EZGO TEXTRON GX-444 GX-444F (FREEDOM) GX-444F HP (FREEDOM HP) SERVICE MANUAL - PDF DOWNLOAD

4 CYCLE GASOLINE POWERED VEHICLES

TECHNICIAN'S REPAIR AND SERVICE MANUAL

MODEL YEARS: 1991-1996

MANUAL NO.: 27206-G01 ISSUED: 12/01/91

REVISED:07/25/95

SAFETY Read and understand all labels located on the vehicle. If there are questions on any of the information, contact an E-Z­ GO representative for clarification.

Read and understand all the information in Safety / Section B of this manual.

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 pre­ vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum gov­ erned speed on level ground. (See vehicle specification.) Limit speed by applying the service brake.

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

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

Use extra caution when towing the vehicle( s). Do not tow a single vehicle at speeds in excess of 12 M.P.H. Do not tow multiple vehicles at speeds in excess of 5 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 part of the permanent service record should the vehicle be re-sold.

NOTES, CAUTIONS AND WARNINGS T hroughout this guide [R!i@u[§, CAUTION and WARNING will be used.

A note indicates a condition that should be observed.

CAUTION A CAUT ION INDICATES A CONDIT ION THAT MAY RESULT IN DAMAGE T O THE VEHICLE .

A

WARNING

A

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

P lease observe these [R!]@'D'[§@, CAUTIONS and WARN­ INGS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous.

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

TECHNICIAN'S REPAIR AND SERVICE MANUAL 4 CYCLE GASOLINE POWERED VEHICLES VEHICLES GX-444 GX-444F (FREEDOM) GX-444F HP (FREEDOM HP) 1992-1994 GXT/1-804 TUFF1 1992-1995 PC4GX 1992-1995 PC4GXI 1992-1994 BC-360

E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA 30903-0388

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Owner's Manual and Service Guide

Page i

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 WARRANTY 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 THE VEHICLE TO OPERATE AT ABOVE FACTORY SETTINGS (12-15 M.P.H.) WILL VOID YOUR VEHILCE WARRANTY.

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GENERAL INDEX GENERAL ......................................... ........................................ A-1 Operating Controls Starting The Engine Servicing - Initial Preventative Maintenance SAFETY PROCEDURES .................................................................. B-1 General Precautions Battery Removal Fuel Tank Removal and Installation Lifting Procedures WHEELS AND TIRES ..................................................................... C-1 Tire Repair Tire Mounting Wheel Installation STEERING ............................................................................. D-1 Steering Assembly Removal Steering Disassembly Steering Shaft Removal Gear and Rack Removal Idler Removal Tie Rod Inspection King Pin Inspection SUSPENSION ........................................................................... E-1 Front Shield Removal Front Suspension Removal Spindle Repair Bearing Adjustment Front Wheel Alignment Front Suspension Bearing Maintenance Rear Suspension Coil Spring Removal Shock Absorber Removal Pivot Bushing Removal SPEED CONTROL ....................................................................... F-1 Accelerator Governor and Carburetor Linkage System Components and Operation Governor Accelerator Pedal Height Accelerator Switch Adjustment Accelerator Cable Adjustment Linkage Rod Adjustment

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GENERAL INDEX BRAKES .............................................................................. G-1 General Daily Braking Performance Test 6 Month Maintenance How the Brakes Work How the Adjuster Works Disassembly of Brake Pedal Hill Brake Release Removal Brake Drum and Shoe Removal Compensating Brake Linkage Adjustment Adjustment of Wheel Brake ENGINE AND CONTROLS ................................................................. H-1 Engine Description Engine Operation Displacement Valve Adjustment Valve Cover Installation Timing Belt Adjustment, Inspection and Replacement Drive Clutch Removal Starter Generator Removal Muffler Removal Engine Removal Cam Removal and Replacement Cylinder Head Removal and Replacement Valve Replacement and Conditioning Valve Seal Replacement Fan Removal Ignition Trigger Replacement Accelerator Linkage Adjustment Cooling System Cleaning FUEL SYSTEM .......................................................................... J-1 Fuel System Description Choke System Carburetor Service, Replacement and Disassembly Float Level Adjustment Throttle Shaft Adjustment Fuel Pump Fuel Lines and Filter Carburetor Main Jets Carburetor Trouble-Shooting

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GENERAL INDEX POWER TRANSMISSION ................................................................. K-1 Power Transmission Description Towing Removing the Drive Belt Drive Clutch Removal and Installation Driven Clutch Removal, Disassembly and Reassembly Driven Clutch Installation and Storage Replacing Broken Ramp Buttons ELECTRICAL ........................................................................... L-1 Circuits and Controls Wiring Testing Ignition Circuit and Starting Circuit Starter I Generator Removal, Inspection and Repair Battery Test and Storage Starter/Generator Specifications Regulator Specifications REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 Differential Lubrication Axle Adjustments Removal of the Rear Axle Rear Axle Installation and Disassembly Brake Drum and Hub Disassembly and Assembly Axle Shaft Removal and Disassembly Axle Shaft Seal Removal and Replacement Axle Shaft Replacement Governor Arm Removal Shift Cable Removal Differential Removal PAINT INSTRUCTIONS .................................................................. Q-1 TROUBLE-SHOOTING ................................................................... R-1 Section A - Starter does not rotate Section B - Starter rotates but vehicle will not start Section C - Starter rotates slowly or has insufficient torque Section D - Engine is hard to start Section E - Engine Runs Rough or Stalls Section F - Loss of power Section G - Engine Overheating Section H - Repeated spark plug fouling Section I - Carburetor Floods Section J - Excessive smoking Section K - Starter/ Generator does not charge battery properly Section L - Backfiring

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GENERAL INDEX Section M - Erratic, surging or sudden change in governed speed Section N - Vibration Component Trouble-shooting Guide Section O - Excessive tire wear Section P - Vehicle pulls to one side Section Q - Binding or erratic steering Section R - Excessive play in steering VEHICLE SPECIFICATIONS ............................................................... S-1 Golf Car (GX-444-4) Freedom (GX-444F-4) Personnel Carriers (PC4GX-4 and PC4GXl-4) Industrial Trucks (GXT / 1-804) Beverage Caddy ( BC360-GX-4)

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INTRODUCTION This 4-Cycle Owner's Operation and Service Manual has been designed to enable you to maintain the vehicle in ac­ cordance with procedures developed by E-Z-GO. Adherence to these procedures and trouble-shooting tips will en­ sure you of the best possible service from the product.

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

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

Indicates a condition that should be observed.

INDICATES A CONDITION THAT MAY RESULT IN DAMAGE TO VEHICLE.

&_WARNING&_

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 ob­ served: 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 op­ eration of all vehicles. If part replacement is necessary, the part must 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 a service procedure or tool, which is not recommended by the vehicle manu­ facturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized 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.

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OPERATION AND SERVICE MANUAL SECTION: GENERAL

A

NOTES, CAUTIONS AND WARNINGS

SERIAL NUMBER PLATE LOCATION (FIG. A-1)

Throughout this manual you will find Note, CAUTION and WARNING used.

The model, serial, and manufacturing numbers are stamped on a plate on the right side of the dash housing of the vehicle.

Always provide these numbers to the dealer when or­ dering parts for the vehicle.

Indicates a condition that should be observed.

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

8WARNING8 INDICATES A CONDITION THAT MAY RESULT IN SERIOUS INJURY TO PERSONNEL AND MAY RE­ SULT IN DAMAGE TO THE VEHICLE.

MAINTENANCE PERSONNEL Although every effort has been made to adequately warn of potentially hazardous operations, it is impossi­ ble to anticipate every situation that a technician may encounter. Before performing any maintenance or serv­ ice, the technician should satisfy himself that the activity will not subject either himself or any other person to any danger.

READ AND UNDERSTAND ALL WARNINGS AND CAUTIONS ON INSIDE COVERS AND ALL MANUAL SECTIONS BEFORE PERFORMING ANY MAINTE­ NANCE. Only authorized, trained personnel should be permitted to work on an E-Z-GO vehicle. The personnel should have the skills normally associated with a trained me­ chanic and as such be aware of potential danger that can result from working with gasoline powered vehicles.

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FIG. A-1 SERIAL NO. PLATE LOCATION CONTROLS The controls of the vehicle consist of a Key Switch, Di­ rection Selector Lever, Accelerator Pedal and Combina­ tion Service Brake and Parking (hill} Brake Pedal.

KEY SWITCH (FIG. A-2) Located on the seat support panel, 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.

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GENERAL Do not operate at full throttle until engine has reached operating temperature.

If the vehicle is equipped with E-2-GO installed custom accessories, some accessories remain operational with the ignition switch in the "OFP' position.

DIRECTION SELECTOR (FIG. A-2)

The engine will only start with the key in the 'ON' position and with either forward or reverse selected. As soon as the engine starts, push the choke in.

Located on the seat support panel adjacent to the Key Switch, this lever permits the selection of either forward or reverse.

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

WHEN SELECTING DIRECTION DESIRED, THE VE­ HICLE MUST BE COMPLETEL YSTOPPED BEFORE MOVING THE DIRECTION SELECTOR. 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.

CHOKE (FIG. A-2) Located on the seat support panel, 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 five(5) seconds after depressing the accelerator pedal.

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

• FIG. A-2 CONTROLS (PANEL MOUNTED)

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GENERAL COMBINATION BRAKE AND PARKING (HILL) BRAKE PEDAL (FIG. A-3)

ing its good performance depends to a large extent on the operator.

The brake pedal incorporates a parking (hill} brake fea­ ture. 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 regu­ lar brake system.

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 ENTERING VEHICLE 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 understand the vehicle, its equipment, and how to use it safely. Although E-Z-GO vehicles have been designed as a safe and reliable vehicle, maintain-

BEFORE INITIAL USE, REMOVE CLEAR PLASTIC SEAT COVERINGS.

Read and understand the following warnings before at­ tempting to operate the vehicle.

&WARNING& WHEN THE VEHICLE IS TO BE LEFT UNATTENDED, TURN KEY TO "OFF" POSITION, REMOVE KEY AND ENGAGE PARKING (HILL) BRAKE, PLACE THE DI­ RECTION SELECTOR IN THE FORWARD POSITION.

FIG.A-3 ACCELERATOR AND BRAKE CONTROLS

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GENERAL 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. DO NOT ALLOW VEHICLE TO COAST (TAKE OUT OF GEAR WHILE IN MOTION).

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 2 OCCU­ PANTS MAXIMUM PER SEAT. ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION. BEFORE ATTEMPTING ANY SERVICE OPERATION, READ AND UNDERSTAND SECTION 'B' OF THIS MANUAL.

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STARTING THE GASOLINE VEHICLE

To start the gasoline vehicle, apply the service brake; place the key in the ignition switch and turn to the "ON" position; move direction selector to the direction de­ sired; release parking (hill) brake by depressing the service brake pedal and depress the accelerator pedal to start the engine (use the choke if required).

Do not allow the starter to operate continuously for more than 30 seconds. Allow 10 seconds before attempting a second time. If vehicle doesn't start by the third attempt, you should shut the vehicle off, lock the hill brake and determine the cause of the problem.

When the direction selector lever is in the reverse posi­ tion, a warning signal will sound. This is a device to indi­ cate 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 park­ ing (hill) brake by depressing the TOP of the brake pedal until it locks in place. To rele.ase the parking (hill) brake, depress the BOTTOM portion of the brake pedal.

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TO AVOID COMPONENT DAMAGE, THE VEHICLE MUST BE BROUGHT TO A COMPLETE STOP BE­ FORE SHIFTING THE DIRECTION SELECTOR. If the vehicle has been running and the engine does not start within 5 seconds, use the choke. To change direc­ tion, bring the vehicle to a complete stop before moving the direction selector to the direction desired. Proceed by depressing the accelerator pedal.

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GENERAL FUEL FUEL GAUGE (FIG. A-4) The fuel gauge is a gauge / cap combination. Located under the driver's side seat, it is a direct reading me­ chanical float type. The gauge vent should be inspected and cleaned on a periodic basis.

&_WARNING&_ 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.

ENGINE FUEL Fill the tank with fresh, clean, automotive grade, un­ leaded, 87 octane gasoline. High altitude applications may benefit from higher octane gasoline.

Do not over fill the fuel tank, allow adequate space for the expansion of gasoline.

TOWING

&_WARNING&_ DO NOT START OR RUN THE VEHICLE WITH THE DIRECTION SELECTOR IN THE TOWING POSITION. INADVERTENT MOVEMENT OF THE DIRECTION SELECTOR MAY CAUSE PERSONAL INJURY AS A RESULT OF SUDDEN AND UNEXPECTED VEHICLE MOVEMENT. To tow the vehicle: Move the direction selector to the towing position (a point between the 'F' and 'R' posi­ tions). Push the vehicle by hand to insure that the trans­ mission is not engaged. The vehicle may now be towed.

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IF THE VEHICLE IS TO BE TOWED IN GEAR, THE DRIVE BELT MUST BE REMOVED. MAXIMUM TOWING SPEED IS 12 M.P.H. A MAXIMUM OF FOUR 4-WHEEL VEHICLES (IN­ CLUDING THE TOW VEHICLE) MAY BE TOWED AT A TIME. TOW BARS NOT INTENDED FOR OFF-COURSE USE. (Tow bars to fit 4-wheel vehicles are available from the E-Z-GO Service Parts Department).

REMOVING THE DRIVE BELT (FIG. A-5)

®

With the vehicle on level ground, remove the drive belt by pulling the belt upwards which causes the driven clutch to open and loosen the belt. The belt may be rolled off the driven clutch.

SERVICING THE GASOLINE VEHICLE

&_WARNING&_

USE ff1 OCTANE UNLEADED GASOLINE

FIG. A-4 FUEL TANK LOCATION

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BEFORE ATTEMPTING ANY SERVICE OPERATION, READ AND UNDERSTAND SECTION 'B' OF THIS MANUAL.

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GENERAL Before a new vehicle is put into operation, it is recom­ mended that the items shown in the INITIAL SERVICE CHART be inspected.

SEATS Preparation of Seats for Service -Remove the protective plastic coverings from the seats before placing the vehicle in service. The ONLY func­ tion 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 may get under under the plastic covering and be ground into the cover material. Water getting under the plastic covering can become trapped and eventually will damage the seat assembly.

ROUTINE MAINTENANCE FIG. A-5 REMOVING THE DRIVE BELT

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 VEHICLE BOTH DEPENDABLE AND ECONOMICAL. No formal running in period is required with this vehicle, but it would be prudent to check for any obvious oil or fuel leaks that could have developed in shipment.

Remove any debris from around the engine oil dipstick (located behind the air cleaner enclosure). Remove the dipstick and wipe off with a lint free rag. Insert the dip­ stick into the engine block and seat firmly; remove the dipstick and check the oil level (FIG. A-13). Add oil if re­ quired (FIG. A-7 and FIG. A-10). Install the dipstick and be sure that it is completely seated. Check that the oil fill cap is firmly in place.

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

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This vehicle will give years of satisfactory service, pro­ vided basic maintenance is followed. The engine, trans­ mission and direction selector are highly reliable but are subject to periodic preventative maintenance. Refer to the periodic maintenance schedule for appropriate serv­ ice intervals.

4-CYCLE POWERTRAIN MAINTENANCE ENGINE The engine routine maintenance consists of 3 basic ar­ eas: 1. OIL - level, periodic replacement, filter cleaning.

2. AIR CLEANER - cleaning, periodic replacement.

3. STARTER / GENERATOR BELT - Tension.

Information on maintenance of these areas is detailed elsewhere in this manual.

INITIAL SERViCE CHART Item

Service Operation

Battery

Check charge condition.

Seats

Remove protective plastic covering.

Brakes

Check operation and adjust if necessary

Fuel

Fill tank with correct fuel.

Tires

Check pressure.

Engine

Check oil level

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GENERAL REAR AXLE The only maintenance required is the periodic inspec­ tion of the lubricant level.Replacement of lubricant is re­ quired after five years. (FIG.A-6)

DIRECTION SELECTOR The direction selector is a mechanical device that oper­ ates cables connected to the transmission. The cables are sealed and do not require lubrication, but may re­ quire occasional adjustment. The only other mainte­ nance required is the periodic lubrication of the other moving parts.

CHANGING THE OIL Tools Required:

Qty.

Wrench, box, 14 mm ........................ 1 Wrench, box, 10 mm ........................ 1 Soft Brush ............. . . .. . .. .... ... . . .. . 1 Drain Pan ................................ 1 Shop Rag ................................ 1 For maximum performance and longevity the engine oil should be replaced after 250-300 hours of operation, or yearly, which ever comes first.

For winter storage, the vehicle may be stored with the old oil and changed as part of spring maintenance. This will remove any moisture that has accumulated during storage.To remove all oil from the engine, the filter must be removed.

TO CHANGE THE OIL: Check the oil level and then run the vehicle for several minutes to be sure that the oil is warm.

Park the vehicle on a level surface, lock the parking (hill) brake and remove the key.

Place a drain pan under the engine.

Wipe the top of the engine clean with a rag. (FIG. A-7) Remove the oil fill cap.

Remove the oil drain plug using a 14 mm wrench and allow the oil to drain into the pan.

Remove the 3 bolts securing the oil filter to the engine using a 10 mm wrench; remove the filter by pulling it from the engine, and allow any remaining oil to drain.

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('O' ring may remain with the engine or the filter).

Inspect the filter.At the first oil change small metal chips and lint may be found; this is normal, resulting from the break in period. At subsequent oil changes the filter should be observed, since evidence of large metal chips could indicate potential engine damage.

Clean the filter by washing in any shop degreaser and brush the metal screen clean with a soft brush.

(FIG.A-8)

fn.WARNING fn.

WEAR EYE PROTECTION TO PREVENT SPLASHED SOLVENT FROM CONTACTING THE EYES; WEAR RUBBER GLOVES TO PROTECT SKIN FROM EXPO­ SURE TO THE DEGREASER. Blow out the filter as shown with low pressure air (30 psi or less from no closer than 3") and allow to dry.

(FIG.A-9) Wipe the crankcase around the filter mount with a lint free cloth and inspect the filter 'O' ring for damage; re­ place the 'O' ring if it is damaged.

Install the filter into the engine.The filter engages with a short nipple into the engine.The filter should slide easily into the nipple and seat against the engine using light hand pressure only.Align the holes in the filter mounting plate with the holes in the engine.

Install the filter and snug the bolts, before tightening them firmly.

Clean the oil drain plug and tighten firmly.

Fill the engine with a high quality oil that meets or ex­ ceeds SAE SF, SG, CC standards.

The selection of oil weight is dependent on the service that the vehicle will operate· under. Most fleet golf car operations will require 1OW 30 weight oil, where as Per­ sonnel! Carriers, Range Vehicles, Ball Pickers, Bever­ age Vehicles and heavily loaded GX-804's require 10W40 weight oil.Vehicles that consume an excess of oil may use 10W40 until the piston rings have fully seated.

Inspect the oil fill cap 'O' ring and replace if it is dam­ aged. (FIG. A-10) Install the oil fill cap. As a final check, the oil level should be checked on the oil dipstick. Run the vehicle for 1 or 2 minutes and check the drain plug and filter for oil leaks.

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GENERAL

CHECK PLUG

FIG. A-6 REAR AXLE LUBRICANT ADD, CHECK AND DRAIN PLUGS Pg.A-8

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GENERAL CHECKING THE OIL LEVEL The oil should be checked with the oil warm and the ve­ hicle on a level surface with the parking (hill) brake locked.

When checking the oil, the area around the dipstick should be blown off or cleaned with a parts brush. This is necessary to prevent debris from falling into the dip­ stick hole when the dipstick is removed. (FIG. A-11)

DO NOT OVERFILL ENGINE. TOO MUCH OIL MAY CAUSE SMOKING OR ALLOW OIL TO ENTER THE AIR FILTER ENCLOSURE. Allow adequate time for oil to drain into crankcase be­ fore checking. Add oil to bring into the "safe operating range" (FIG. A-13).

Remove the dipstick and wipe off the entire area indi­ cated with a lint free rag. (FIG. A-12)

AIR CLEANER INSPECTION/ REPLACEMENT

Insert the dipstick FULLY into the dipstick hole and re­ move. Examine the level of the oil left on the dipstick. Oil should be added to bring the level into the safe operating range. Remember that oil expands as it gets hot.

DO NOT ALLOW DUST OR FOREIGN MATERIAL TO DROP INTO THE AIR DUCT.

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.

&WARNING& DO NOT USE GASOLINE OR OTHER VOLATILE SOLVENTS TO CLEAN THE ELEMENT.

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FIG.A-8 CLEANING THE OIL FILTER Pg.A-9

GENERAL

30 PSI MAXIMUM

"O" RING

FIG.A-9 BLOWING OUT OIL FILTER WITH LOW PRESSURE AIR

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USE ONLy SAE SF, SG, cc ENGINE OILS

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FIG.A-10 CHECK OIL FILL PLUG 'O' RING AND ADD ENGINE OIL The air cleaner element is accessible by unsnapping the top clips from the air box (FIG. A-14), and swing­ ing the cover forward and down to remove it. The air cleaner element can be removed and examined using a 60 watt light bulb. If the light can be seen through the bottom pleats, the filter is acceptable. If no light can be seen, the filter must be replaced (Remove the rubber gasket surrounding the element if original does not

Pg.A-10

have one). Do not attempt to wash the filter, which is made with a resin coated paper that is not designed to be cleaned. If the element is in acceptable condition; loose dirt may be removed by tapping the filter lightly.

Install the element in the same way that it was re­ moved; attach the lower portion of the enclosure and swing it up into place. Secure with the top clips.

(FIG. A-15)

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GENERAL

FIG. A-11 CLEAN AROUND OIL DIPSTICK

FIG. A-12 CLEAN ENTIRE DIPSTICK 12/01/91

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Pg. A-11

GENERAL

FILL COLD ENGINE TO THIS POINT-j

I

DO NOT OVERFILL!

0

0

Ly-)

SAFE OPERATING RANGE HOT ENGINE

DISREGARD! (ADD 1/2 PINT AT THIS LEVEL)

FIG. A-13 CHECK OIL LEVEL ON DIPSTICK

RUBBER GASKET (MUST BE REMOVED FROM NEW ELEMENT BEFORE INSTALLING IF ORIGINAL ELEMENT DID NOT HAVE ONE)

FIG.A-14 REMOVING THE AIR FILTER FROM ITS ENCLOSURE

Pg.A-12

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GENERAL Raise the rear of the vehicle (FIG.A-16) and support on jack stands. Disconnect the fuel line from the engine AT THE FUEL TANK. Start the engine and allow to run until the engine stops due to lack of fuel. Remove the air filter and spray a commercial fogging or cylinder oil into the carburetor while operating the starter for 2 - 3 seconds.

Reinstall the air filter and attach the fuel line to the tank.

Add fuel stabilizer to the tank in accordance with the manufacturers recommendations.

PRESS TABS DOWN INTO SLOTS

REAR AXLE Tools Required: FIG. A-15 INSTALLING AIR CLEANER COVER WINTER OR PROLONGED STORAGE Tools Required:

Qty.

Floor Jack ............................ • .... 1 Jack Stands ............................... 2 Chocks ................................... 4 Wrench 13 mm ............................. 1

Qty.

Floor Jack ................................ 1 Jack Stand ............................... 2 Chocks .................................. 4 Preparing the engine for winter or a prolonged storage calls for a few simple steps to prevent a build up of var­ nish and gum in the carburetor and corrosion in the en­ gine.

&WARNING& KEEP HANDS, CLOTHING, JEWELRY AWAY FROM MOVING PARTS. USE CARE NOT TO CONTACT HOT OBJECTS. RAISE THE REAR OF THE VEHICLE AND SUPPORT ON JACK STANDS BEFORE AT­ TEMPTING TO RUN ENGINE.

The rear axle is provided with a lubricant level check plug located on the driver's side at the rear of the hous­ ing. In general the lubricant should only be checked at 250- 300 hour intervals or annually, which ever comes first. Replace lubricant in accordance with Periodic Service Schedule.

CHECKING THE LUBRICANT LEVEL (FIG. A-17) Clean the area around the check and fill plugs. The check plug should be removed using a 13 mm wrench; the correct lubricant level is just below the bottom of the threaded hole. If lubricant is to be added, remove the fill plug and add lubricant using a funnel. A dd lubricant slowly until lubricant starts to seep from the check plug.

Install the check plug and the fill plug. In the event that the lubricant is to be replaced; a drain plug is provided at the bottom of the drivers differential casting.

STARTER/ GENERATOR BELT TENSION Tools Required:

Qty.

Krikit (belt tension indicator) ................... 1 Wrench, 3/4" ............................... 1 Wrench, 9/16" .............................. 1 Ratchet, 3/8" Drive .......................... 1 Socket, 3/4", 3/8" Drive ...................... 1

FIG. A-16 RAISE THE REAR WHEELS 12/01/91

! ! 4!C!G! 9! 1l

The starter / generator belt tension should be checked after the first 15- 20 hours of use and set to 75- 80 lbs.

Pg. A-13

GENERAL

CHECK PLUG

FIG. A-17 REAR AXLE LUBRICANT ADD, CHECK AND DRAIN PLUGS

A loose belt can cause audible vibration and squeal.

Tighten a NEW starter/ generator belt to90 -110 lbs tension when a gauge (Gates 'Krikit' available from NAPA automotive parts store or equivalent) is applied half way between the two pulleys. (FIG. A-18) Although not as accurate; the belt may be depressed with a finger. A maximum deflection of 3/8" inch is ac­ ceptable. (FIG. A-19)

Pg.A-14

Re- tighten an EXISTING belt to 75 - 80 lbs tension us­ ing the same technique. A maximum deflection of1/2" is acceptable. (FIG. A-19)

ADJUSTING THE BELT Using a 3/4" socket and open end wrench, loosen the starter/ generator pivot bolt.

Use a9/16" wrench to loosen the nut on the underside of the adjuster mounting bracket. (FIG. A-20)

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GENERAL

'?KRIKIT"

I STEP #1 FIG. A-18 CHECKING BELT TENSION

MOVE BOTTOM WRENCH

FIG. A-20 LOOSEN THE BOTTOM NUT Use the same wrench to hold the nut on top of the ad­ juster mounting bracket, while rotating the adjuster counter-clockwise with a 9/16" wrench. (FIG. A-21)

3/8" MAXIMUM DEFLECTION (NEW BELT) 1/2" MAXIMUM DEFLECTION (EXISTING BELT)

HOLD BOTTOM WRENCH

FIG. A-19 CHECKING BELT TENSION

I STEP #2 FIG. A-21 ADJUST THE TENSION

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Pg. A-15

GENERAL

HOLD TOP WRENCH

I STEP #3

MOVE BOTTOM WRENCH

FIG.A-22 LOCKING THE ADJUSTER IN PLACE After the correct tension is achieved; re-tighten the nut at the underside of the adjuster mounting bracket.

(FIG. A-22) Using a 3/4" socket and open end wrench, tighten the starter I generator pivot bolt.

COOLING FINS (FIG.A-23, FIG.A-24) Every 50 hours, check for a build up of debris in the air intake and cooling fins. Blow or brush out debris from these areas (FIG. A-23 and FIG. A-24).

FIG.A-23 CLEANING AIR INTAKE Using an appropriate 13/16" spark plug wrench, remove the spark plugs at 250 hours or annually and inspect and regap to .030. The plug should be a white/gray color, and if it has been burned beyond .038, it should be re­ placed. A plug that is black fouled, indicates either a clogged air cleaner or incorrectly adjusted valves. Gap the new plug to .030. (FIG. A-25)

lff!JliiJIJlii

SPARK PLUGS Tools Required:

Qty.

Wrench, Spark Plug, 13/16" 3/8" Drive . . . . . . . . . . 1

USE CARE NOT TO OVER TIGHTEN THE PLUG. OVER TIGHTENING CAN CAUSE DAMAGE TO THE ALUMINUM CYLINDER HEAD THREADS.

Plug Gauge, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Ratchet, 3/8" Drive . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pg.A-16

Tighten to 10 ft lbs. torque.

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GENERAL DAILY CHECK LIST After the vehicle has been put into service, it is recom­ mended that the following items be checked daily. The driver can be a great asset to a proper maintenance pro­ gram if he makes it a point 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 adjust­ ments.

1.

Perform the Daily Braking Performance Test.

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

filWARNINGfil FIG. A-24 CLEANING THE COOLING FINS

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

OWNER/ OPERATOR

PLUG

The recommended way of performing the daily brake test and determining a vehicles braking performance is to 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. If the vehicle stops in a significantly greater distance, or pulls to one side, the vehicle should immediately be re­ moved from service and inspected by a qualified me­ chanic.

. .030 GAP

MECHANIC

FIG. A-25 GAPPING THE SPARK PLUG

GENERAL PREVENTATIVE MAINTNANCE E-Z-GO suggests that preventative maintenance be performed under the following headings: Daily, Weekly, Quarterly, Semiannually and Annually.

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I ! 4!C!GI 9! 11

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.

If the vehicle is to be used commercially we suggest that you also follow lists 2 and 3.

E�GDii:t;.i1t•J:1

Pg. A-17

GENERAL 2.

Inspect the following: • Check the tires for cuts or wear and proper air pressure.

• 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.

• 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.

• Damaged or missing equipment.

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 install the valve dust cap after checking or inflating.

WEEKLY, QUARTERLY, SEMIANNUAL AND AN­ NUAL service requirements are detailed in the 'Periodic Service Schedule.

DO NOT LUBRICATE CABLES OR PARKING (HILL) BRAKE LATCH SINCE OIL WILL CAUSE FOREIGN MATTER TO ADHERE TO THESE SURFACES WHICH WILL ACCELERATE WEAR.

• Mechanical damage.

• Tom seats.

• Check the fuel tank and fill if required.

CARE AND CLEANING OF THE VEHICLE

• Check the engine oil at each filling.

3.

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

Clean the vehicle.

• Wipe seats.

• Clean floormat.

• Remove trash from dash tray.

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

• Wash accumulated dirt from engine compart­ ment and underbody.

If the engine does not start, or runs improperly after washing; remove the spark plug wires from the spark plugs (by pulling on the wire boots, never the wires) and blow them dry. Re-install the wires.

TIRES Tire condition should be inspected on a daily basis. In­ flation 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

Pg. A-18

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 vinyl/rubber cleaner.

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

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

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

Occasional cleaning and waxing with appropriate mate­ rials (non-abrasive products designed for 'clear coat' automotive finishes) will enhance the appearance and durability of the painted surfaces.

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GENERAL 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.

scratches may be removed using a commercial plastic polish.

IR1Jliii'n1i

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

TORQUE SPECIFICATIONS FOR UN­ SPECIFIED HARDWARE

WINDSHIELD (IF EQUIPPED) Clean with lots of water and a clean cloth.

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.

Minor

ALL TORQUE FIGURES ARE IN FOOT POUNDS Unless otherwise noted in the text, tighten all hardware in accordance with this chart.

Bolt size Grade 2 Grade 5

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 6 9

11 18

19 31

30 50

45 75

66 110

93 150

3/4"

7/8"

1"

150 250

202 378

300 583

FIG. A-26 TORQUE SPECIFICATIONS

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Pg. A-19

GENERAL

PACK WHEEL BEARINGS, 2 EACH WHEEL

--

j[)I)

..,____

..,____

OIL DIP STICK ON TOP FRONT OF ENGINE

fjl

STEERING UNIT ENGINE OIL FILL ON TOP OF ENGINE

ti!

jj)O STEERING IDLER ARM- FITTINGS AT TOP & BOTTOM OF ASSEMBLY

ENGINE OIL DRAIN

REAR AXLE FILL ON TOP LEFT SIDE OF DIFFERENTIAL

REAR AXLE DRAIN

REAR AXLE CHECK

FIG. A-27 LUBRICATION POINTS

Pg.A-20

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! 4!C!G! 9! 1!

GENERAL

• Check for smooth operation and correct free travel • Check brake performance and adjust if required • Check brake performance and adjust if required • Check operation when direction selector is in reverse • Examine for cuts and excessive wear

•

Check charge condition and connections to battery Check at each fueling, DO NOT OVERFILL

•

Check for sealing of cap and proper operation of fuel gauge (at each fueling).

Check that fuel cap vent is free of dirt

+

Clean with baking soda solution

• 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 • Check for unusual noise, vibration, acceleration • Check for tension, wear, cracks • Check for abnormal play, tightness of all hardware • Check for excessive play, bent components or loose connections • Check pressure, see specifications • Check all wiring for loose connections and broken/missing insulation • Check coil / spark plug wires for cracks/loose connections • Check for damage to axle and loose or missing hardware • Check for oil leakage and loose fasteners ••• • Check for loose hardware, cracks at attachment points • • Check if tire wear is unusual, align per Service Manual • Check for leaks at tank cap, lines, filters, pump, carburetor. Check lines for cracks/deterioration • Check for bent / binding linkage rod and damage or wear to latch arm or catch bracket. + Lubricate, use light oil. Do not lubricate cables or brake latch.

FIG. A-28 PERIODIC SERVICE SCHEDULE 12/01/91

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Pg. A-21

GENERAL

•

Check filter element see Service Manual Clean body components and wax all painted components

•

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

.a. .a. + +

Replace filter element if req'd Replace, DO NOT OVERFILL SAE 1 0W-30/1 0W40 SF, SG, CCOil Adjust see Service Manual Pack, use Shell Alvania EP-2 multi-purpose grease

• Check for dirt build up Replace as required

.a.

• Check mounting hardware and for leaks at head and muffler pipes

+

Clean in solvent (at oil change) replace 'O' ring if req'd

.a. Gap (replace if req'd) .030 • Check tension, signs of wear/damage Replace only if worn or damaged

.a.

• Check lubricant if oil seepage is evident, add rear axle lubricant as required Replace after 5 years

.a. .

• Check cold at cam (intake/exhaust) + Adjust as Required

D E EDULE (CONTINUED) • check .._ Replacfl�-�-;��,���? IC S RVICE SCH

Pg.A-22

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I 4!C!G! 9! 11

GENERAL SISTEMA

DIARIAMENTE

SEMANALMENTE

1 MES 20 HORAS

3 MESES 50 HORAS

SEMIANUALMENTE 125 HORAS

ANUALMENTE 250-300 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.

DISPOSITIVO 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.

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

ACElTE DEL MOTOR .• ..• .• ..• .. . . • Revisar cuando se abastece de combustible. NO SOBRELLENAR el carter.

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 def 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.

Vsrillaje del carburador • ...• .• .• • • • .• ...• .•.• .• • + Revisar las conexiones, ajustar segun se requiera.

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

MOTOR ...................................., ... • 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.

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

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.

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

• Revlsar

• Camblar

+ Umplai; ajustar, etc.

PROGRAMA DE MANTENIMIENTO PERIODICO DEL VEHICULO CON MOTOR DE 4 TIEMPOS 12/01/91

1 l4ic!Gl9I 11

Pg. A-23

GENERAL SISTEMA

DIARIA- SEMANALMENTE MENTE

1 MES 20 HORAS

3 MESES 50 HORAS

SEMIANUALMENTE 125 HORAS

ANUALMENTE 250-300 HORAS

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

VARILLAJE DEL ACELERADOR/GOBERNADOR •.. ......... .. .. • Revisar el funcionamiento y medir la velocidad gobernada.

FILTRO DE AIRE .......• .. ... .. .. ... .. .. . . ... ....... ...... ............• ....... .. • Revisar el elemento del filtro. Ver el Manual de servicio.

CARROCERIA ............ . ... .. ... .. .. . ... . ..... ... ......... ...... ....... .......

+

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 tornilleria de montaje.

FILTRO DE AIRE ...........................·-· ..•.........•...•....•........•..•..... ; ..... A Cambiar el elemento segun se requiera.

ACEITE DEL MOTOR _ ........................ .. ................................. .. .........._. ... A Cambiar; NO SOBRELLENAR. Aceite SAE10W-30/10W40 API, SF, SG, CC. COJINETES DE LAS RUEDAS DELANTERAS ...•...•....•.. .. ...• ............. ..•...........

+ +

Ajustar; ver el Manual de servicio.

Empacar con grasa universal Shell Alvania EP-2.

FILTRO DE COMBUSTIBLE ...........; . ; .., .. .. ...................... .. ..................... • Buscar acumulaciones de mugre. + Cambiar segun se requiera.

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

FILTRO DE ACEITE ......� ....................................... ....: ....• -�, ...............

+

Limpiar en solvente (durante el cambio de aceite); cambiar el anillo "0" segun se requiera.

BUJIAS DE ENCENDIDO ...............................; .•... ... : ............................. A Ajustar la separaci6n ( 0.030 in.) · (cambiar segun se requiera).

CORREA DE DISTRIBUCION ; •.. , ........•.•. .•....·-· •...., ...____;_. ·•· •... . .. .....•.•-..•..• .• .... • Revisar la tensi6n, buscar seiiales de desgaste/daiios. + Cambiarla solamente si esta desgastada o daiiada.

TRANSEJE .............-· ...............-.....................:_.• n •••••• '.•·•••••••••• ; •••••

Revisar el lubricante Si hay seiiales de fugas. Agregar lubricante segun se requiera.

A Cambiar despues de 5 anos.

•

VAJ.VULAS ............................................•·........ ............................ • Medir el juego de las valvulas de admisi6n y escape (motor trio; en el arbol de levas). + Ajustar segun se requiera.

• Revlsar

A Camblar

• Umplar, aJuatar, etc.

PROGRAMA DE MANTENIMIENTO PERIODICO DEL VEHICULO CON MOTOR DE 4 TIEMPOS (CONTINUACION) Pg.A-24

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l 4lClGl 9l 1l

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.

B

WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE THE EYES TO POTENTIAL INJURY. IN PARTICULAR USE CARE WHEN WORKING AROUND THE BATTERY, WHEN USING SOLVENTS OR COMPRESSED AIR.

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

Indicates a condition that should be observed.

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

fllWARNINGfll 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.

Read and understand the following warnings before at­ tempting to service the vehicle.

fllWARNINGfll 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.

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WEAR EYE PROTECTION DURING THIS OPERATION

fllWARNINGfll ENGINE EXHAUST GAS (CARBON MONOXIDE) IS DEADLY CARBON MONOXIDE IS AN ODORLESS, COLOR­ LESS GAS FORMED AS A NATURAL PART OF THE INCOMPLETE COMBUSTION OF HYDROCARBON FUELS. CARBON MONOXIDE IS A DANGEROUS GAS THAT CAN CAUSE UNCONSCIOUSNESS AND IS POTENTIALLY LETHAL. THE FOLLOWING ARE SYMPTOMS OF CARBON MONOXIDE INHALATION: 1. DIZZINESS 2. VOMITING 3. INTENSE HEADACHE. 4. MUSCULAR TWITCHING 5. WEAKNESS AND SLEEPINESS 6. THROBBING IN TEMPLES IF YOU EXPERIENCE ANY OF THESE SYMPTOMS GET FRESH AIR IMMEDIATELY. NEVER WORK AROUND OR OPERATE A VEHICLE IN AN ENVIRONMENT THAT DOES NOT VENTILATE EXHAUST GASES FROM THE AREA.

Pg. 8-1

SAFETY PROCEDURES STARTING A VEHICLE WITH A DISCHARGED BATTERY

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

&_WARNING&_ DO NOT ATTEMPT TO 'JUMP START' A VEHICLE FROM ANOTHER VEHICLE. THE ENGINE WILL ONLY RUN WITH FORWARD OR REVERSE SE­ LECTED. The vehicle is equipped with a starter/generator. When starting the engine, the starter/generator functions as a starter, however with the engine running it functions as a generator.

With the short running times associated with this kind of vehicle, the generator is more than adequate to main­ tain the battery charge level. The generator is NOT de­ signed to charge a discharged battery.

JUMP STARTING IS NOT RECOMMENDED since the engine stops when the accelerator is released.

If the vehicle battery has become discharged, it must be charged using a 12V automotive type charger that is rated at 10 amps or less.

Observe all instructions provided with the charger.

&_WARNING&_ SET THE (HILL) PARKING BRAKE BEFORE WORK­ ING ON THE VEHICLE. NEVER WORK ON THE ENGINE WHILE IT IS HOT.

NEVER OPERATE THE STARTER WITH THE SPARK PLUGS REMOVED, UNLESS THE IGNITION SYS­ TEM IS DISABLED AND THE ENGINE COLD. FUEL MAYBE DlSCARDED THROUGH THE SPARK PLUG OPENING AND COULD BE IGNITED BY THE IGNI­ TION SYSTEM OR A HOT ENGINE COMPONENT. NEVER TEST THE IGNITION SYSTEM WITHOUT CONNECTING THE SPARK PLUG LEAD TO A TESTER OR SPARE GROUNDED SPARK PLUG. IF YOU WISH TO OBSERVE THE OPERATION OF THE SPARK PLUG, BE SURE TO INSERT A SPARE PLUG INTO THE OPEN CYLINDER BEFORE OPERATING THE STARTER. NEVER TEST THE FUNCTION OF A FUEL PUMP IN THE VICINITY OF A HOT ENGINE OR SOURCE OF FIRE OR COMBUSTION. NEVER CONFUSE THE HOSES TO AND FROM THE FUEL PUMP. VERIFY THAT THE FEED AND PULSE LINES ARE CORRECTLY CONNECTED BEFORE STARTING ENGINE.

BATTERY REMOVAL AND INSTALLATION Tools Required:

Qty.

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.

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

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.

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.

KEEP SMOKING MATERIALS, FLAME AND SPARKS AWAY FROM GASOLINE AND THE BAT­ TERY. ALWAYS REMOVE THE KEY FROM THE SWITCH BEFORE CONNECTING OR DISCONNECTING THE BATTERY OR OTHER ELECTRICAL COMPONENT.

Pg.B-2

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

&_WARNING&_

At the battery terminals, remove the negative(-) cable and then the positive(+) cable.

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. Lift the battery from the ve­ hicle. Installation is in the reverse order of removal.

E�GClii=>;,i1t•J:I

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l4k51$1911I

SAFETY PROCEDURES FUEL TANK REMOVAL AND INSTALLATION Tools Required:

Qty.

Wrench, box, 1/2" .......................... 2 Wrench, box, 7/16" ......................... 1 Pliers •.......•........................... 1

WHEN LIFTING THE VEHICLE; POSITION JACKS AND JACK STANDS ONLY ON THE AREAS INDI­ CATED (FIG.B-1).NEVER LIFT OR SUPPORT THE VEHICLE ON THE ENGINE FRAME COMPONENTS. WHEN LIFTING THE 'U' TUBE BE CAREFUL NOT TO .. POSITION THE JACK SO THAT IT COULD DAMAGE THE BRAKE CABLES OR HANGERS.

Tools Required:

Qty.

Jack, hydraulic, floor type ..................... 1 Jack stands •.........•.................... 4 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.

&_WARNING&_ DO NOT STORE THE FUEL TANK IN AN AREA SUB­ JECTED TO HIGH TEMPERATURES, OPEN FLAME OR SPARKS. Installation is in the reverse order of removal.

Some servicing operations may require that the rear wheels or the entire vehicle be 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 OF AND BEHIND THE WHEELS THAT ARE NOT TO BE RAISED. USE EXTREME CARE SINCE THE VEHICLE IS EXTREMELY UNSTABLE DURING THE LIFTING PROCESS. Install chocks under the front of and behind each front wheel. Place the jack under the passenger's side of the rear axle as close to the differential housing as possible.

Raise the vehicle, and locate a jack stand under the outer end of each rear axle.

Place the jack at the center of the front axle. Raise the vehicle and position jack stands under the outer ends of the front axle.

Lower the jack and test the stability of the vehicle on the 4 jack stands.

&_WARNING&_ ANY SERVICING THAT REQUIRES THAT ADJUST­ MENTS BE MADE TO THE POWERTRAIN WHILE THE ENGINE IS RUNNING, MUST BE MADE WITH BOTH DRIVE WHEELS RAISED.

! !4!C!G!9!1 !

&_WARNING&_

Lower the jack and test the stability of the vehicle on the 2 jack stands.

LIFTING THE VEHICLE (FIG. B-1)

12/01/91

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

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

Lower the vehicle by reversing the lifting sequence.

E�GDii:i;,i;t•l:I

Pg.B-3

SAFETY PROCEDURES

0

0

!

!

LOCATIONS FOR JACKING/JACKSTANDS AS INDICATED SHADED AREAS ARE SUITABLE FOR JACKING/LIFTING FIG. B-1 LIFTING THE VEHICLE

Pg.B-4

12/01/91 I l4t!Gl911I

SAFETY PROCEDURES DAILY BRAKE PERFORMANCE TEST Vehicle maintenance personnel should make it a prac­ tice to look, listen and feel for any unusual conditions while driving the vehicle. This practice can prevent mi­ nor maintenance chores from becoming major repair jobs.

After the vehicle has been put into service, it is recom­ mended that the brakes be tested daily.

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

OWNER/OPERATOR The recommended way of performing the daily brake test and determining a vehicles braking performance is

12/01/91

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to latch the hill brake at a predetermined reference point on a paved surface while traveling at maximum governed speed. Note the stopping distance from the reference point. If the vehicle stops in a significantly greater distance than average, or pulls to one side, it should immediately be removed from service and in­ spected by a qualified mechanic.

MECHANIC 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.

Pg.B-5

SAFETY PROCEDURES

Pg.B-6

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OPERATION AND SERVICE MANUAL SECTION: WHEELS AND TIRES

WHEEL AND TIRE SERVICE Tools Required:

Qty.

C

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

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

TIRE REPAIR

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 nec­ essary, proceed as follows: If tire is flat, remove wheel and inflate tire to approximately 20 psi. Immerse 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, carefully re-

--A--

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 rub­ ber mallet and tire tool. Remove valve core and position bead against narrow flange side. Apply air pressure through stem while pressing around center of tread.

Pressure will build up and snap beads in place. Remove pressure and install valve core. Inflate to recommend pressure (see Specifications Section). ADJUSTto de­ sired pressure.

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

TIGHTEN LUG NUTS TO 50 - 60 FT. LBS. TORQUE DO NOT EXCEED 60 FT. LBS. TORQUE

�

4 TAPERED LUG NUTS

VALVE STEM IS ALWAYS TO OUTSIDE OF WHEEL

FIG. C-1 WHEELS AND TIRES 12/01/91

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E�GDii:i;,i1t•l:I

Pg. C-1

WHEELS AND TIRES

Pg.C-2

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OPERATION AND SERVICE MANUAL SECTION:STEERING

GENERAL

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, 2lb. ........... . ......... 1 Torque wrench, 1/2" drive .................... 1 Ball joint pulling tool ........................ 1 Pliers .................................... 1 Mallet ................................... 1

STEERING ASSEMBLY REMOVAL (FIG. D-2) Remove the front shield to provide access to the steer­ ing arm area. (See section E, Suspension.) Turn the steering wheel full travel to the right to position the rack end ball joint.

Remove the cotter pin (1) from the slotted nut (2) and back the nut off until it protects the ball joint stud threads.

Using a ball joint pulling tool as a lever, apply pressure to the ball joint and tap the nut with a hammer to release the ball stud. Remove the nut and lift the stud from the arm. Remove the three bolts (3) and lock washers (4) securing the steering box to the floorboard and lift the assembly out of the vehicle. (FIG.D-2) Reinstall the steering assembly in the reverse order of disassembly. Tighten the ball joint stud slotted nut (2) to 40 ft.lbs.torque. Insert a new cotter pin. (FIG.D-2)

DISASSEMBLY STEERING WHEEL REMOVAL (FIG. D-1) If the vehicle is equipped with a scorecard clip: Remove the two screws (1) holding the scorecard assembly (2) located on the back of the steering wheel (3). If the vehi­ cle has a cover installed over the center hub it must be gently pried out.

Loosen the 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 the mallet sharply with a hammer. The combina­ tion of upwards pressure and striking the mallet will

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3

FIG. D-1 STEERING WHEEL AND SCORECARD HOLDER

IR:Jiiii'Jl1i

TO PREVENT DAMAGE TO STEERING SHAFT THREADS, DO NOT STRIKE THE STEERING NUT OR THE END OF THE STEERING SHAFT DIRECTLY WITH A HAMMER.

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

Reinstall steering wheel as follows: Lightly coat the splines of the steering shaft with never­ seize. Slide the steering wheel onto the steering shaft splines. Install the steering nut and tighten to 10-15ft. lbs. torque. Reinstall scorecard holder or hub cover in the reverse order of disassembly.

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

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

Pg. D-1

STEERING

FIG.D-2 STEERING Pg.D-2

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STEERING GEAR AND RACK REMOVAL (FIG.D-2) Remove the steering column (7) from the gear box.

I IDJ®TI� I

IDLER ARM REMOVAL (FIG.D-3) Tools Required: ................... Qty. Pliers .................................... 1

When removing the 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 reduction gear (16).

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

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

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 steering gear ball joint (4) at the top of the idler arm using the proce­ dure outlined under 'Steering Assembly Removal'.

Lift the front of the vehicle per procedures in 'Safety Pro­ cedures' (Section B) and remove the cotter pin (5).Us­ ing a pair of pliers or vice grips, rotate the 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 removed.

Clean all parts with solvent and check for wear. Replace worn or damaged parts with new parts. Repack the gear box with a high quality gear grease. E-Z-GO recom­ mends Shell Alvania EP-2 multi purpose grease. Apply grease liberally to gear pins, rack, and gears before reassembly.

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

Pins (20) MUST be lubricated prior to reassembly.

Lift front of vehicle per procedures in 'Safety Proce­ dures' (Section B) and check for vertical movement of tie rod which would indicate a worn condition.

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

IDLER ARM (FIG.D-3) If the idler arm assembly (1) is worn or has excessive play, the idler arm bushings (2) must be replaced.

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TIE ROD INSPECTION

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

E-2-GDii:t;,i,t•l:I

Pg.D-3

STEERING

FIG. D-3 IDLER ARM REMOVAL

Pg.D-4

E'2-GDiiHi1t•l:I

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OPERATION AND SERVICE MANUAL

SECTION:SUSPENSION FRONT SHIELD REMOVAL (FIG. E-1)

FRONT SUSPENSION

(FIG. E-2)

Tools Required: Tools Required:

Qty.

E Qty.

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

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

Wrench, open end, 9/16" ..................... 1

FRONT SUSPENSION REMOVAL

Ratchet, 3/8" drive .......................... 1 Socket, 9/16", 3/8" drive ..................... 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.

Remove the screws {11), flat washers (12), lock wash­ ers (13) and nuts (14). Remove the support (9).

Reassemble using the reverse order of disassembly.

Installation is in the reverse order of removal.

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

Remove the tie rod assembly (7) from the idler arm as­ sembly (1) as follows: Remove the cotter pin (8) from the slotted nut (9) and back it off until it protects the ball

FIG. E-1 FRONT SHIELD 12/01/91

l !4!C!G!9!1 !

Pg. E-1

SUSPENSION

1

FIG.E-2 FRONT SUSPENSION Pg.E-2

I

12/01/91 ! 4!C!G!9! 1 I

SUSPENSION joint threads. Using a pulling tool as a lever, apply pres­ sure to the rod end ball joint and TAPthe nut with a ham­ mer 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). Collapse the shock absorbers. Remove the bolts (14), lock washers (15), nuts (16), and plate (17).Remove the front suspen­ sion assembly from the vehicle.

Replace all broken or worn parts and reinstall in reverse 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" diameter ............... 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 spin­ dle (1 8) or (19). Clean the spindle with a solvent and in­ spect for damage 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 BEARINGS (FIG. E-3) When maintenance is performed on wheel bearings, they must be repacked with grease to assure proper lu­ brication during operation. Pack bearings as follows: Use a grease packing device or use the following man­ ual procedure (see Periodic Service Schedule for grease specification).

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

FIG. E-3 FRONT SPINDLE 12/01/91

! !4!C!G!9!1!

Pg.E-3

SUSPENSION bearing into the grease, pushing the grease up between the rollers of the bearing. This must be done around the complete bearing until all surfaces are coated with grease. Fill the area between the rollers and apply a thin coat to the bearing race. Reinstall the bearings.

BEARING ADJUSTMENT With the front of the vehicle raised (see procedures in Section B) rotate the wheel while tightening the castel­ lated nut. Tighten the nut until the wheel becomes no­ ticeably resistant to being turned and turn the wheel 2 3 full turns to displace excess grease.

DO NOT OVER TIGHTEN THE NUT. Loosen the castle nut to permit a cotter pin to be inserted in the first slot / hole combination. Check for smooth ro­ tation of the wheel without any play, when the wheel is grasped by the outside of the tire.

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

FIG. E-4 INSTALLING GREASE SEAL

Install a new cotter pin and bend the excess against the flats of the nut and clip any excess length.

BE SURE THAT THE SEAL RETAINING SURFACE OF THE HUB IS CLEAN AND FREE OF GREASE. Install the grease seal and the dust cap.

When installing grease seals into hubs, insert the grease seals, flange side inward (FIG. E-4), and tap lightly and evenly around the seal with an installation tool or large socket until the seal is flush with the outer side of the hub assembly. Lubricate the seal surface with oil.

WHEEL ALIGNMENT (FIG. E-5) To check the front end alignment, lift the front of the ve­ hicle (see procedures in Section B) and rotate each 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-5).

Toe-in front dimension is to be 3/16" ± 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

Pg.E-4

X1 X1 �---FRONT--i�

FIG. E-5 WHEELFRONT END ALIGNMENT 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".

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SUSPENSION FRONT WHEEL BEARINGS (FIG. E-6) Tools Required:

Qty.

Wrench, box end, 1 1/2" ..................... 1 Jack, hydraulic, trolley ....................... 1

Worn or damaged parts should be replaced.If the bear­ ings cups(8) are worn or damaged, use a punch to re­ move them and press in new cups. Replace the bearing (5). 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).

Jack stands ............................... 4 Pliers, needle nose ................. . ....... 1 Pliers, channel lock ......................... 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 Loosen the front wheel lug nuts one tum. Lift the front of vehicle( see procedures in Section B) so that wheels are off the floor and install jack stands. Test the vehicle for stability. Remove the wheel lug nuts and remove the wheel.

Remove the dust cap(1), remove the cotter pin(2), re­ move the slotted nut (3), remove the hub (4) and the outer bearing(5) from the spindle( 6). To remove the in­ side 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. Inspect for wear or damage.

BESURE THA T THESEA L RETAIN INGSURFACEOF THE HUB IS CLEAN AND FREE OF GREASE. I nstall seal( FIG.E-4). Lubricate the seal with oil. Re­ assemble using the reverse order of disassembly.

REAR SUSPENSION Tools Required:

(FIG. E-7) Qty.

Socket, 3/4", 1/2" drive ....................... 1 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 negative(-) ground wire from both the battery and engine bolt. The rear suspension consists of two coil springs, two shock absorbers and four rubber bushings in pivot tubes that connect the inner frame to the main frame. To disassemble, proceed as follows:

1

FIG. E-6 FRONT SPINDLE 12/01/91

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Pg.E-5

SUSPENSION

FIG.E-7 REAR SUSPENSION Pg.E-6

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SUSPENSION SHOCK ABSORBER REMOVAL

PIVOT BUSHING REMOVAL

Remove the nuts (6) and washers (7) from the upper shock stud and pull the shock absorbers away from the frame. Reassemble in reverse order of disassembly.

Tighten top shock absorber nuts (6) until they contact the shoulder of the shock stud.

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).

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, WIRING AND CA­ BLES ARE NOT PLACED UNDER TENSION.

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EXTRA CARE MUST BE TAKEN WHEN LOWERING FRAME OR FUEL LINES, WIRING AND CABLES MAY BE DAMAGED. Remove worn bushings and insert new bushings. Lubri­ cate with a rubber lube (soap solution) to assist in as­ sembly. Reinstall the bolts (9) and washers (10), and tighten the nuts (11) to 60 - 80 ft. lbs. torque.

Pg.E-7

SUSPENSION

Pg.E-8

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OPERATION AND SERVICE MANUAL SECTION:SPEED CONTROL

ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE. (FIG. F-1) Tools Required:

GOVERNOR Qty.

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

Pliers, slip joint . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screwdriver, straight blade . . . . . . . . . . . . . . . . . . .

Wrench, open end, 9/16" . . . . . . . . . . . . . . . . . . . .

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

Wrench, open end, 3/8" . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1

The linkages that control the accelerator, governor and carburetor 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 depressed, the adjust­ able accelerator rod (2) is moved towards the rear of the vehicle overcoming the resistance of a compression spring (3). The rear of the accelerator rod is attached to a bellcrank (4) by means of a ball joint (5). The accelera­ tor rod moves the bellcrank and energizes the control circuit of the electrical system by closing the limit switch (6) and pulling 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).

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 extension spring, the carburetor and its torsion spring and friction from all bearings and ball joints. As the accelerator ca­ ble compression spring overcomes the combined resis­ tance of the components the governor bellcrank moves the carburetor lever, opening the carburetor.

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F

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 turn starts to close the carburetor.

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. 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.

Pg. F-1

SPEED CONTROL

&_WARNING&_ TO PREVENT INADVERTENT MOVEMENT OF THE VEHICLE AND THE POSSIBLE PERSONAL INJURY THAT MAY RESULT, THE NEGATIVE(-) BATTERY WIRE MUST BE REMOVED FROM THE BATTERY. REFER TO SECTION B OF THIS MANUAL FOR AD­ DITIONAL CAUTIONS AND WARNINGS.

ACCELERATOR PEDAL HEIGHT (FIG. F-2) Measure the pedal height (distance of the accelerator pedal to the floor). A dimension of 5 3/4 to 6 inches is acceptable. Lubricate 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) With the accelerator pedal in the released (upright) posi­ tion, check that the accelerator bellcrank (8) is contact­ ing the cross member. Loosen the flanged lock nut (9) and turn the large headed screw (10) in against the bellcrank. Turn the screw out until it contacts the limit switch actuator and continue turning until a CLICK is heard. Rotate the screw ONE additional full turn. Hold the adjusting screw and tighten the flanged lock nut firmly. As a guide, the top of the accelerator pedal

Pg.F-2

should move no more than 1/2" before the limit switch clicks.

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

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 keep the cable clean.

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 lever moves. If the switch is activated AFTER the lever starts to move an adjustment is re­ quired and is made at the accelerator switch end of the cable. Slide the boot off the threaded section of the ac­ celerator 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 lever while keeping the slack in the cable to an absolute minimum to reduce excessive motion at the ac­ celerator pedal before the engine starts. Replace the boot.

ACCELERATOR SPRING PIVOT Inspect 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 lever.

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SPEED CONTROL

8

FIG. F-1 ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE 12/01/91

! !4!C!G!9!1l

Pg.F-3

SPEED CONTROL

4

1

FIG. F-2 ACCELERATOR LINKAGE REMOVAL AND ADJUSTMENT

Pg.F-4

E�GDiiHi1!•J:I

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SPEED CONTROL GOVERNOR LEVER (FIG.F-3), (FIG.F-4), (FIG. F-5)

WHEN REMOVING/INSTALLING THE LINKAGES TO THE GOVERNOR LEVER, USE EXTREME CARE NOT TO DAMAGE OR BEND THE LEVER. SUPPORT THE GOVERNOR LEVER AND SQUEEZE THE BALL JOINT COMPONENTS TOGETHER (FIG. F-4). FAIL­ URE TO OBSERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE GOVERNOR AND RE­ SULT IN THE NEED FOR A COMPLETE REAR AXLE REMOVAL AND DISASSEMBLY. Service tip: To remove the female plastic portion of the ball joint linkage, place 3/8" open end wrench on jam nut and rotate clockwise until black female plastic portion separates from ball. (FIG. F-3)

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

Move the bellcrank and check for smooth operation against the spring. (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.

FIG. F-3 BALL JOINT REMOVAL

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At the carburetor, remove the solid linkage (2) at the car­ buretor end. Move the throttle lever (3) and check for smooth action and that carburetor torsion spring closes the carburetor.

Pg.F-5

SPEED CONTROL NOTE: TAMPERING WITH, OR REMOVAL OF GOVERNOR SEAL BY OTHER THAN AUTHORIZED E-Z GO SERVICE OR BRANCH PERSONNEL WILL VOID WARRANTY. 9 11

:\ -:,IA"

12

\

PRE-ADJUST GAP TO 1 3/4" WITH THE ACCELERATOR RELEASED AND ALL OTHER ADJUSTMENTS MADE BEFORE RUNNING ROAD TEST.

FIG. F-5 CARBURETOR AND GOVERNOR LINKAGE ADJUSTMENTS

Pg.F-6

E�GDii:S:!i1t•J:I

1/01/89 ! 4!C!G! 9! 1 (

SPEED CONTROL adjustment to the rod, loosen the jam nuts and ro­ tate the rod until an alignment is achieved. Tighten jam nuts.

FIG. F-6 BALL JOINT ADJUSTMENT LINKAGE ROD ADJUSTMENTS (FIG. F-5 AND 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.

Clean all ball joints. Hold the governor lever closed to be sure that the governor lever return spring is fully closing the governor. Adjust the horizontal linkage rod(1) between the governor lever and the engine mounted bellcrank by loosening the jam nut (8) and rotating the socket to either lengthen or shorten the rod. The correct length is achieved when the governor is held in the closed position and the arm of the bellcrank is parallel to the rear engine shroud.

2. . · Remove the vertical linkage rod from the carbure­ tor and check that the throttle stop screw is cor­ rectly adjusted.

3.

While holding the governor closed check to see that the carburetor ball joint socket aligns with the carburetor ball. If an exact alignment requires an

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! !4!C!G!9!1!

4.

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.

5.

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

TAMPERING WITH OR ADJUSTING OF GOVERNOR TO PERMIT VEHICLE TO OPERATE AT ABOVE FAC­ TORY SETTING (12 to 15 MPH) WILL VOID WAR­ RANTY. IN CASES WHERE THE GOVERNOR REQUIRES SERVICE, VEHICLES EQUIPPED WITH A GOVER­ NOR SEAL (12) MUST BE SERVICED AND RESEALED BY AN AUTHORIZED E-Z-GO SERVICE BRANCH OR DISTRIBUTOR.

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 Irs HOUSING WHICH WILL RESULT IN THE PREMATURE FAIL­ URE OF THE CABLE.(FIG. F-5) 1.

Remove the jam nut (9).

2.

Pre-adjust the governor compression spring (11) by rotating the adjuster (10) until a dimension of 1 3/4" is achieved between inside dimensions of cup washers (13). Note: This is a pre-adjust­ ment gap made before running the road test.

3.

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 17 to 14 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. Seal governor.

Pg.F-7

SPEED CONTROL

Pg.F-8

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OPERATION AND SERVICE MANUAL SECTION:BRAKES

To assure proper braking performance, all periodic maintenance inspections and procedures should be performed as indicated in the Periodic Service Schedule (Section A). It is most important that a daily perform­ ance test be conducted and that the brake system be serviced at 6 monthly intervals.

The overall brake system consists of: (a) Self-adjusting wheel brake units which nor­ mally do not require adjustment until internal components have worn to a point of needing replacement. (b) Actuating linkages requiring periodic adjust­ ment to compensate for normal wear of sys­ tem components and/or their replacement.

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 sys­ tem, the following test should be performed daily:

fn.WARNING/n.

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 if any vehicles have unacceptable 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

! !4!C!G!9!1!

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.

6 MONTH BRAKE MAINTENANCE

GENERAL

12/01/91

G

Raise the entire vehicle as specified in Safety Proce­ dures Section B of the Operation and Service manual.

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

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

Determine that the free pedal travel is within specifica­ tions.

Again rotate each wheel by hand and feel for a dragging 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 re­ placed.

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 re­ placed. Operate the brake pedal and observe the move­ ment 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, ex­ cess 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 move­ ment or failure of the brake cables to return fully indi­ cates a dragging brake cable which MUST be replaced.

Remove each brake drum and shoes according to pro­ cedures indicated in BRAKE DRUM, SHOE AND BRAKE ASSEMBLY REMOVAL section. Clean and inspect all brake parts. If there is evidence of rust or if the adjuster does not move smoothly.in the backing plate, the surfaces must be cleaned and smoothed us­ ing an emery cloth. The backing plate MUST be re­ placed if excessive wear such as gouges or galling are in evidence on the backing plate.

E�GDii=ni1t•l:I

Pg. G-1

BRAKES INSPECTION OF BRAKE SHOES

The brakes are the "servo acting" type.

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 A and C will always be to the rear of the vehicle.

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

After lubricating the backing plate and adjuster mecha­ nism at the lubrication points shown in illustration (FIG. G-8), re-assemble and adjust the complete brake system according to the procedures outlined in the sec­ tion 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 com­ ponent replacement.

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.

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 vehi­ cle is moving forward the rear brake shoe moves up­ wards 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)

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

DRUM ROTATION

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

B B

DRUM ROTATION

I I

I I

PASSENGER SIDE BRAKE

-1-

DRIVER'S SIDE BRAKE

--1A

A

D D FORWARD -----�•

FORWARD

FIG. G-1 BRAKE WEAR

Pg. G-2

E�GD•i=ni1t•l:1

12/01/91 !4!C!G!9!1 !

BRAKES

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 ad­ juster 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 ro­ tate the star wheel since lever movement is limited to ap-

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! !4!C!G!9!1!

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

As the brake shoe wears, the lever's motion increases 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

ILLUSTRATIONS SHOWS PASSENGER SIDE ONLY. DRIVER'S SIDE IS MIRROR IMAGE

..-- BRAKE ACTUATOR LEVER ADJUSTER HOUSING (2) STAR WHEEL REAR

(3) ADJUSTER SCREW FRONT SHOE

1U

FRONT BRAKE SHOE IS PULLED FORWARD

BY SLIDE ACTION OF ADJUSTER HOUSING

(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 DISENGAGED.

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 ENGAGED.

AS SHOE WEAR INCREASES, ADJUSTER LEVER TRAVEL INCREASES, THUS TURNING THE STAR WHEEL. (C)

POSITION OF ADJUSTER LEVER WITH BRAKES ENGAGED AND SHOE 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. (D)

POSITION OF ADJUSTER LEVER WITH BRAKES DIS­ ENGAGED 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-SET­ TING THE PROPER SHOE/DRUM CLEARANCE. (E)

POSITION OF ADJUSTER LEVER WITH BRAKES EN­ GAGED DURING READJUST­ MENT OF SCREW.

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

POSITION OF ADJUSTER LEVER WITH BRAKES DISEN­ GAGED AND READJUSTMENT COMPLETED.

NOTE POSITION OF TEETH

FIG. G-3 HOW THE BRAKE ADJUSTER WORKS

Pg. G-4

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!4!C!G!9!1!

BRAKES 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 re­ move 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 posi­ tion of the two springs (5). Remove the "push on" re­ tainer nut (6) (new nut required for assembly), and re­ move the hinge pin (7). Reassemble in the reverse or­ der 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 remove the pivot arm shaft (4).The cam (6) and nylon spacer (9) will come out when the pivot arm shaft is removed.

If the spacer (9) or bearings (1O and 11) are worn, re­ place them with new spacers or bearings.

Reassemble in the reverse order of disassembly.

FIG.G-4 BRAKE PEDAL SPRING REMOVAL

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

E�GCJii=t:,i,!•J:I

Pg. G-5

BRAKES

----A----

FIG. G-5 BRAKE "KICK OFP' LINKAGE BRAKEDRUM,SHOEANDBRAKE ASSEMBLV REMOVAL (FIG. G-6, AND 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 Puller (E-Z-Go P/N 19779-G1) ............... 1

Pg. G-6

DRUM REMOVAL (FIG. G-7) Loosen lug nuts on rear wheels 1/8 to 1/4 turn. Raise the vehicle (see procedure in Section B). Remove the rear wheel(s).

Remove the cotter pin (5) and clevis pin (6) from the brake lever. Remove the co�er pin (8) from the axle nut (9) and remove the nut and washer (10). TAPthe brake drum (11) with a plastic faced hammer 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 hole is located 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 mechanism when in this position. Insert a flat blade screwdriver be­ tween the adjuster lever and the adjuster screw hous­ ing. Insert a second flat blade screwdriver 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.

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BRAKES TRAILING BRAKE SHOE

PASSENGER SIDE

DRIVER'S SIDE

2

2 1

LIGHT SPRING

FIG. G-6 WHEEL BRAKES DRIVER'S AND PASSENGER SIDE

::,:,:::�71.::

FRONT Of

ALWAYS FACES FRONT

SELF-ADJUSTING BRAKES (DRIVER'S SIDE)

FRONT OF

ALWAYS FACES REAR

REAR� OF VEHICLE

4 LIGHT

FIG. G-7 WHEEL BRAKE COMPONENTS 12/01/91

! i4iClGi9i1!

E�GClii:i:, i,t•l:I

Pg. G-7

BRAKES BRAKE SHOE REMOVAL Using a pair of pliers, compress the brake shoe retainer springs (1) at the open end of the spring.

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

Grasp the brake shoes (3) in the center and tilt them out­ wards 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-8) WITH COMMER­ CIALLY AVAILABLE BRAKE COMPONENT LUBRICANT (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 backing plate and ad­ juster mechanism using a brush or air hose.

BACKING PLATE

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 removed.

When reinstalling the brake mounting bolts, tighten to 23-35 ft. lbs. torque.

REPLACING BRAKE SHOES (FIG. G-6 AND FIG. G-7)

I IDJOO'IT� I

The metal portion of the brake shoes differs between front and rear shoes. The identical ends of the shoes fit against the fixed anchor. The shoe with the straight end engages in the slot in the adjusting screw, while the tri­ angular ended shoe engages in the rear of the adjusting mechanism.

The springs must be inserted with the light spring clos­ est to the adjuster. The long hook is installed down through the rear brake shoe. The heavier top spring is installed with the spring hooks facing up.

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

Clean the axle shaft to remove grease, dirt and all for­ eign matter. Apply a small amount of lubricant (Never­ seize) to the spline.

- LUBRICATE SHADED AREA

LUBRICATE THESE POINTS

LUBRICATE BOTH FRONT AND BACK SURFACES AROUND THIS SLOT

FIG. G-8 BRAKE LUBRICATION AREAS

Pg. G-8

12/01/91 ! 4!C!G! 9! 1 !

BRAKES Insert a straight blade screwdriver between the adjust­ ing lever and the adjusting mechanism. Rotate the star wheel counter clockwise until the shoes have retracted sufficiently to permit the brake drum to be installed. In­ stall thin 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 align­ ment is achieved.

ADJUSTMENT OF THE WHEEL BRAKE 4.

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

5.

Reinstall wheel.

6.

Reconnect compensating linkage (2).

I 001001r� I

Minimum torque is 70 ft.lbs. Torque readings to 140 ft. lbs.are acceptable.

Always use a new cotter pin (3).

Install new cotter pin (8).

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

ADJUSTING COMPENSATING SPRING 7.

COMPENSATING BRAKE LINKAGE AD­ JUSTMENT (FIG. G-9) Tools Required:

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

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

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

Wrench, open end, 1/2" ...................... 1 Pliers .................................... 1 Hammer, ball pein .......................... 1 Raise the vehicle (see procedure in Section B) 1.

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.

2.

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

3.

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

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! !4!C!G!9!1 i

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 RELEASE. Repeat twenty (20) times.

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

Pg. G-9

BRAKES 10.

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

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

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

service. If the brake performance is unacceptable the 6 month maintenance MUST be performed again in its en­ tirity.

PARKING (HILL) BRAKE ADJUSTMENT (FIG. G-10) The parking (hill) brake engagement and holding force should be properly adjusted if the brakes have been ad­ justed per the "recommended brake adjusting proce­ dure."

PARKING (HILL) BRAKE FUNCTION 1.

12. Tighten jam nut (8).

To check for proper parking (hill) brake function, 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.

fl::::.WARNINGfl::::.

13. Lower vehicle.

14. Perform the "DAILY BRAKING PERFORMANCE TEST" described at the beginning of this section and return to service if the brake performance is ac­ ceptable. If performance is unacceptable, the brake shoes must be burnished to conform to the brake drum.

TO TEST FOR THE AUDIBLE "CLICK" OF THE MI­ CRO SWITCH, THE VEHICLE MUST HAVE THE REAR WHEELS RAISED TO PREVENT THE POSSI­ BILITY OF INJURY IF VEHICLE IS ACTIVATED. 2.

Remove the seat, place the direction selector in the "forward" position, turn the ignition switch to the "on" position, and fully engage 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 assembly ac­ tivates the solenoid). If the solenoid is activated (clicked) AFTER the parking (hill) brake is re­ leased, the parking (hill) brake is functioning prop­ erly.

4.

If the accelerator switch solenoid is activated prior to complete parking (hill) brake disengagement, the cause may be one or a combination of the fol­ lowing:

BURNISHING NEW BRAKE SHOES

fl::::.WARNINGfl::::.

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 vehicle has stopped, the vehicle is operated in the reverse direction at maximum governed speed and the parking (hill) brake latched. This braking operation in both directions is considered as one burnishing cycle. Burnish the brakes for 15 cycles. If the brake performance is accept­ able after burnishing, the vehicle may be returned to

Pg. G-10

a)

E�GDii:i:1i1!•J:I

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

12/01/91 ! 4!C!G! 9! 1 !

BRAKES

----- DETAIL A----­ ADJUST PASSENGER I SIDE BRAKE LEVER

•

ADJUST DRIVER'S SIDE BRAKE LEVER

FRONT

NOTTO EXCEED 1/8'

VIEW FROM BELOW

EQUALIZER (1)

(3) _/

t ''

.,,��,.:c..,....,,1,,..,._,,,...

A

r

WITH PARKING (HILL) BRAKE DISENGAGED

=i

3 15/32"

��

DETAILC

ADJUSTING NUT ����PRING (7)

3/32 "WITH PARKING (HILL) BRAKE ENGAGED

i-

YOKE (9)

i=rr====���5)

ACCELERATOR ROD ADJUSTING NUT (10)

DETAIL D NOTE: SPACER HARDWARE MAY VARY

FIG. G-9 BRAKE LINKAGE ADJUSTMENT 12/01/91

I l4lclGl911 I

E�GDiiHi1t•l:I

Pg. G-11

BRAKES 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 vehicle (see procedures in Section B). If the vehicle 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)

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

3. Using a 7/16" wrench, remove the 1/4" x 3/4" long bolts (3), lock washers (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 NOTbe any gap between the top of the cam and the latch arm (FIG. G-10).

e)

If the cam requires adjustment, proceed as follows:

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

If the catch bracket needs replacing, 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 re­ move 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.

2

.03 MAX GAP AFTER ADJUSTMENT OF CAM

5

CAM MUST BE AGAINST LATCH ARM AT THIS POINT 0.0" GAP

7

1/4" MAX GAP AT THIS POINT

FIG. G-10 CATCH BRACKET ADJUSTMENT Pg. G-12

12/01/91 ! 4!C!G! 9! 1 !

BRAKES

©

@

WITH PARKING (HILL) BRAKE ENGAGED, LOOSEN SETSCREWS.

ROTATE CAM COUNTER CLOCKWISE UNTIL TOP OF CAM CONTACTS LATCH ARM.

®

ROTATESHAFT CLOCKWISE TO REMOVE LINKAGE FREE-PLAY. HOLD WITH HAND WHILE PROCESSING.

@

RE-TIGHTEN SETSCREW.

FIG. G-11 PIVOT ARM ASSEMBLY

12/01/91

l l4lClGl9l1'

Pg. G-13

BRAKES

Pg. G-14

12/01/91 ! 4!C!G! 9'1 !

OPERATION AND SERVICE MANUAL SECTION:ENGINE AND CONTROLS

Engine Model ......................... EH 29 Type ................... 4-cycle, overhead cam Number of cylinders ........... 2 cylinder in-line Spark plug type ................... NGK BP 5ES Spark plug gap .............. . . .......... .030 Engine displacement ... ................. 295 cc Rated Horsepower ........................ 8.5 Cooling ................................ Fan Oil filter ..................Washable, Permanent Oil pump ............................ Gerotor

ENGINE DESCRIPTION (FIG. H-1) The engine is a 4-cycle air cooled, in-line, twin cylinder, overhead cam. It incorporates pressure lubrication, a washable permanent oil filter and a counter rotating bal­ ance shaft.

The engine has electronic ignition that fires both spark plugs together, which enables the engine to operate without the complexity of a distributor. The power strokes of the pistons are 'staggered' to provide smooth uninterrupted power that is not possible with a single cyl­ inder 4-cycle powerplant.

ENGINE OPERATION (FIG. H-2) The engine is an air cooled 4-cycle type. A 4-cycle en­ gine has a power stroke for each piston once in every 4 cycles or 2 revolutions of the crankshaft. The E-Z-Go twin has two pistons therefore the engine has a firing stroke for every rotation of the crankshaft.If we consider 1 cylinder alone and refer to (FIG.H-2) the engine op­ eration is as follows: The first cycle takes place with the piston moving down and the intake valve open. Fuel is drawn in to the com­ bustion chamber from the carburetor through the intake valve. As the piston reaches the bottom (bottom dead center) of its stroke and starts to move upwards the sec­ ond cycle or compression cycle begins. The intake

12/01/91

i !4!C!G!9!1!

H

valve closes which seals the combustion chamber and causes the fuel air mixture to be compressed as the pis­ ton rises. As the piston passes through the top of its travel (top dead center) the spark plug is fired which causes a rapid burning of the air fuel mixture. The tem­ perature rises rapidly which causes the fuel air mixture to expand and force the piston down into its third, or 'power' cycle. As the piston starts to rise, the exhaust valve opens and the burned fuel air mixture is forced out of the combustion chamber which completes the fourth cycle. As the piston starts it's downwards travel the first cycle is started and the process is repeated.

In a single cylinder 4-cycle engine, there is only one pis­ ton with one power stroke for each two revolutions of the crankshaft.This results in vibration which must be com­ pensated for with a counter balancer. In contrast, the E-Z-GO engine has a second piston with it's power stroke timed to coincide with the first cylinder's exhaust cycle. This greatly reduces vibration and provides smooth power. The use of a gear driven, counter rotat­ ing balancer further reduces vibration to a level that is unattainable in a single cylinder engine.

Although both spark plugs are fired simultaneously, only one cylinder will have both valves closed and con­ tain the fuel air mix required for the power cycle. This system eliminates the need for a distributor and the as­ sociated gears required to operate it.

The preceding description of the 4 cycles is only theo­ retical, since in practice the spark plug fires just before the piston reaches top dead center and momentum of the flywheel takes the piston over top dead center as the fuel expands to maximize the available power. Similarly the valves do not open and close exactly at top and bot­ tom dead center, but are timed by the individual lobes of the camshaft to provide the most efficient intake and ex­ haust cycles.

The timing of the camshaft to crankshaft is determined by a cog belt which is quieter than a chain or gear drive.

The balancer is gear driven directly by the crankshaft.

Spark plug timing is electronically controlled by the ig­ nitor, and operates from an electronic signal received from a pick up that is triggered from a timing actuator on the crankshaft hub.

Pg. H-1

ENGINE AND CONTROLS

SCREW TYPE ADJUSTER CAM LOBE DOWN

CAM LOBE UP

VALVE OPEN

VALVE CLOSED VALVE OPERATION VALVE COVER CAMSHAFT OILING

TIMING BELT PULLEY

CAMSHAFT

CAM LOBE

TIMING BELT

NOTE: THIS IS A SIMPLIFIED DIAGRAM FOR EXPLANATORY USE ONLY. ROCKERS, GUIDES, SEALS, ETC. HAVE BEEN OMMITTED. FIG. H-1 OVERHEAD CAMNALVE SYSTEM

Pg. H-2

E�GDiiHi1!•W

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i !4!C!G!9!1!

ENGINE AND CONTROLS

EXHAUST

INTAKE

FIRST REVOLUTION

POWER

COMPRESSION

EXHAUST SECOND REVOLUTION

NOTE: THIS IS A SIMPLIFIED DIAGRAM FOR EXPLANATORY USE ONLY. ROCKERS, GUIDES, SEALS, ETC. HAVE BEEN OMMITTED. FIG. _H-2 4-CYCLE OPERATION 12/01/91

i !4!C!G!9!1!

E�GDii:t;,i1!•l:I

Pg. H-3

ENGINE AND CONTROLS COUNTER BALANCE SYSTEM In any engine, vibration is caused by the reciprocal mo­ tion of the pistons. To minimize this vibration, the crank­ shaft has counterbalance weights to compensate for the mass of the pistons and connecting rods. The E-Z-GO engine is designed with a counter rotating, gear driven balancer which rotates in synchronization with each power stroke. This design, when combined with the twin cylinder engine layout, reduces vibration to a lower level than is possible in most single cylinder powerplants.

VALVE ADJUSTMENT (FIG. H-3)

Tools Required:

Qty.

Flat feeler gauge, .003 . . . . . . . . . . . . . . . . . . . . . . 1 Screwdriver, straight blade . . . . . . . . . . . . . . . . . . . 1 Wrench, box, 10 mm . . . . . . . . . . . . . . . . . . . . . . . . 1 The valves should be checked yearly (250 hours) to in­ sure that they are in adjustment. A valve that is set too tight can cause excessive wear to the cam and rocker and cause burned valves. The same is true for a valve that is set too loose. The valve that is too loose will make

SCREW TYPE ADJUSTER

itself known by a clacking or tapping noise. However, the noise can often be masked by other noises and go undetected.Poor performance and fouled spark plugs can result from improper valve adjustment In an overhead cam engine, the valve clearances are easily adjustable from the top of the engine and done with the engine cold. As a precaution against inadver­ tent starting, the negative (-) battery cable should be re­ moved. As a yearly (250 hour) inspection, the valve clearance check consists of removing the valve cover and sliding a .003 flat feeler gauge between the valve rocker and the cam while at the lowest portion (heel) of the cam. If the gauge slides in and out with some light drag felt the valve does not need adjustment. If the gauge is hard to insert or withdraw the valve is too tight, similarly if the gauge slides out with no resistance it is too loose. To correct either of the unacceptable condi­ tions, loosen the jam nut of the adjuster and loosen or tighten the adjuster with a screwdriver (that fits the slot in the adjuster snugly) and a 10mm wrench while sliding the feeler gauge between the rocker and the cam.

When the gauge requires a light pull to withdraw it, the jam nut must be tightened while holding the adjusting screw still. Confirm the adjustment with the gauge and

ADJUST WITH SCREWDRIVER RELEASE YTURN­ ING WRENCH CAM LOBE DOWN

HOLD SCREWDRIVER LOCK BY TURNING WRENCH

VALVE OPEN

VALVE CLOSED

.003 VALVE CLEARANCE MEASURED HERE WITH THE ENGINE COLD

FIG. H-3 OVERHEAD VALVE ADJUSTMENT

Pg.H-4

E�GDii,.:,i,!•l:I

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!4!C!G!9!1!

ENGINE AND CONTROLS readjust if required. Manually rotate the engine until the cam rotates to a lobe down condition for the next valve and check/adjust the clearance. Repeat this procedure until all of the valves are in correct adjustment.

VALVE COVER INSTALLATION (FIG. H-4)

Tools Required:

in the sequence shown in FIG. H-4 to 60 - 65 in lbs. torque.

TIMING BELT (FIG. H-5) Timing Belt Adjustment

Qty.

Tools Required:

Qty.

Torque wrench, 3/8" drive, (inch lbs.) .......... . 1

Socket, 12 mm, 3/8" drive .................... 1

Socket, 1O mm, 3/8" drive ... . .. . ... .... . . .. . . 1

Ratchet, 3/8" drive .......................... 1

It is important to use proper tightening procedures when replacing the valve cover, since distortion of the valve cover may result in oil leakage.

Screwdriver, straight blade ... .. ... ............ 1

Examine the 'O' ring gasket for tears or damage and re­ place if any damage is found. Wipe the valve cover and gasket clean, paying special attention to the inner groove surface. Wipe off the cylinder head sealing sur­ face. Place the gasket in the groove in the valve cover and apply a light coat of oil to the gasket. Install the valve cover and bolts finger tight. Stage tighten the bolts

Extension, 3", 3/8" drive ...................... 1 Remove the negative(- ) battery wire in to prevent in­ advertent engine starting.

At yearly intervals, the belt tension should be adjusted.

To do this, remove the rubber plug in the timing cover to provide access to the idler pulley adjusting bolt. Use a 12mm hex socket to loosen the tensioning bolt between 1/4 and 1/2 turn.

FIG. H-4 VALVE COVER TIGHTENING SEQUENCE 12/01/91

l !4!C!G!9!1!

E�GDii:j:,i1!•l:I

Pg.H-5

ENGINE AND CONTROLS

1/8 -1/4" DEFLECTION AT 10 LBS 'PUSH'

IDLER CLAMP BOLT TIGHTEN TO 10-13 FT LBS TORQUE

ALIGN KEY WAY WITH MARK IDLER

REMOVE COVER TO ALIGN KEY WAY REPLACE AFTER ALIGN­ ING

FIG. H-5 TIMING BELT INSTALLATION

Pg.H-6

12/01/91

! l4!C!Gl9l1!

ENGINE AND CONTROLS Rotate the engine by hand at least one full turn which will allow the spring to tension the belt. Tighten the idler adjusting nut to10-13 ft lbs torque. Spray the rubber plug with 'Armorall' or an equivalent in order to ease the installation of the plug. Insert the plug in the timing belt cover.

Qty.

Socket, 1O mm, 3/8" drive .................... 1 Ratchet, 3/8" drive .......................... 1 Extension, 3", 3/8" drive ..................... 1 The timing belt is designed to last for the life of the en­ gine without needing replacement, but given the impor­ tance of its function, we suggest that it be inspected for unusual wear at 2 year intervals.

To inspect the belt's condition, the timing belt cover must be removed. Remove the negative (-) battery wire to prevent inadvertent engine starting. Remove the Drive Clutch and the Governor Rod. Remove the timing belt cover and rotate the engine by hand while ex­ amining the belt for signs of wear or abrasion. When satisfied with the overall condition of the belt, the belt tension must be tested. To do this, apply 10 pounds of force to the belt midway between the pulleys. A deflec­ tion of 1/8 -1/4" indicates that the belt tension is satisfac­ tory. If there is too much deflection the belt must be tightened by adjusting the idler pulley as previously de­ scribed.

Timing Belt Replacement (FIG. H-5)

Tools Required:

Socket, impact, 1 1/8", 1/2" drive ............... 1 Extension, 1/2", 10" minimum length ............ 1 Clutch puller (E-Z-GO P/N 19779-G2) .......... 1

8WARNING8

Timing Belt Inspection (FIG. H-5)

Tools Required:

Impact swivel .............................. 1 Socket, impact, 5/8", 1/2" drive ................ 1

Qty.

IMPACT SWIVEL MUST BE USED, DO NOT USE STANDARD UNIVERSAL JOINT WITH AN IMPACT WRENCH. USE ONLY IMPACT SOCKETS WITH AN IMPACT WRENCH

Drive Clutch Removal Raise the rear of the vehicle (see procedures in Section B) and support the vehicle under each side of the rear bumper, to permit the powertrain to fully extend the rear shocks.

Loosen the starter generator and remove the starter and drive belts.

Remove the clutch bolt.

Install a well lubricated clutch puller into the clutch and hand tighten for several turns. Remove the clutch by driving it off with the impact wrench and the clutch puller.

In some extreme cases, the clutch will be resistant to re­ moval. In stubborn cases the clutch removal tool should be removed and the cavity filled with grease. Install the clutch puller and use the impact wrench to drive off the clutch. The combination of hydraulic pressure and the impact wrench will remove the most stubborn clutch. To prevent damage to the clutch, be sure to remove all grease from the body of the clutch. Grease penetrating the seal may cause premature clutch failure.

Socket, 10 mm, 3/8" drive .... ................ 1

Remove the timing belt cover.

Socket, 12 mm, 3/8" drive .................... 1

If the belt shows signs of wear, it must be replaced.

Loosen the idler pulley bolt and pull the pulley back in order to remove the belt.

Socket, 3/4", 3/8" drive ...................... 1 Ratchet, 3/8" drive .......................... 1 Extension, 3", 3/8" drive ..................... 1 Wrench, 9/16" ............................. 2 Wrench, 3/4" .............................. 1 Impact wrench, 1/2" ......................... 1

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! !4!C!G!9!1!

When replacing the belt, it is important that the cam and crankshaft be in correct alignment before installing a new belt. Remove the cover from the crankshaft pulley and rotate the engine by hand until the key way aligns with the mark on the engine case. Rotate the camshaft until the small hole is aligned with the notch at the top of

E�GOiiHi1M:I

Pg.H-7

ENGINE AND CONTROLS the timing cover mounting surface. With both the crank­ shaft and cam shaft aligned,install the new belt. Re­ lease the idler pulley and rotate the engine one full turn by hand. Recheck the crankshaft and camshaft pulley alignment before tightening the idler pulley to 1 O -13 ft.lbs torque. Replace the crankshaft cover. Replace the timing belt cover.

Assembly is in the reverse order of disassembly. Adjust belt tension as shown in Section A.

, MUFFLER REMOVAL

STARTER GENERATOR REMOVAL Tools Required:

not being replaced, it may be carefully moved and tied to a frame member to prevent damage to the wires and their connections.

Qty.

Tools Required:

Qty.

Ratchet, 3/8" drive .......................... 1

Ratchet, 3/8" drive .......................... 1

Socket, 12 mm, 3/8" drive .................... 1

Socket, 1O mm, 3/8" drive .................... 1

Socket, 1/2", 3/8" drive ....................... 1

Socket, 3/4", 3/8" drive ...................... 1

Extension, 6", 3/8" drive ...................... 1

Extension, 3", 3/8" drive ..................... 1

Extension, 8", 3/8" drive ...................... 1

Wrench, 9/16" ............................. 2

Extension, 30", 3/8" drive ..................... 1

Wrench, 3/4" .............................. 1

Wrench, 12 mm .................... . ....... 1

Remove the negative battey cable. Loosen the starter generator belt as shown in Section A of this manual. Re­ move the through bolt. Remove the wiring from the starter/generator if the unit is to be replaced. If the unit is

Loosen the two lower bolts, washers, lock washers and nuts attaching the muffler to the rear engine frame. Re­ move the top bolts and washers from the muffler and ex­ haust manifold and remove the muffler.

FIG. H-6 STARTER GENERATOR REMOVAL

Pg.H-8

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! 4!C!GI 9! 1 I

ENGINE AND CONTROLS When installing the muffler, use a new exhaust gasket, and bolt the muffler loosely to the exhaust manifold be­ fore installing the remaining muffler mounting hardware.

Tighten the bolts securing the manifold and muffler.

Tighten the top and bottom bracket bolts.

Extension, 30", 3/8" drive ..................... 1 Screwdriver, straight blade .................... 1 Socket, 10 mm, 1/4" drive .................... 1 Wrench, open end, 1/2" ...................... 2 Wrench, open end, 7/8" ...................... 1 Wrench, 9/16" .............................. 1 Wrench,12 mm ............................. 1 Screwdriver, straight blade .................... 1 Allen wrench, 5/64" ......................... 1 Pliers, needle nose .......................... 1 Wire cutters ............................... 1

Two persons or a suitable hoist are required to lift the en­ gine from the vehicle.

Remove the muffler and engine frame mounting bolts, washers and nuts from the isolation mounts. Remove the ground strap from the engine. Remove all wiring from the starter/generator. Remove the accelerator and choke cables. Remove and plug the fuel line and pulse line from the engine at the carburetor. Remove the drive belt. Remove the short linkage between the bellcrank and the governor arm. The engine, engine frame, starter generator and drive clutch may be removed as an assembly. Inspect the isolation mounts for cracks in the rubber and replace if any cracks are found.

CAM REMOVALJ REPLACEMENT

FIG. H-7 MUFFLER REMOVAL

Tools Required: ENGINE REMOVAL

Tools Required:

Qty.

Ratchet, 3/8" drive .......................... 1

Qty.

Socket, 10 mm, 3/8" drive .................... 1 Extension, 3", 3/8" drive ...................... 1

Ratchet, 3/8" drive .......................... 1

Wrench, open end, 10 mm .................... 1

Ratchet, 1/4" drive .......................... 1

The cam may be removed without removing the engine.

Socket, 9/16", 3/8" drive ..................... 1 Socket, 12 mm, 3/8" drive ......... • .......... 1 Socket, 1/2", 3/8" drive ...................... 1 Extension, 6", 3/8" drive ..................... 1 Extension, 8", 3/8" drive ..................... 1

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Remove the air cleaner/coil mounting bracket. Remove the cooling shroud. Remove the camshaft cover and gasket. Remove the valve cover and loosen the jam nut and adjuster on each rocker arm, pressing each rocker against its valve stem.Pull the camshaft from the cylin­ der head.

Pg.H-9

ENGINE AND CONTROLS

FIG.H-8 CYLINDER HEAD REMOVAL

2_ 1- -

FIG.H-9 CHECKING CYLINDER HEAD FLATNESS Pg.H-10

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ENGINE AND CONTROLS CYLINDER HEAD REMOVAUREPLACE­ MENT (FIG. H-B)(FIG. H-9)

Remove the 7 head bolts being careful to note the three lengths of bolts that are used and their locations.

Tools Required:

Remove the cylinder head complete with valves.

Qty.

Ratchet, 3/8" drive . • • . • . . . . . . . . . • . . . . . . . . . • • 1 Socket. 12 mm, 3/8" drive . . . . . • . . . . . . • . . . . . . . 1 Extension, 3", 3/8" drive . . . . . . • . . . . . . . . . . . . . . 1 Torque wrench, 3/8" drive . . . . . . . . . . . . . . . . . . . . 1 Straight edge, 12" . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Feeler gauge • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Remove the following components. Refer to other sec­ tions of this manual for specific instructions.

• • • • • • •

Check the gasket surface of the cylinder head for flat­ ness by laying a straight edge across the middle, and di­ agonals of the head (FIG. H-9). Use a feeler gauge to determine the maximum warp. If warp exceeds .002 the cylinder head may be resurfaced by a machine shop; no more than .010 may be removed in the resurfacing proc­ ess. Warpage in excess of .006 will require replacing the cylinder head. Remove carbon deposits from both the cylinder head and the valve.

Stage tighten cylinder head bolts to 17-19.5 ft.lbs. torque.

Drive clutch Muffler Exhaust manifold Air filter Rear shroud Coil/Air cleaner mounting bracket Fan shroud

NEVER USE A WIRE BRUSH OR ANY ABRASIVE PRODUCT WHEN REMOVING CARBON FROM THE ALUMINUM CYLINDER HEAD.

VALVE REPLACEMENT/CONDITION­ ING(FIG. H-10)

Tools Required:

Qty.

Valve lapping compound, fine . . . . . . . . . . . . . . . . . 1

•

Valve cover

Valve lapping tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

•

Timing belt cover

•

Timing belt

•

Camshaft pulley

If it becomes necessary to replace a valve, it must be lapped to conform with the valve seat in the cylinder head. The seat is a much harder material than the valve, therefore it will be the valve that will conform to the valve seat.

Remove the valve cover and loosen the jam nut and ad­ juster on each rocker arm. Remove the camshaft cover and gasket. Gently pull the camshaft from the cylinder head.

Carefully slide the rocker shaft out of the cylinder head by engaging a screwdriver in the groove in the shaft and gently pushing the shaft out of the cylinder head.

Remove the rockers and spacers and set them aside, in the order removed, for reassembly.

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! !4!C!G!9!1!

Lightly lubricate the valve stem and insert it into the valve guide of the inverted cylinder head. Coat the valve seats with a fine grinding compound. Moisten the suc­ tion cup on the valve lapping tool and attach it to the valve. Rotate the lapping tool in alternating directions by rotating the tool with the palms of both hands. Lift the tool frequently and continue the grinding process until both the valve and seat are polished at the contact point.

Remove the valve and the lapping tool. Flush all re­ maining lapping compound from the valve and cylinder head. Repeat the process with the next valve. Clean all components and reassemble.

Pg. H-11

ENGINE AND CONTROLS

FIG. H-10 VALVE LAPPING VALVE SEAL REPLACEMENT (CYLINDER HEAD INSTALLED) (FIG. H-11) Tools Required:

Qty.

Ratchet, 3/8" drive .. .. . .............. . .. . ... 1 Socket, 10 mm, long reach, 1/4 drive . .... . ..... 1 Socket, spark plug, 3/8 drive ... . ... . ... ..... . . 1 Rope' 1/4" . .. . . . . . . .... . . . . ..... . ......... 1 The valve seals may be replaced with the engine in the vehicle and with the cylinder head in place. Remove the camshaft and turn the rockers up out of the way of the valve stems. Remove the spark plug from the cylinder containing the valve seal to be replaced. The valve must be held in place by either compressed air(fed through an adapter in the spark plug hole}, or feeding 8-12" of 1/4" rope into the cylinder.Slowly rotate the engine by hand until the valve is held in the closed position. Always use enough rope to prevent the end from being lost in the cylinder.

Valve seals may be replaced by moving the piston of the effected cylinder to Top Dead Center (TDC).The piston will prevent the valve from falling.

Pg.H-12

DO NOT DAMAGE THE SEAL OR VALVE RETAINER GROOVE

Remove the valve retainer and spring. Gently pry the old seal from the cylinder head. Lubricate a new seal and carefully place it over the valve stem. Press in place using a suitably sized socket to seat it over the valve guide. Replace the valve spring, retainer and cam. Ro­ tate the engine by hand to lower the piston.Remove the rope and replace the spark plug. Adjust the valves. Re­ place the valve cover.

VALVE SEAL REPLACEMENT (CYLINDER HEAD REMOVED) Tools Required:

Qty.

Socket, 10 mm, long reach, 1/4 drive ............ 1 Screwdriver, straight blade .................... 1 Remove the valve retainer and valve spring. Gently pry the old seal from the cylinder head. Lubricate a new seal and place it over the valve guide. Press in place using a suitably sized socket. Replace the valve, spring, and retainer.

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!4!C!G!9!1!

ENGINE AND CONTROLS IGNITION TRIGGER REPLACEMENT (FIG. H-12)

LONG REACH SOCKET

Tools Required:

;-VESEAL

Qty.

Socket, 10 mm, 3/8 drive ..................... 1 Ratchet, 3/8" drive ........... ............... 1 --Screwdriver, Phillips .. . .. .. ... ..... .... ... ... 1

It is not necessary to remove the flywheel to gain access to the ignition trigger.

Remove the fan from the flywheel.

PIS�

00000

Remove the two screws attaching the ignition trigger to the engine and remove the trigger.

AIR PRESSURE OR ROPE

ACCELERATOR LINKAGE ADJUSTMENT

HOLDS VALVE IN PLACE

In order to obtain satisfactory performance and govern­ ing characteristics, it must be realized that all linkages are interdependent. Do not make a change to a linkage without first being sure that the other components are in proper adjustment.

FIG. H-11 VALVE SEAL REPLACEMENT

COOLING SYSTEM CLEANING (FIG. H-13)

FAN REMOVAL (FIG. H-12) Tools Required:

Qty.

Socket, 30 mm, 1/2 drive . . . . . . ... .... ....... 1 Ratchet, 1/2" drive . . ...• . • . . ... . ... . ........ 1 Socket, 1O mm, 3/8 drive . . .... ... .......... . 1 Ratchet, 3/8" drive . ......... . . . .... . ........ 1 Flywheel puller E-Z-GO P/N 27111-G01 ....... 1 Remove the large nut that retains the fan/flywheel to the crankshaft. Remove the bolts that retain the fan to the flywheel and remove the fan.

Use the E-Z-GO flywheel puller to remove the flywheel from the crankshaft.

12/01/91 I !4!C!G! 9! 1 I

Refer to Section F for adjustment procedures.

At least once a year (more often under adverse condi­ tions) the cooling system should be completely cleaned to ensure that an adequate supply of air is available to remove excess heat from the cooling fins. In Section A, compressed air is used for periodic cleaning.However, operation in wet or damp weather or over freshly cut grass may result in a variety of debris adhering to the in­ ternal shrouds and fins of the cooling system. In this case, proceed as follows: With the engine cold, a strong stream of water should be directed at the cylinder head fins beside the timing belt cover. Avoid spraying electrical components. Allow the water to flow freely over the cooling fins and through the blower housing before blowing dry with low pressure compressed air.

E�E:iDiiHi1!•l:I

Pg.H-13

ENGINE AND CONTROLS

FIG. H-12 FAN REMOVAL

I FIG. H-13 DRYING COOLING SYSTEM WITH COMPRESSED AIR

Pg.H-14

12/01/91 ! !4!C!G!9!1!

OPERATION AND SERVICE MANUAL SECTION:FUEL SYSTEM

GENERAL

J

CABLE AND HOUSING REMOVAL

The fuel system consists of a fuel tank, fuel lines, fuel fil­ ter, fuel pump and carburetor.

_Tools Required:

CARBURETOR OPERATION

Wrench, open end, 1/2" ....•.•............... 2

The carburetor is constructed with four different sys­ tems: the float system, the pilot system, the main sys­ tem, and the choke system.

Qty.

Wrench, 7/8" ............................... 1 Wrench, Allen, 5/64" ......................... 1

FLOAT SYSTEM The float chamber is located on the underside of the car­ buretor, and the correct fuel level is maintained by means of the float and needle valve.

As the fuel flows from the fuel pump into the float cham­ ber through the needle valve the float rises, and when the buoyancy force of the float is exceeds to the fuel pressure, the needle valve closes to maintain the cor­ rect fuel level.

PILOT SYSTEM The pilot system functions to deliver fuel during low speed operation.Fuel flow is determined by the pilot jet and screw setting.

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-1) Loosen the set screw attaching the swivel (1) to the choke cable. 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 ca­ ble to the seat wrap and slide it onto the cable. Pull the cable through the nut and the vertical seat support.

MAIN SYSTEM

CHOKE CABLE INSTALLATION

The main jet system functions to deliver the fuel during acceleration and during heavy load conditions. The fuel flow is determined by the main jet. The air measured by the main air jet is mixed with the fuel through the bleed opening of the main nozzle. This mixture passes into the carburetor venturi as atomized air/fuel and is mixed with intake air for delivery to the engine.

Feed the choke cable through the hole in the vertical seat support and install the nut (4) finger tight.Slide the threaded portion of the housing through the carburetor 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 tightening the set screw securely.

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.

CHOKE SYSTEM The choke functions to make initial starting of the engine easier in cold weather. The choke plate restricts air flow to enrich the air/fuel ratio.

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.

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! !4!C!G!9!1 !

CARBURETOR SERVICE Disconnect battery (see procedure in Section B).Before servicing the carburetor and fuel system, be sure that the ignition circuit and its components are in proper op­ erating condition.

Pg. J-1

FUEL SYSTEM

FIG. J-1 CHOKE SYSTEM

Pg. J-2

E�GDii:S:,i1!•l:1

!

12/01/91 !4!C!G!9!1 !

FUEL SYSTEM

FUEL FILTER

FUEL PUMP

PULSE LINE FROM ENGINE

FUEL LINE TO CARBURETOR

FIG. J-2 FUEL SYSTEM 12/01/91

! !4!C!G!9!1!

:J:,

E�GD ii i 1M: I

Pg. J-3

FUEL SYSTEM REMOVAL FROM ENGINE (FIG. J-2), (FIG. J-3), (FIG. J-4), (FIG. J-5)

Tools Required:

Qty.

Socket, 10 mm, 1/4" drive .................... 1 Ratchet, 1/4" drive .......................... 1 Extension, 3" 1/4" drive ... ................... 1 Pliers, needle nose ...... ................... 1 Pliers, parallel jaw .......................... 1 Screwdriver, straight blade ................... 1 Allen wrench, 5/64" ......................... 1 Wrench, open end 9/16" ..................... 2

nut and rotate clockwise until black female plastic portion seperates from ball.

(FIG.J-4) Remove the linkage from the carburetor as detailed elsewhere in this manual.

Remove the air filter and cover as shown in Section A. Remove the 2 bolts and flat washers that secure the air box to the bracket on the passenger side of the engine.

Remove the two nuts and lock washers and the two flanged bolts securing the air box and baffle to the car­ buretor.

Remove the choke bracket and carefully swing out of the way.

Remove the fuel line from the carburetor and plug with a suitable size bolt.Slide the carburetor away from the en­ gine on it's studs.

Wrench, open end 3/8" ...................... 1 Socket, 3/4", 3/8" drive ...................... 1 Ratchet, 3/8" drive .............. . . .......... 1 Extension, 3" 3/8" drive ..................... . 1 Wrench, open end 3/4" ...................... 1

If the carburetor contacts the starter/generator, it will be necessary to remove the starter belt and tilt the starter generator to permit the carburetor removal. See starter/ generator instructions elsewhere in this manual.

'Krikit' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Unsnap the two retaining clips securing the cover to the air box and remove the cover. Carefully swing the air box cover out of the way.

Remove the air filter element.

Remove the PCV valve hose between the bottom of the 1air box and the crankcase at the air box.

Disconnect the fuel line (1) at the carburetor (3) and plug the fuel line. Disconnect the solid linkage from the car­ buretor throttle lever. Remove the choke cable from the choke arm.

DO NOT LET THE CARBURETOR VENT HOSE BE­ COME CLOGGED OR KINKED. ENGINE HEAT WILL CAUSE THE FUEL IN THE CARBURETOR TO EX­ PAND AND MAY RESULT IN FUEL BEING INTRO­ DUCED INTO THE AIR FILTER AND ITS ENCLO­ SURE IF UNABLE TO VENT THROUGH THE VENT TUBE. Assembly is in the reverse order of disassembly. Use a new gasket to ensure good sealing of the carburetor.

WHEN REMOVING/INSTALLING THE LINKAGE 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-5).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 linkage, place 3/8" open end wrench on the jam

Pg. J-4

CARBURETOR DISASSEMBLY (FIG. J-6) Tools Required:

Qty.

Socket, 12 mm, 1/4" drive .................... 1 Pliers .................................... 1 Ratchet, 1/4" drive .......................... 1 Screwdriver, straight blade (narrow) ............ 1 Before disassembling the carburetor, clean the outside of the carburetor thoroughly with solvent.

12/01/91

l4!C!Gl9l1 !

FUEL SYSTEM

AIR BOX

FIG. J-3 CARBURETOR REPLACEMENT

FIG. J-4 BALL JOINT REMOVAL 12/01/91

I !4!C!G!9!1I

FIG. J-5 BALL JOINT RE-ATTACHMENT

E�GDiiHi,(•]:I

Pg. J-5

FUEL SYSTEM

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) ,by removing the retaining screw.

Inspect the"O" ring gasket (3) for nicks or cuts. Remove the float pin (4), float (5) and the inlet valve. Inspect the needle for any wear at its tip.

DO NOT bend the float pin during removal.

Remove the main jet (2) Remove the main nozzle (8) and inspect holes. Blow clean with compressed air.

Remove the pilot screw (9) and the pilot jet (10).

I lfflOO'IT� I

The pilot screw is factory set. It MUSTbe reinstalled to the SAME factory setting. See Section R, (CARB. TROUBLE SHOOTING).

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) Invert carburetor, (tum upside-down). Remove 12mm screw and copper gasket from the bottom of carburetor bowl. Remove bowl. With carburetor inverted, the "B" side top edge of a properly adjusted float will be slightly above parellel to the bowl gasket surface, and both sides of float will be level with each other, see (FIG. J-8). If not level or if "B" side of float is not slightly above parellel with bowl gasket surface, then adjust by insert­ ing needle nose pliers into slot on top of Tang 1 and hold firmly, adjusting the black floats by gently lifting or pushing with other hand. Re-install bowl, copper gas­ ket, and screw. Check for leaks.

When adjusting float, NEVER bend the float arm, al­ ways bend the tang 1.

Pg. J-6

After adjusting the float level, reassemble the carburetor in the reverse order of disassembly. Assemble the pilot screw being sure to replace it to its original factory set­ ting.

Check for free movement of the choke shaft and butter­ fly before the carburetor is installed on the engine. Lubri­ "Cate bushings with WD-40.

THROTTLE SHAFT ADJUSTMENT (FIG. J-6) To adjust throttle shaft (12) and throttle valve (13), 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 (11) clockwise until it contacts the tab on the throttle shaft; tum the screw clockwise one eighth to one quarter tum.

When reinstalling the carburetor to the engine, installa­ tion of a new gasket is recommended to assure an air tight seal. Ensure that fuel line and air intake hose con­ nections are air tight. Inspect the air intake hose for damage and replace if required.

DO NOT LET THE CARBURETOR VENT HOSE BE­ COME CLOGGED OR KINKED. ENGINE HEAT WILL CAUSE THE FUEL IN THE CARBURETOR TO EX­ PAND AND MAY RESULT IN FUEL BEING INTRO­ DUCED INTO THE AIR FILTER AND ITS ENCLO­ SURE IF UNABLE TO VENT THROUGH THE VENT TUBE. Replace the carburetor and air box in the reverse order of disassembly being sure that the deflecter is in place and the vent tube is located without kinking the vent tube.

&WARNING& CLOGGED OR KINKED CARBURETOR VENT HOSES ARE NOT ONLY DETRIMENTAL TO THE PROPER OPERATION AND PERFORMANCE OF THE VEHICLE, BUT CAN ALSO BE A SAFETY HAZ­ ARD IN THE CASE OF FUEL LEAKING ON A HOT ENGINE.

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FUEL SYSTEM

PILOT JET ACCESS SCREW

THROTTLE VALVE 13

STOP SCREW 11

�

�� I ! , ......sa�·

�

I

10

�

'1 J c.,

�

----12 THROTTLE SHAFT

0

CHOKE PLATE

VENT HOSE NOZZLE

3 "O" RING GASKET

---BOWL DRAIN SCREW

1 FLOAT BOWL

I

®---- COPPER GASKET ft. ___ RETAINING � SCREW

FIG. J-6 CARBURETOR 12/01/91

i i4iCiGi9l1 I

Pg.J-7

FUEL SYSTEM FUEL PUMP (FIG. J-7) Tools Required:

Tools Required: Qty.

Socket, 7/16, 3/8" drive • . . . . • . • • • . • . . . . . . • . . . 1 Ratchet, 3/8" drive . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Screwdriver, straight blade . . . . . . . . . . . . . . . . . . . 1 Pliers, needle nose . • . . . . . . . . . . . . . . . . . • . . . . . 1

&WARNING& TESTS THAT INVOLVE FUEL FLOW SHOULD BE AVOIDED IF AT ALL POSSIBLE. IF A TEST TO DE­ TERMINE FUEUVAPOR PRESENCE OR FLOW IS REQUIRED, THE IGNITION SYSTEM MUST BE DIS­ ABLED IN ORDER TO PREVENT IGNITION SPARK THAT COULD IGNITE THE FUEUVAPOR. NEVER PERMIT SMOKING OR OPEN FLAME IN AN AREA THAT CONTAINS FUEL. CLEAN UP ALL FUEL SPILLS IMMEDIATELY. The fuel pump is mounted behind the seat support on the driver's side and is operated by crankcase pressure impulses from the engine. As the pistons move up into the cylinders, a negative pressure moves the diaphram (1) in the fuel pump. 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 pistons move downward into 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, supplying fuel to the carburetor bowl.

The length of the pulse line from the engine crankcase is important for efficient pump operation. The hose should be replaced with one of the same length if replacement is required.

Make note of the location of the hoses since it is impor­ tant that the pulse hose be attached to the correct fuel pump connection. Remove the hoses. The pump is re­ moved by undoing its two mounting nuts and lifting the pump from its bracket. Assembly is in the reverse order of disassembly. Refer to (FIG. J-2).

FUEL LINES AND FILTER (FIG. J-2) Pg. J-8

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. Fuel filter, fuel lines and the fuel tank cap vent should be inspected on a periodic basis for leaks, a clogged tank vent or clogged filter, etc. Filter should be replaced when necessary, but under no circumstances should the period of time be­ tween filter changes exceed one year. (250 hours).

IHiJiiii'l�i

THE FILTER IS MARKED WITH A FLOW DIRECTION ARROW. BE SURE ARROW POINTS TOWARD THE FUEL PUMP IN THE DIRECTION OF THE FUEL FLOW. The fuel tank should be drained and any foreign matter removed after the vehicle has been stored for a lengthy period.

&WARNING& DO NOT ATTEMPT TO REPAIR A DAMAGED OR LEAKING FUEL TANK, IT MUST BE REPLACED. (SEE THE PROCEDURE IN SECTION B).

FUEL TANK REMOVAL/INSTALLATION See the proper safety procedure for tank removal in Section B. PULSE LINE TO CARBU

OR �

FROM FUEL TANK

FIG. J-7 FUEL PUMP 12/01/91 !4!C!G!9!1 !

FUEL SYSTEM

TANG# 1 FLOAT SIDE A

ADJUST FLOAT SIDE B SLIGHTLY ABOVE PARALLEL TO GASKET SURFACE

TANG#2

I. 1' NEEDLE AND SEAT

FLOATS MUST BE LEVEL WITH EACH OTHER

TANG2

FIG. J-8 FLOAT ADJUSTMENT 12/01/91

I l4lclGl911I

E�GDii:i:,i1t•l:I

Pg. J-9

FUEL SYSTEM

£WARNING£ TESTS THAT INVOLVE FUEL FLOW SHOULD BE AVOIDED IF AT ALL POSSIBLE. IF A TEST TO DETERMINE FUELNAPOR PRESENCE OR FLOW IS REQUIRED, THE IGNITION SYSTEM MUST BE DISABLED IN ORDER TO PREVENT IGNITION SPARK THAT COULD IGNITE THE FUELNAPOR. NEVER PERMIT SMOKING OR OPEN FLAME IN AN AREA THAT CONTAINS FUEL. CLEAN UP ALL FUEL SPILLS IMMEDIATELY.

CARBURETOR TROUBLE-SHOOTING SYMPTOM OVERFLOW

POSSIBLE REMEDY

Worn inlet valve or dirty valve seat

Replace valve or clean valve seat

Improper fuel level in float chamber

Adjust float

Worn float mounting tang

Replace float

Worn float pin

Replace pin

Damaged float bowl gasket

Replace gasket

Deformed float

Replace float

POOR LOW SPEED PERFORMANCE Pilot screw improperly adjusted

Adjust pilot screw

Clogged bypass or idle port

Clean

Clogged low speed jet

Clean

Loose low speed jet

Tighten jet

POOR FUEL ECONOMY Fuel level too high

Adjust float

Clogged bleed tube

Clean

Loose jets

Tighten

Choke not opening fully

Adjust

Dirty air cleaner

Replace filter

POOR ACCELERATION Clogged fuel passages

Clean

Clogged low speed jet or bleed tube

Clean

Fuel level too low

Adjust float

HARD STARTING Choke plate not operating properly

Pg.J-10

Adjust choke system

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l4!C!Gl9l1 l

FUEL SYSTEM Dirty carburetor

Clean

Loose carburetor

Tighten

Fuel overflow

Inspect float and valve. Repair or replace

POOR HIGH ACCELERATION Fuel pump faulty

Repair or replace

Loose main jet

Tighten

Incorrect fuel level in float bowl

Adjust float adjusting tang for correct fuel level

Dirt in fuel tank or lines

Clean

Clogged fuel filter

Replace

Clogged main jet or main air passage

Clean

Dirt in air filter

Replace

ABNORMAL COMBUSTION (Fuel mixture) Dirty carburetor

Clean

Dirt in fuel tank, lines or filter

Clean

Clogged air or fuel filter

Replace

LOSS OF POWER (Insufficient Fuel) Faulty fuel pump

Repair or replace

Dirty carburetor

Clean

Dirt in fuel tank or lines

Clean

Clogged fuel filter

Replace

Air leaking in system

Check mounting hardware and gaskets.Repair or replace

LOSS OF POWER (Insufficient air) Dirty air cleaner

Replace filter

Throttle linkage

Repair or replace

Loose jets

Tighten

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! !4!C!G!9!1!

E�E:iDii:i:si,t•J:I

Pg. J-11

FUEL SYSTEM

Pg.J-12

E�GDii:$:,i1!•l:I

12/01/91

! !4!C!G!9!1 !

OPERATION AND SERVICE MANUAL SECTION:POWER TRANSMISSION

GENERAL (FIG. K-1) The two clutch assemblies perform as a continuously variable transmission (CVT). This drive system 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 centrifugal member (mounted on engine crankshaft) is moved inward to en­ gage the drive belt. Centrifugal force is supplied by the cams (weights) operating in the movable sheave hous­ ing. 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

K

the engine speed is increased, the movable sheave will move inward against the belt, thus engaging the belt be­ tween the two clutch sheaves. At this point, the drive is at maximum ratio of almost 4 to 1. With increasing en­ gine speeds, the moveable sheave is forced toward the stationary sheave which increases the belt pitch diame­ ter. This decreases the ratio, shifting the drive for higher speeds.

The driven clutch is a variable pitch sheave which main­ tains an equilibrium condition with the driven clutch at all speeds. Sheave pressure varies directly with load input so that the drive "down shifts" its ratio with increased load without appreciable change of engine speed. The moveable sheave spiral ramp and followers are acti­ vated by belt friction. The spring is used to ensure con­ stant belt contact under all operating conditions.

IDENTIFY DRIVE SET BY BLACK BAND AND NO RED DOT ON FACE OF DRIVE CLUTCH

DRIVE CLUTCH

� DRIVEN CLUTCH

1

FIG. K-1 CLUTCHES AND BELTS 12/01/91

! !4!C!G!9!1!

Pg. K-1

POWER TRANSMISSION TOWING

If the belt is frayed or badly worn, it should be replaced.

See section 'A' for towing vehicles.

DRIVE CLUTCH

REMOVING THE DRIVE BELT (FIG. K-2)

Tools Required:

With the vehicle on level ground, remove the drive belt by pulling the belt upwards which causes the driven clutch to open and loosen the belt. The belt may be rolled off the driven clutch.

Hammer, plastic tipped ..... ................. 1 Socket, 3/8", 3/8" drive ....................... 1 Ratchet, 3/8" drive .......................... 1

Qty.

Clutch puller (E-Z-GO, P/N 19778-G2) ......... 1 Socket, impact, 1 1/8", 1/2" drive ............... 1 Impact wrench, 1/2" drive (air or electric) ......... 1 Sealant, Loctite .......................... AR Torque wrench, 1/2" drive .................... 1

DRIVE CLUTCH REMOVAL (FIG. K-1)

8WARNING8 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 The Drive Belt' procedure). Remove the drawbolt (4) and washers (2, 3) from shaft end. Install a well lubricated clutch puller (part number 19779-G2) and use an impact wrench turning clockwise to remove the clutch.

FIG. K-2 REMOVING THE DRIVE BELT

DRIVE CLUTCH INSTALLATION (FIG. K-1)

8WARNING8 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.

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.

Pg.K-2

DO NOT INSTALL THE BOLT WITH AN IMPACT TOOL. 1. Clean both the engine shaft and clutch bore.

2.

Slide the clutch onto the engine shaft. Rotate it and lightly push the moveable sheave in and out sev­ eral times to seat the clutch on the tapered engine shaft.

3. Position the lock washer (3) and large clutch pilot washer (2) onto the clutch bolt (4).

4.

Apply locking sealant to the threads of the clutch bolt (4).

5. Install the clutch bolt and tighten to 55 ft. lbs. torque.

E:ZGDii:i:!i1!•l:1

12/01/91 ! 4!C!G! 9! 1 !

POWER TRANSMISSION

I IDJ®TIT� I

DRIVEN CLUTCH (FIG. K-3) Tools Required

Qty.

Pliers, external snap ring . . . . . . . . . . • . . . . . . . . . . 1 Screwdriver, Phillips . . . . . . . • . • . . • • . . . . . . . . . . 1 Sealant, Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-3) Remove the drive belt (refer to 'Removing The Drive Belt' procedure). Remove the bolt (1), lock washer (2) and retaining washer (3) and slide the clutch off.

DRIVEN CLUTCH DISASSEMBLY (FIG.K-3) Remove the external retaining ring (14) and separate the ramp and dust seal (13) as an assembly.

Remove the spring (12) and moveable sheave (9).

REPLACING BROKEN RAMP BUTTONS (FIG.K-3) The ramp buttons (10) may be replaced by removing screw (11) and substituting a new ramp button and re­ placing the screw.

12/01/91

I l4ICIGl911I

REMOVE ALL FRAGMENTS AND DIRT BEFORE REASSEMBLY.

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 caus­ ing excessive vibration or shaft wear, the clutch must be replaced. Clutch reassembly is the reverse order of dis­ assembly.

INSTALLATION Coat the rear axle input shaft with a light appliation of "Neverseize" and slide clutch onto the shaft. Assemble the drawbolt, lock washer and pilot bushing before coat­ ing the drawbolt threads with locking sealant and install­ ing 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 drive clutche should be protected from cor­ rosion. Remove the drive belt (see 'Drive Belt Removal' procedure) and spray all external surfaces with WD-40 or equivalent.

Pg.K-3

POWER TRANSMISSION

FIG. K-3 DRIVEN CLUTCH

Pg.K-4

12/01/91

l !4!C!G!9!1!

OPERATION AND SERVICE MANUAL SECTION:ELECTRICAL

CIRCUITS AND CONTROLS The electrical system is a negative grounded 12 volt system and contains a starter/ generator, voltage regu­ lator, starter solenoid, ignitor, accelerator limit switch, key switch, and ignition pick up. The limit switches are devices to ensure that the electrical contacts are in a fully engaged position before becoming energized.

STARTER (FIG.L-1) When starting the engine, the field coils are in series with the armature and the starter / generator operates as a motor. This circuit is controlled by a key switch, a fuse, an accelerator switch, and a solenoid switch. With the key switch in the "ON" position, battery current is available to the accelerator limit switch which remains open until the accelerator pedal is depressed.When the pedal is depressed, the plunger on the switch is re­ leased, the contacts close and the ignition circuit is ener­ gized. Battery current then energizes the starter sole­ noid which closes the contacts and energizes the starter circuit. The starter/ generator now functions as a motor to start the engine.

GENERATOR (FIG.L-1) 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 1 5.5 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.

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 "V O M" (Volt Ohm Meter), available through the E-Z-G O Service Parts / distributor or any automotive or electronics outlet. Set the meter selector knob to the ohms scale and check continuity between each circuit component as indicated. Example: If a switch is open or

12/01/91

! !4!G!C!9!1!

L

if there is a hidden break in the wiring, the meter will read infinity.

TESTING IGNITION CIRCUIT

This section assumes that the fuel system is functioning and that the engine is receiving fuel

Tools Required:

Qty.

V.O.M. ................................... 1 lgnitor Coil ....... ........... . ............. 1 Spark Plug Wire ............................ 1 Spark Plug ............... . .... ............ 1 If the engine will NOT run but the starter will turn the en­ gine.

&WARNING& NEVER OPERATE THE STARTER UNLESS BOTH SPARK PLUGS ARE INSTALLED OR THE IGNITION SYSTEM IS DISABLED. FUEL DRAWN INTO THE CYLINDERS WILL BE EXPELLED THROUGH THE SPARK PLUG OPENING AND COULD BE IGNITED

BY THE IGNITION SYSTEM, 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 COIL OR IGNITOR IF PLUG IS NOT GROUNDED. The engine incorporates an ignition system that fires both plugs simultaneously. There is no distributor and both spark plugs fire together (see engines and con­ trols).

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.

1. Check for loose wires at the terminals and connec­ tions of each of the following components:

E�GDiiHi1t•l:I

Pg.L-1

ELECTRICAL BATTERY BLACK SOLENOID REVERSE WARNING

rhBLK

RED BLK---­ RED/WHT

BLU

WHT

LIMIT SWITCH REVERSE WARNING

RED RED KEY SWITCH

LIMIT SWITCH BLK

VOLTAGE REGULATOR

---RED----1-BLK GRN

SOLENOID TERMINAL CONFIG ATION A,;

D

PULSER COIL

I

ENGINE

L ______________

----

B C

NOTE; EARLY PRODUCTION STARTER/ GENERATORS HAD A RED AND GREEN WIRE AT THE 'DF' TERMINAL - - - WHICH MATED TO CONNECTORS AT HARNESS

FIG. L-1 ELECTRICAL SYSTEM WIRING DIAGRAM

Pg.L-2

E�E:iiDii:S:,i1!•l:1

12/01/91 ! 4!C!GI 9! 1 l

ELECTRICAL 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 grounded en­ gine 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 .030" using a wire type spark plug gauge.

4.

If there is either a weak arc or no arc, try a new spark plug, then check the spark plug ignition wires condition and for loose terminals. Check the igni­ tion wire by substituting with one that is known to be good.

5.

4.

Check the complete electrical system for correct circuitry(FIG. L-1).

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 the VOM to the ohms scale, place positive (+) probe on the terminal with one of the red wires at­ tached and negative(-) probe to the terminal with the other red 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.

Turn the key switch to "OFP'

Check the ignition coil by temporarily attaching to the bracket, another one that is known to be good .

Place one probe of the VOM(set to ohms scale) on the red wire at the limit switch. Place the other probe on the solenoid terminal with the blue wire.

Depress the accelerator and observe the VOM. A reading of less than 2 ohms indicates a good limit switch. A reading of greater than 2 ohms indicates that the switch terminals should be checked. A reading of infinity indicates that the switch must be replaced.

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.

&WARNING&

If the engine then operates, replace the ignitor.

TO PREVENT THE POSSIBILITY OF INJURY RE­ SULTING FROM THE VEHICLE INADVERTENTLY STARTING, THE DRIVE BELT MUST BE REMOVED OR BOTH REAR WHEELS RAISED. (See proce­ dures in Section B)

TESTING STARTING CIRCUIT

Connect the battery.

It is not necessary to mount the ignitor; just attach the wires.

8.

8WARNING8 DISCONNECT BATTERY FOR STEPS 1 THROUGH 8 (SEE PROCEDURE IN SECTION B).

Check the starting solenoid operation. Turn the key switch to the "ON" position. a)

Place the VOM (set to the appropriate D.C. volts scale) positive(+) probe on terminal "A" of the solenoid (FIG. L-1). Place the nega­ tive(-) probe on terminal "B". The voltmeter should indicate approximately 12 V.

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 14.0 volts. Inspect for loose or dirty battery post connections.

b)

2.

Check for a blown in line fuse and replace if neces­ sary with a 7 amp fuse.

Depress the accelerator pedal. The VOM will indicate "O" voltage if the solenoid contacts are closed.

c)

3.

Check for loose wires at all terminal connections.

If "O" voltage is not indicated while the accel­ erator pedal is depressed, replace the sole­ noid.

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E�t:iDii:i;,i1!•J:I

Pg.L-3

ELECTRICAL TESTING CHARGING CIRCUIT The charging circuit consists of a starter / generator, voltage regulator and battery. The solenoid must be functional in order to start the vehicle, but is not consid­ ered as part of the charging circuit.

1.

If the battery charge is inadequate, check the fol­ lowing: a)

Check the battery voltage and inspect for loose or corroded terminal posts / connec­ tions.

b)

Check charging circuit component terminals for proper clean tight connections.

c)

Check for charging voltage by the following method.

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 reading 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 mal­ function. b) Start the engine and accelerate to governed speed. c) A reading of 14.5 V to 15.5 V should be observed. d) With the engine off, check between the ground strap and D-, D+, and DF terminals; the reading should be "O" ohms.

Pg.L-4

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.

STARTER/GENERATOR REMOVAL See Engine and Controls

STARTER/GENERATOR DISASSEMBLY (FIG. L-3) AND (FIG. L-4)

In general, starter/generator service is best performed by trained motor technicians who have the skill and equipment to overhaul the unit. Some checks and re­ pairs can be accomplished by a skilled mechanic. You should make your own evaluation of the equipment and skills available before starting disassembly.

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-4). Remove the through bolts(2) and the rear cover(3). Remove the frame and the field coils(4).

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) .

Install a bearing adapter at the rear side of the bearing as shown in(FIG. L-5). Using an automotive 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.

Inspect 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.

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!4!G!C!9!1!

ELECTRICAL

\

w 1-

z ?;

---

/

FIG. L-2 ELECTRICAL SYSTEM (PHYSICAL LOCATIONS) 12/01/91

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Pg.L-5

ELECTRICAL 4.

Inspect the field coil insulators and lead wire.

BATTERY REMOVAL

5.

Check the bearings for free rotation and lack of end play.

See procedures in Section B.

REPAIR

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.

1.

Commutator - Clean with a soft, clean cloth.

2.

Replace any damaged or cracked brush holders or brushes worn to less than 11/16" in length.

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.

THE HYDROGEN GAS FORMED DURING BATTERY CHARGING IS EXPLOSIVE. AVOID ANY ELECTRI­ CAL SPARK OR OPEN FLAME NEAR BATTERIES.

4.

Using a circuit tester, check the field coils for conti­ nuity between "F1" and "F2" and "OF" 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 .

If the temperature of the battery or the ambient tem­ perature 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.

Clean all parts to be reinstalled and reassembling reverse order of disassembly. Tighten bolts and nuts to the following torques:

DO NOT OVERCHARGE BATTERY.

5.

&WARNING&

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) Tighten terminal nuts to the following torques: F1-F2 ......... 43-52 in.lbs. (50-60 kg-cm) OF ............ 26-35 in.lbs. (30-40 kg cm)

Pg.L-6

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.

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!4!G!C!9!1!

ELECTRICAL

r::f 7 i

3

'� 4

�

'

�

�

�·:

�

FIG. L-3 STARTER/GENERATOR 12/01/91

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ELECTRICAL BRUSH SPRING

BRUSH

COMMUTATO

FIG. L-4 STARTER/GENERATOR BRUSH REMOVAL

PULLER

BEARING ADAPTER (PULLER)

FIG. L-5 BEARING REMOVAL

Pg.L-8

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l !4!G!C!9!1!

OPERATION AND SERVICE MANUAL SECTION: REAR AXLE

M

GENERAL

AXLE ADJUSTMENTS

The vehicle's rear axle is a high efficiency unit featuring a matched set of low friction helical cut gears. The axle is equipped with an internal ground speed sensing gov­ ernor with an external lever that interacts with the accel­ erator cable and the carburetor linkage. The vehicle is equipped with expanding shoe drum brakes on the rear wheels. Brake service instructions are covered in the Brake Section of this manual.

The helical axle has no external or internal adjustments or shims; therefore, no disassembly is required except Jo replace worn or defective components caused by conditions beyond normal control.

DIFFERENTIAL LUBRICATION Tools Required:

Qty.

Screwdriver, phillips, large ................... 1 Screwdriver, straight blade ................... 1 Socket, 13 mm, 3/8" drive .................... 1 Ratchet, 3/8" drive .......................... 1 Funnel with flexible tube ..................... 1 The lubricant level should be checked in accordance with the Periodic Service Schedule contained in Section '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 direction selector lever in the 'F' posi­ tion, remove the trunk lid.

Remove the check bolt from the driver's side of the dif­ ferential and observe if lubricant 'seeps' from the hole. If oil seeps from the hole the level is correct.

If no oil seeps from the check hole, the plastic fill plug should be removed and the specified lubricant added slowly until lubricant flows from the check plug. Replace the check plug.

Reinstall the trunk lid.

If there is evidence of accumulated greasy dirt around the rear axle differential casing, 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 lubrication from the rear axle.

12/01/91 i !4!C!G!9!1 !

REMOVING THE REAR AXLE FROM THE VEHICLE (FIG. M-1 AND FIG. M-2) Tools Required: Qty.

Ratchet, 3/8" drive ................. . ... . . ... 1 Socket, deep well, 9/16", 3/8" drive ............. 1 Wrench, open end, 9/16 .............. . ....... 1 Pliers, needle nose .. . ....................... 1 Jack, hydraulic, trolley ............. .......... 1 Jack stands ..... . ... . . . . . . . . . . . . . . . ..... .. 2 Disconnect the ground wire from battery.

Remove the drive belt (See drive belt removal).

Remove the driven belt (See driven clutch removal).

Loosen rear axle lug nuts approximately one tum.

&_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. Raise the vehicle per instru�tions in section 'B' except that the rear jacks and jack stands are placed under the rear bumper not the U-tube (1). Lift until the shock ab­ sorbers are clear of the mounting brackets. Then sup­ port the U-tube on jack stands.

Remove the wheel and tire assemblies.

Remove retaining rings (2), clevis pins (3) and cotter pins (4) on both brake assemblies.

To disconnect the shifter cables (5), remove the shifter nut (6) that attaches the lever shifter to the rear axle.

Pg. M-1

REAR AXLE Remove spring from governor arm to accelerator cable differential bracket.

curing the lower end of the shock absorbers (17) to the rear axle mounting pads.

Remove nuts (7) and washers (8) freeing the accelera­ tor cable differential bracket (9).

&WARNING&

To remove the governor arm (1O), turn two setscrews (11) out approximately 2 turns and lift the arm off.

Service tip: To remove the female plastic portion of the ball joint linkage, place 3/8" open end wrench on jam nut and rotate clockwise until the black female plastic portion separates from the ball.

Disconnect the governor linkage rod (12) where it meets the governor control arm ball joint (13).

Remove the bolts (14), washers (15), and nuts (16) se-

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. Support the weight of the rear axle on the jack and re­ move the bolts (18), nuts (19), and washers (20) that secure the rear axle to the U-tube.

Support the rear axle while slowly lowering the jack and rear axle to the floor. Slide the axle from under the vehi­ cle.

9

2

(_� ,� 4

FIG. M-1 Pg. M-2

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12/01/91 !4!G!C!9!1 !

REAR AXLE

"-0 C') N .-

FIG. M-2 12/01/91

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E�GDii:S;,i,t•l:I

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 GOVERNOR ARM AND SQUEEZE THE BALL JOINT COMPONENTS TOGETHER. FAILURE TO OB­ SERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE GOVERNOR AND RESULT IN THE NEED FOR A COMPLETE REAR AXLE REMOVAL AND DISASSEMBLY. Installation is in the reverse order of removal.

REAR AXLE 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 SNAP RINGS MUST BE REMOVED / INSTALLED WITH CARE TO PREVENT DAMAGE TO BEARINGS, SEALS AND BEARING BORES.

IIDI®'if�I

It is recommended that whenever a bearing, seal or 'O' ring is removed, it be replaced with a new one regard­ less of mileage. Always wipe the seals and 'O' rings with a light oil before installing.

Removal of the brake assemblies are not required for the disassembly of the rear axle.

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

Tools Required:

Qty.

Arbor press ................................ 1 Pliers, needle nose . . . . . . .. .. . .. . . . .. .. . . . . . . 1 Pliers, snap ring, internal ..................... 1 Slide hammer (E-Z-GO P/N 18753 -G1) ......... 1

BRAKE DRUM AND HUB DISASSEMBLY/ASSEMBLY

Tools Required:

Qty.

Pliers, needle nose . . . . . . . . . . . .. . .. . ........ 1 Jack, hydraulic, trolley . . . . . . . . . . . . ... .... .... 1 Socket, 1 1/16", 1/2" drive . . . . .. . . . . ..... .. ... 1

The following procedure does not require the removal of the rear axle from the vehicle.

Loosen the rear wheel lug nuts approximately one turn.

Raise the vehicle and support on jack stands as speci­ fied in section 'B'. Remove the rear wheels.

Pg. M-4

E�GDiiHi1t•l:i

FIG. M-4 12/01/91

!4!G!C!9!1!

REAR AXLE AXLE SHAFT SEAL REMOVAL AND REPLACEMENT

Remove the outer snap ring (2) from the axle tube.

(FIG.M-4 )and (FIG.M-9)

Tools Required:

Qty.

Pliers, snap ring, internal ............ . ........ 1 Puller, seal 0

.................... . .......... 1

Seal installer (E-Z-GO P/N 18739-G1) ......... 1 Hammer, ball pein .......................... 1

FIG. M-5 Attach a slide hammer to the axle shaft thread and re­ move the axle and bearing from the axle tube.

(FIG.M-5)

FIG. M-7 Remove the inner snap ring (3). (FIG. M-7) 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 pressure to the threaded end of the axle shaft.(FIG.M-6)

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Pg. M-5

REAR AXLE Install the inner snap ring.(FIG.M-7)

AXLE SHAFT REPLACEMENT Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with the differential side gears. Install the outer snap ring (2).

(FIG.M-5)

Coat the outboard spline of the axle with an anti-seize compound. Install the brake hub and drum, thrust wash­ er, nut, and a new cotter pin.

Tighten the axle nut to 70 ft.lbs.torque minimum 1 40 ft lbs torque maximum.Continue to tighten until the slot in the nut aligns with the cotter pin hole.

GOVERNOR ARM REMOVAL

FIG. M-8 Use a puller to remove the seal (4). (FIG. M-8) and (FIG.M-9)

Tools Required:

Qty.

Wrench, open end 1/4" ... .................... 1 Wrench, open end 1/2" ....................... 1 Screwdriver, straight blade, small ............. . 1 Vise grips ................................. 1

SPINDLE CAP ADAPTER

BEARING OUTER SNAP RING

WHEN THE REAR ASSEMBLY IS TO BE REMOVED FROM THE VEHICLE, THE GOVERNOR ARM MUST FIRST BE REMOVED TO PREVENT DAMAGE TO THE GOVERNOR SHAFT.

FIG. M-9

lff!Jlli11n11

USE CARE TO PREVENT DAMAGE TO THE INNER SURFACE OF THE AXLE TUBE AT THE SEALING AREA. To install the seal use the special E-Z-GO seal installer to drive the seal into its correct position.(FIG.M-9) and

Pg. M-6

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. FAILURE TO OB­ SERVE THIS CAUTION MAY RESULT IN SERIOUS DAMAGE TO THE GOVERNOR AND RESULT IN THE NEED FOR A COMPLETE REAR AXLE REMOVAL AND DISASSEMBLY.

Remove the solid linkage from the governor arm.

Service tip: To remove the female portion of the ball joint linkage, place 3/8" open end wrench on jam nut and rotate clockwise until black female plastic por­ tion separates from ball.

E�GDiiHi1t•l:I

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!4!G!C!9!1 !

REAR AXLE Back the two setscrews out approximately 2 turns.

Remove the spring from the governor arm. Remove the governor arm from the governor shaft.

SHIFT CABLE REMOVAL Wrench, open end, 1/2" ...................... 1 Wrench, open end, 3/8" ...................... 1

ify that the transmission is in gear. With the bottom spring compressed the top spring should not be looser than its free length. If the top spring is loose it should be adjusted by tightening the lock nut until the spring just starts to compress.

Repeat the procedure with the transmission in the re­ verse position.

Socket, 3/8", 3/8" drive ...................... 1 Ratchet, 3/8" drive .......................... 1 Extension, 3/8", 6" .......................... 1 Vise grips ................................ 1

DIFFERENTIAL REMOVAL Tools Required:

Qty.

Socket, 17 mm, 1/2" drive .................... 1 In order to prevent damage to the cable, hold the mov­ able inner cable while removing or tightening the lock nut.

Socket, 13 mm, 1/2" drive .........•.......... 1

Remove the lock nuts that retain the springs at the rear axle shift arm. Remove the spring and retainers. In early models remove and discard the pins that pass through the shift arm. Remove the cables from the re­ tainer plate.

AXLE TUBE REMOVAL AND DISASSEMBLY

Re-assembly is in the reverse order of disassembly ex­ cept that the pins used in early models are discarded.

Install the shifter springs with the lever in the neutral po­ sition. Adjust the lock nuts until the 1.62 dimension (measured from cup washer to cup washer) is achieved.

Shift the transmission into the forward position and ver-

12/01/91

l !4!C!Gl9l1!

Ratchet, 1/2" drive .......................... 1 Pan, oil drain ........................ ...... 1

Remove the left and right axle assemblies as detailed elsewhere in this section.

Remove the fill and check drain plug from the differen­ tial case and allow the oil to drain.

Remove the 1O nuts and lock washers that secure the axle tube flanges to the differential casting and remove the differential case.

The seals may now be removed from the differential case and replaced with new seals.

Pg. M-7

REAR AXLE

0 REMOVE AND DISCARD PINS IF EQUIPPED

II II

NEUTRAL

u

INSTALL LENGTH 1.62

TOP SPRING

II II II II II

II II II II FORWARD

Ll

u TOP SPRING

REVERSE

II II II II II u

FIG. M-10 SHIFT CABLE ADJUSTMENT Pg. M-8

E�GDii:t;,i,(•l:I

12/01/91 i4!GICl9l1 I

OPERATION AND SERVICE MANUAL SECTION:PAINT INSTRUCTIONS

Q

fn.WARNING/n.

FOLLOW ALL PAINT MANUFACTURERS/OSHA CAUTIONS AND WARNINGS FOR USE OF PAINTS AND SOL­ VENTS.

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 sys­ tem 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 environment.

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 how­ ever 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 touch­ ing 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 thinner #R7K212 to a viscosity of 24-26 Saybolt Universal Sec­ onds. Add retarder R7K6251 as necessary to slow dry­ ing 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 thinner #R7K6204 to a viscosity of 24-26 Saybolt Universal 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 measur�d 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.

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.

I IDJOOTI� I

I IDJOOTI� I

12/01/91

! !4!C!G!9!1!

I IDJOOTI� I

I IDJOOTI� I

Pg. Q-1

PAINT INSTRUCTIONS

Pg. Q-2

12/01/91 ( (4(C!G!9!1!

OPERATION AND SERVICE MANUAL SECTION:TROUBLE-SHOOTING

R

&WARNING& 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

1• �B

STARTER ROTATES TOO SLOWLY (INSUFFICIENT TORQUE)

.+c

I

I

STARTER DOES NOT ROTATE

I

.. A

POOR PERFORMANCE

ENGINE HARD TO START

D

LOSS OF POWER

.. F

REPEATED SPARK PLUG FOULING

.. H

EXCESSIVE SMOKING

J

BACKFIRING

L

VIBRATION

N

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ENGINE STARTS BUT RUNS ROUGH OR STALLS OVERHEATING CARBURETOR FLOODING INADEQUATE BATTERY CHARGING ERRATIC GOVERNED SPEED

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TROUBLE-SHOOTING THE FOLLOWING IS AN ALPHABETICAL LISTING OF COMPONENT TOPICS COVERED IN THE POWERTRAIN SECTION OF THIS TROUBLE-SHOOTING SECTION. ACCELERATOR (LIMIT) SWITCH

Go to page 13

BATTERY

Go to page 13

CARBURETOR

Go to page 13

FUEL

Go to page 13

FUEL FILTERS

Go to page 14

FUEL LINES

Go to page 14

FUEL PUMP

Go to page 14

FUEL TANK

Go to page 14

FUSE

Go to page 14

INTAKE AIR SYSTEM

Go to page 14

KEY SWITCH

Go to page 14

SOLENOID

Go to page 14

SOLID STATE IGNITION SYSTEM. (S.S.I.)

Go to page 15

SPARK PLUGS

Go to page 15

SPARK PLUG WIRES

Go to page 16

STARTER/GENERATOR

Go to page 16

TIMING

Go to page 16

TRANSMISSION

Go to page 16

VOLTAGE REGULATOR

Go to page 17

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TROUBLE-SHOOTING SECTION 'A' (STARTER DOES NOT ROTATE) DEAD BATTERY 0 Recharge or Replace.

BLOWN FUSE O Replace with a fuse of identical type and value. If the fuse blows again, investigate and correct the cause before replacing the fuse again.

IGNITION SWITCH O Check function and replace if required.

ELECTRICAL SYSTEM O Trouble-shoot per the Electrical section 'L' of this manual. Repair or replace as required.

STARTER SOLENOID O 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 0 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 O Check for excessively worn brushes and replace if required.

0 Check for a dirty armature commutator and clean as described in the Electrical section 'L' of this manual.

O Check for damaged field coils and replace if damage is found.

0 Check for broken wire terminals at the starter generator. Repair.

SECTION 'B' (STARTER ROTATES BUT VEHICLE WILL NOT START)

&_WARNING&_ TESTS THAT INVOLVE FUEL FLOW SHOULD BE AVOIDED IF AT ALL POSSIBLE. IF A TEST TO DETERMINE FUELJVAPOR PRESENCE OR FLOW IS REQUIRED, THE IGNITION SYSTEM MUST BE DISABLED IN ORDER TO PREVENT IGNITION SPARK THAT COULD IGNITE THE FUELJVAPOR. NEVER PERMIT SMOKING OR OPEN FLAME IN AN AREA THAT CONTAINS FUEL. CLEAN UP ALL FUEL SPILLS IMMEDIATELY.

FUEL O Check adequate fuel level. Fill with the correct grade of gasoline.

O Check for a plugged fuel tank vent in the fuel tank gauge. Clean vent or replace cap/gauge.

NO FUEL TO CARBURETOR O Fuel pump not functioning. Repair or replace.

O Loose fuel line clamp permitting air to enter fuel line. Tighten or replace clamp.

O Clogged fuel filter(s). Check and replace both primary and secondary filters if required.

O Fuel line clogged. Clean or replace.

O Broken fuel line. Replace broken portion.

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TROUBLE-SHOOTING CARBURETOR O Main jet contaminated. Clean or replace jet.

O Carburetor throttle lever motion restricted. Check for full free motion.

ENGINE FLOODED O 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.)

ENGINE FUEL STARVED O 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 O Check that the air intake louvers are not deformed or blocked with foreign matter. Repair or clean.

0 Check for restricted air flow at convoluted hose between the seat wrap air intake plenum and the air cleaner enclosure. Adjust or replace.

0 Check condition of filter element. Replace as required.

SPARK PLUGS 0 Check for a disconnected spark plug wire at plug or coil. Connect.

0 Check that coil wires are correctly attached. Check wiring diagram in Electrical section.

O Check for broken wires. Repair or replace.

O Remove the spark plug and check condition and gap. Clean fouled plug or replace with a clean correctly gapped one.

0 Check if plug wire is worn and has shorted to ground. Replace.

O Inoperative coil. (See ignition circuit diagnostic flow chart.) Replace.

O Inoperative ignitor. (See ignition circuit diagnostic flow chart.) Replace.

O Inoperative pulser unit. (See ignition circuit diagnostic flow chart.) Replace.

EXHAUST O Stinger deformed or plugged muffler. Repair or replace.

O Restricted exhaust pipe. Clean or replace.

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TROUBLE-SHOOTING IGNITION CIRCUIT DIAGNOSTIC FLOW CHART NO SPARK

PULSER ASSEMBLY

CONFIRM ALL OTHER COMPONENTS ARE FUNCTIONING BEFORE REPLACING

IGNITION COIL COMPLETE

CHECK BY SUBSTITUTING A 'KNOWN TO BE GOOD' IGNITION COIL.

CONTROL MODULE (IGNITOR)

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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TROUBLE-SHOOTING

SPARK BUT LOW POWER

�,

�,

SPARK PLUG

ENGINE

�, �, �, �, �,

SOLID STATE IGNITION

PULSER ASSEMBLY

IGNITION COIL COMPLETE

CONTROL MODULE (IGNITOR)

--

--------

REFER TO 'NO SPARK'

REFER TO 'NO SPARK'

REFER TO 'NO SPARK'

CHARGING CIRCUIT

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TROUBLE-SHOOTING SECTION 'C' (STARTER ROTATES SLOWLY OR HAS INSUFFICIENT TORQUE) BATTERY 0 Corrosion on battery terminals. Clean the battery posts using a battery post cleaning tool and a baking soda solution.

O Low charge. Recharge or replace.

O Damaged battery post. Replace battery.

WIRING O Corrosion at wire connections. Clean or replace.

0 Disconnected connection. Connect.

O Broken wire. Repair or replace.

O Open circuit. Trouble-shoot per Electrical section 'L' and repair or replace as required.

O Short circuit. Trouble-shoot per Electrical section 'L' and repair or replace as required.

O Poor connection at terminals. Clean, repair or tighten.

STARTER/GENERATOR O Armature commutator dirty or rough. Clean or re-surface.

0 Poor brush to commutator contact. Repair or replace.

0 Short in armature windings. Replace.

0 Open circuit in armature winding. Replace.

O Short in field coils. Replace.

O Open circuit in field coils. Replace O Grounded field coils. Replace O Grounded terminal. Repair or replace.

ENGINE O Oil too heavy for winter operation. Replace with recommended oil.

VOLTAGE REGULATOR O Incorrect output. Replace.

O Poor ground connection. Repair.

O Worn points. Replace.

O Dirty points. Replace.

0 Open or short circuit. Replace.

SECTION 'D' (ENGINE HARD TO START) ELECTRICAL 0 Spark plug wires are in poor condition. Replace.

0 Loose or poor wires at coil, battery, ignitor and module. Repair or replace.

SPARK PLUGS O Remove the spark plug and check the condition and gap. Clean fouled plug or replace with a clean, correctly gapped one.

INTAKE AIR SYSTEM O Check that the air intake louvers are not deformed or blocked with foreign matter.

0 Check for restricted air flow at convoluted hose between the seat wrap air intake plenum and the air cleaner enclosure. Adjust or replace.

O Check condition of filter element. Replace as required.

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TROUBLE-SHOOTING EXHAUST O Muffler or stinger plugged. Repair or replace.

FUEL SYSTEM

&WARNING&

TESTS THAT INVOLVE FUEL FLOW SHOULD BE AVOIDED IF AT ALL POSSIBLE. IF A TEST TO DETERMINE FUEL/VAPOR PRESENCE OR FLOW IS REQUIRED,THE IGNITION SYSTEM MUST BE DISABLED 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. O Fuel pump has a ruptured diaphragm. Replace.

O Loose fuel line clamp permitting air to enter fuel line. Tighten or replace clamp.

O Partially clogged fuel filter(s). Check and replace.

O Fuel line restricted. Clean or replace.

O Water and or dirt in the fuel system. Drain tank and fuel lines, replace fuel filter.

CYLINDER 0 Check compression. Check cylinder head tightness and tighten if required. Overhaul engine if compression is less than 1 00 psi.

ENGINE O Valve sticking. Repair or replace.

SECTION 'E' (ENGINE RUNS ROUGH OR STALLS) SPARK PLUGS 0 Remove the spark plugs and check the condition and gap. Clean a fouled plug or replace it with a clean correctly gapped one.

VALVES O Weak or damaged valve springs. Replace.

O Damaged intake/exhaust valves. Replace.

INTAKE AIR SYSTEM O Check that the air intake louvers are not deformed or blocked with foreign matter.

0 Check for restricted air flow at convoluted hose between the seat wrap air intake plenum and the air cleaner enclosure. Adjust or replace.

O Check condition of filter element. Replace as required.

0 Carburetor loose. Tighten.

0 Water and or dirt in the fuel system. Drain tank and fuel lines, replace fuel filter.

0 Check for a plugged fuel tank vent in the fuel tank gauge. Clean vent or replace cap/gauge.

CARBURETOR 0 Main jet contaminated. Clean or replace jet.

O Carburetor throttle lever motion restricted. Check for full free motion.

O Carburetor incorrectly adjusted. Adjust to specification.

EXHAUST O Stinger deformed or plugged muffler. Repair or replace.

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TROUBLE-SHOOTING WIRING 0 Loose wire(s) in the ignition system or to battery. Tighten.

SECTION 'F' (LOSS OF POWER) FUEL SYSTEM O Fuel pump has a ruptured diaphragm. Replace.

CYLINDER 0 Check compression. Check cylinder head tightness and tighten if required. Overhaul engine if compression is less than 100 psi.

EXHAUST 0 Stinger deformed or plugged muffler. Repair or replace.

CARBURETOR 0 Carburetor lever motion restricted. Check for full free motion.

INTAKE AIR SYSTEM 0 Check that the air intake louvers are not deformed or blocked with foreign matter.

O Check for restricted air flow at convoluted hose between the seat wrap air intake plenum and the air cleaner enclosure. Adjust or replace.

0 Check condition of filter element. Replace as required.

ENGINE OVERHEATS O Check for foreign matter in cylinder fins, blower housing and fan. Clean cooling system.

0 Check that the correct main jet for temperature and altitude is being used.

O Excessive carbon build up. Disassemble and clean.

O Leaking valves. Repair or replace.

0 Insufficient quantity of oil. Add oil, DO NOT OVER FILL.

PRE-IGNITION O Check octane and quality of fuel. Use correct fuel.

O Excessive carbon in cylinder head. Disassemble and clean.

0 Poor spark plugs. Replace.

O Loose cam shaft pulley. Tighten or replace.

0 Incorrect valve timing. Adjust.

O Incorrect valve adjustment. Adjust.

SECTION 'G' (ENGINE OVERHEATING) CLOGGED COOLING FINS O Check for foreign matter in cylinder fins, blower housing and fan. Clean cooling system.

EXHAUST 0 Stinger deformed or plugged muffler. Repair or replace.

ENGINE 0 Leaking valve. Repair or replace.

0 Inadequate oil supply. Clean oil system. Repair oil pump.

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TROUBLE-SHOOTING SECTION 'H' (REPEATED SPARK PLUG FOULING) SPARK PLUG 0 Wrong spark plug type. Replace.

0 Wrong spark plug gap. Adjust.

FUEL O Unsuitable gasoline. Use correct fuel, 87 to 100 octane R.O.M.

INTAKE AIR SYSTEM 0 Air leak in intake air system is allowing dirt/dust to bypass air filter. Repair.

CHOKE O Choke sticking closed. Repair.

CARBURETOR 0 Wrong main jet for altitude and temperature conditions. Replace.

SECTION 'I' (CARBURETOR FLOODS) CARBURETOR 0 Inlet valve/seat dirty or damaged. Clean or replace.

O Fuel contamination. Clean fuel system, clean carburetor.

0 Incorrect float level. Adjust.

O Vent hose pinched or clogged. Clear.

INTAKE AIR SYSTEM 0 Check that the air intake louvers are not deformed or blocked with foreign matter.

0 Check for restricted air flow at convoluted hose between the seat wrap air intake plenum and the air cleaner enclosure. Adjust or replace.

0 Check condition of filter element. Replace as required.

SECTION 'J' {EXCESSIVE SMOKING) OIL O Wrong oil type. Replace with recommended oil.

O Requires changing. Change.

O Crankcase over filled. Drain to proper specifications.

O Check PVC valve condition.

O Piston rings worn or broken. Replace rings and rebuild engine.

0 Valves worn. Replace valves or complete cylinder head assembly.

O Valve seals or valve guides worn. Replace.

SECTION 'K' (STARTER/GENERATOR DOES NOT CHARGE BATTERY PROPERLY) WIRING 0 Open or short circuit in charging circuit. Trouble-shoot per Electrical section 'L' and repair or replace as required.

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TROUBLE-SHOOTING STARTER/GENERATOR

0 Battery terminals corroded. Clean or replace.

O Armature commutator dirty or rough. Clean or re-surface.

0 Poor brush to commutator contact. Repair or replace.

O Short in armature windings. Replace.

0 Open circuit in armature winding. Replace.

O Short in field coils. Replace.

O Open circuit in field coils. Replace O Grounded field coils. Replace O Grounded terminal. Repair or replace.

VOLTAGE REGULATOR

O Incorrect output. Replace.

O Poor ground connection. Repair.

O Poor points. Replace.

O Dirty points. Replace.

O Open or short circuit. Replace.

SECTION 'L' (BACKFIRING) CARBURETOR

O Loose muffler or leaking gasket. Repair.

0 Carburetor throttle valve lever motion restricted. Repair.

0 Carburetor throttle valve lever not closing fully. Adjust.

0 Idle screw preventing throttle valve lever from closing fully. Adjust.

0 Carburetor throttle valve spring weak or broken. Replace.

0 Incorrect adjustment of accelerator, governor and carburetor linkage. Adjust per section 'F'.

O Carburetor throttle lever shaft bent. Replace or rebuild carburetor.

O Governor torsion spring weak or broken. Replace.

O Accelerator limit switch out of adjustment. Adjust.

SECTION 'M' (ERRATIC, SURGING, OR SUDDEN CHANGE IN GOVERNED SPEED) GOVERNOR O Return torsion spring broken. Replace.

0 Problem with the adjustment of accelerator, governor and carburetor linkage. Adjust per section 'F'.

0 Bent governor arm. Replace.

O Bent governor shaft. Replace.

O Internal governor failure (within the rear axle). Repair.

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TROUBLE-SHOOTING SECTION 'N' (VIBRATION) STARTER/GENERATOR BELT 0 Incorrect belt tension. Adjust.

O Damaged or worn belt. Replace.

O Damaged or worn isolation mounts. Replace.

DRIVE BELT O Damaged or worn belt. Replace.

DRIVE CLUTCH O Damaged sheave. Replace.

0 Stuck weight. Rebuild or replace.

O Stuck roller. Rebuild or replace.

O Worn bushing. Rebuild or replace.

DRIVEN CLUTCH O Damaged sheave. Replace.

O Worn bushings. Replace clutch.

ISOLATION MOUNT O Damaged isolation mount. Replace.

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TROUBLE-SHOOTING THE FOLLOWING TROUBLE-SHOOTING GUIDE IS ALPHABETICAL BY COMPONENT. ACCELERATOR LIMIT SWITCH 1.

2.

With the actuator in the 'OUT position, check for switch continuity using a VOM . Replace switch if no continuity is indicated.

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 12.6 volts. 12.0 volts is minimum accept­ able voltage. (Note that a battery voltage below 12.0 volts is a discharged 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.

Corroded Terminals.

CARBURETOR 1.

Check bowl for leaks. Repair.

2.

Check bowl for contamination. Clean.

3.

Check main jet for contamination. Clean or replace.

4.

Check pilot jet for contamination. Clean or replace.

5.

Check for adequate fuel level by checking the float. Adjust.

6.

Float needle valve worn. Replace.

7.

Contamination in float needle valve or seat. Clean or replace.

8.

Check nozzle for contamination. Clean.

9.

Check that nozzle is correctly seated. Repair.

10. Check the throttle butterfly shaft for bends. Replace or rebuild.

11. Check the throttle butterfly shaft bearings. Replace carburetor.

12. Check that torsion spring closes butterfly. Replace spring.

13. Check adjustment of stop screw. 1/8 to 1/4 turn after contacting screw. Adjust.

14. Check that pilot air screw is open 1 1/4turns (factory setting}. Adjust.

15. Check for free and complete motion of choke. Adjust 16. Check choke cable for free and smooth motion. Replace choke cable.

17. Check that spring will close choke and return cable to 'OFF' position. Replace spring.

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TROUBLE-SHOOTING FUEL 1.

Check for adequate fuel in tank. Fill.

2.

Check volatility grade (A through Eis acceptable depending on temperature and altitude). Use correct grade.

3.

Check brand. Use different brand if problems are only with one brand.

4.

Check Octane. Use higher octane as a method of checking.

FUEL FILTERS 1.

Check fuel filter for contamination, cracks or holes. Replace.

2.

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 that gaskets are not covering crankcase hole. Repair.

2.

Check for contamination in check valves. Clean or replace.

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. (7 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.

2.

Check for restricted air flow at convoluted hose between the seat wrap air intake plenum and the air cleaner en­ closure. Adjust or replace.

3.

Check condition of filter element. Replace as required.

4.

Check tightness of tie wraps. Tighten or replace.

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TROUBLE-SHOOTING 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'.

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.

&_WARNING&_ NEVER OPERATE THE STARTER UNLESS BOTH SPARK PLUGS ARE INSTALLED OR THE IGNITION SYS­ TEM DISABLED. FUEL DRAWN INTO THE CYLINDERS WILL BE EXPELLED THROUGH THE SPARK PLUG OPENING AND COULD BE IGNITED BY THE IGNITION SYSTEM, RESULTING IN A FIRE.

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.

When testing the control module or the ignition coil, substituting a known to be good component is the recommended way of determining the serviceability of the component. Remember that replacing the component will require that electrical connections to be changed. Before replacing a component you should be sure that all connections are clean and tight and that the component not poor connections is the cause of the engine malfunction.

CONTROL MODULE (IGNITOR) 1.

Check that ground connections are clean and tight at all ground locations. Clean and tighten.

2.

Use a known to be good ignitor to determine if the existing jgnitor has failed. If the engine runs correctly with the known to be good ignitor, replace the unit.

IGNITION COIL 1.

Check that ground connections are clean and tight at all ground locations. Clean and tighten.

2.

Use a known to be good ignition coil to determine if the existing coil has failed. If the engine runs correctly with the known to be good ignition coil, replace the unit.

3.

Check that the aluminum 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 mounting screws.

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TROUBLE-SHOOTING PULSER COIL 1.

Since extensive labor is required to disassemble the engine in order to remove the pulser coil, it is important to be sure that all other components are functioning correctly. If there is no spark present after verifying the functional­ ity of of other components and wiring; the ignitor coil must be replaced.

SPARK PLUGS 1.

Check Spark Plug Gap..:030 Inches; Re-gap with a wire type plug gauge.

2.

Check for fouling or contamination. Clean and gap or replace plug.

3.

Check spark plug type. Replace with recommended NGK-BP5ES spark plug.

SPARK PLUG TROUBLE-SHOOTING Inspection of spark plugs immediately after they have been removed can tell a great deal about the condition of engine components such as rings, valves, carburetor and the ignition system.

1. Wet and shiny deposits on the base, insulator and electrodes is an indication of an oil fouled plug. Oil fouling may indicate worn rings/piston. Loose valves/seals, incorrect function of ignition system or a weak battery.

2.

A sooty black, fluffy dry deposit indicates a carburetor that is too rich.

3.

A white or light brown glassy looking deposit is an indication of an overheated plug. Indications of crack in the insulator or errosion of the electrodes may also be present. The glassy deposit is a conductor when hot and can result in a misfire at higher R.P.M. These conditions result from an engine that is running too hot, an air/fuel mixture that is too lean, or valves that are not seeting correctly.

A spark plug exhibiting these symptoms should be replaced.

4.

A white, yellow or light tan-rusty brown deposit that is powdery in apearance is an indication of aplug that is oper­ ating efficiently. The deposits may be removed with a light cleaning and the plug returned to service.

SPARK PLUG WIRE 1.

Using a VOM, check for continuity. Replace spark plug wire.

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.

Check amperage. 50 amps maximum, 11 amps continuous at 14 volts is acceptable. Repair or replace if output value is incorrect.

4.

Check brush length. 16 to 24 mm is acceptable. Replace all brushes if any one is shorter than specified length.

TIMING 1.

Check valve timing. Adjust timing belt and inspect cam gear to cam connection.

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TROUBLE-SHOOTING TRANSMISSION (SHIFTS HARD) 1.

Damaged shift cable. Replace cable.

2.

Damaged shift springs. Replace springs.

3.

Transmission oil to heavy for winter conditions. Replace transmission oil.

4.

Shifter components bent or broken. Replace damaged components.

5.

Comers of clutch dogs worn. Replace worn components.

TRANSMISSION (JUMPS OUT OF GEAR) 1.

Shifter cable improperly adjusted or binding. Adjust or replace cable.

2.

Internal shifter components damaged or worn. Replace damaged/worn components.

3.

Damaged shifter springs. Replace springs.

4.

Damaged gears. Replace gears.

VALVE TRAIN NOISE 1.

Valves out of adjustment. Adjust.

2.

Cam or cam gear worn. Replace worn components.

3.

Rocker arm binding on shaft. Repair or replace.

4.

Valve sticking in guide. Repair or replace.

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 O Incorrect tire pressure. Inflate to specified pressure.

WHEEL O Bent wheel rim. Replace.

WHEEL ALIGNMENT O Check Alignment. Adjust.

O Spring and suspension component deterioration. Repair.

WHEEL BRAKE O Dragging wheel brake. Adjust.

SECTION 'P' (VEHICLE PULLS TO ONE SIDE) WHEEL O Incorrect tire pressure. Inflate to specified pressure.

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TROUBLE-SHOOTING NON-POWERTRAIN SYSTEMS SUSPENSION AND STEERING

i-----1

EXCESSIVE TIRE WEAR

0

BINDING OR ERRATIC STEERING

p

VEHICLE PULLS TO ONE SIDE

Q

EXCESSIVE PLAV IN STEERING

R

BRAKE SYSTEM

TO MANUAL SECTION

G

O Mismatched tires on same axle. Replace with same type tire.

O Bent wheel rim. Replace.

WHEEL ALIGNMENT O Check alignment. Adjust.

0 Spring and suspension component deterioration. Repair.

WHEEL BRAKE 0 Dragging wheel brake. Adjust.

FRONT FORK O Fork bent. Replace.

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TROUBLE-SHOOTING SECTION 'Q' (BINDING OR ERRATIC STEERING) TIRES 0 Incorrect tire pressure. Inflate to specified pressure.

WHEEL ALIGNMENT 0 Check alignment. Adjust.

O Spring and suspension component deterioration. Repair.

SUSPENSION AND STEERING COMPONENTS 0 Dry lubrication joints. Lubricate or replace and lubricate joints.

STEERING BOX O Damaged steering box components. Repair or replace.

SECTION 'R' (EXCESSIVE PLAY IN STEERING) SUSPENSION COMPONENTS O Worn suspension components. Repair.

STEERING WHEEL 0 Cracked steering wheel insert (hub). Remove steering wheel and inspect. Replace steering wheel if cracked.

O Damaged or stripped splines in steering wheel insert (hub). Remove steering wheel and inspect. Replace steering wheel if damaged. (Do not exceed specified torque).

0 Damaged or stripped splines on steering shaft. Remove steering wheel and inspect. Replace steering shaft if damaged.

O Loose steering wheel nut. Tighten to specified torque. (Do not exceed specified torque).

O Worn reduction gear. Replace.

0 Worn pinion gear. Replace.

O Worn rack and rod assembly. Replace

STEERING BOX O Loose steering box. Tighten.

IDLER ARM O Worn idler arm bushing. Replace.

WHEEL BEARINGS 0 Loose wheel bearings. Inspect, re-pack and tighten or pack and replace.

WHEEL BRAKE O Wheel brake and entire brake system adjustment and repair is covered under the Brakes section 'G' of this manual.

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OPERATION AND SERVICE MANUAL SECTION: GENERAL SPECIFICATIONS

s

GOLF CAR (GX-444-4) Fleet Car WEIGHT (DRY) ........... ...... ................. 68 5 POUNDS LENGTH ........................................ 94 INCHES WIDTH (AT REAR WHEELS) ....................... 48 INCHES TREAD CENTERS (REAR WHEELS) ................. 39 INCHES TREAD CENTERS (FRONT WHEELS) ................ 33 1/2 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 ................................... 29INCHES LOAD CAPACITY INCLUDING OPERATOR, PASSENGER($), ACCESSORIES AND CARGO ....... 800 POUNDS SEATING ....................................... 2 OCCUPANTS STEERING .... ..... ...... .... ..... .............. RACK AND PINION, DOUBLE REDUCTION FRONT SUSPENSION ..... ........... ............ LEAF SPRINGS AND HYDRAULIC SHOCK ABSORBERS REAR SUSPENSION .............................. COIL SPRINGS AND HYDRAULIC SHOCK ABSORBERS TIRES .......................................... 18.0 X 8.50 X 8 POWER RIB, 4 PLY RATED TIRE PRESSURE ................................ 12-18 PSI CLEARANCE CIRCLE ............................. 19'- 6" BRAKES ...... .......... .................. ...... DRUM, MECHANICAL, AUTO-ADJUSTING (REAR WHEELS) PARKING (HILL) BRAKE ........................... MECHANICAL, AUTOMATIC RELEASE, SELF-COMPENSATING ELECTRICAL SYSTEM ............................ 12V NEGATIVE GROUND BATTERY ....................................... 12V GROUP 26 - MAINTENANCE FREE CHASSIS ... ................... ....... .......... RECTANGULAR STEEL TUBING BODY ...... ................... .... .... ... . ..... ALL REPLACEABLE STEEL AND PLASTIC BODY COMPONENTS BODY PROTECTION .............................. WRAP AROUND VINYL BUMPER, FLEXIBLE COWL CAP, REAR FLEXIBLE FENDER CAPS, SEAT WRAP KICK GUARD

ENGINE AND POWERTRAIN SPECIFICATIONS

TYPE ..........................................

BORE X STROKE ................................

DISPLACEMENT ............ ........... ........ ..

COMPRESSION RATIO ...........................

HORSEPOWER ..................................

COOLING .......... .............. ...............

LUBRICATION ............ .. .............. .. . ....

4-CYCLE, 2 CYLINDER IN-LINE, OVERHEAD CAM 2.52 X 1.n IN. (6 4 X 4 5 MM) 295 CC 9:1 8.5 RATED HORSEPOWER FAN COOLED POSITIVE PRESSURE, GE ROTOR OIL PUMP WITH WASHABLE PERMANENT FILTER SCREEN CYLINDERS ....... ... ................ ... ...... .. DIE CAST ALUMINUM WITH CAST IRON LINER IGNITION ....................................... ELECTRONIC (SSI) STARTING SYSTEM .............................. STARTER/GENERATOR CARBURETOR .................................. FIXED JET, SEPARATE FUEL PUMP .

AIR CLEANER ........... ................ ...... .. DRY, REPLACEABLE CARTRIDGE, REMOTE AIR INTAKE SPARK PLUG TYPE ....... ... ...... .............. NGK BP 5ES SPARK PLUG GAP ... ......... ............... .... .03 0 INCHES FUEL TANK CAPACITY ............................ 5 U.S.GALLONS (18.9 LITERS) FUEL .......................................... 87 TO 100 OCTANE ENGINE OIL ..................................... SAE 1 0W--30 WT OIL, API SF, SG, CC TRANSMISSION .. .......... ..................... FORWARD AND REVERSE TORQUE CONVERTER ........................... AUTOMATIC, VARIABLE SPEED, DRY TYPE, CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TRANSAXLE .................................... HELICAL GEAR AXLE, 13.32:1 RATIO - DIFFERENTIAL LUBRICATION ...................... SAE--3 0 WT OIL, API SF, SG, CC, 40-42 OZ. GOVERNOR ....... .............. ............... GROUND SPEED SENSING SPEED ......................................... 12 M.P.H.(GOVERNED)

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GENERAL SPECIFICATIONS GOLF CAR (GX-444F-4) Freedom WEIGHT (DRY) ..... ..................... ........ 688 POUNDS LENGTH ........................................ 94 INCHES WIDTH (AT REAR WHEELS) ....................... 48 INCHES TREAD CENTERS (REAR WHEELS) ........... ...... 39 INCHES TREAD CENTERS (FRONT WHEELS) ................ 331/2 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 ................................... 29INCHES LOAD CAPACITY INCLUDING OPERATOR, PASSENGER($), ACCESSORIES AND CARGO ....... 800 POUNDS SEATING ....................................... 2OCCUPANTS STEERING ......................... ............. RACK AND PINION, DOUBLE REDUCTION FRONT SUSPENSION ................ ............ LEAF SPRINGS AND HYDRAULIC SHOCK ABSORBERS REAR SUSPENSION ........................... ... COIL SPRINGS AND HYDRAULIC SHOCK ABSORBERS TIRES .......................................... 18.0 X 8.50 X 8 POWER RIB, 4 PLY RATED TIRE PRESSURE ................................ 12-18 PSI CLEARANCE CIRCLE ............................. 1 9' - 6" BRAKES ................ ....... ................. DRUM, MECHANICAL, AUTO-ADJUSTING (REAR WHEELS) PARKING (HILL) BRAKE ........................... MECHANICAL, AUTOMATIC RELEASE, SELF-COMPENSATING ELECTRICAL SYSTEM ............................ 12V NEGATIVE GROUND BATTERY ....................................... 12V GROUP 26- MAINTENANCE FREE LIGHTING ...................................... DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS HORN .......................................... ELECTRIC CHASSIS ....................................... RECTANGULAR STEEL TUBING BODY .......................................... ALL REPLACEABLE STEEL AND PLASTIC BODY COMPONENTS BODY PROTECTION .............................. WRAP AROUND VINYL BUMPER, FLEXIBLE COWL CAP, REAR FLEXIBLE FENDER CAPS, SEAT WRAP KICK GUARD

ENGINE AND POWERTRAIN SPECIFICATIONS

TYPE ............ ...... ....... ........ .........

BORE X STROKE ................................

DISPLACEMENT ........................... ......

COMPRESSION RATIO ...........................

HORSEPOWER ..................................

COOLING .............. ............... ..........

LUBRICATION ......................... ..........

4-CYCLE, 2CYLINDER IN-LINE, OVERHEAD CAM 2.52 X 1.n IN (6 4 X 4 5 MM) 295 CC 9:1 8.5 RATED HORSEPOWER FAN COOLED POSITIVE PRESSURE, GE ROTOR OIL PUMP WITH WASHABLE PERMANENT FILTER SCREEN CYLINDERS . .................................... DIE CAST ALUMINUM WITH CAST IRON LINER IGNITION ......... ...................... ........ ELECTRONIC (SSI) STARTING SYSTEM .............................. STARTER/GENERATOR CARBURETOR .................................. FIXED JET, SEPARATE FUEL PUMP AIR CLEANER ... ..... ........ ................... DRY, REPLACEABLE CARTRIDGE, REMOTE AIR INTAKE SPARK PLUG TYPE ... .. ....... ..... . ............ NGK BP 5ES SPARK PLUG GAP ............................... .0 30 INCHES FUEL TANK CAPACITY ............................ 5 U.S.GALLONS (18.9LITERS) FUEL .......................................... 87 TO 100 OCTANE ENGINE OIL ..................................... SAE 1 0W--30 WT OIL, API SF, SG, CC TRANSMISSION ...... ....................... .... FORWARD AND REVERSE TORQUE CONVERTER ........................... AUTOMATIC, VARIABLE SPEED, DRY TYPE, CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TRANSAXLE .................................... HELICAL GEAR AXLE, 1 3.32:1 RATIO DIFFERENTIAL LUBRICATION ...................... SAE--30 WT OIL, API SF, SG, CC, 40-42 OZ. GOVERNOR .... ................................ GROUND SPEED SENSING SPEED ......................................... 12M.P.H.(GOVERNED)

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GENERAL SPECIFICATIONS TURF TRUCK (GXT-804) INDUSTRIAL TRUCK (GXl-804)

WEIGHT (DRY) ..................................

LENGTH ........................................

WIDTH (AT REAR WHEELS) .......................

TREAD CENTERS (REAR WHEELS) .................

TREAD CENTERS (FRONT WHEELS) ................

WHEEL BASE ...................................

HEIGHT AT STEERING WHEEL .....................

HEIGHT AT FLOOR ...............................

GROUND CLEARANCE (AT DIFFERENTIAL) ..........

SEAT HEIGHT ...................................

LOAD BED HEIGHT ..............................

LOAD BED SIZ E .................................

LOAD CAPACITY INCLUDING OPERATOR, PASSENGER(S) , ACCESSORIES AND CARGO .......

8 45 POUNDS 106 INCHES 48 INCHES 39 INCHES 33 1/2 INCHES 71 INCHES 48 5/8 INCHES 11 INCHES 5 INCHES 29 INCHES 24 INCHES 44 INCHES WIDE, 40 INCHES LONG, 8 INCHES DEEP (8 CUBIC FEET)

SEATING .......................................

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

FRONT SUSPENSION ... .........................

REAR SUSPENSION . .............................

TIRES ..........................................

2 OCCUPANTS RACK AND PINION, DOUBLE REDUCTION HEAVY DUTY LEAF SPRINGS AND HYDRAULIC SHOCK ABSORBERS HEAVY DUTY COIL SPRINGS AND HYDRAULIC SHOCK ABSORBERS REAR, 18.0 X 8.50 X 8 SOFT TRAC, 4 PLY RATED (GXT-804) FRONT, 18.0 X 8.50 X 8 POWER RIB, 4 PLY RATED (GXT-804) 5.70 X 8 , INDUSTRIAL TYPE, 4 PLY RATED (GXl-804) 12-18 PSI (GXT-800-4) 50-60 PSI (GXl-800-4) 19" - 10' 78 INCHES DRUM, MECHANICAL, AUTO-ADJUSTING (REAR WHEELS) MECHANICAL, AUTOMATIC RELEASE, SELF-COMPENSATING 12V NEGATIVE GROUND 12V GROUP 26 - MAINTENANCE FREE DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS (GXl-804-4).

ELECTRIC RECTANGULAR STEEL TUBING ALL REPLACEABLE STEEL AND PLASTIC BODY COMPONENTS

TIRES ..........................................

TIRE PRESSURE ................................

TIRE PRESSURE ................................

CLEARANCE CIRCLE .............................

INTERSECTING AISLE CLEARANCE ................

BRAKES ........ ........ ........................

PARKING (HILL) BRAKE ...........................

ELECTRICAL SYSTEM ............................

BATTERY ........... ............................

LIGHTING ......................................

HORN ......................... .......... .......

CHASSIS .......................................

BODY ..................... ........ .............

1,000 POUNDS

ENGINE AND POWERTRAIN SPECIFICATIONS

TYPE ..........................................

BORE X STROKE ................................

DISPLACEMENT ............ .....................

COMPRESSION RATIO ...........................

HORSEPOWER ..................................

COOLING .......................... .............

LUBRICATION ...................................

4-CYCLE, 2 CYLINDER IN-LINE, OVERHEAD CAM 2.52 X 1.77 IN (64 X 45 MM) 295 CC 9:1 8.5 RATED HORSEPOWER FAN COOLED POSITIVE PRESSURE, GE ROTOR OIL PUMP WITH WASHABLE PERMNENT FILTER SCREEN CYLINDERS............................... ...... DIE CAST ALUMINUM WITH CAST IRON LINER IGNITION .................. ................. .... ELECTRONIC (SSI) STARTING SYSTEM .............................. STARTER/GENERATOR CARBURETOR .................................. FIXED JET, SEPARATE FUEL PUMP AIR CLEANER ................................... DRY, REPLACEABLE CARTRIDGE, REMOTE AIR INTAKE SPARK PLUG TYPE ......................... ..... NGK BP5ES SPARK PLUG GAP ................... ............ .030 INCHES FUEL TANK CAPACITY............................ 5 U.S. GALLONS (18.9 LITERS) FUEL .......................................... 8 7 TO 100 OCTANE ENGINE OIL..................................... SAE 10W--30 WT OIL, API SF, SG, CC TRANSMISSION ................................. FORWARD AND REVERSE TORQUE CONVERTER ........................... AUTOMATIC, VARIABLE SPEED, DRY TYPE, CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TRANSAXLE .................................... HELICAL GEAR AXLE, 13.32:1 RATIO DIFFERENTIAL LUBRICATION ...................... SAE--30 WT OIL, API SF, SG, CC, 40-42 OZ. GOVERNOR ............... ................. .... GROUND SPEED SENSING SPEED ......................................... 12 M.P.H. (GOVERNED)

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GENERAL SPECIFICATIONS PERSONNEL CARRIER (PC4GX-4) PERSONNEL CARRIER (PC4GXl-4) WEIGHT (DRY) ............... ......... .......... 83 5 POUNDS LENGTH ........................................ 106 INCHES WIDTH (AT REAR WHEELS) ....................... 48 INCHES TREAD CENTERS (REAR WHEELS) ................. 39INCHES TREAD CENTERS (FRONT WHEELS) ................ 33 1/2 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 ................................... 29INCHES LOAD CAPACITY INCLUDING OPERATOR, PASSENGER($), ACCESSORIES AND CARGO ....... 800 POUNDS SEATING ....................................... 4 OCCUPANTS STEERING ............. ......................... RACK AND PINION, DOUBLE REDUCTION FRONT SUSPENSION .............. ......... ..... HEAVY DUTY LEAF SPRINGS AND HYDRAULIC SHOCK ABSORBERS REAR SUSPENSION .............................. HEAVY DUTY COIL SPRINGS AND HYDRAULIC SHOCK ABSORBERS TIRES .......................................... 18.5 X 8.50 X 8 POWER CUSHION, 6 PLY RATED (PC4GX-4) TIRES .......................................... 5.70 X 8, INDUSTRIAL TYPE, 6 PLY RATED (PC4GXl-4) TIRE PRESSURE ................................ 12-18 PSI (PC4GX-4) CLEARANCE CIRCLE .. ..... ...... ................ 19" - 6' INTERSECTING AISLE CLEARANCE ................ 7 5 INCHES (PC4GXl-4) BRAKES ................... ............... ...... DRUM, MECHANICAL, AUTO-ADJUSTING (REAR WHEELS) PARKING (HILL) BRAKE ........................... MECHANICAL, AUTOMATIC RELEASE, SELF-COMPENSATING ELECTRICAL SYSTEM ............................ 12V NEGATIVE GROUND BATTERY ....................................... 12V GROUP 26-MAINTENANCE FREE LIGHTING ...................................... DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS HORN .......................................... ELECTRIC CHASSIS ....................................... RECTANGULAR STEEL TUBING BODY .......................................... ALL REPLACEABLE STEEL AND PLASTIC BODY COMPONENTS BODY PROTECTION .............................. WRAP AROUND VINYL BUMPER, FLEXIBLE COWL CAP, VINYL REAR MUD GUARDS, REAR GUARD

ENGINE AND POWERTRAIN SPECIFICATIONS

TYPE ......................... ................. 4-CYCLE, 2 CYLINDER IN-LINE, OVERHEAD CAM BORE X STROKE ... ...... ....................... 2.52 X 1.n IN (64 X 4 5 MM) DISPLACEMENT .. .... .... ...... ........... ...... 295 CC COMPRESSION RATIO ........................... 9:1 HORSEPOWER .................................. 8.5 RATED HORSEPOWER COOLING .............. .............. ........... FAN COOLED LUBRICATION ...... ............................. POSITIVE PRESSURE, GE ROTOR OIL PUMP WITH WASHABLE PERMANENT FILTER SCREEN CYLINDERS . ............. ...... ................. DIE CAST ALUMINUM WITH CAST IRON LINER IGNITION ...................... ........... .. .... ELECTRONIC (SSI) STARTING SYSTEM .............................. STARTER/GENERATOR CARBURETOR .................................. FIXED JET, SEPARATE FUEL PUMP AIR CLEANER ................................... DRY, REPLACEABLE CARTRIDGE, REMOTE AIR INTAKE SPARK PLUG TYPE .......... .................... NGK BP 5ES SPARK PLUG GAP .. ...... ................. ...... .030 INCHES FUEL TANK CAPACITY ............................ 5 U.S.GALLONS (18.9LITERS) FUEL .......................................... 8 7 TO 100 OCTANE ENGINE OIL ..................................... SAE 10W--30 WT OIL, API SF, SG, CC TRANSMISSION ................................. FORWARD AND REVERSE TORQUE CONVERTER ........................... AUTOMATIC, VARIABLE SPEED, DRY TYPE, CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TRANSAXLE .................................... HELICAL GEAR AXLE, 13.32:1 RATIO DIFFERENTIAL LUBRICATION ...................... SAE--30 WT OIL, API SF, SG, CC, 40-42 OZ. GOVERNOR .. ....... ........................... GROUND SPEED SENSING SPEED ......................................... 12 M.P.H.(GOVERNED)

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GENERAL SPECIFICATIONS BEVERAGE CADDY (BC36D-GX-4) WEIGHT(DRY) ...................... ............ 1,042 POUNDS .

LENGTH ........................................ 108 INCHES WIDTH(AT REAR WHEELS) ....................... 48 INCHES TREAD CENTERS(REAR WHEELS) .... ............. 39INCHES TREAD CENTERS(FRONT WHEELS) ................ 33 1/2 INCHES WHEEL BASE ..... ..... ......................... 71 INCHES HEIGHT AT STEERING WHEEL ..................... 48 5/8 INCHES HEIGHT AT FLOOR ............................... 11 INCHES GROUND CLEARANCE(AT DIFFERENTIAL) .......... 5 INCHES SEAT HEIGHT ................................... 29INCHES LOAD HEIGHT ................................... 39INCHES LOAD CAPACITY INCLUDING OPERATOR, ICE CHESTS(+ CONTENTS) AND ACCESSORIES ..... 850 POUNDS COOLER CAPACITY .............. . ............... LARGE - 7.6 CUBIC FEET, SMALL - 1.6 CUBIC FEET(3 60 CANS) SEATING ....................................... 1 DRIVER STEERING ...................................... RACK AND PINION, DOUBLE REDUCTION FRONT SUSPENSION ............................ HEAVY DUTY LEAF SPRINGS AND HYDRAULIC SHOCK ABSORBERS REAR SUSPENSION .................. ............ HEAVY DUTY COIL SPRINGS AND HYDRAULIC SHOCK ABSORBERS TIRES ............................... ........... REAR, 18.5 X 8.50 X 8 SOFT TRAC, 4 PLY RATED FRONT, 18.5 X 8.50 X 8 POWER RIB, 4 PLY RATED TIRE PRESSURE ................................ 12-18 PS CLEARANCE CIRCLE ............................. 19" - 10' BRAKES ............ ..... ...... ................. DRUM, MECHANICAL, AUTO-ADJUSTING(REAR WHEELS) PARKING(HILL) BRAKE ........................... MECHANICAL, AUTOMATIC RELEASE, SELF-COMPENSATING ELECTRICAL SYSTEM ............................ 12V NEGATIVE GROUND BATTERY ..... ..................... ............. 12V GROUP 2 6 - MAINTENANCE FREE LIGHTING ...................................... DUAL HALOGEN HEADLIGHTS, TAILLIGHTS AND BRAKE LIGHTS HORN ............ ............. ................. ELECTRIC CHASSIS ....................................... RECTANGULAR STEEL TUBING BODY ........ .................................. ALL REPLACEABLE STEEL AND FIBERGLASS BODY COMPONENTS BODY PROTECTION .............................. SUN CANOPY STANDARD

ENGINE AND POWERTRAIN SPECIFICATIONS

TYPE .......................................... 4-CYCLE, 2 CYLINDER IN-LINE, OVERHEAD CAM BORE X STROKE ································ 2.52 X 1.nlN ( 64 X 4 5 MM) DISPLACEMENT ................ ................. 295 CC COMPRESSION RATIO ........................... 9:1 HORSEPOWER .................................. 8.5 RATED HORSEPOWER COOLING .......................... ....... . ..... FAN COOLED LUBRICATION .............. ................. .... POSITIVE PRESSURE, GE ROTOR OIL PUMP WITH WASHABLE PERMANENT FILTER SCREEN CYLINDERS ................ ..................... DIE CAST ALUMINUM WITH CAST IRON LINER IGNITION . ...... ..................... ........... ELECTRONIC(SSI) STARTING SYSTEM .............................. STARTER/GENERATOR CARBURETOR .................................. FIXED JET, SEPARATE FUEL PUMP AIR CLEANER .................. ................. DRY, REPLACEABLE CARTRIDGE, REMOTE AIR INTAKE SPARK PLUG TYPE . ...... ................. ...... NGK BP 5ES SPARK PLUG GAP .......... ............... ...... .030 INCHES FUEL TANK CAPACITY ............................ 5 U.S.GALLONS(18.9LITERS) FUEL .......... ...... ............. ............. 87 TO 100 OCTANE ENGINE OIL ..................................... SAE 10W-30 WT OIL, API SF, SG, CC TRANSMISSION ................................. FORWARD AND REVERSE TORQUE CONVERTER ............... ............ AUTOMATIC, VARIABLE SPEED, DRY TYPE, CONTINUOUSLY VARIABLE TRANSMISSION(CVT) TRANSAXLE .................................... HELICAL GEAR AXLE, 13.32:1 RATIO DIFFERENTIAL LUBRICATION ...................... SAE-30 WT OIL, API SF, SG, CC, 40-42 OZ. GOVERNOR .. ............. ................. .... GROUND SPEED SENSING SPEED ......................................... 12 M.P.H.(GOVERNED)

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GENERAL SPECIFICATIONS

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Read and understand the following warnings before attempt­ ing to operate the vehicle:

_A WARNING _A WHEN VEHICLE IS TO BE LEFT UNATTENDED, MOVE DIRECTION SELECTOR TO FORWARD {F) POSITION, TURN KEY TO 'OFF' POSITION, REMOVE KEY AND ENGAGE PARKING {PARK) BRAKE. DRIVE VEHICLE ONLY AS FAST AS TERRAIN AND SAFETY CONSIDERATIONS ALLOW. CONSIDER THE TERRAIN AND EXISTING TRAFFIC CONSIDER ENVIRONMENTAL CONDITIONS. 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 CONTROL SPEED WHEN TRAVELING DOWN AN INCLINE. USE EXTRA CARE AND REDUCED SPEED WHEN DRIVING ON POOR SURFACES, SUCH AS LOOSE DIRT, WET GRASS, GRAVEL, ETC. ALL TRAVEL SHOULD BE DIRECTLY UP OR DOWN HILLS. USE EXTRA CARE WHEN DRIVING THE VEHICLE ACROSS ANY INCLINE. STAY IN DESIGNATED AREAS AND AVOID STEEP SLOPES. USE THE PARKING BRAKE WHENEVER THE VEHICLE IS PARKED. KEEP FEET, LEGS, HANDS AND ARMS INSIDE VEHICLE AT ALL TIMES. AVOID EXTREMELY ROUGH TERRAIN. CHECK THE AREA BEHIND THE BEFORE OPERATING IN REVERSE.

VEHICLE

MAKE SURE THE DIRECTION SELECTOR IS IN CORRECT POSITION BEFORE ATTEMPTING TO START THE VEHICLE. SLOW DOWN BEFORE AND DURING TURNS. ALL TURNS SHOULD BE EXECUTED AT REDUCED SPEED. ALWAYS BRING VEHICLE TO A COMPLETE STOP BEFORE SHIFTING THE DIRECTION SELECTOR. STANDARD VEHICLE IS LIMITED OCCUPANTS MAXIMUM PER SEAT.

TO TWO

ALWAYS REMAIN SEATED AND HOLD ON WHILE VEHICLE IS IN MOTION

Read and understand the following warnings before attempt­ ing to service the vehicle:

_A WARNING _A BEFORE WORKING ON VEHICLE: REMOVE ALL JEWELRY. BE SURE THAT NO LOOSE CLOTHING OR HAIR CAN CONTACT MOVING PARTS OF POWERTRAIN. USE CARE NOT TO CONTACT HOT OBJECTS. RAISE REAR OF VEHICLE AND SUPPORT ON JACK STANDS BEFORE ATTEMPTING TO RUN OR ADJUST POWERTRAIN. WEAR EYE PROTECTION WHEN WORKING ON ANYTHING THAT COULD EXPOSE EYES TO POTENTIAL INJURY. IN PARTICULAR USE CARE WHEN WORKING AROUND BATTERY, USING SOLVENTS OR COMPRESSED AIR.

_A WARNING _A ENGINE EXHAUST GAS {CARBON MONOXIDE) IS DEADLY. CARBON MONOXIDE IS AN ODORLESS, COLORLESS GAS THAT IS FORMED AS A NATURAL PART OF INCOMPLETE COMBUSTION OF HYDROCARBON FUELS. CARBON MONOXIDE IS A DANGEROUS GAS THAT CAN CAUSE UNCONSCIOUSNESS AND IS POTENTIALLY LETHAL. THE FOLLOWING ARE SYMPTOMS OF CARBON MONOXIDE INHALATION: 1. DIZZINESS 2. VOMITING 3. INTENSE HEADACHE 4. MUSCULAR TWITCHING 5. WEAKNESS AND SLEEPINESS 6. THROBBING IN TEMPLES IF YOU EXPERIENCE ANY OF THESE SYMPTOMS, GET FRESH AIR IMMEDIATELY. NEVER WORK AROUND OR OPERATE A VEHICLE IN AN ENVIRONMENT THAT DOES NOT VENTILATE EXHAUST GASES FROM THE AREA.

E-Z-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