYING ELECTRICAL SYSTEMS

WIRING

/l:::,.WARNING/l:::,.

CIRCUITS AND CONTROLS The electrical system is a negative grounded 12 volt system and contains a starter/generator, voltage regu­ lator, starter solenoid, forward-neutral-reverse switch, igniter, pulser coil, accelerator limit switch, "Neutral" limit switch, key switch, and ignition coil. The limit switches are devices to ensure that the electrical con­ tacts are in a fully engaged position before becoming energized.

STARTER (FIG. L-2) When starting the engine, the field coils are in series with the armature and the starter/generator operates as

4/1/92

I I I ILlo!GI

BEFORE MAKING ANY TEST OF WIRING COMPO­ NENTS, DISCONNECT THE BATTERY CABLES FROM THE BATTERY POSTS (SEE PROCEDURE IN SECTION B).

Electrical tests of the wiring for continuity may be made with a "multi-tester" meter, available through E-Z-GO Service Parts or the nearest E-Z-GO distributor. Set the meter selector knob to the ohms scale and check continuity between each circuit component as indicated.

Example: If the cut out switch is open or if there is a hid­ den break in the wiring, the meter will read infinity.

E.ZGDii�:,it{•J:I

Pg.L-21

ELECTRICAL - STARTING LATE 1990

BL

BLK

BLK

BLK

F1

'

BLK',

BLK

F2 NEUTRAL I LIMIT SWITCH

STARTER/GENERATO

BLK

BLK

REVERSE WARNING DEVICE IGNITION SWITCH

GRN

OF

BLK

VOLTAGE REGULATOR

BLK

RED

IGNITION COIL

GRN

15AMP FUSE RED

-­ < >

BLK

ORN

SOLENOID

REVERSE

VELJRED

FORWARD POWER WIRING

BLK

CONTROL WIRING

FIG. L-2 ELECTRICAL SYSTEMWIRING DIAGRAM- LATER 1990 Pg.L-22

4/1/92

I I I !UO!G!

ELECTRICAL - STARTING LATE 1990

F1 +12V DC FROM r SOL I A1

ISTARTER/GENERATOR ! !

t

rrm _.i I •'--1F2-� cr

+12V DC FROM SOL

TO SOL

I I I STARTER/GENERATOR �_J I ,o.L '--)F2 ' rrm -iE:.J

CLOCKWISE ARMATURE ROTA­ TION (VIEW FROM PULLEY END)

STARTER/GENERA­ TOR (VIEW FROM PULLEY END)

COUNTER-CLOCKWISE ARMATURE ROTATION (VIEW FROM PULLEY END)

FIG.L-3 CIRCUIT DIAGRAM, STARTER/GENERATOR DIRECTION - LATER 1990 IGNITION SWITCH

BLK

F-N-R MICRO SWITCH

BLK

IGNITION COIL F-N-R SWITCH

RED

RED GRN

ACCELERATOR MICRO SWITCH BLK

ORG

RED BLK BLK YEURED

RED GRN BLK

SOLENOID

+12V DC BATTERY

ORG

BLK STARTER/ GENERATOR

FIG. L-4 SOLID STATE IGNITION SYSTEM WIRING DIAGRAM - LATER 1990 4/1/92

I I I !Uo!G!

E�GDi ,,.:, i1t•J:I

Pg.L-23

ELECTRICAL - STARTING LATE 1990

Pg.L-24

E�GDii:$:,i1t•l:I

4/1/92 I I I IUo!Gl

OPERATION AND SERVICE MANUAL SECTION: REAR AXLE

GENERAL

AXLE ADJUSTMENTS

The vehicle's rear axle is a high efficiency unit fea­ turing a matched set of low friction helical cut gears.

The axle is equipped with an internal ground speed sensing governor with an external lever that interacts with the accelerator cable and the carburetor link­ age. The vehicle is equipped with expanding shoe drum brakes on the rear wheels. Brake service in­ structions are covered in the Brake Section of this manual.

DIFFERENTIAL LUBRICATION

Tools Required:

Qty.

Screwdriver, Phillips, large ................... 1 Wrench, open end, 7/8" .................... 1 Dipstick, service E-Z-GO # 24710-G1 ......... 1 The lubricant level should be checked in accordance with the Periodic Service Schedule contained in Sec­ tion 'A' of this manual. With the vehicle parked on a level surface, the parking (hill) brake set, the key in the 'OFF' position and the F-N-R switch in the 'N' position, remove the trunk lid. If the vehicle is not equipped with a cover plate with a check/fill plug, remove the vent plug from the axle and use a serv­ ice dipstick to determine the fluid level. If lubricant is in the 'ADD' range add lubricant as required to bring to the acceptable level (see Periodic Service Schedule for recommended lubricant). The axle contains 8-10 oz. of lubricant when in the accept­ able range. Remove the dipstick and replace the vent plug being careful not to kink the vinyl tubing.

Reinstall the trunk lid.

If the vehicle is equipped with a check/fill plug in the cover plate, remove the plug and feel for the level of lubricant, if the lubricant cannot be felt add until lu­ bricant can be felt or pours out of the plug hole.

If there is evidence of accumulated greasy dirt around the rear axle cover, axle shafts or input shaft, the lubricant level should be checked immedi­ ately. Low lubricant level is an indication of a leak which should be identified and corrected.

The axle shaft wheel bearings are lubricated and sealed at the factory and do NOT receive any lubri­ cation from the rear axle.

1/01/89

! i i !M!9k3!

M

The helical axle has no external or internal adjust­ ments or shims; therefore, no disassembly is re­ quired except to replace worn or defective compo. nents caused by conditions beyond normal control.

REMOVING THE REAR AXLE FROM THE VE­ HICLE (FIG. M-1)

Tools Required:

Qty.

Ratchet, 3/8" drive ........................

Socket, deep well, 9/16", 3/8" drive .. .......

Wrench, open end, 9/16 ....................

Pliers, needle nose ................ . .......

Jack, hydraulic, trolley ......... .............

Jack stands ..............................

1 1 1 1 1 2

&WARNING&

WHEN LIFTING THE VEHICLE, BE CAREFUL NOT TO RAISE IT TOO HIGH WHICH COULD RESULT IN THE FUEL LINE BEING PULLED APART AT A JOINT. FUEL COULD SIPHON FROM THE FUEL TANK RESULTING IN A FIRE HAZARD.

WHEN REMOVING/INSTALLING THE LINKAGES TO THE GOVERNOR ARM USE EXTREME CARE NOT TO DAMAGE OR BEND THE ARM. SUPPORT THE GOV­ ERNOR ARM AND SQUEEZE THE BALL JOINT COM­ PONENTS TOGETHER. FAILURE TO OBSERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE GOVERNOR AND RESULT IN THE NEED FOR A COM­ PLETE REAR AXLE REMOVAL AND DISASSEMBLY. Remove the accelerator cable (1) from the axle tube and governor arm. At the governor end, remove the solid linkage from between the carburetor and the governor arm. (See Engine and Controls).

Service tip: To remove the female portion of the ball joint, insert a thin straight blade screwdriver in the slot adjacent to the joint and gently pry apart.

(See Linkage Handling Instructions (FIG. M-2).

Remove the governor arm (FIG. M-11). Remove the drive belt (See drive belt removal). Remove the driven clutch (See driven clutch removal). Loosen the rear axle lug nuts approximately one turn. Re­ move the bolts (2), washers (3), and nuts (4) se­ curing the lower end of the shock absorbers (5) to the rear axle mounting pads. Remove bolts (6),

Pg. M-1

REAR AXLE snubber washer (7), washers (8) lockwashers (9) and nut (10) securing the rear engine vibration mounts to the axle. Raise the vehicle per instruc­ tions in section B except that the rear jacks and jack stands are placed under the rear bumper NOT the engine (inner} frame. Lift until the shock absorbers are clear of the mounting brackets. Raise and sup­ port the engine (inner} frame on jack stands; re­ move the rear wheels.

Disconnect the brake cables after first loosening the adjusting yoke to remove tension from the brake ca­ bles. (Refer to the Brake section for readjustment procedures}.

&WARNING&

CARE MUST BE TAKEN WHEN REMOVING THE AXLE AND CLUTCH FROM THE VEHICLE. DO NOT ALLOW THE UNIT TO STRIKE THE JACK STANDS SUPPORTING THE VEHICLE. PROTECT THE GOV­ ERNOR ARM. Place jack stands under the rear of the engine frame (11}. Support the weight of the rear axle on the jack and remove the bolts (12), nuts (13), and washers (14) that secure the axle to the inner frame. Sup­ port the rear axle while slowly lowering the jack and rear axle to the floor. Slide the axle from under the vehicle.

5

2

3

4

1

FIG. M-1

Pg. M-2

I

1/01/89 I f.119PI

REAR AXLE

(/)

z

0

�

a: ::,

C, u:::

z

0 C)

a., co a., .,..

FIG. M-2 1/01/89

I I I fJl9k3I

Pg. M-3

REAR AXLE REAR AXLE INSTALLATION

WHEN REMOVING/INSTALLING THE LINKAGES TO THE GOVERNOR ARM USE EXTREME CARE NOT TO DAMAGE OR BEND THE ARM. SUPPORT THE GOV­ ERNOR ARM AND SQUEEZE THE BALL JOINT COM­ PONENTS TOGETHER. FAILURE TO OBSERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE GOVERNOR AND RESULT IN THE NEED FOR A COM­ PLETE REAR AXLE REMOVAL AND DISASSEMBLY. Installation is in the reverse order of removal.

REAR AXLE DISASSEMBLY (FIG. M-2)

THE REAR AXLE/GOVERNOR IS A PRECISION AS­ SEMBLY, AND AS SUCH ANY REPAIR OR REPLACE­ MENT OF PARTS MUST BE DONE WITH GREAT CARE IN A CLEAN ENVIRONMENT. BEFORE ATTEMPTING TO PERFORM ANY SERVICE ON THE AXLE, READ AND UNDERSTAND ALL OF THE FOLLOWING TEXT AND PHOTOGRAPHS BEFORE ADJUSTING OR DISAS­ SEMBLING THE UNIT.

BRAKE DRUM AND HUB DISASSEMBLY/AS­ SEMBLY Tools Required:

Qty.

Pliers, needle nose •..•••••••••••.•.•••••.. 1 Jack, hydraulic, trolley •.•..••••.....•.•...• 1 Socket, 1 1/16", hex, 1/2" drive ••.••..•••••. 1 Jack, hydraulic, trolley ..... ••••..•..•••..•• 1

The following procedure does not require the re­ moval of the rear axle from the vehicle.

Loosen the rear wheel lug nuts approximately one turn. Raise the vehicle and support on jack stands (see procedures in section B). Remove the rear wheels.

IF YOU HAVE HAD PREVIOUS EXPERIENCE WITH THE E-Z-GO ELECTRIC AXLE, IT IS ESSENTIAL THAT YOU DO NOT USE THE SAME DISASSEMBLYIAS­ SEMBLY TECHNIQUES SINCE COSTLY IRREPARABLE 'DAMAGE CAN RESULT FROM INCORRECT PROCEDURES. HANDLE ALL GEARS WITH EXTREME CARE SINCE EACH IS PART OF A MATCHED SET. DAMAGE TO ONE WILL REQUIRE REPLACEMENT OF THE ENTIRE SET OR RESULT IN AN UNACCEPTABLY HIGH NOISE LEVEL SNAP RINGS MUST BE REMOVED/INSTALLED WITH CARE TO PREVENT DAMAGE TO BEARINGS, SEALS AND BEARING BORES.

FIG. M-3 Remove the cotter· pin, axle nut, washer, and the spindle cap adapter, if equipped. (FIG. M-3) and (FIG. M-9) Remove the brake drum and washer (1)• -

AXLE SHAFT REMOVAL AND DISASSEMBLY

It is recommended that whenever a bearing, seal or 'O' ring is removed, it be replaced with a new one regardless of mileage. Always wipe the seals and 'O' rings with a light oil before installing.

Tools Required:

Removal of the brake assemblies are not required for the disassembly of the rear axle.

Pliers, snap ring, internal •••••.••••••••.•••• 1

Pg. M-4

Qty.

Arbor press ••.•••••••••••••••.•••••••••••• 1 Pliers, needle nose ••••..••••••••••••••.••. 1 Slide hammer ••••••••...•••••••••••••••••• 1

1/01/89

! ! !M!9k3!

REAR AXLE

FIG. M-4

Remove the outer snap ring (2) from the axle tube.

(FIG. M-4) and (FIG. M-9)

FIG. M-6 Remove the bearing by supporting the inner race of the bearing on an arbor press bed and apply pres­ sure to the threaded end of the axle shaft.

(FIG. M-6)

AXLE SHAFT SEAL REMOVAL AND RE­ PLACEMENT

Tools Required

Qty.

Pliers, snap ring, internal ...... • .. • ... • .....

Puller, seal ....................... • • .....

Seal installer, E-Z-GO PIN 18739-G1 .........

Hammer, ball pein .......... • .. • . • . . .......

1 1 1 1

FIG. M-5 Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube.

(FIG. M-5)

1/01/89

I I I IMl9@I

FIG. M-7 Remove the inner snap ring (3). (FIG. M-7) and (FIG. M-9)

Pg. M-5

REAR AXLE

FIG. M-8

FIG. M-10

Use a puller to remove the seal (4). (FIG. M-8) and (FIG. M-9)

To install the seal use the special E-Z-GO seal in­ staller to drive the seal into its correct position.

(FIG. M-9) and (FIG. M-10) Install the inner snap ring. (FIG. M-7)

AXLE SHAFT REPLACEMENT

WASHER

'1 ,•

COTTER PIN

---·

SP INE LOCK ,• •- ·, •: • INNER SNAP RING WASHER

OUTER SNAP RING

Coat the outboard spline of the axle with an anti­ seize compound. Install the brake hub and drum, thrust washer, nut, and a· new cotter pin.

Tighten the axle nut to 70 ft. lbs. torque mini­ mum/140 ft lbs torque maximum. Continue to tighten until the slot in the nut aligns with the cotter pin hole.

GOVERNOR ARM REMOVAL

FIG. M-9

Tools Required:

USE CARE TO PREVENT DAMAGE TO THE INNER SURFACE OF THE AXLE TUBE AT THE SEALING AREA.

Pg. M-6

Carefully insert the axle shaft and bearing through the oil seal.

Rotate the shaft until the spline en­ gages with the differential side gears. Install the outer snap ring (2). (FIG. M-4)

Qty.

Socket, 7 /16", 3/8 drive . . . . . . . . . . . . . . . . . . . .

Ratchet, 3/8" drive . • . . . . . . . . . . . . . . . . . . . . . .

Screwdriver, straight blade, small . . . . . . . . . . . .

Pliers, needle nose . . . . . . . • . . . . . . . . . . . . . . . .

E�GDii:flitM:t

1 1 1 1

1/01/89 ! ! !M!9!GI

REAR AXLE DIFFERENTIAL REMOVAL WHEN REMOVING/INSTALLING THE LINKAGES TO THE GOVERNOR ARM USE EXTREME CARE NOT TO DAMAGE OR BEND THE ARM. SUPPORT THE GOV­ ERNOR ARM AND SQUEEZE THE BALL JOINT COM­ PONENTS TOGETHER. FAILURE TO OBSERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE GOVERNOR AND RESULT IN THE NEED FOR A COM­ PLETE REAR AXLE REMOVAL AND DISASSEMBLY.

Tools Required:

WHEN THE AXLE IS TO BE REMOVED FROM THE VE­ HICLE, THE GOVERNOR ARM MUST FIRST BE RE­ MOVED TO PREVENT DAMAGE TO THE GOVERNOR SHAFT.

Drain pan ...••...•.......••......•....... 1

Remove the solid linkage from the governor arm.

Service tip: To remove the female portion of the ball joint, insert a thin straight blade screwdriver in the slot adjacent to the joint and gently pry apart.

Qty.

Ratchet, 3/8" drive •...•..•••..••....•••... 1 Socket, 1/2", 3/8" drive ....••..••...••••... 1 Putty knife ...••...••...•...•.............. 1 Pan, oil drain .•....•.......•..•......•..•. 1 Sealant, Permatex 20536-G1 ....•.....•..... 1

AXLE SHAFT REMOVAL AND DISASSEMBLY

THE REAR AXLE/GOVERNOR IS A PRECISION AS­ SEMBLY, AND AS SUCH ANY REPAIR OR REPLACE­ MENT OF PARTS MUST BE DONE WITH GREAT CARE IN A CLEAN ENVIRONMENT. BEFORE ATTEMPTING TO PERFORM ANY SERVICE ON THE AXLE, READ AND UNDERSTAND ALL OF THE FOLLOWING TEXT AND PHOTOGRAPHS BEFORE ADJUSTING OR DISAS­ SEMBLING THE UNIT. HANDLE ALL GEARS WITH EXTREME CARE SINCE EACH IS PART OF A MATCHED SET. DAMAGE TO ONE WILL REQUIRE REPLACEMENT OF THE ENTIRE SET OR RESULT IN AN UNACCEPTABLY HIGH NOISE LEVEL Remove the left and right axle assemblies as de­ tailed elsewhere in this section.

FIG. M-11 For 1989/90 remove the cotter pin (1) (1991 models are equipped with a push nut) that secures the ac­ celerator cable (2) to the spring assembly (3) of the governor arm (4). Remove the accelerator cable.

FIG. M-11 Remove the spring loop from the governor arm.

Remove the governor arm from the governor shaft and note the location of the spring (5), special washer (6), lockwasher (7) and nut (8).

Remove the ten cover plate bolts and remove the cover plate. Drain the lubricant into a drain pan.

(FIG. M-12)

12/15/90

I I I !M!H3!

Pg. M-7

REAR AXLE

Late 1989 models and on have a cover plate with a check/fill plug.

DO NOT DAMAGE THE MACHINED SURFACES OF THE BEARING CAPS.

USE CARE NOT TO DAMAGE THE SEALING SUR­ FACES.

FIG. M-14 Remove the four cap screws and remove the bear­ ing caps. (FIG. M-14)

FIG. M-13

A putty knife may be required to separate the cover plate from the housing. (FIG. M-13) All sealant must be removed from both the cover plate and the housing sealing surfaces.

FIG. M-15 The bearing caps are marked for identification.

They MUST be reassembled in their original position.

Pg. M-8

Remove the differential case from the housing.

(FIG. M-15)

1/01/89 i !M!9!Gl

REAR AXLE Remove the snap ring from the governor shaft and remove the threaded bushing from the housing.

(FIG. M-17)

FIG. M-16 Do not remove the bearing from the differential case unless a bearing failure is evident. If a bearing fail­ ure has occurred, remove it using a bearing puller and replace with new bearings. (FIG. M-16)

DIFFERENTIAL INSTALLATION Installation is in the reverse order of removal. Use Permatex sealant as required between the housing ,and the cover plate.

GOVERNOR ACTUATOR FORK REMOVAL Remove the differential.

FIG. M-18 The governor actuator fork can be rotated away from the governor and removed from the inside of the housing. (FIG. M...:18)

INTERMEDIATE GEAR REMOVAL Tools Required:

Qty.

Pliers, snap ring, internal ................... 1 Drift, brass ............................... 1 Puller, bearing, inner diameter ........... • ... 1 Puller, bearing, jaw type .................. • . 1 Screwdriver, Phillips ......................... 1 Drill, 3/8", electric or air ................. • . 1 Drill bit, 1/8" ............................. 1 Punch, center ............................. 1 Hammer, ball pein ............. • ........... 1

FIG. M-17

1/01/89

! ! ! !M!9k3!

HANDLE ALL GEARS WITH EXTREME CARE SINCE EACH IS PART OF A MATCHED SET. DAMAGE TO ONE WILL REQUIRE REPLACEMENT OF THE ENTIRE SET OR RESULT IN AN UNACCEPTABLY HIGH NOISE LEVEL.

E�GCJii:f:,it(•J:I

Pg. M-9

REAR AXLE

The intermediate gear shaft is located behind the metal plugs, and is recessed within the bearing bore. Each end of the shaft is countersunk which provides adequate clearance to drill out the metal plugs.

FIG. M-20 Remove the snap ring from the FLANGED side of the intermediate gear. (FIG. M-20)

FIG. M-19

Lightly punch the center of the intermediate gear shaft plugs. Drill through each plug using a 1 /8" diameter drill being careful not to drill into the shaft below the plug. Insert a suitable Phillips head sheet metal screw into the drilled hole and screw in until the metal plug is forced out of the bearing bore.

(FIG. M-19) Clean any remaining sealant from the bore before proceeding using care not to damage the housing bore.

Pg. M-10

FIG. M-21 Remove the snap ring from the FLANGED side of the input gear. (FIG. M-21)

1/01/89

! ! !M!9PI

REAR AXLE

f&lml .

.. . . ••:•.• · -.· ·· ·· ·· ··

DO NOT ATTEMPT TO DRIVE THE INTERMEDIATE GEAR AWAY FROM THE HOUSING FLANGE SINCE SERIOUS DAMAGE WILL BE CAUSED TO THE GOV­ ERNOR. TAP THE INTERMEDIATE GEAR TOWARDS THE FLANGED SIDE OF THE HOUSING, THIS WILL CAUSE THE INTERMEDIATE GEAR TO CONT ACT THE INPUT GEAR'S BEARING AND MOVE IT PARTIALLY OUT OF THE HOUSING. DO NOT TAP THE SHAFT AFTER THE INPUT BEARING HAS CONTACTED THE INSIDE OF THE HOUSING.

FIG. M-23 Remove the snap ring from the GOVERNOR side of the intermediate gear. (FIG. M-23)

FIG. M-22

Use a brass drift to TAP the intermediate gear TO­ WARDS the flanged side, continue until the interme­ diate gear contacts the inside of the housing.

(FIG. M-22)

1/01/89 I I I IMl9@I

FIG. M-24

Use an inner diameter bearing puller to pull the inter­ mediate gear bearing from the governor side of the housing. (FIG. M-24)

Pg. M-11

REAR AXLE

HANDLE ALL GEARS WITH EXTREME CARE SINCE EACH IS PART OF A MATCHED SET. DAMAGE TO ONE WILL REQUIRE REPLACEMENT OF THE ENTIRE SET OR RESULT IN AN UNACCEPTABLY HIGH NOISE LEVEL.

If the intermediate gear's bearing moves with shaft it may be retained by wrapping with tape. Do not hold with pliers unless the bearing is to be replaced.

FIG. M-26

Tilt the intermediate gear and remove from the housing. (FIG. M-26) Use the brass drift to remove the remaining interme­ diate gear bearing.

INPUT/GOVERNOR GEAR REMOVAL

FIG. M-25 Using a brass drift punch TAP the intermediate shaft away from the flanged side of the housing and out of the bearing. (FIG. M-25)

Pg. M-12

FIG. M-27

The input gear is removed by applying hand pres­ sure to the input shaft and pulling it from the hous­ ing. (FIG. M-27)

1/01/89 I IMl9ijl

REAR AXLE INPUT/GOVERNOR BEARING REPLACEMENT Tools Required:

2.

Install the intermediate gear bearing opposite the flanged side and it's retaining ring before attempting to tap the gear into place. This will prevent the gear from striking the governor as­ sembly during installation. (FIG. M-28)

3.

Coat the edges of the metal plugs with sealant and tap into pace using a socket and a ham­ mer.

Qty.

Arbor press ..•...•....•.....•.....••...... 1

WHEN REPLACING EITHER OF THE BEARINGS OB­ SERVE THE FOLLOWING:

DIFFERENTIAL DISASSEMBLY

PROTECT THE GEAR TEETH FROM DAMAGE. PRESS THE GEARS INTO PLACE USING AN ARBOR PRESS AND A SUITABLE ADAPTER THAT WILL TRANSFER ALL FORCES TO THE INNER RACE ONLY.

The differential assembly is available ONLY as a complete assembly.

GEAR SET REPLACEMENT (Input Shaft and Governor, intermediate and output)

DIFFERENTIAL GEAR REMOVAL

Tools Required:

Tools Required:

Qty.

Qty.

Drift, brass •..........••................... 1

Wrench, 9/16" box end .........•....•..... 1

Hammer, ball pein ......•................••. 1

Socket, 9/16", 1/2 drive .................... 1

Sealant, Loctite RC 609 E-Z-GO # 12572-G3 ... 1

Ratchet, 1/2" drive ...•...•..••.....•.....• 1

Socket, 1 1/2" .......•........•......•..... 1

Hammer, plastic tipped ••..........••....... 1

Pliers, snap ring, internal ..•................. 1

FIG. M-28 Assembly is in the reverse order of disassembly.

1. Install new 'O' rings.

1/01/89

I I I IMl91GI

FIG. M-29 Remove the four bolts and nuts that secure the large output gear to the differential case. (FIG. M-29)

EeGDii:f:1it{•l:I

Pg. M-13

REAR AXLE

kl!JilmjaJQ

THE HEAD OF THE BOLT MUST BE AGAINST THE DIF­ FERENTIAL CASE AND THE NUT AGAINST THE LARGE OUTPUT GEAR. FAILURE TO FOLLOW THIS CAUTION WILL RESULT IN SERIOUS DAMAGE TO THE OTHER COMPONENTS. Position the ring gear on the differential case and start the drive gear bolts into the gear.

Tighten the bolts, alternating back and forth across the gear until the gear is pulled evenly into place.

Tighten the bolts to 45 - 65 ft. lbs. torque (FIG. M-32).

FIG. M-30 If the large output gear does not separate easily from the differential case, it may require the use of a plastic tipped hammer to remove it. (FIG. M-30) Reassemble in the reverse order of disassembly.

Press new bearings onto differential assembly.

(FIG. M-31).

FIG. M-31

Pg. M-14

1/01/89

I I fJl9k3I

REAR AXLE

FIG. M-32

1/01/89

I I I !M!9k3!

Pg. M-15

REAR AXLE

Pg. M-16

1/01/89 ! ! !M!9!G!

OPERATION AND SERVICE MANUAL SECTION: HORN AND ACCESSORY WIRING

HORN CIRCUIT (IF EQUIPPED)

1.

Check for loose wires at each terminal connec­ tion and for worn insulation or bare wires touch­ ing the frame. BARE WIRES MAY CAUSE A SHORT CIRCUIT. (Refer to FIG. 0-1 for meter set-up).

2.

Check for adequate battery volts (nominal 12 VDC) by setting VOM to 12 VDC range 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 at­ tached. A reading of 11 VDC or better indi­ cates adequate battery co.ndition. No reading indicates (a) a poor connection between the probes and the battery terminals; (b) a defec­ tive VOM. A voltage reading below 11 volts in­ dicates poor battery condition and the vehicle should be recharged before proceeding with the test.

The horn circuit is a 12 volt system and consists of a horn switch, fuse block, fuse, horn, and central wir­ ing harness.

HORN When the horn switch is depressed, the horn circuit is completed permitting current to flow from the bat­ tery to the fuse and through the horn causing it to sound. The horn will operate if the vehicle is in either the ON or OFF position.

TESTING THE HORN CIRCUIT (FIG. 0-1, FIG. 0-2)

Tools Required:

Qty.

0

V.O.M. ................................... 1

IF THE VEHICLE RUNS BUT THE HORN IS IN­ OPERATIVE:

Due to the resistance of the wires involved within the harness, voltage readings may be somewhat lower

RED

BLACK

FIG. 0-1 VOM SET UP

10/01/89

I I I !C!O!A!

Pg. 0-1

HORN AND ACCESSORY WIRING than battery voltage. A reading of 1 volt below bat­ tery voltage is acceptable.

3.

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

Green wire supplies power to the entire fuse block.

4.

5.

6.

Place the red probe (+) to the orange/white wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a defective fuse; replace with a good 15 amp fuse.

Place the red probe (+) to the yellow connec­ tion at the horn switch. A reading of battery voltage indicates that the yellow wire supplying power to the switch is in good condition. If no reading is indicated, move the probe to the other yellow wire terminal at the horn switch and repeat test.

Place the red probe (+) to the other horn switch terminal (yellow wire) and depress horn switch button. A reading of battery voltage indicates a good horn switch. No reading indicates a de­ fective switch; replace it with a good horn switch.

If any VOM readings indicate a defective wire, it is recommended that the condition of the terminals and wire junction be examined. A defective 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 defective wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

HEADLIGHT AND TAILLIGHT CIRCUIT (IF EQUIPPED) The headlight and taillight circuit is a 12 volt system and consists of a light switch, fuse block, fuse, headlights, taillights, and central wiring harness.

HEADLIGHTS AND TAILLIGHTS When the headlight/taillight switch is pulled to the 'ON' position, the circuit is completed permitting current to flow from the battery to the fuse and through the lights causing them to illuminate. The headlights/taillights will operate if the vehicle keys­ witch is in either the ON or OFF position.

TESTING THE HEADLIGHTS AND TAIL­ LIGHTS CIRCUIT (FIG. 0-1, FIG. 0-3, FIG. 0-4, FIG. 0-5)

Tools Required:

Qty.

V.O.M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 If the vehicle runs but the headlights and taillights are inoperative: Proceed to Step 1. If any lights are functional proceed to Step 7.

7.

Place the red probe (+) to the horn terminal with the yellow wire. Depress horn button. A reading of battery voltage indicates a good yel­ low wire.

1.

Check for loose wires at each terminal connec­ tion and for worn insulation or bare wires touch­ ing the frame. BARE WIRES MAY CAUSE A SHORT CIRCUIT. Refer to (FIG. 0-1) for meter set-up.

8.

Remove the black wire from the horn. Select ohms x 1 (continuity) position on the VOM. Place the red probe (+) to the terminal of the black wire. A reading of .00 on a digital VOM or less than 5 ohms on a needle type meter indi­ cates that the black wire is in good condition.

All wiring has now been checked; therefore, the horn is defective. Replace with a good horn.

2.

Check for adequate battery volts (nominal 12 VDC) by setting VOM to the 12 voe range 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 at­ tached. A reading of 11 VDC or better indi­ cates adequate battery condition. No reading indicates (a) a poor connection between the

Pg. 0-2

10/01/89 !C!O!A!

II

HORN AND ACCESSORY WIRING probe (-) to the ring terminal with the black wire that is attached to the headlight mounting bolts.

A reading of battery voltage indicates that either the socket is corroded or defective, or that the bulb is defective. Replace the bulb af­ ter inspecting the socket and reconnect the wir­ ing.

probes and the battery terminals; (b) a defec­ tive VOM. A voltage reading below 11 volts in­ dicates poor battery condition and the vehicle should be recharged before proceeding with the test.

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 bat­ tery voltage is acceptable.

3.

Firmly attach the black probe (-) to the battery post with the black wire attached to perform Steps 3 through 4 and the red probe (+) to the green terminal at the fuse block. A reading of battery voltage indicates that the green wire is in good condition.

8.

At taillights, repeat the process except that the black harness wire should be disconnected from the black light module wire and the black probe (-) should be placed on the black wire terminal.

TWO TAILLIGHTS SYSTEMS ARE IN USE 1.

Multiple taillights are made up of individual lamp modules. To replace a rear lamp module, gently pry the lamp module from its retaining bezel using a straight blade screwdriver.

(Use caution to prevent breakage). Unplug the lamp module from the plug and replace by snapping into the bezel. Replace all wires disconnected in the test.

2.

The single taillight is a conventional single bulb, two filament type that may be ac­ cessed by removing the two screws in the lens.

This wire supplies power to the entire fuse block.

4.

Place the red probe (+) to the blue/white wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condi­ tion. No reading indicates a defective fuse, re­ place with a good 15 amp fuse.

5.

Place the red probe (+) to the blue/white con­ nection at the light switch. A reading of battery voltage indicates that the orange/white wire is in good condition.

6.

Disconnect both wires from the light switch.

Select ohms x 1 (continuity) position on the VOM. Place the red probe (+) to one terminal and the black probe (-) to the other. Pull out switch button. A reading of .00 on a digital VOM or less than 5 ohms on a needle type me­ ter indicates that the switch is in good condi­ tion. A reading of infinity indicates a defective switch. Replace with a good switch and recon­ nect the wiring.

7.

IF ONE OR MORE LIGHTS ARE OPERATIONAL,

check for defective wiring or a defective bulb or module (rear light). Check for voltage to head­ lights. Pull out light switch and disconnect blue/ white wire at the defective headlight. Set the VOM to 12 voe range, place the red probe (+) to the blue/white wire terminal and the black

10/01/89

I I I tcK>tAI

If any VOM readings indicate a defective wire, it is recommended that the condition of the terminals and wire junction be examined. A defective 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 defective wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

BRAKE LIGHT CIRCUIT (IF (FIG. 0-1, FIG. 0-6, FIG. 0-7)

EQUIPPED)

The brake circuit is a 12 volt system and consists of a brake pedal operated micro switch, a fuse block, fuse, brake lights, and a central wiring harness.

When the service brake pedal is depressed, a micro switch is closed which completes the brake light cir­ cuit which permits current to flow to the brake lights.

The brake lights will operate if the vehicle is in either the ON or OFF position.

Pg. 0-3

HORN AND ACCESSORY WIRING GREEN -�BLACK

SOLENOID

1:11:Jlblbl

FRAME � GROUND J"VJ BLK

- bl

� GREEN (+12 VDC)

(GASOLINE VEHICLE)

(ELECTRIC VEHICLE)

t========== HARNESS ATTACHMENT ==========I

(n')

BLKU_

HEADLIGHT

HEADLIGHT BLU/WHT

(n')

#BLK BLK

BLU/WHT BRN

(-)

BLK

BLK BLK

BRN BLU/WHT

BLK

VEHICLES WITH � � �WHT MULTIPLE TAIL-� � � LIGHTS TAILLIGHT BRAKE LIGHT

B l VEHICLES WITH SINGLE TAIL­ LIGHT

I

WHT�

� � BRAKE LIGHT TAILLIGHT mHT

l

:��

BRN RED @ TAILLIGHT

�

� �

BRAKE LIGHT

rI

RED

K

i

@

BRAKE LIGHT

BRN

TAILLIGHT

FIG. 0-2 HORN CIRCUIT

Pg. 0-4

E�GCHi½Jh!•l:I

10/01/89 I I I lclc>IAI

HORN AND ACCESSORY WIRING GREEN -�BLACK

Ctrlldl;.J -

SOLENOID FRAME � GROUND J� BLK

�

(ELECTRIC VEHICLE)

� GREEN (+12 VDC)

(GASOLINE VEHICLE)

t========== HARNESS ATTACHMENT ==========t

{n')

BLK:l;:t:_

HEADLIGHT

HEADLIGHT

{n')

l;t:BLK

BLU/WHT

BLK

BLK BRN BLU/WHT

BLK

VEHICLES WITH SINGLE TAIL­ LIGHT

iI J

BAN

®

TAILLIGHT

1t

WHT� �

VEHICLES WITH � � �WHT MULTIPLE TAIL-� � � LIGHTS TAILLIGHT BRAKE LIGHT

� � � BRAKE LIGHT TAILLIGHT K

��mHT RED

BRAKE LIGHT

fii

RED

@

BRAKE LIGHT

BAN

TAILLIGHT

FIG. 0-3 HEADLIGHT AND TAILLIGHT CIRCUIT 10/01/89

I I I !C!O!A!

Pg. 0-5

HORN AND ACCESSORY WIRING ll:.<[Q) =DRIVER'S SIDE �=PASSENGER SIDE

� �DRIVER'S SIDE

P �PASSENGER SIDE

BLU/WHT==c::0 �BRN BRN

��

€ �

:JJ

c-L �RED------------�WHT

RED �>�WHT, :::;:;o=iEJ GRN= BLK 1:::i:=-:0 � BLK

:::=e<0

BLK E);:v1 BLK WHT � EJ;:iJ:iWHT YEL� BLU/ WHT

'==�

BLK

=:::n::::0 1,=L]

EJ;.:wJHT �BLK

FIG. 0-5 TAILLIGHT INSTALLATION WITH­ OUT TURNSIGNAL SWITCH Pg. 0-6

E�E:iDiii:1it{•]:I

10/01/89

I I I !C!O!A!

HORN AND ACCESSORY WIRING TESTING THE BRAKE LIGHT CIRCUIT

Tools Required:

3.

Qty.

Y.O.M. ........................... ........ 1 1.

BRAKE LIGHTS FIG. 0-7) a)

(FIG. 0-1,

FIG. 0-6,

IF ONLY ONE BRAKE LIGHT IS INOPERA­ TIVE, the overall system is functional;

therefore, the following steps should be followed: If no brake lights are functional proceed to Step 1b. Assure that the brown wire from the harness is attached to the white wire from the inoperative lamp mod­ ule plug. If the lamp still fails to light when the brake pedal is depressed, proceed as follows. Separate the brown harness wire from the white lamp module wire. Select the 12 YDC range of the YOM. Place the red probe (+) to the brown wire and the black probe (+) to the black wire connec­ tion at the battery. Depress the brake pedal. A reading of 12 VDC volt indicates that the brown wire is in good condition and that the lamp module is defective. The taillights are made up of individual lamp modules. To replace a rear lamp module, gently pry the lamp module from its retain­ ing bezel using a straight blade screw­ driver. (Use caution to prevent breakage).

Unplug the lamp module from the plug and replace by snapping into the bezel. Re­ place all wires disconnected in the test. b)

IF BOTH BRAKE LIGHTS ARE INOPERA­ TIVE AND THE VEHICLE RUNS. Visually

check for disconnected wires under the floorboard, at the micro switch and at the rear lights.

2.

Check for loose wires at the terminal-connec­ tions and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIRCUIT.

10/01/89

I I I lclolAI

Check for adequate battery volts (nominal 12 VDC) by setting YOM to 12 VDC range 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 at­ tached. A reading of 11 VDC or better indi­ cates adequate battery condition. No reading indicates (a) a poor connection between the probes and the battery terminals; (b) a defec­ tive VOM. A voltage reading below 11 volts in­ dicates poor battery condition and the vehicle should be recharged before proceeding with the test.

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 bat­ tery voltage is acceptable.

4.

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

This wire supplies power to the entire fuse block.

5.

Place the red probe (+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a defective fuse, replace with a good 20 amp fuse.

Check for correct operation and function of brake pedal actuated micro switch.

6.

Raise the front of vehicle (see Safety Proce­ dures in Section B).

7.

Depress service brake pedal and listen for audi­ ble click from micro switch. Release pedal and listen for an audible click.

An audible click in both the up and down pedal posi­ tions indicates a correct micro switch adjustment.

If the switch is not activated and released correctly, it may be adjusted by loosening the two bolts that secure the micro switch and moving the switch until

Pg. 0-7

HORN AND ACCESSORY WIRING

I NORMAL DRIV ING POSITION I MICRO SWITCH OPEN

I

BRAKING POSITION

I

MICRO SWITCH CLOSED AND BRAKE LIGHTS ACTIVATED

PARKED WITH HILL BRAKE ENGAGED MICRO SWITCH OPEN

NOTE: AUDIBLE CLICK WHILE APPLYING AND RELEASING BRAKES INDICATES PROPER SWITCH ADJUSTMENT.

FIG. 0-6 BRAKE SYSTEM MICRO SWITCH

Pg. 0-8

10/01/89

I I !C!O!AI

HORN AND ACCESSORY WIRING the appropriate adjustment is achieved. If the switch is in correct adjustment and the brake lights are not activated, it is necessary to check for defec­ tive wiring or components.

Set the VOM to the 12 voe range and attach the black probe (-) to the negative battery post with the black wire attached. Place the red probe (+) to the micro switch terminal with the brown wire attached.

Depress the brake pedal. A reading of battery volt­ age indicates that the service brake micro switch is operating correctly. If no voltage is indicated, the micro switch must be tested.

8.

9.

Move the red probe (+) to the service brake micro switch terminal with the red wire at­ tached. A reading of battery voltage indicates that the red wire is in good condition. Move the red probe (+) to the other terminal of the service brake micro switch and manually acti­ vate the switch by pressing the roller of the ac­ tuating arm toward the switch until an audible click is heard. A reading of battery voltage indi­ cates that the switch is in good condition. No reading indicates that the micro switch needs replacement.

Move to the rear of the vehicle, and access the lights. Move the red probe (+) to the brake light at the brown wire. Depress the service brake. A reading of battery voltage indicates that the brown wire is in good condition.

10. Disconnect the connector from the light module and move the red probe (+) to the white termi­ nal. Depress the service brake. A reading of battery voltage indicates that the connector wir­ ing is in good condition.

When replacing micro switches, be sure to check the switch adjustment.

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 bat­ tery voltage is acceptable.

TURN SIGNALS AND FLASHER CIRCUIT (IF EQUIPPED) The turn signal and flasher is a 12 volt system and consists of a turn signal/flasher switch, fuse block, fuse, front and rear lamps, and central wiring har­ ness.

TURN SIGNALS AND FLASHER When the turn signal/flasher switch is activated, the circuit is completed permitting current to flow from the battery to the fuse and through the flasher caus­ ing the appropriate lights to flash. The turn signal/ flasher will operate if the vehicle is in either the ON or OFF position.

TESTING THE TURN SIGNAL/FLASHER CIR­ CUIT (FIG. 0-1, FIG. 0-8, FIG. 0-9) The test procedure for this test is the same for both the single and multiple unit taillight vehicles. A dif­ ference DOES exist in the turn signal switch wiring (brown wire). BOTH CIRCUIT DIAGRAMS ARE PRO­ VIDED FOR REFERENCE.

Tools Required:

Qty.

V.O.M. .................................. 1 IF THE VEHICLE RUNS BUT ALL TURN SIGNALS AND FLASHER ARE INOPERATIVE:

1.

If any VOM readings indicate a defective wire, it is recommended that the condition of the terminals and wire junction be examined. A defective 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 defective wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

10/01/89

I I I !C!O!A!

Check for loose wires at each terminal connec­ tion and for worn insulation or bare wires touch­ ing the frame. BARE WIRES MAY CAUSE A SHORT CIRCUIT.

2.

Check for adequate battery volts (nominal 12 VDC) by setting VOM to 12 voe range 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 at­ tached. A reading of 11 voe or better indi-

Pg. 0-9

HORN AND ACCESSORY WIRING

(ELECTRIC VEHICLE)

BLK

(+)

r··F;-7 I I I I I 20 A F2

12 VDC:

(-)

20 A F3

L--�-�_J

(n)

�

BLU/WHT./

'I )

)

RED

(GASOLINE VEHICLE)

ATTACHMENT ===========1 HEADLIGHT

HEADLIGHT

BLU/WHT

�

<� �

(n)

#

BLK

BLK

BLU/WHT

S2

(��1--B-RN____ S4

HORN YEL EL RN/WH f (( o½, R� >

BLK

� BLK

BLK

BRN BLU/WHT

BLK

VEHICLES WITH � MULTIPLE TAIL-� LIGHTS

VEHICLES WITH SINGLE TAIL­ LIGHT

� GREEN (+12 VDC)

FRAME � GROUND J� BLK

a========== HARNESS

GRN

SOLENOID

� �WHT � �

TAILLIGHT BRAKE LIGHT

K

T

BRAKE LIGHT TAILLIGHT

if x =�� l'fi

BR RED � TAILLIGHT

BRAKE LIGHT

BRN RED ®

BRAKE LIGHT

TAILLIGHT

FIG. 0-7 BRAKE LIGHT CIRCUIT

Pg. 0-10

10/01/89 I I I lclolAI

HORN AND ACCESSORY WIRING

_ii:::::= GREEN FRAME � CJc'� BLACK GROUND II J,v BLK c-'ClHAR ESS ATT

@

= E = LE C = = T =RIC====V E= HI= C= L E= ===== N 1==== L E FT TURN @HEADLIGHT SIGNAL

�GREEN (+12 VDC) SOLENOID

@

(GASOLIN E V EHICLE )

ACHMENT ===========I HEADLIGHT@

RIGHT TURN SIGNA

BLU/WHT BLK R ED

GRN

TURN SIGNAL

BLK

BLK ORN BLU/WH

°7. BLU/WHT

S1 �

FLASHER S2

F2

BRN

12 VD C

BLK BLU/WHT BRN

YEL

FIG. 0-8 TURN SIGNAUFLASHER CIRCUIT (MULTIPLE TAILLIGHT VEHICLES) 10/01/89

I I I !CIQIAI

Pg. 0-11

HORN AND ACCESSORY WIRING -� BLACK Cle'� GREEN

c-'C-

= E L= E C CL=E=== = = T= Rl=C = E= H= l= = V

@

l==== LE FT TURN SIGNAL

II J�

FRAM E � GROUND BLK

� GREEN (+12 VDC) SOLENOID

(GASOLINE VEHICLE )

@

HARNESS ATTACHM ENT ===========1 HEADLIGHT@

RIGHT TURN SIGNA

BLU/WHT BLK

____________...,___.,....

RN..,.._________..,___..,_. .______ R_ E D.,. .,...,G...

YE L WHT BRN

.....-----TURN SIGNAL

ORN

r-F1I

I I I

BLU/WH

12 VDC

1

I :

F3

�s_A_J L

S1 �

07,

BLK

)

RED4

((

S2

S3

�

®

TAILLIGHT

LE FT TURN SIGNAL AND BRAKE LIGHT

)-mBiii,i,, R..

N _......, HORN

RN/WH Y AYE (( EL �J§(�

�

BLK BLU/WHT

WHT

BLU/WHT

FLASHER

I I

F2

BLK

BLK

r· YE L

TAILLIGHT RIGHT TURN SIGNAL AND BRAKE LIGHT

FIG . 0-9 TURN SIG NAUFLASHER CIRCUIT (SINGLE UNIT TAILLIGHT VEHICLES) Pg. 0-12

10/01/89 lclolAI

II

HORN AND ACCESSORY WIRING i::c.=([Ql=DRIVER'S SIDE :o:;;;[eJ=PASSENGER SIDE

cc::::(QJ =DRIVER'S

�BLK=o::CJ � BLK ,___..._'-

_.--J

RED 11....?-:=::=GRN ---=====BLK

TURN SIGNAL

3

c:i<[QJ)EJ;;;PBRN ,� �BLK

FIG. 0-10 HEADLIGHT INSTALLATION WITH TURNSIGNAL SWITCH 10/01/89

I I I lclolAI

P =PASSENGER SIDE

m=0

BLU/WHT �BRN WHT � "'RED YEL '::=ffi/E):;J:)

BLU====o=.D E);;J:lBLU �

..........,

SIDE

BLK � E:J;;J:1 WHT

BLK��BLK WHT ��WHT YEL�"'-,J.>-',>-' r-BLU/WHT �===BLK

0:.::::0 I CU

�HT �BLK

FIG. 0-11 TAILLIGHT INSTALLATION WITH. TURNSIGNAL SWITCH

E�GDii£1it{•l:I

Pg. 0-13

HORN AND ACCESSORY WIRING cates adequate battery condition. No reading indicates (a) a poor connection between the probes and the battery terminals; (b) a defec­ tive VOM. A voltage reading below 11 volts in­ dicates poor battery condition and the vehicle should be recharged before proceeding with the test.

9.

If the system does not function after the above check, the turn signal switch and harness as­ sembly must be replaced.

If the left, right, or emergency flasher works, the flasher unit is satisfactory and a defective bulb or wiring should be suspected.

10. Select the 12 VDC range of the VOM. Place the red probe (+) to:

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 bat­ tery voltage is acceptable.

3.

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

This green wire supplies power to the entire fuse block.

Left Front ......... ............. Red Wire Left Rear ........ . ........... White Wire Right Front ...... ............. Green Wire Right Rear ................... Yellow Wire and the black probe (-) to the black wire con­ nection at the negative post of the battery.

Turn on the appropriate turn signal. A pulsating reading of 12 VDC indicates that power is avail­ able to the light, therefore, the light module is defective. If no voltage is present a defective wire is indicated.

To replace a front lamp module, gently pry lamp module from its retaining bezel using a straight blade screwdriver. (Use caution to pre­ vent breakage.) Unplug the lamp module from the plug and replace by snapping into the bezel. Replace all wires disconnected in test.

4.

Place the red probe (+) to the red wire terminal on the fuse block. A reading of battery voltage indicates that the fuse is in good condition. No reading indicates a defective fuse, replace with a good 20 amp fuse.

5.

Remove the flasher from its socket. Select ohms x 1 (continuity) position on the VOM. Place the red probe (+) on one of the flasher terminals and the black probe (-) on the other flasher terminal. A reading of .0 0 on a digital VOM or less than 5 ohms on a needle type me­ ter indicates that the flasher is in good condi­ tion.

If any VOM readings indicate a defective wire, it is recommended that the condition of the terminals and wire junction be examined. A defective 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 defective wire should be cut back close to the harness and the ends protected with vinyl electrical tape.

6.

Inspect the flasher socket for corrosion before replacing the flasher.

HOUR METER CIRCUIT (IF EQUIPPED)

7.

Separate the harness to turn signal connector and inspect for corrosion and correct place­ ment of pins and sockets in the connector housings.

The hour meter circuit is a 36 volt system for electric vehicles and a 12 volt system for gasoline vehicles.

Both consists of a hour meter and central wiring har­ ness.

8.

Check that the black wire from the flasher sock­ et is attached to the red wire from the harness and that the black wire from the turn signal is attached to the black wire from the harness, and the black wire from the flasher is firmly at­ tached to the orange wire from the turn signal.

HOUR METER

Pg. 0-14

The hour meter is wired to the vehicle's batteries and indicates the number of hours that the vehicle has operated. The hour meter will operate only when the vehicle is running.

10/01/89

I I lclolAI

HORN AND ACCESSORY WIRING TESTING HOUR METER CIRCUIT - Electric Vehicle Only (FIG. 0-1, FIG. 0-12)

Tools Required:

the yellow and gray wires from the rear of the hour meter. Place the black probe (-} on the gray wire terminal. Place the red probe (+} on the yellow wire terminal. Turn key switch to ON and depress accelerator pedal. A reading of 31.5 voe or better indicates adequate battery condition. No reading indicates (a} a poor con­ nection between the probes and the terminals; (b} a defective V O M. A voltage reading below 31.5 volts indicates poor battery charge and the vehicle should be recharged before proceeding with the test.

Qty.

V.O.M. ................................... 1 If the vehicle runs but the hour meter is inoperative: 1.

Check for loose wires at the terminal connections and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIRCUIT.

2.

Raise vehicle (see safety procedures in Section B}.

4.

&WARNING&

If battery voltage is in excess of 31.5 voe and the hour meter does not function, the hour me­ ter should be replaced being careful to rewire with gray to the negative terminal (-} and yellow to the positive terminal (+}.

THIS TEST WILL CAUSE VEHICLE WHEELS TO TURN. BE SURE THAT VEHICLE IS ADEQUATELY SUPPORTED WITH BOTH REAR WHEELS CLEAR OF FLOOR. KEEP CLEAR OF ROTATING WHEELS. CLOTHING BECOMING TRAPPED BY WHEEL COULD CAUSE SERIOUS PERSONAL INJURY.

Tools Required:

3.

V.O.M. .................................. 1

TESTING HOUR METER CIRCUIT - Gaso­ line Vehicle Only (FIG. 0-1, FIG. 0-13)

Check for adequate battery volts (nominal 36 VOC} by setting V O M to 36 voe range, unplug

Qty.

If the vehicle runs but the hour meter is inoperative:

GREEN HARNESS ATTACH MENT

CJ ··+

-

+

-• -• •+

-•

BLACK

GRAY

•+

•+ (ELECTRIC VEHICLE}

FIG. 0-12 HOUR METER CIRCUIT - ELECTRIC VEHICLE ONLY

10/01/89

I I I lc©IAI

Pg. 0-15

HORN AND ACCESSORY WIRING 1.

Check for loose wires at the terminal connec­ tions and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE

the yellow and gray wires from the rear of the hour meter. Place the black probe (-) on the gray wire terminal. Place the red probe (+) on the yellow wire terminal. Turn key switch to ON and depress accelerator pedal. A reading of 11 VDC or better indicates adequate battery condi­ tion. No reading indicates (a) a poor connec­ tion between the probes and the terminals; (b) a defective VOM. A voltage reading below 11 volts indicates poor battery charge and the ve­ hicle should be recharged before proceeding with the test.

A SHORT CIRCUIT.

2.

Raise vehicle (see procedures in Section B).

&_WARNING&_ THIS TEST WILL CAUSE VEHICLE WHEELS TO TURN. BE SURE THAT VEHICLE IS ADEQUATELY SUPPORTED WITH BOTH REAR WHEELS CLEAR OF FLOOR. KEEP CLEAR OF ROTATING WHEELS. CLOTHING BECOMING TRAPPED BY WHEEL COULD CAUSE SERIOUS PERSONAL INJURY. 3.

4.

Check for adequate battery volts (nominal 12 VDC) by setting VOM to 12 VDC range, unplug

FROM BATTERY

If battery voltage is in excess of 11 VDC and the hour meter does not function, the hour meter should be replaced being careful to rewire with gray to the negative terminal (-) and ye!low to the positive terminal (+).

YELLOW -12

GRAY

voe HOUR METER

SOLENOID

(GASOLINE VEHICLE)

TO FRAME GROUND

FIG. 0-13 HOUR METER CIRCUIT - GASOLINE VEHICLE .ONLY

STATE OF CHARGE METER (IF EQUIPPED) - Electric Vehicle Only

TESTING STATE OF CHARGE METER CIR­ CUIT (FIG. 0-1 , FIG. 0-14)

The state of charge circuit is a 36 volt system and consists of a state of charge meter and central wir­ ing harness.

Tools Required:

STATE OF CHARGE METER

1.

The state of charge meter is wired to the 36 volt battery set of the vehicle and indicates the charge condition of the battery set. The state of charge · meter will operate if the vehicle is in either the ON or OFF position.

Pg. 0-16

Qty.

V.O.M. .................................. 1 If the vehicle runs but the state of charge meter is inoperative: Check for loose wires at the terminals-connec­ tions and for worn insulation or bare wires touching the frame. BARE WIRES MAY CAUSE A SHORT CIRCUIT.

2.

Check for adequate battery volts (Nominal 36 VDC) by setting VOM to 36 voe range, unplug the green and gray wires from the rear of the

E�GDii:£1i,t•J:I

10/01/89

I I lclolAI

HORN AND ACCESSORY WIRING state of charge meter. Place the red probe (+) on the green wire terminal. Place the black probe (-) on the gray wire terminal. A reading of 36 voe ±sv or better indicates adequate battery condition. No reading indicates (a) a poor connection between the probes and the battery terminals; (b) a defective VOM. A volt­ age reading below 32 volts indicates poor bat-

tery charge and the vehicle should be re­ charged before proceeding with the test.

3.

If battery voltage meets the criteria specified and the state of charge meter does not func­ tion, the state of charge meter should be re­ placed being careful to rewire with gray to the negative (-) terminal and green to the positive (+) terminal.

GREEN

GREEN

STATE OF CHARGE METER

BLACK

GRAY

HARNESS ATTACHMENT

F-1 �

··-

-• •+

+ ..._...

10/01/89

I I I lclolAI

Fl

•+

(ELECTRIC VEHICLE)

�

FIG. 0-14 STATE OF CHARGE METER CIRCUIT

Pg. 0-17

HORN AND ACCESSORY WIRING

Pg. 0-18

10/01/89 I I I lclolAI

OPERATION AND SERVICE MANUAL SECTION: BODY AND TRIM

p

GENERAL The following five pages describe the general as­ sembly methods used in securing body and trim components to the vehicle. Refer to the body and associated parts pages of the service parts manual for construction details. By referring to the service parts pages the general construction methods may be determined while these general assembly meth­ ods indicate the disassembly and assembly methods required.

TRIM Trim consists of a vinyl extrusion that is installed around the outside edges of the body panels and the rear edge of the dash tray. The ends of the trim (except for the rear of the dash tray) are secured to the vehicle with a pop rivet.

TRIM REMOVAL (FIG. P-1)

drill bit to drill out the rivet head. Using an awl or other suitable punch, push out the remainder of the rivet. Grasp the loose end of the trim and pull down and away from the body panel. The removal of the trim running along the edge of the floormat on either side of the vehicle varies with the model of the vehicle.

VEHICLES EQUIPPED WITH ONE PIECE ROCKER PANEL (FIG. P-2) The removal of the vinyl trim running along the floor­ board will require that the stainless steel rocker panel be removed. The rocker panel is retained by two stainless steel truss head screws, washers and lock nuts. Care must be used when tightening the hardware not to over tighten the hardware which would distort the rocker panel.

Use either an air or electric powered drill with a 1 /4"

/ VINYL TRIM PULL DOWN AND AWAY FROM PANEL

FIG. P-1 TRIM REMOVAL 1/01/89

! ! ! !P!9k3!

FIG. P-2 ROCKER PANEL REMOVAL STAINLESS STEEL Pg. P-1

BODY AND TRIM VEHICLES EQUIPPED WITH TWO PIECE ROCKER PANELS (FIG. P-3)

TRIM INSTALLATION (FIG. P-4, FIG. P-5, .

FIG. P-6)

Remove the stainless steel portion of the rocker panel by removing the two stainless steel carriage bolts and lock nuts. The stainless steel portion of the rocker panel can then be removed from the plastic portion by tilting out and then lifting straight up. Removal of the plastic section must be done with care to prevent damage to the attached fasten­ ers. Grasp the front of the plastic rocker panel and pull it out and down. Move rearwards pulling out and down at each fastener until the rocker panel has been removed. When installing the rocker panel be sure that the slots in the body panels are not dis­ torted. Install the rocker panel by carefully aligning the front fastener with the front slot and tapping home using a rubber mallet. Repeat the operation with each adjacent fastener until the rocker panel is installed.

In order to make the vinyl trim flexible and pliable it should first be heated. Under field conditions, this can best be accomplished by immersing the trim in a container of hot water (110 ° to 120 ° ) for approxi­ mately ten minutes. Hook the trim over the flange on the outside of the panel and press down while push­ ing the lower edge over the flange at the outside of the panel.

1

2

3

FIG. P-4 TRIM INSTALLATION TAINLESS STEEL ROCKER PANEL ®-wASHER �LOCK NUT

FIG. P-3 ROCKER PANEL REMOVAL, STAINLESS STEEL AND PLASTIC

Pg. P-2

Service tip: Short sections of trim that have been pulled loose, can be replaced by heating with a heat gun or hair dryer to improve the trim flexibil· ity. The section can then be pressed into place using the same technique as indicated above.

After the trim is installed it is secured with a rivet.

Use an awl inserted through the rivet hole in the body panel and forced through the trim to locate the hole. Drill through the vinyl trim and install the rivet.

1/01/89

! !P!9!A!

BODY AND TRIM Use a sharp utility knife and a straight edge to cut the excess trim to the correct contour.

TO PREVENT CUTTING THROUGH THE PAINT AND BODY PANEL PROTECTIVE COATING, EXTREME CARE SHOULD BE USED WHEN CUTTING THE TRIM. ALWAYS USE A STRAIGHT EDGE AND A SHARP KNIFE TO PROVIDE A PROFESSIONAL APPEARANCE.

BODY COMPONENTS

&WARNING&

DISCONNECT OR REMOVE BATTERIES BEFORE PROCEEDING. OBSERVE THE PROCEDURES IN SECTION B (SAFETY PROCEDURES).

A variety of methods are used to attach body com­ ponents and each has a recommended method of removal and installation.

SPOT WELDS (FIG. P-7)

&WARNING&

USE EYE AND EAR PROTECTION WHEN USING EITHER A HAMMER OR AN AIR POWERED CHISEL. USE EYE PROTECTION WHEN USING ANY POWER TOOLS.

The welds can be broken using a hammer and chisel; however, an air powered chisel is recom­ mended.

FIG. P-5 INSTALLING RIVETS

� r:

Many sheet metal components have been secured using spot welds. The components can be removed by breaking each weld; this is accomplished by driv­ ing a 5/8" chisel through each weld. (FIG. P-7) In the field sheet metal service components are se­ cured to the vehicle with self-drilling and tapping screws or with nuts attached to studs that are at­ tached to the replacement component.

:IGHT EDGE

-

SPOT WELD

UTILITY KNIFE

FIG. P-6 FINISHING TRIM

1/01/89

l l l lPl9!A!

FIG. P-7 BREAKING SPOT WELDS

Pg. P-3

BODY AND TRIM METAL RIVETS (FIG. P-8)

J�

PUSH PIN WITH SCREWDRIVER

8WARNING8 USE EYE PROTECTION WHEN USING ANY POWER TOOLS.

I

FIG. P-9 REMOVAL OF PLASTIC RIVETS

WHEN DRILLING OUT RIVETS, DRILL OUT RIVET HEAD ONLY. BE CAREFUL NOT TO DRILL INTO BODY PANELS

Metal rivets are removed by drilling into the head with a drill bit that is larger than the shank. Drill until the rivet head separates from the shank. Use a punch to drive out the remains of the rivet. Replace rivet with a new one.

PLASTIC CHRISTMAS TREE FASTENERS (FIG. P-10) Plastic CHRISTMAS TREE fasteners are removed by prying out of the body panel. In general, this is best accomplished by prying away the material being at­ tached as close to the fastener as possible.

In many cases the fastener can be reused; however, excessive distortion or tearing of the holding tabs will require the use of a new fastener.

CHRISTMAS TREE FASTENER

REMOVE RIVET : WITH PRY BAR·

FIG. P-8 REMOVAL OF METAL RIVETS PLASTIC RIVETS (FIG. P-9) Plastic rivets may be removed and reused by push­ ing out the pin from the rear of the rivet using a straight blade screwdriver. Remove the pin from the rivet, and remove the rivet from the body panels.

The rivet may be reused by inserting it firmly into place and pressing the rivet pin flush with the head of the rivet with the flat portion of a screwdriver.

Pg. P-4

FIG. P-10 CHRISTMAS TREE FASTENER REMOVAL SELF-DRILLING (FIG. P-11)

AND

TAPPING

SCREWS

&WARNING& USE EYE PROTECTION WHEN USING ANY POWER TOOLS.

1/01/89

! ! !P!9!A!

BODY AND TRIM Self-drilling and tapping screws can be removed with a suitably sized Phillips screwdriver; however, due to the self-tapping feature this is frequently im­ practical. Removal of these screws is best accom­ plished with the use of an impact driver with a suit­ ably sized Phillips bit.

Installation requires an electric or air powered hand drill and a suitably sized Phillips bit. The screw will drill and tap its own hole.

"U" NUTS (FIG. P-13) Several types of "U" nuts are used in the vehicle and may be removed from body panels by spread­ ing gently with a flat bladed screwdriver and sliding from the panel. Unless the nut is distorted or other­ wise damaged, it may be reused on new panels.

INSTALL WITH DRILL AND PHILLIPS DRIVE BIT

·u· FIG. P-11 SELF-DRILLING AND TAPPING SCREW INSTALLATION

NUT

FIG. P-13 REMOVAL OF "U" NUTS

WELD STUDS (FIG. P-12) Weld studs are attached to many production and service parts that are attached to frame members with lock nuts.

FIG. P-12 WELD STUDS

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BODY AND TRIM

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OPERATION AND SERVICE MANUAL SECTION: PAINT INSTRUCTIONS

Q

PAINT SYSTEM CONTRAST E-Z-GO uses high solids paints in its production facility for two reasons: Firstly, the paint provides a high quality finish and excellent color retention. Secondly, as a continuous high volume painting facility we are required to use this system to permit us to conform with E.P.A. regulations. Note that in our system we have the facilities for baking the paint.

There are significant problems involved with using high solids Polane paint in a low volume body shop environ­ ment. Primer and top paint mixing is more complicated than when using the old polane and the mixed primer and paint has a shorter pot life (2 hours).

Some minor difference in luster may be determined between side by side panels painted with the two systems however and the old polane may fade somewhat faster with extended U.V. exposure.

Panels that are to be touched up, should be painted in their entirety to assure accurate color match. Spray cans are not available in high solids paints but are compatible with high solids paints. Spray cans are only recommended for touching up a minor imperfection.

POLANE REPAINTING INSTRUCTIONS

HIGH SOLIDS REPAINTING INSTRUCTIONS

Step 1 - Lightly sand with water using #320 paper until all gloss is removed and the desired finish obtained. Do not remove the galvanneal surface from the metal. Silver chips in the sanding dust will indicate galvanneal removal.

Step 2 - Clean surface with solvent - mineral spirits or naptha.

Step 3 - Mix Polane catalyst #V66-V29 at a ratio of 1 to 8 (16 oz. per gallon of paint). Reduce with thin­ ner #R7K212 to a viscosity of 24-26 Saybolt Univer­ sal Seconds. Add retarder R7K6251 as necessary to slow drying time.

Step 1 - Lightly sand with water using #320 paper until all gloss is removed and the desired finish obtained. Do not remove the galvanneal surface from the metal. Silver chips in the sanding dust will indicate galvanneal removal.

Step 2 - Clean surface with solvent - mineral spirits or naptha.

Step 3 - Mix Polane catalyst #V66-V29 at a ratio of 1 to 4 (32 oz. per gallon of paint). Reduce with thin­ ner #R7K6204 to a viscosity of 24-26 Saybolt Univer­ sal Seconds. Add retarder R7K6208 as necessary to slow drying time.

Viscosity should be measured by standard cup such as a Zahn or Ford. The cup can be purchased at most paint supply outlets. A cup filled with paint mixture should flow through the bottom orifice at the above time frame.

Viscosity should be measured by standard cup such as a Zahn or Ford. The cup can be purchased at most paint supply outlets. A cup filled with paint mixture should flow throi,igh the bottom orifice at the above time frame.

Step 4 - Apply paint spray in a light tack coat followed by the heavier coat until a thickness of one mil is obtained.

Step 4 - Apply paint spray in a light tack coat followed by the heavier coat until a thickness of one mil is obtained.

A one mil thickness is the normal coverage required to hide primer or bare metal.

A one mil thickness is the normal coverage required to hide primer or bare metal.

Step 5 - Allow 4-6 hours drying time for finished coat. Most topcoats have small transparent bubbles at initial application. Most will disappear after a cure of 2-3 days.

Step 5 - Allow 4-6 hours drying time for finished coat. Most topcoats have small transparent bubbles at initial application. Most will disappear after a cure of 2-3 days.

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PAINT INSTRUCTIONS

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OPERATION AND SERVICE MANUAL SECTION:TROUBLE-SHOOTING

R

/1.WARNING/1.

NEVER ATTEMPT ANY TROUBLE-SHOOTING WITHOUT TAKING MEASURES TO PROTECT YOURSELF AND OTHERS IF THE VEHICLE WAS TO INADVERTENTLY START. REFER TO WARNINGS IN SECTION 'A' AND SAFETY PROCEDURES IN SECTION 'B'.

POWERTRAIN VEHICLE WILL NOT START

ENGINE ROTATES BUT WILL NOT START

B

STARTER ROTATES TOO SLOWLY (INSUFFICIENT TORQUE)

STARTER DOES NOT ROTATE

A

E

C POOR PERFORMANCE

ENGINE HARD TO START

D

ENGINE STARTS BUT RUNS ROUGH OR STALLS

LOSS OF POWER

F

OVERHEATING

REPEATED SPARK PLUG FOULING

H

G

CARBURETOR FLOODING

EXCESSIVE SMOKING

J

I

BACKFIRING

L

VIBRATION

N

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INADEQUATE BATTERY CHARGING

K

ERRATIC GOVERNED SPEED

M

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Pg. R-1

TROUBLE-SHOOTING THE FOLLOWING IS AN ALPHABETICAL LISTING OF COMPONENT TOPICS COVERED IN THE POWERTRAIN SECTION OF THIS TROUBLE-SHOOTING SECTION. ACCELERATOR (LIMIT) SWITCH

Gotopage 11

BATTERY

Gotopage 11

CARBURETOR

Gotopage 11

FUEL FILTERS

Gotopage 12

FUEL

Gotopage 12

FUEL TANK

Goto page 12

FUEL LINES

Gotopage 12

FUEL PUMP

Gotopage 12

FUSE

Gotopage 12

F-N-R SWITCH

Goto page 12

INTAKE AIR SYSTEM

Gotopage 13

KEY SWITCH

Gotopage 13

OIL PUMP

Gotopage 13

SOLENOID

Gotopage 13

SOLID STATE IGNITION SYSTEM. (S.S.I.)

Gotopage 13

SPARK PLUG

Gotopage 14

SPARK PLUG WIRE

Gotopage 14

STARTER/GENERATOR

TIMING

Gotopage 14 Gotopage 15

VOLTAGE REGULATOR

Gotopage 15

SECTION 'A' {STARTER DOES NOT ROTATE)

&WARNING&

NEVER OPERATE THE STARTER UNLESS THE SPARK PLUG IS INSTALLED OR THE IGNITION SYSTEM IS DISABLED. FUEL DRAWN INTO THE CYLINDERS WILL BE EXPELLED THROUGH THE SPARK PLUG HOLE AND COULD BE IGNITED BY THE IGNITION SYSTEM, RESULTING IN A FIRE.

DEAD BATTERY • Recha rge or Replace.

BLOWN FUSE • Replace with a fuse of identical type and value. If the fuse blows again, investigate and cor rect the cause before replacing the fuse again.

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TROUBLE-SHOOTING F-N-R SWITCH

• Check function and clean or replace if required.

IGNITION SWITCH

• Check function and replace if required.

ELECTRICAL SYSTEM

• Trouble-shoot per the Electrical section 'L' of this manual. Repair or replace as required.

STARTER SOLENOID

• Listen for an audible 'click' when system is activated. If there is no 'click', check power and ground to the solenoid. Replace solenoid if power and ground connections are good.

ACCELERATOR LIMIT SWITCH

• Manually check the function of the switch by pressing the accelerator pedal. Listen for an audible 'click' when the pedal is depressed. If no 'click' is heard, check the adjustment of the limit switch actuating screw. If adjustment is satisfactory, replace the limit switch and adjust as described in the Accelerator, governor, carburetor and oil pump linkage section 'F' of this manual.

STARTER

• Check for excessively worn brushes and replace if required.

• Check for a dirty armature commutator and clean as described in the Electrical section 'L' of this manual.

• Check for damaged field coils and replace if damage is found.

• Check for broken wire terminals at the starter generator. Repair.

SECTION 'B' (STARTER ROTATES BUT VEHICLE WILL NOT START) FUEL

• Check fuel level and fill with the correct grade of gasoline. Check oil tank level and fill with E-Z-GO 2 cycle oil.

•

Check for a plugged fuel tank vent in the fuel tank gauge. Clean vent or replace cap/gauge.

NO FUEL TO CARBURETOR

• Fuel pump not functioning. Replace.

• Loose fuel line clamp permitting air to enter fuel line. Tighten or replace clamp.

• Clogged fuel filter(s). Check and replace both primary and secondary filters if required.

• Fuel line clogged. Clean or replace.

• Broken fuel line. Replace broken portion.

CARBURETOR

• Main jet contaminated. Clean or replace jet.

• Carburetor throttle lever motion restricted. Check for full free motion (76_).

ENGINE FLOODED

• Push choke in. Fully depress and hold accelerator pedal until the engine starts. (Do not operate starter for more than ten seconds at a time.)

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TROUBLE-SHOOTING ENGINE FUEL STARVED • Use the choke for the first start of the day or if the vehicle does not start within ten seconds. Push choke in as soon as the engine starts.

INTAKE AIR SYSTEM • Check that the air intake louvers are not deformed or blocked with foreign matter. Repair or clean.

• Check for restricted air flow at convoluted hose between the seat wrap air intake and the funnel. Repair or adjust for correct alignment.

• Check for restricted air flow at convoluted hose between the air cleaner and the carburetor. Repair.

• Check condition of filter element. Remove the entire canister as an assembly and disassemble outside of the vehicle. Clean or replace as required (filter may be washed a maximum of six times).

SPARK PLUG • Check for a disconnected spark plug wire at plug or coil. Connect.

• Check that coil wires are correctly attached. Check wiring diagram in Electrical section.

• Check for broken wires. Repair or replace.

• Remove the spark plug and check condition and gap. Clean fouled plug or replace with a clean correctly gapped one.

• Check if plug wire is worn and has shorted to ground. Replace.

• Inoperative coil. (See ignition circuit diagnostic flow chart.) Replace.

• Inoperative igniter. (See ignition circuit diagnostic flow chart.) Replace.

• Inoperative pulser unit. (See ignition circuit diagnostic flow chart.) Replace.

EXHAUST • Stinger deformed or plugged muffler. Repair or replace.

• Restricted exhaust pipe. Clean or replace.

SECTION 'C' {STARTER ROTATES SLOWLY OR HAS INSUFFICIENT TORQUE) BATTERY • Corrosion on battery terminals. Clean the battery and terminals with a baking soda solution.

• Low charge. Recharge or replace.

• Damaged battery post. Replace battery.

WIRING • F-N-R switch contacts are dirty or pitted. Clean or replace.

• Corrosion at wire connections. Clean or replace.

• Disconnected connection. Connect.

• Broken wire. Repair or replace.

• Open circuit. Trouble-shoot per Electrical section 'L' and repair or replace as required.

• Short circuit. Trouble-shoot per Electrical section 'L' and repair or replace as required.

• Poor connection at terminals. Clean, repair or tighten.

STARTER/GENERATOR • Armature commutator dirty or rough. Clean or resurface.

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TROUBLE-SHOOTING IGNITION CIRCUIT DIAGNOSTIC FLOW CHART

NO SPARK

PULSER ASSEMBLY

PULSER COIL CONTINUITY TEST. BETWEEN RED AND BLUE WIRES: RESISTANCE 75 OHMS 20%AT20_C

IGNITION COIL COMPLETE

CONTROL MODULE (IGNITOR)

PRIMARY AND SECONDARY COILS CONTINUITY TEST. RESISTANCE BETWEEN IGNITION COIL ORANGE AND GREEN WIRES: 2.88 TO 4.32 OHMS AT20_C RESISTANCE BETWEEN IGNITION COIL ORANGE AND HIGH TENSION WIRES: RESISTANCE 9.36 TO 14.04 K OHMS 20%AT20_C

CHECK BY SUBSTITUTING A 'KNOWN TO BE GOOD' CONTROL MODULE (IGNITOR).

SPARK PLUG

IGNITION CIRCUIT DIAGNOSTIC FLOW CHART CONTINUED ON FOLLOWING PAGE.

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Pg.R-5

TROUBLE-SHOOTING SPARK BUT LOW POWER

ENGINE CHECK IGNITION TIMING WITH AN INDUCTIVE PICK-UP TIMING LIGHT. STANDARD SETTING; FORWARD: 18_ + 3_/1,500 R.P.M. REVERSE: 21_ + 3_/1,500 R.P.M. CHECK THAT THE TIMING MARK LINE ON THE CIR­ CULAR ALUMINUM PULSER MOUNTING PLATE IS ALIGNED WITH THE CENTER OF ONE OF THE MOUNTING SCREWS. (SEE SECTION L, FIG. L-14)

PULSER ASSEMBLY

REFER TO 'NO SPARK'

IGNITION COIL COMPLETE .,..1---1 REFER TO 'NO SPARK'

CONTROL MODULE (IGNITOR)

REFER TO 'NO SPARK'

CHARGING CIRCUIT

---E----1 CHECK THE COLOR IDENTIFICATION OF WIRES AT THE COUPLER. (SEE SECTION L, FIG. L-13)

SPARK PLUG

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TROUBLE-SHOOTING • Poor brush to commutator contact. Repair or replace.

• Short in armature windings. Replace.

• Open circuit in armature winding. Replace.

• Short in field coils. Replace.

• Open circuit in field coils. Replace • Grounded field coils. Replace • Grounded terminal. Repair or replace.

VOLTAGE REGULATOR • Incorrect output. Replace.

• Poor ground connection. Repair.

• Worn points. Replace.

• Dirty points. Replace.

• Open or short circuit. Replace.

SECTION 'D' (ENGINE HARD TO START) SPARK PLUG • Remove the spark plug and check the condition and gap. Clean fouled plug or replace with a clean, correctly gapped one.

INTAKE AIR SYSTEM • Check that the air intake louvers are not deformed or blocked with foreign matter.

• Check for restricted air flow at convoluted hose between the seat wrap air intake and the funnel.

• Check for restricted air flow at convoluted hose between the air cleaner and the carburetor.

• Check condition of filter element. Remove the entire canister as an assembly and disassemble outside of the vehicle. Clean or replace as required.

FUEL SYSTEM

• Fuel pump has a ruptured diaphragm. Replace.

• Loose fuel line clamp permitting air to enter fuel line. Tighten or replace clamp.

• Partially clogged fuel filter(s). Check and replace both primary and secondary filters if required.

• Fuel line restricted. Clean or replace.

• Water and or dirt in the fuel system. Drain tank and fuel lines, replace both fuel filters.

CYLINDER

• Check compression. Check cylinder head tightness and tighten if required. Overhaul engine if compression is less than 100 psi.

CRANKSHAFT SEALS • Check for leaking seals. Replace.

TIMING

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Pg.R-7

TROUBLE-SHOOTING D Check timing as per Electrical section 'L'. Adjust.

SECTION 'E' (ENGINE RUNS ROUGH OR STALLS) SPARK PLUG • Remove the spark plug and check the condition and gap. Clean fouled plug or replace with a clean correctly gapped one.

TIMING • Check timing as per Electrical section 'L'. Adjust.

INTAKE AIR SYSTEM • Check that the air intake louvers are not deformed or blocked with foreign matter.

• Check for restricted air flow at convoluted hose between the seat wrap air intake and the funnel.

• Check for restricted air flow at convoluted hose between the air cleaner and the carburetor.

• Check condition of filter element. Remove the entire canister as an assembly and disassemble outside of the vehicle. Clean or replace as required.

• Intake manifold or carburetor loose. Tighten.

• Water and or dirt in the fuel system. Drain tank and fuel lines, replace both fuel filters.

• Check for a plugged fuel tank vent in the fuel tank gauge. Clean vent or replace cap/gauge.

CARBURETOR • Main jet contaminated. Clean or replace jet.

• Carburetor throttle lever motion restricted. Check for full free motion (76_).

EXHAUST • Stinger deformed or plugged muffler. Repair or replace.

• Restricted exhaust pipe. Clean or replace.

WIRING • Loose wire(s) in the ignition system.

SECTION 'F' (LOSS OF POWER) FUEL SYSTEM • Fuel pump has a ruptured diaphragm. Replace.

CYLINDER • Check compression. Check cylinder head tightness and tighten if required. Overhaul engine if compression is less than 1 00 psi.

TIMING • Check timing as per electrical section 'L'. Adjust.

EXHAUST • Stinger deformed or plugged muffler. Repair or replace.

• Restricted exhaust pipe. Clean or replace.

CARBURETOR • Carburetor lever motion restricted. Check for full free motion (76_}.

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! ! !R!9!Gl

TROUBLE-SHOOTING INTAKE AIR SYSTEM • Check that the air intake louvers are not deformed or blocked with foreign matter. Repair.

• Check for restricted air flow at convoluted hose between the seat wrap air intake and the funnel. Repair.

• Check for restricted air flow at convoluted hose between the air cleaner and the carburetor. Repair.

• Check condition of filter element. Remove the entire canister as an assembly and disassemble outside of the vehicle. Clean or replace as required.

ENGINE OVERHEATS • Check for foreign matter in cylinder fins, blower housing and fan. Clean cooling system.

• Check that the correct main jet for temperature and altitude is being used.

• Check that the oil pump is correctly calibrated and functioning properly.

PRE-IGNITION • Check octane and quality of fuel. Use correct fuel.

• Crankcase leak, ruptured crankshaft seals. Repair.

SECTION 'G' (ENGINE OVERHEATING) CLOGGED COOLING FINS • Check for foreign matter in cylinder fins, blower housing and fan. Clean cooling system.

EXHAUST • Stinger deformed or plugged muffler. Repair or replace.

• Restricted exhaust pipe. Clean or replace.

SECTION 'H' (REPEATED SPARK PLUG FOULING) SPARK PLUG • Wrong spark plug type. Replace.

OIL • Wrong oil type. Replace with E-Z-GO 2 cycle oil.

• Oil pump calibration incorrect. Adjust.

FUEL • Unsuitable gasoline. Use correct fuel, 87 to 100 octane R.O.M.

INTAKE AIR SYSTEM • Air leak in intake air system is allowing dirt/dust to bypass air filter. Repair.

CHOKE • Choke sticking closed. Repair.

CARBURETOR • Wrong main jet for altitude and temperature conditions. Replace.

SECTION 'I' (CARBURETOR FLOODS) CARBURETOR VALVES. 4/01/92

! ! ! !R!9!G!

Pg.R-9

TROUBLE-SHOOTING D Inlet valve/seat dirty or damaged. Clean or replace.

CARBURETOR FLOAT.

• Incorrect float level. Adjust.

INTAKE AIR SYSTEM • Check that the air intake louvers are not deformed or blocked with foreign matter. Repair.

• Check for restricted air flow at convoluted hose between the seat wrap air intake and the funnel. Repair.

• Check for restricted air flow at convoluted hose between the air cleaner and the carburetor. Repair.

• Check condition of filter element. Remove the entire canister as an assembly and disassemble outside of the vehicle. Clean or replace as required.

SECTION 'J' (EXCESSIVE SMOKING) OIL

• Wrong oil type. Replace with E-Z-GO 2 cycle oil.

• Calibration or function of oil injection pump. Adjust or replace.

SECTION 'K' (STARTER/GENERATOR DOES NOT CHARGE BATTERY PROPERLY) WIRING • Open or short circuit in charging circuit. Trouble-shoot per Electrical section 'L' and repair or replace as required.

• F-N-R switch contacts are dirty or pitted. Clean or replace.

STARTER/GENERATOR

• Armature commutator dirty or rough. Clean or resurface.

• Poor brush to commutator contact. Repair or replace.

• Short in armature windings. Replace.

• Open circuit in armature winding. Replace.

• Short in field coils. Replace.

• Open circuit in field coils. Replace • Grounded field coils. Replace • Grounded terminal. Repair or replace.

VOLTAGE REGULATOR

• Incorrect output. Replace.

• Poor ground connection. Repair.

• Poor points. Replace.

• Dirty points. Replace.

• Open or short circuit. Replace.

SECTION 'L' (BACKFIRING) CARBURETOR Pg.R-10

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TROUBLE-SHOOTING • Carburetor throttle valve lever motion restricted. Repair.

• Carburetor throttle valve lever not closing fully. Adjust.

• Idle screw preventing throttle valve lever from closing fully. Adjust.

• Carburetor throttle valve spring weak or broken. Replace.

• Incorrect adjustment of accelerator, governor, carburetor and oil pump linkage. Adjust per section 'F'.

• Carburetor throttle lever shaft bent. Replace or rebuild carburetor.

• Governor torsion spring weak or broken. Replace.

SECTION 'M' (ERRATIC, SURGING, OR SUDDEN CHANGE IN GOVERNED SPEED) GOVERNOR

• Return torsion spring broken. Replace.

• Problem with the adjustment of accelerator, governor, carburetor and oil pump linkage. Adjust per section 'F'. (12 m.p.h.)

• Bent governor arm. Replace.

• Bent governor shaft. Replace.

• Internal governor failure (within the rear axle). Repair.

SECTION 'N' (VIBRATION) STARTER/GENERATOR BELT

• Incorrect belt tension. Adjust.

• Damaged or worn belt. Replace.

DRIVE BELT

• Damaged or worn belt. Replace.

DRIVE CLUTCH

• Damaged sheave. Replace.

• Stuck weight. Rebuild or replace.

• Stuck roller. Rebuild or replace.

• Worn bushing. Rebuild or replace.

DRIVEN CLUTCH

• Damaged sheave. Replace.

• Worn bushings. Replace clutch.

ISOLATION MOUNT

• Damaged isolation mount. Replace.

THE FOLLOWING TROUBLE-SHOOTING GUIDE IS ALPHABETICAL BY COMPONENT. ACCELERATOR LIMIT SWITCH 1.

With the actuator in the 'OUT position, check for switch continuity using a VOM . Replace switch if no continuity is indicated.

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Pg. R-11

TROUBLE-SHOOTING 2.

Resistance should read 'Infinity' when actuator is in the 'IN' position. Replace switch if value is incorrect.

BATTERY

1.

Using a VOM, check the battery voltage with no load. Voltage should be 13.6 volts. 12.0 volts is minimum accept­ able voltage. (Note that a battery voltage below 12.0 volts is a dead battery.) Recharge, and replace battery if 12.0 volts cannot be achieved.

2.

Using a VOM, check the battery voltage while under load (starter operating). Voltage should be 12.0 volts. 10.00 volts is minimum acceptable voltage. Recharge, and replace battery if 10.0 volts cannot be achieved.

3.

Amperage (190 Amperage spike) 20 to 100 amps.

CARBURETOR 1.

Check bowl for leaks. Repair.

2.

Check bowl for contamination. Clean.

3.

Check main jet size. (a) Golf cars -Standard is #90.0 see temperature/altitude table for special applications. (b) All other applications -Standard is# 102.5 see temperature/altitude table for special applications. Replace.

4.

Check main jet for contamination. Clean or replace.

5.

Check pilot jet size. Standard is #80 for Golf Cars and #47.5 for all other applications. Replace.

6.

Check pilot jet for contamination. Clean or replace.

7.

Check for adequate fuel level by checking the float. (a) Golf cars - Bottom of the float to the carburetor body should be .040 to .119 when measured with the carburetor inverted. (b) All other applications - Bottom of the float to the carburetor body should be .190 to .250 when measured with the carburetor inverted. Adjust.

8.

Float needle valve worn. Replace.

9.

Contamination in float needle valve or seat. Clean.

10. Check nozzle size. (a) Golf cars -Standard is #40A. (b) All other applications -Standard is #44A. Replace.

11. Check nozzle for contamination. Clean.

12. Check that nozzle is correctly seated. Repair.

13. Check the throttle butterfly shaft for bends. Replace.

14. Check the throttle butterfly shaft bearings. Replace.

15. Check that torsion spring closes butterfly. Replace spring.

16. Check adjustment of stop screw. 1/8 to 1/4 turn after contacting screw. Adjust.

17. Check that air screw is open 2 turns (factory setting). Adjust.

18. Check for free and complete motion of choke. Adjust 19. Check choke cable for free and smooth motion. Replace choke cable.

20. Check that torsion spring will close choke and return cable to 'OFF' position. Replace spring.

F-N-R SWITCH

1.

Check for pitted or arced contacts. Replace components as required.

2.

Using a VOM, and with F-N-R switch in the'F' position check for continuity between 'A' to 'B' contacts and 'C' to 'D' contacts. Repair or replace switch if 'O' is not indicated.

Pg.R-12

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TROUBLE-SHOOTING 3.

Using a VOM, and with F-N-R switch in the 'R' position check for continuity between 'A' to 'D' contacts and 'B' to 'C' contacts. Repair or replace switch if 'O' is not indicated.

FUEL 1.

Check for adequate fuel in tank. Fill.

2.

Check volatility grade (A through E is acceptable depending on temperature and altitude). Use correct grade.

3.

Check brand. Use different brand if problems are only with one brand.

FUEL FILTERS 1.

Check main filter for contamination, cracks or holes. Replace.

2.

Check secondary filter for contamination, cracks or holes. Replace.

3.

Check hose connections.

FUEL LINES 1.

Check all joints and clamps for air leaks. Tighten clamps.

2.

Check condition of all hoses. Replace or clean.

FUEL PUMP 1.

Check pump rate. 1O to 12 fluid ounces per minute at 3000 R.P.M. Replace or repair fuel pump.

2.

Check that gaskets are not covering crankcase hole. Repair.

3.

Check that 'O' ring is not damaged or missing. Replace 'O' ring.

4.

Check that diaphragm is not ruptured. Replace fuel pump.

5.

Check for contamination in check valves. Clean.

FUEL TANK 1.

Check for fuel tank leak. Replace fuel tank.

2.

Check fuel pickup. Pickup should be within 1/4" to 3/8" of tank bottom. Repair or replace.

3.

Check connection between pickup tube and tank fitting. Replace.

4.

Check for plugged vent hole in cap/gauge. Clean or replace cap/gauge.

5.

Check for cracked cap/gauge. Replace cap/gauge.

FUSE 1.

Check rating. (25 amp)

2.

Use a VOM to check continuity. Replace fuse if 'O' is not indicated.

3.

Check to see that fuse is seated and that contacts are clean. Clean and replace fuse.

INTAKE AIR SYSTEM 1.

Check that the air intake louvers are not deformed or blocked with foreign matter. Repair.

2.

Check for restricted air flow at convoluted hose between the seat wrap air intake and the funnel. Repair.

3.

Check for restricted air flow at convoluted hose between the air cleaner and the carburetor. Repair.

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Pg.R-13

TROUBLE-SHOOTING 4.

Check condition of filter element. Remove the entire canister as an assembly and disassemble outside of the vehicle. Clean or replace as required.

5.

Check tightness of clamps. Tighten.

6.

Check that carburetor adapter is tight. Tighten.

KEY SWITCH 1.

Use a VOM to check continuity when KEY is in the 'ON' position. Replace switch if reading does not indicate .00 (digital meter) or under 5 ohms (analog meter).

2.

Resistance should read 'Infinity' when key is in the 'OFF' position. Replace switch if reading does not indicate 'infinity'.

OIL PUMP 1.

Check that the pump actuating lever provides full range of motion. Adjust.

2.

Check that the air bleed screw is closed. Close.

3.

Check that the system does not contain air bubbles. Bleed.

4.

Check that the oil lines are not kinked or cracked. Replace.

5.

Check that the hose clamps are in position and tight. Position correctly.

6.

Check for pumping function. Replace.

SOLENOID 1.

Using a VOM, and with the solenoid in the unenergized position, check for continuity between the small terminals.

Replace solenoid if no continuity is indicated.

2.

Using a VOM, and with the solenoid in the energized position disconnect the 6 gauge wire (solenoid to battery), check for continuity between the large terminals. Replace solenoid if no continuity is indicated.

3.

Using a VOM, and with the solenoid in the unenergized position, check that resistance between the large termi­ nals indicates infinity. Replace solenoid if value is incorrect.

SOLID STATE IGNITION SYSTEM (S.S.1.)

1.

To determine S.S.I function, check for presence of spark using an inductive pickup timing light.

TO PREVENT DAMAGE TO THE SOLID STATE IGNITION SYSTEM, DO NOT ARC THE SPARK PLUG WIRE TO GROUND WHEN CHECKING FOR IGNITION SYSTEM FUNCTION. USE A KNOWN TO BE GOOD SPARK PLUG THAT IS PROPERLY GROUNDED OR A SPARK INDICATOR.

PULSER COIL 2.

Using a VOM, check cold resistance. Red(+) to Blue(-) should be 75 ohms. Replace pulser coil if value is incor­ rect.

3.

Using a VOM, check hot resistance. Red(+) to Blue(-) should be 125 to 200 ohms. Replace pulser coil if value is incorrect.

4.

Check air gap. .016 to .022 is acceptable. Adjust if not to specifications.

CONTROL MODULE (IGNITOR) 5.

Check that ground connections are clean and tight at all ground locations. Clean and tighten.

Pg.R-14

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TROUBLE-SHOOTING 6.

If all other components within the S.S.I system are known to be good and no spark is present, the control module is suspect. Replace.

IGNITION COIL 7.

Using a VOM, check the primary coil resistance. Orange to Green should be 3.6 to 3.8 ohms. Replace ignition coil if value is incorrect.

8.

Using a VOM, check the secondary coil resistance. Orange to Spark plug wire should be 11.5 to 12.5 K ohms.

Replace ignition coil if value is incorrect.

9.

Check that the aluminum or plastic isolators between the ignition coil and the mounting bracket are in place. Use a magnet to check that each isolator and isolator mounting screw is non-magnetic. Install brass isolator mount­ ing screws.

SPARK PLUG 1.

Check Spark Plug Gap. .028 to .030 Inches. Re-gap.

2.

Check for fouling or contamination. Clean and gap or replace plug.

3.

Check spark plug type. NGK-BP5HS or Champion L92-YC are recommended. Replace with recommended spark plug.

SPARK PLUG WIRE 1.

Using a VOM, check for continuity. Replace spark plug wire if value is incorrect.

2.

Check that wire is fully inserted into the ignition coil.

3.

Check that wire insulator has not worn through and is shorting to ground. Replace spark plug wire.

4.

Check that there is no rubber flashing from the spark plug cap trapped between the plug and the wire connector.

Remove excess rubber.

5.

Check that spark plug wire connector is firmly attached to the spark plug. Connect plug wire.

STARTER/GENERATOR 1.

Check that all electrical connections are clean and tight. Clean and tighten.

2.

Check belt tension and condition. Adjust tension and replace defective belt.

3.

Using a VOM, check field coil resistance. Terminals F1 to F2 should read .0056 ohms (digital VOM)which may read as O ohms. Replace field coils if value is incorrect.

4.

Using a VOM, check field coil resistance. Terminals F1 to OF should read 5 ohms. Replace field coils if value is incorrect.

5.

Using a VOM, check armature resistance. Measure between A1 and A2. Resistance should read .0134 ohms (digital VOM). Replace armature if value is incorrect.

6.

Using a VOM, check voltage output. 15 volts at 3000 R.P.M. is acceptable. Repair or replace if output value is incorrect.

7.

Check amperage. 50 amps maximum, 11 amps continuous at 14 volts is acceptable. Repair or replace if output value is incorrect.

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I I I tR!9!G!

E�GCii:j:,i1t•l:I

Pg.R-15

TROUBLE-SHOOTING 8.

Check brush length. 16 to 24 mm is acceptable. Replace all brushes if anyone is shorter than specified length.

TIMING 1.

Forward: 18_ 3_at 1500 R.P.M.

2.

Reverse: 21_ 3_ at 1500 R.P.M.

VOLTAGE REGULATOR 1.

Check for clean tight connections. Clean and tighten.

2.

Check voltage setting. Replace.

3.

Using a VOM, and with engine running check that output voltage is 15.0 .5 volts at 77_F. Replace regulator if out of tolerance.

SECTION 'O' (EXCESSIVE TIRE WEAR) TIRES • Incorrect tire pressure. Inflate to specified pressure.

WHEEL • Bent wheel rim. Replace.

WHEEL ALIGNMENT • Check Alignment. Adjust.

• Spring and suspension component deterioration. Repair.

WHEEL BRAKE • Dragging wheel brake. Adjust.

SECTION 'P' (VEHICLE PULLS TO ONE SIDE) WHEEL • Incorrect tire pressure. Inflate to specified pressure.

• Mismatched tires on same axle. Replace with same type tire.

• Bent wheel rim. Replace.

WHEEL ALIGNMENT • Check alignment. Adjust.

• Spring and suspension component deterioration. Repair.

WHEEL BRAKE • Dragging wheel brake. Adjust.

Pg.R-16

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TROUBLE-SHOOTING NON-POWER TRAIN SYSTEMS SUSPENSION AND STEERING

EXCESSIVE TIRE WEAR

-- BINDING OR ERRATIC STEERING

0 p

VEHICLE PULLS TO ONE SIDE

Q

EXCESSIVE PLAY IN STEERING

R

BRAKE SYSTEM

TO MANUAL SECTION

G

FRONT FORK • Fork bent. Replace.

SECTION 'Q' (BINDING OR ERRATIC STEERING) TIRES • Incorrect tire pressure. Inflate to specified pressure.

WHEEL ALIGNMENT • Check alignment. Adjust.

• Spring and suspension component deterioration. Repair.

SUSPENSION AND STEERING COMPONENTS • Dry lubrication joints. Lubricate or replace and lubricate joints.

STEERING BOX • Damaged steering box components. Repair or replace.

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Pg.R-17

TROUBLE-SHOOTING SECTION 'R' (EXCESSIVE PLAY IN STEERING) SUSPENSION COMPONENTS • Worn suspension components. Repair.

STEERING WHEEL • Cracked steering wheel insert (hub). Remove steering wheel and inspect. Replace steering wheel if cracked.

• Damaged or stripped splines in steering wheel insert (hub). Remove steering wheel and inspect. Replace steering wheel if damaged. (Do not exceed specified torque).

• Damaged or stripped splines on steering shaft. Remove steering wheel and inspect. Replace steering shaft if damaged.

• Loose steering wheel nut. Tighten to specified torque. (Do not exceed specified torque).

• Worn reduction gear. Replace.

• Worn pinion gear. Replace.

• Worn rack and rod assembly. Replace

STEERING BOX • Loose steering box. Tighten.

IDLER ARM • Worn idler arm bushing. Replace.

WHEEL BEARINGS • Loose wheel bearings. Inspect, repack and tighten or pack and replace.

WHEEL BRAKE • Wheel brake and entire brake system adjustment and repair is covered under the Brakes section 'G' of this manual.

Pg.R-18

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OPERATION AND SERVICE MANUAL SECTION: GENERAL SPECIFICATIONS

s

GOLF CARS (GX-440/GX-444) GX-440 NOT AVAILABLE FROM 1990 MODEL YEAR WEIGHT (DRY)

644 POUNDS (3 WHEEL) 685 POUNDS (4 WHEEL)

LENGTH

88 1/2 INCHES (3 WHEEL) 93 INCHES (4 WHEEL)

WIDTH (AT REAR WHEELS)

48 INCHES

TREAD (REAR WHEELS)

39 INCHES

WHEEL BASE

60 INCHES (3 WHEEL) 66 INCHES (4 WHEEL)

HEIGHT AT STEERING WHEEL

48 5/8 INCHES

HEIGHT AT FLOOR

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL)

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

17 FEET 6 INCHES (3 WHEEL) 19 FEET 6 INCHES (4 WHEEL)

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S) AND ACCESSORIES

800 POUNDS

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL) BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

18.0 x 8.50 x 8, 4 PLY RATED

TIRE PRESSURE

12-18 PSI (NORMAL), 22 PSI (CONVERTIBLE CARRIER KIT)

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22.7 LITERS)

FUEL

87 TO 100 OCTANE

12/15/90

! ! ! ISl91GI

AUTO-ADJUSTING

(REAR

Pg. S-1

GENERAL SPECIFICATIONS DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1. 7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BPSHS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) WITH SPEED AND LOAD SENSING

TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION

COIL SPRINGS AND SHOCK ABSORBERS (3 WHEEL) LEAF SPRINGS AND SHOCK ABSORBERS (4 WHEEL)

REAR SUSPENSION

COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE PLASTIC AND STEEL BODY COM­ PONENTS

CHASSIS

RECTANGULAR STEEL TUBING

INOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-2

12/15/90

! ! !S!9!G!

GENERAL SPECIFICATIONS SPIRIT (GX-444J) WEIGHT (DRY)

688 POUNDS

LENGTH

94 INCHES

WIDTH (AT REAR WHEELS)

48INCHES

TREAD (REAR WHEELS)

39INCHES

WHEEL BASE

66INCHES

HEIGHT (AT STEERING WHEEL)

48 5/8 INCHES

HEIGHT (AT FLOOR)

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL)

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S) AND ACCESSORIES

800 POUNDS

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL) BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

18.0 X 8.50 X 8, 4 PLY RATED

TIRE PRESSURE

12-18 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22.7 LITERS)

FUEL

87 TO 100 OCTANE

DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1.7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BP5HS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) WITH SPEED AND LOAD SENSING

12/15/90

! ! ! !S!9k3!

AUTO-ADJUSTING

(REAR

Pg. S-3

GENERAL SPECIFICATIONS TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION

LEAF SPRINGS AND SHOCK ABSORBERS

REAR SUSPENSION

COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE COMPONENTS

CHASSIS

RECTANGULAR STEEL TUBING

LIGHTING

DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS. OPTIONAL FRONT AND REAR TURN SIGNAL SWITCH/INDICATOR.

HORN

ELECTRIC

PLASTIC

AND

STEEL

BODY

INOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-4

12/15/90 ! ! ISl91GI

GENERAL SPECIFICATIONS FREEDOM (GX-444J) WEIGHT (DRY)

688 POUNDS

LENGTH

94 INCHES

WIDTH (AT REAR WHEELS)

48 INCHES

TREAD (REAR WHEELS)

39 INCHES

WHEEL BASE

66 INCHES

HEIGHT (AT STEERING WHEEL)

48 5/8 INCHES

HEIGHT (AT FLOOR)

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL)

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S) AND ACCESSORIES

800 POUNDS

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL} BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

18.0 X 8.50 X 8, 4 PLY RATED

TIRE PRESSURE

12-18 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22.7 LITERS)

FUEL

87 TO 100 OCTANE

DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1.7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BP5HS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) WITH SPEED AND LOAD SENSING

12/15/90

! ! ! !S!9!G!

AUTO-ADJUSTING

(REAR

Pg. S-5

GENERAL SPECIFICATIONS TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION

LEAF SPRINGS AND SHOCK ABSORBERS

REAR SUSPENSION

COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE COMPONENTS

CHASSIS

RECTANGULAR STEEL TUBING

LIGHTING

DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS. OPTIONAL FRONT AND REAR TURN SIGNAL SWITCH/INDICATOR.

HORN

ELECTRIC

PLASTIC

AND

STEEL

BODY

INOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-6

12/15/90

! ! !S!9iG!

GENERAL SPECIFICATIONS LIBERTY (PC4GXJ) WEIGHT (DRY)

838 POUNDS

LENGTH (INCLUDING FOOT REST}

107INCHES

WIDTH (AT REAR WHEELS)

48INCHES

TREAD (REAR WHEELS)

39 INCHES

WHEEL BASE

66 INCHES

HEIGHT (AT STEERING WHEEL}

48 5/8 INCHES

HEIGHT (AT FLOOR)

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL}

5INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S) AND ACCESSORIES

800 POUNDS

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL) BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

18.5 X 8.50 X 8, 6 PLY RATED

TIRE PRESSURE

12-18 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATEIGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22. 7 LITERS)

FUEL

87 TO 100 OCTANE

DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1.7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BP5HS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT} WITH SPEED AND LOAD SENSING

12/15/90

! ! ! !S!9!G!

AUTO-ADJUSTING

(REAR

Pg. S-7

GENERAL SPECIFICATIONS TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION REAR SUSPENSION

HEAVY DUTY LEAF SPRINGS AND SHOCK ABSORBERS ·· HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE COMPONENTS

CHASSIS

RECTANGULAR STEEL TUBING

LIGHTING

DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS. OPTIONAL FRONT AND REAR TURN SIGNAL SWITCH/INDICATOR.

HORN

ELECTRIC

PLASTIC

AND

STEEL

BODY

INOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-8

12/15/90

! ! !S!9!G!

GENERAL SPECIFICATIONS PERSONNEL CARRIER (PC4GX) WEIGHT (DRY)

835 POUNDS

LENGTH (INCLUDING FOOT REST)

106 INCHES

WIDTH (AT REAR WHEELS)

48 INCHES

TREAD (REAR WHEELS)

39 INCHES

WHEEL BASE

66 INCHES

HEIGHT (AT STEERING WHEEL)

48 5/8 INCHES

HEIGHT (AT FLOOR)

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL)

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S) AND ACCESSORIES

800 POUNDS

INTERSECTING AISLE CLEARANCE

75 INCHES

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL) BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

18.5 X 8.50 X 8, 6 PLY RATED

TIRE PRESSURE

12-18 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22.7 LITERS)

FUEL

87 TO 100 OCTANE

DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1.7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BP5HS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

12/15/90

! ! f !S!9k3f

AUTO-ADJUSTING

(REAR

Pg. S-9

GENERAL SPECIFICATIONS POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) WITH SPEED AND LOAD SENSING

TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION

HEAVY DUTY LEAF SPRINGS AND SHOCK ABSORBERS

REAR SUSPENSION

HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE COMPONENTS

CHASSIS

RECTANGULAR STEEL TUBING

LIGHTING

DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS. OPTIONAL FRONT AND REAR TURN SIGNAL SWITCH/INDICATOR.

HORN

ELECTRIC

PLASTIC

AND

STEEL

BODY

INOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-10

12/15/90

! ! !S!9!G!

GENERAL SPECIFICATIONS INDUSTRIAL PERSONNEL CARRIER (PC4GXI) WEIGHT (DRY)

835 POUNDS

LENGTH (INCLUDING FOOT REST}

106 INCHES

WIDTH (AT REAR WHEELS}

48 INCHES

TREAD (REAR WHEELS)

39 INCHES

WHEEL BASE

66 INCHES

HEIGHT (AT STEERING WHEEL)

48 5/8 INCHES

HEIGHT (AT FLOOR)

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL)

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S) AND ACCESSORIES

800 POUNDS

INTERSECTING AISLE CLEARANCE

75 INCHES

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL) BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

5.70 X 8, INDUSTRIAL TYPE, 6 PLY RATED

TIRE PRESSURE

12-18 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22.7 LITERS)

FUEL

87 TO 100 OCTANE

DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1.7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BP5HS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

12/15/90

! ! ! !S!9k3!

AUTO-ADJUSTING

(REAR

Pg. S-11

GENERAL SPECIFICATIONS POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) WITH SPEED AND LOAD SENSING

TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION

HEAVY DUTY LEAF SPRINGS AND SHOCK ABSORBERS

REAR SUSPENSION

HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE COMPONENTS

CHASSIS

RECTANGULAR STEEL TUBING

LIGHTING

DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS. OPTIONAL FRONT AND REAR TURN SIGNAL SWITCH/INDICATOR.

HORN

ELECTRIC

PLASTIC

AND

STEEL

BODY

I NOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED

OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-12

12/15/90 I I lsl91GI

GENERAL SPECIFICATIONS TURF TRUCK (GXT-300/800) GXT-300 NOT AVAILABLE FOR 1990 MODEL YEAR WEIGHT (DRY)

775 POUNDS (3 WHEEL) 845 POUNDS (4 WHEEL)

LENGTH

97 INCHES (3 WHEEL} 106 INCHES (4 WHEEL)

WIDTH (AT REAR WHEELS)

48 INCHES

TREAD (REAR WHEELS)

39 INCHES

WHEEL BASE

65 INCHES (3 WHEEL) 71 INCHES (4 WHEEL)

HEIGHT AT STEERING WHEEL

48 5/8 INCHES

HEIGHT AT FLOOR

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL)

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES (3 WHEEL) 19 FEET10 INCHES (4 WHEEL)

LOAD BED HEIGHT

24 INCHES

LOAD BED SIZE

44 INCHES WIDE, 40 INCHES LONG, 8 INCHES DEEP

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER($) AND ACCESSORIES

1,000 POUNDS

BRAKES

DRUM, MECHANICAL, WHEELS)

PARKING (HILL) BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

18.0 X 8.50 X 8, 4 PLY RATED

TIRE PRESSURE

12-18 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22. 7 LITERS)

FUEL

87 TO 100 OCTANE

DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

12/15/90

! ! ! !S!9!G!

AUTO-ADJUSTING

(REAR

Pg. S-13

GENERAL SPECIFICATIONS OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1. 7 LITERS}

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BPSHS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT} WITH -sPEED -AND LOAD SENSING

TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED}

FRONT SUSPENSION

HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS (3 WHEEL} HEAVY DUTY LEAF SPRINGS AND SHOCK ABSORBERS (4 WHEEL}

REAR SUSPENSION

HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE PLASTIC AND STEEL BODY COM­ PONENTS

CHASSIS

RECTANGULAR STEEL TUBING

HORN

ELECTRIC

INOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. S-14

E�GDii:£1M•m

12/15/90

! ! !S!9k3!

GENERAL SPECIFICATIONS INDUSTRIAL TRUCK (GXl-300/800) WEIGHT (DRY}

775 POUNDS (3 WHEEL} 845 POUNDS (4 WHEEL}

LENGTH

97 INCHES (3 WHEEL} 106 INCHES (4 WHEEL}

WIDTH (AT REAR WHEELS}

48 INCHES

TREAD (REAR WHEELS}

39 INCHES

WHEEL BASE

65 INCHES (3 WHEEL} 71 INCHES (4 WHEEL}

HEIGHT AT STEERING WHEEL

48 5/8 INCHES

HEIGHT AT FLOOR

11 INCHES

GROUND CLEARANCE (AT DIFFERENTIAL}

5 INCHES

SEAT HEIGHT

29 INCHES

CLEARANCE CIRCLE

19 FEET 6 INCHES (3 WHEEL} 19 FEET10 INCHES (4 WHEEL}

!INTERSECTING AISLE CLEARANCE

73 INCHES (3 WHEEL} 78 INCHES (4 WHEEL}

LOAD BED HEIGHT

24 INCHES

LOSO BED SIZE

44 INCHES WIDE, 40 INCHES LONG, 8 INCHES DEEP

LOAD CAPACITY (INCLUDING OPERATOR, PASSENGER(S} AND ACCESSORIES

1,000 POUNDS

BRAKES

DRUM, MECHANICAL, WHEELS}

PARKING (HILL} BRAKE

MECHANICAL, AUTOMATIC RELEASE, SELF-COMPEN­ SATING

TIRES

5.70 X 8, INDUSTRIAL TYPE, 4 PLY RATED

TIRE PRESSURE

50-60 PSI

BATTERY

12V GROUP 26 - MAINTENANCE FREE

ELECTRICAL SYSTEM

12V NEGATIVE GROUND

ENGINE

244 C.C. AIR COOLED, SOLID STATE IGNITION, FIXED JET CARBURETION

STARTER/GENERATOR

EXTERNAL, BELT DRIVE, 55 AMP CAPACITY

FUEL TANK CAPACITY

6 U.S. GALLONS (22.7 LITERS}

FUEL

87 TO 100 OCTANE

12/15/90

! ! ! !S!9!G!

AUTO-ADJUSTING

(REAR

Pg. S-15

GENERAL SPECIFICATIONS DIFFERENTIAL LUBRICATION

SAE-30, 8-10 OZ.

OIL INJECTION

TANK CAPACITY - 1.5 QUARTS (1.7 LITERS)

OIL

E-Z-GO 2-CYCLE OIL

SPARK PLUG TYPE

NGK - BPSHS OR CHAMPION L92-YC

SPARK PLUG GAP

.028-.030 INCHES

POWER TRANSMISSION

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) WITH SPEED AND LOAD SENSING

TRANSAXLE

DOUBLE REDUCTION HELICAL GEARING WITH AUTO­ MOTIVE TYPE DIFFERENTIAL, 14.78:1 RATIO

GOVERNOR

GROUND SPEED SENSING

SPEED

12 M.P.H. (GOVERNED)

FRONT SUSPENSION

HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS (3 WHEEL) HEAVY DUTY LEAF SPRINGS AND SHOCK ABSORBERS (4 WHEEL)

REAR SUSPENSION

HEAVY DUTY COIL SPRINGS AND SHOCK ABSORBERS

HILL CLIMBING

40% GRADE

STEERING

RACK AND PINION

BODY

ALL REPLACEABLE COMPONENTS

CHASSIS

RECTANGULAR STEEL TUBING

LIGHTING

DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS.

HORN

ELECTRIC

PLASTIC

AND

STEEL

BODY

I NOTEI For vehicles equipped with the oil injection system, only use gasoline in the fuel tank. DO NOT USE PREMIXED OIL AND GASOLINE IN OIL INJECTION EQUIPPED VEHICLES.

Pg. 5-16

12/15/90

! ! !S!9k3!

GENERAL SPECIFICATIONS

CARBURETOR JE I I ING ALTITUDE TABLES

12/15/90

l ! ! !S!9k3!

Pg. S-17

GENERAL SPECIFICATIONS

1989/1990/1991 MODELS GX-440, GX-444, GX-444J, GX-444F ALTITUDE/TEMPERATURE CHANGES MAIN JET SELECTION ................ .......... ........................... ........................... ........................... ··························· ........................... ........................... ........................... ........................... ........................... ...................... .. ...

A.tJ'if.l.ipE

l�F,�$'1'

fgMP�A.ArUij�i i� d�aAEg$ # IHHI HHHHIH /\/\i\\T 40 so n <so ::1.0 HO ::10 :20: 30 ================================================================:::::::::l ········ ................................. . ................................ ....

:::::::::::::::::;:::

::::::::::::::;:::::: ..................... .....................

.......... ............. ......................

..................... ..................... ::::::::::::::::::::: ..........................................

:::::::::: ::::::::::::: ..................... .

1:ll]lllllllllllllllll]l:i:l==

...........................

Ht)

87.5

87.5

85

85

85

85

82.5

82.5

82.5

80

80

87.5

85

85

85

82.5

82.5

82.5

80

80

80

80

85

85

82.5

82.5

82.5

82.5

80

80

80

77.5

77.5

H/4000

05

82.5

82.5

82.5

80

80

80

80

77.5

77.5

77.5

82.5

82.5

80

80

80

80

77.5

77.5

77.5

75

75

H$PQ<>:

82.5

80

80

80

77.5

77.5

77.5

77.5

75

75

75

80

80

80

77.5

77.5

77.5

75

75

75

75

75

80

77.5

77.5

77.5

75

75

75

75

75

75

75

77.5

77.5

77.5

75

75

75

75

75

75

75

75

77.5

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

........................... ···························

jppt)

iooo

::::::::::::::::::::::::::: ........................... ..........................

�PQ<> H

............................ ..........................

::::::::::::::::::::::::::: ···························

>

6000

.......................... .............. ........ ......

Y7ooOY

:::::::::;:::.::::::::::::: ........................... ...........................

8000

........................... ........................... ...........................

9000

........................... ··························· ···························

10.0QQQ

Main jet selection should be based on coldest temperature and lowest altitude at which vehicle will operate.

Use one (1) jet size larger then recommended for extremely hilly terrain, hauling heavy loads or long sustained runs.

It may be necessary to increase the main jet one or two sizes larger when using gasoline with alcohol additives or with an octaine rating below 87.

If a vehicle does not perform satisfactorily after changing the main jet, increase the pilot jet one size at a time until acceptable performance levels are achieved.

Pg. S-18

12/15/90

! ! !S!9!G!

GENERAL SPECIFICATIONS

1989/1990/1991 MODELS GXl-300/800, GXT-300/800, PC4GX, PC4GXJ, PC4GXI ALTITUDE/TEMPERATURE CHANGES MAIN JET SELECTION ............. .............. .............. ............. ................ ............. .............. ............... ............. .............. .............. .............. .............. ............... .............

.................. ................... . ........ -....... .... .............. ..................

························ ·························· .::::::::::::::::::::::::::: .................. . ....... .::::::::::::::::::::::::::: ....... ................... ...........................

•A4tiTQb�

jp

.:::::::::::::::::: ................. .:::::::::::::::::: ....... ... ....... :::::::::::::::::: ..................

\20:•• 30

... .... .... ..... ... .... .... ... . ... ..... .... .... .... ... .....

110·•··

. . . . . . . . .::•• l============================================================::::::::1 ir\JF¢¢'J"

................ .... ..... ..........................

0

........................... ........................... ...........................

1000 •

2000

........................... ........................... ...........................

/

�Q()()

4000/

...........................

102.5

102.5

102.5

100

100

100

97.5

97.5

97.5

95

95

102.5

100

100

100

97.5

97.5

97.5

95

95

92.5

92.5

100

100

100

97.5

97.5

97.5

95

95

92.5

92.5

92.5

100

97.5

97.5

97.5

95

95

95

92.5

90

90

90

97.5

97.5

95

95

95

92.5

92.5

92.5

90

87.5

87.5

95

95

95

95

92.5

92.5

92.5

90

90

87.5

87.5

95

95

92.5

92.5

92.5

90

90

87.5

87.5

87.5

87.5

92.5

92.5

92.5

90

90

90

87.5

87.5

87.5

85

85

92.5

90

90

90

87.5

87.5

87.5

87.5

85

85

85

90

90

87.5

87.5

87.5

87.5

85

85

85

82.5

82.5

87.5

87.5

87.5

85

85

85

85

82.5

82.5

80

80

...........................

$PP<>:

........................... ...........................

6000.

.::::;:::;:::::::::::::::::

7000

............. ............. :;;;;::::;::::;;::::::;:::: ...........................

sooo

.......................... ::::::;:;::;:::::::::::::::

9000

:::::::::::::;:::::::::::::

H>PPQ<>: •

Main jet selection should be based on coldest temperature and lowest altitude at which vehicle will operate.

Use one (1} jet size larger then recommended for extremely hilly terrain, hauling heavy loads or long sustained runs.

It may be necessary to increase the main jet one or two sizes larger when using gasoline with alcohol additives or with an octaine rating below 87.

If a vehicle does not perform satisfactorily after changing the main jet, increase the pilot jet one size at a time until acceptable performance levels are achieved.

12/15/90

! ! ! !S!9k3!

Pg. S-19

GENERAL SPECIFICATIONS

Pg. S-20

12/15/90

! ! ! !S!9k3!

Read and understand the following warnings before at­ tempting to operate the vehicle.

&WARNING& WHEN THE VEHICLE IS TO BE LEFT UNATTENDED, MOVE THE DIRECTION SELECTOR TO THE NEU­ TRAL (N) POSITION, TURN THE KEY TO THE 'OFF' POSITION, REMOVE KEY AND ENGAGE THE PARKING (HILL) BRAKE. DRIVE THE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CON­ SIDER THE TERRAIN AND EXISTING TRAFFIC CONDITIONS. ALSO CONSIDER THE ENVIRON­ MENTAL FACTORS WHICH EFFECT THE TERRAIN AND YOUR ABILITY TO CONTROL THE VEHICLE. AVOID DRIVING FAST DOWN HILL. SUDDEN STOPS OR CHANGE OF DIRECTION MAY RESULT IN A LOSS OF CONTROL. USE BRAKE TO CON­ TROL SPEED WHEN TRAVELING DOWN AN IN­ CLINE. 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 (HILL) BRAKE WHEN­ EVER THE VEHICLE IS PARKED. KEEP FEET, LEGS, HANDS, AND ARMS INSIDE THE VEHICLE AT ALL TIMES. AVOID EXTREMELY ROUGH TERRAIN. CHECK THE AREA BEHIND THE VEHICLE BEFORE BACKING UP. MAKE SURE THAT THE DIRECTION SELECTOR IS IN THE CORRECT POSITION BEFORE ATTEMPT­ ING TO START THE VEHICLE.

SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING THE VEHICLE TO A COMPLETE STOP BEFORE SHIFTING THE DIRECTION SELEC­ TOR. STANDARD VEHICLE IS LIMITED TO 3 OCCU­ PANTS MAXIMUM PER SEAT, EXCEPT FOR FRONT SEAT THAT IS RESTRICTED TO 2 OCCUPANTS ALWAYS REMAIN SEATED AND VEHICLE IS IN MOTION.

HOLD ON WHILE

Read and understand the following warnings before at­ tempting to service the vehicle.

&WARNING& BEFORE WORKING ON THE VEHICLE: REMOVE ALL RINGS AND WATCHES AND BE SURE THAT NO LOOSE CLOTHING OR HAIR CAN CONTACT THE MOVING PARTS OF THE POWERTRAIN. USE CARE NOT TO CONTACT HOT OBJECTS. RAISE THE REAR OF THE VEHICLE AND SUPPORT ON JACK STANDS BEFORE ATTEMPTING TO RUN OR ADJUST THE POWERTRAIN. WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE THE EYES TO POTENTIAL INJURY. IN PARTICULAR USE CARE WHEN WORKING AROUND THE BATTERIES, WHEN USING SOLVENTS OR COMPRESSED AIR.

&WARNING& HYDROGEN GAS IS FORMED WHEN CHARGING BATTERIES. DO NOT CHARGE BATTERIES WITH­ OUT ADEQUATE VENTILATION. DO NOT PERMIT OPEN FLAME OR ANYONE TO SMOKE IN AN AREA BEING USED FOR CHARGING BATTERIES. CON­ CENTRATIONS OF 4% HYDROGEN GAS OR MORE IS EXPLOSIVE.

E-2-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388

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