Gear Selector Neutral Spring Adjustment 2003 Ezgo Txt UPDATED

Gear Selector Neutral Spring Adjustment 2003 Ezgo Txt

  • Contents

Quick Links

  • 5

    Table of Contents

  • 11

    General Information & Routine Maintenance

  • 29

    Safety

  • 45

    Front end Intermission and Steering

    • 48

      Maintenance

    • 51

      Front Suspension

    • 55

      Steering

  • 65

    Speed Control

    • 67

      Section Title

    • 67

      Organisation Operation

    • 68

      Speed Control

    • 68

      Troubleshooting

    • 70

      Pedal Box Adjustments

  • 73

    Engine

  • 85

    Fuel System

  • 95

    Continuously Variable Transmission (Cvt)

  • 109

    Electrical

614276

TECHNICIAN'Southward

REPAIR AND SERVICE Manual

GASOLINE POWERED PERSONNEL

CARRIERS

ISSUED Feb 2010

Chapters

  • 5

    Table of Contents

  • 11

    Full general Information & Routine Maintenance

  • 29

    Safety

  • 45

    Front end Suspension and Steering

    • 48

      Maintenance

    • 51

      Front Suspension

    • 55

      Steering

  • 65

    Speed Control

    • 67

      Department Championship

    • 67

      System Operation

    • 68

      Speed Command

    • 68

      Troubleshooting

    • 70

      Pedal Box Adjustments

  • 73

    Engine

  • 85

    Fuel System

  • 95

    Continuously Variable Manual (Cvt)

  • 109

    Electric

Troubleshooting

loading

  Related Manuals for Due east-Z-Get TXT Armada

  Summary of Contents for Eastward-Z-Become TXT Armada

  • Page one 614276 TECHNICIAN'S REPAIR AND SERVICE Transmission GASOLINE POWERED PERSONNEL CARRIERS ISSUED Feb 2010...

  • Page ii: Safety

    S AF Due east T Y For any questions on textile contained in this manual, contact an authorized representative for clarification. Read and empathize all labels located on the vehicle. Always replace whatsoever damaged or missing labels. On steep hills it is possible for vehicles to declension 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 than the maximum speed on level footing.
  • Page 3 TXT VALOR Starting Model Year 2010 E-Z-GO Partitioning of TEXTRON Inc. reserves the correct to incorporate engineering and pattern changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Transmission may be revised periodically past the E-Z-Go Division, and therefore is subject to alter without notice.

  • Page 4: General Information

    Full general INFORMATION This vehicle has been designed and manufactured in the The states (U.s.) as a 'Earth Vehicle'. The Standards and Specifications listed in the following text originate in the Usa unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    Table OF CONTENTS TITLE PAGE Safe ........................... Inside Covers Full general Information...........................ii Safety Information ..........................v Title Department General Information & Routine Maintenance ...................A Rubber ...............................B Body ..............................C Wheels and Tires ..........................D Front Suspension and Steering ......................E Speed Control ..........................F Engine .............................
  • Folio 6 Tabular array OF CONTENTS NOTES: Repair and Service Transmission Page iv...

  • Page 7: Safety Information

    REQUIREMENTS. This restriction is of import to the SAFE Apply AND OPERATION of the product. On behalf of E-Z- GO, I am directing that East-Z-GO Branch personnel, Distributors and Dealers propose all customers to adhere to this SAFETY RESTRICTION, in connectedness with the use of all products, new and used, the Distributor or Dealer has rea- son to believe may be operated in personal transportation applications.
  • Page 8 Safety INFORMATION Read all of Section B and this section before attempting any process. Pay detail attention to all Notices, Cautions Warnings and Dangers Never modify the vehicle in any way that volition change the weight distribution of the vehicle, decrease its stability or increase the speed across the factory specification.
  • Page 9 Prophylactic INFORMATION Read all of Section B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions,Warnings and Dangers • Insulate whatsoever tools used inside the battery surface area in guild to foreclose sparks or battery explosion acquired by shorting the battery terminals or associated wiring.
  • Page 10 Rubber Information Read all of Section B and this section before attempting any process. Pay particular attending to all Notices, Cautions Warnings and Dangers NOTES: Page 8 Repair and Service Manual...

  • Page 11: Full general Information & Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR Department 'A' Section Championship PAGE NO. Serial NUMBER LOCATION ................. A - 1 STARTING THE VEHICLE WITH A DISCHARGED Battery........ A - 1 SERVICING THE VEHICLE ..................A - 1 FUEL......................... A - 2 TOWING ........................
  • Page 12 General Data & ROUTINE MAINTENANCE Read all of Section B and this section before attempting whatever process. Pay item attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page A-ii Repair and Service Manual...

  • Page 13: Starting The Vehicle With Adischarged Bombardment

    GENERAL Data & ROUTINE MAINTENANCE Read all of Department B and this section before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. SERIAL NUMBER PLATE AND Observe all instructions provided past the manufacturer of the charger. LOCATION SERVICING THE VEHICLE Two series number and manufacture date code labels are...

  • Folio fourteen: Fuel

    GENERAL Data & ROUTINE MAINTENANCE Read all of Department B and this section earlier attempting whatsoever process. Pay detail attention to all Notices, Cautions, Warnings and Dangers. the safety of yourself and those around you lot, should the component move unexpectedly. Some components are heavy, spring loaded, highly corro- FUEL sive, explosive, may produce amperage or reach loftier...

  • Page 15: Routine Maintenance

    General Information & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. ward) or 'R' (reverse) while being towed, causing possible ROUTINE MAINTENANCE damage to the rear beam. This vehicle volition give years of satisfactory service, provid- Use actress caution when towing vehicle.

  • Page 16: Brakes

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section earlier attempting whatever process. Pay detail attention to all Notices, Cautions, Warnings and Dangers. BRAKES Summit AND WINDSHIELD After the vehicle has been put into service, it is recom- mended that the brakes exist checked past periodically con- ducting a brake operation test.

  • Folio 17: Vehicle Care Products

    GENERAL Information & ROUTINE MAINTENANCE Read all of Section B and this section before attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Removal of oil, tar, asphalt, shoe polish, etc. will require HARDWARE the use of a commercially available vinyl/rubber cleaner. Periodically the vehicle should be inspected for loose The painted surfaces of the vehicle provide attractive fasteners.

  • Folio 18: Torque Specifications

    General Information & ROUTINE MAINTENANCE Read all of Section B and this section earlier attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.

  • Page nineteen: Periodic Service Schedule

    General INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting whatever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - Cheque C&A - Cheque & Adapt CL - Clean R - REPLACE REMARKS Tires - pressure, status of tires &...
  • Page 20 GENERAL Information & ROUTINE MAINTENANCE Read all of Department B and this department before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. REMARKS Necktie Rods - excessive play, bent rods, loose or missing hardware Rear Beam - fluid level, oil leakage, noise, loose or missing hardware Rear Beam - bleed &...
  • Page 21 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-9...
  • Page 22 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting whatever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page A-10 Repair and Service Transmission...

  • Page 23: Safety

    SAFETY Table OF CONTENTS FOR SECTION 'B' SECTION TITLE Folio NO. NOTES, CAUTIONS AND WARNINGS ..............B - 1 Of import Rubber WARNING ................B - 1 MODIFICATIONS TO VEHICLE................B - 1 GENERAL MAINTENANCE..................B - 1 Before SERVICING THE VEHICLE............... B - 1 Bombardment Removal and Installation..............
  • Page 24 Safety Read all of Section B and this section before attempting any process. Pay particular attending to all Notices, Cautions, Warnings and Dangers. NOTES: Page B-ii Repair and Service Manual...

  • Page 25: General Maintenance

    Rubber Read all of Section B and this department before attempting whatsoever procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. Notice, CAUTIONS AND WARNINGS Throughout this manual, the following NOTICE, CAUTIONS, WARNINGS and DANGERS are used. For the protection of all personnel and the vehicle, exist enlightened Changes to the weight distribution or the cen- of and notice the following:...
  • Page 26 SAFETY Read all of Section B and this section earlier attempting whatsoever process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Gear up the parking 'PARK' brake before per- forming whatsoever work on the vehicle. If repairs are to be fabricated that will require welding or cutting, the battery and fuel To forestall illness or decease, discover the follow- tank must be removed and the fuel system...

  • Folio 27: Lifting The Vehicle

    Prophylactic Read all of Section B and this section before attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. two). Middle the jack nether the rear frame crossmember. Enhance the vehicle and locate a jack stand nether the outer ends of the rear axle.
  • Page 28 SAFETY Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page B-four Repair and Service Transmission...
  • Page 29 Torso TABLE OF CONTENTS FOR SECTION 'C' Section Championship Page NO. Body ..................................C - 1 Full general ................................C - 1 Body COMPONENT REPLACEMENT ........................C - 1 Instrument Panel Replacement ........................C - 4 Cowl Replacement ............................C - iv Front Shield Replacement ..........................
  • Page 30 Trunk Read all of Section B and this section before attempting whatsoever process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page C-2 Repair and Service Manual...

  • Page 31: Body Component Replacement

    BODY Read all of Section B and this section earlier attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BODY NOTICE Drill Out Rivet Pop Rivet Caput Only In the following text, there are references to removing/install- ing bolts etc.

  • Page 32: Fig. two Body Components (Front)

    BODY Read all of Section B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Frame Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...

  • Page 33: Fig. 3 Trunk Components (Rear)

    Body Read all of Section B and this section before attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 3 Body Components (Rear) Repair and Service Transmission Page C-3...

  • Page 34: Torso

    BODY Read all of Section B and this section before attempting whatever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. From underneath the cowl, remove the ratchet fastener (xviii) attaching the middle of the splash panel (19) to the frame cross fellow member.

  • Page 35: Body Replacement

    Trunk Read all of Section B and this section earlier attempting whatever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Body Replacement Remove the rivets (32) that secure the floor of the handbag- well surface area to the frame underneath. Tool List Qty.
  • Page 36 Body Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page C-half dozen Repair and Service Manual...

  • Folio 37: Minor Scratches

    Torso-PAINT Read all of Department B and this section before attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers PAINTING hol and dry. 2. Mask the area to be painted (mutual masking tape is Follow the paint manufacturer's recommendations for adequate) prior to repair and use aerosol blazon touch on- specific painting procedures and information.
  • Page 38 Body-PAINT Read all of Department B and this department before attempting any process. Pay particular attention to all Notes, Cautions, Warnings and Dangers NOTES: Page C-8 Repair and Service Transmission...

  • Folio 39: Wheels And Tires

    WHEELS AND TIRES Tabular array OF CONTENTS FOR SECTION 'D' Department TITLE Folio NO. WHEEL AND TIRE SERVICE ................... D - ane Tire Repair ....................... D - ane Bike Installation..................... D - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tire Installation ................. D - 2 Repair and Service Manual Folio D-i...
  • Page forty WHEELS AND TIRES Read all of Department B and this department before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page D-2 Repair and Service Transmission...
  • Page 41 Do not utilise depression inflation pressure level tires on whatever E-Z-GO vehicle. Practice not use any tire which has To forbid injury, be sure mount- a recommended inflation pressure level less than...
  • Page 42 WHEELS AND TIRES Read all of Department B and this section before attempting whatever procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stalk to the outside, mount the wheel onto the hub with lug nuts. Finger tighten lug basics as shown. So, tighten lug nuts to l - 85 ft.
  • Page 43 WHEELS AND TIRES Read all of Department B and this section earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-three...
  • Page 44 WHEELS AND TIRES Read all of Section B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Folio D-4 Repair and Service Transmission...

  • Page 45: Front Intermission And Steering

    Forepart SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION 'E' Section TITLE PAGE NO. MAINTENANCE ......................Eastward - 2 Lubrication ..........................East - 2 Wheel Begetting and King Pin Bushing Inspection ..............E - 2 Wheel Bearing Packing ......................E - 2 Wheel Bearing Aligning ....................E - three Cycle Alignment ........................E - three FRONT Suspension ....................
  • Page 46 FRONT Pause AND STEERING Read all of Section B and this section earlier attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page E-2 Repair and Service Manual...
  • Page 47 Front end SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Band Unit U-Joints...

  • Page 48: Maintenance

    Front SUSPENSION AND STEERING Read all of Section B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Wheel Bearing and King Pin Bushing MAINTENANCE Inspection NOTICE In the following text, there are references to removing/installing To prevent possible injury or death resulting bolts etc.

  • Page 49: Wheel Bearing Adjustment

    Front end SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. the bearing is removed for inspection. It is recom- If completing a bicycle bearing adjustment every bit office of mended that a bearing packer attached to a grease gun another procedure, tighten front wheels per WHEELS be used;...
  • Page 50 Front SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. Test drive vehicle and confirm steering wheel is cor- rectly centered. If it is not centered, disconnect interme- Rear diate shaft from steering shaft and centre steering cycle (Ref.

  • Page 51: Front Break

    Front Interruption AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Role of Frame Office of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.

  • Page 52: Front Axle Replacement

    Front end SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. Front Beam Replacement At the 3 ane/ii" long commodities (20) securing front end of left leap, annotation location of washer (22) and remove it from terminate of Tool Listing Qty.

  • Page 53: Hub Replacement

    FRONT Break AND STEERING Read all of Section B and this section before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Loosen front wheels. Lift and support front of vehicle per NOTICE Safe section. In add-on, support front end axle with jack stands.

  • Page 54: Wheel Begetting And Race Replacement

    Front SUSPENSION AND STEERING Read all of Section B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Remove the dust cap (1), cotter pin (ii) and castellated Bike Bearing and Race Replacement nut (iii) (Ref.

  • Page 55: Steering

    Forepart Pause AND STEERING Read all of Department B and this section before attempting whatsoever process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. STEERING Forepart of Vehicle Flat Section Fig. eleven Steering Components Rack Ball Joint Replacement To remove rack ball articulation (one), loosen rider side front wheel and elevator and back up forepart of vehicle per Tool Listing...

  • Page 56: Tie Rod Inspection/Replacement

    FRONT SUSPENSION AND STEERING Read all of Department B and this department before attempting any process. Pay detail attention to all Notices, Cautions, Warnings and Dangers. To install new rack ball joint close to its correct position, Tie Rod Inspection/Replacement mensurate amount of threads exposed from jam nut (Ref.

  • Page 57: Bellows Replacement

    Front SUSPENSION AND STEERING Read all of Department B and this department before attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Remove cotter pivot (ix) and loosen castellated nut (10) until necktie rod ball articulation (half-dozen) threads are protected. Using a ball joint separator equally a lever, utilize pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm.

  • Page 58: Spindle Replacement

    Forepart SUSPENSION AND STEERING Read all of Section B and this section earlier attempting whatever procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. Spindle Replacement Tool List Qty. Required Needle nose pliers ............1 Secure rack and pinion unit in vice by the mounting ears Wrench, eleven/sixteen".............ane only.

  • Folio 59: Rack And Pinion Unit Disassembly And Inspection

    FRONT SUSPENSION AND STEERING Read all of Section B and this department before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Spindle installation is the contrary society of disassembly. (3) and pinion (4) (Ref. Fig. 17). Loosen jam nut (v) and remove rack ball joint (half dozen) from rack extension (7).

  • Page lx: Checking/Adjusting Rack Extension-To-Rack And Pinion Unit Clearance

    Front SUSPENSION AND STEERING Read all of Section B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Tighten castellated nut (three) to 36 ft. lbs. (50 Nm) torque and proceed to tighten equally needed to insert new cotter pin.

  • Page 61: Steering Cycle Replacement

    FRONT Suspension AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTICE Front of Vehicle To maintain right orientation when replacing steering bike, starting time turn wheels direct ahead. To forestall harm to the clipboard, perform the follow- ing removal procedure.

  • Page 62: Steering Shaft And Column Replacement

    FRONT Interruption AND STEERING Read all of Department B and this section earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Loosen the steering wheel retaining nut (6) 2 to iii Loosen front wheels. Lift and support forepart of vehicle per turns (Ref.
  • Page 63 Forepart SUSPENSION AND STEERING Read all of Department B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Install with arch Small up as shown Retaining Ring Steering Shaft Begetting Groove Fig. 23 Small Retaining Band Orientation Slide moving ridge washer into base of operations of steering cavalcade.
  • Page 64 Forepart Intermission AND STEERING Read all of Section B and this department earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Folio Due east-xviii Repair and Service Manual...

  • Page 65: Speed Control

    SPEED CONTROL TABLE OF CONTENTS FOR SECTION 'F' SECTION TITLE PAGE NO. Organisation Operation ..................F - 1 Pedal Box Operation ..................F - one Governor Operation ..................F - 2 TROUBLESHOOTING ....................F - 2 SPEED CONTROL....................F - 2 Accelerator Cablevision Removal at Governor ............
  • Page 66 SPEED Control Read all of Section B and this section before attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. NOTES: Page F-2 Repair and Service Manual...

  • Page 67: System Operation

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. Accelerator Cable Governor Lever - Upper Governor Lever - Lower Governor Leap Accelerator Compression Spring Fig. one Accelerator and Speed Control System System Functioning NOTICE Pedal Box Functioning...

  • Page 68: Governor Operation

    SPEED CONTROL Read all of Department B and this section earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Governor Operation Drill bit, 3/16"..............ane Rivet gun..............one Until the vehicle reaches its governed speed, the vehicle will continue to advance in relation to the accelerator pedal position.

  • Folio 69: Accelerator Cablevision Removal At Pedal Box

    SPEED Control Read all of Section B and this section before attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Accelerator Cable Removal at Pedal Box Accelerator Cablevision Adjustment (Ref Fig. three) To conform the accelerator cable, position the cable in the To access the micro switch, remove the rocker panel (4), accelerator cablevision bracket at the rear axle so that the lift the floor mat (5) and remove the access encompass (half dozen)

  • Page seventy: Pedal Box Adjustments

    SPEED Control Read all of Section B and this department before attempting any process. Pay particular attending to all Notices, Cautions, Warnings and Dangers. PEDAL BOX ADJUSTMENTS rear axle) should have some slack present and not prove any movement until after the micro switch clicks. Tool Listing Qty.
  • Page 71 SPEED CONTROL Read all of Section B and this section earlier attempting any procedure. Pay detail attending to all Notices, Cautions, Warnings and Dangers. speed specified in the GENERAL SPECIFICATIONS section. Determine speed by measuring the time it takes to travel a known gear up distance with vehicle at maximum speed.
  • Page 72 SPEED CONTROL Read all of Section B and this department earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page F-6 Repair and Service Manual...

  • Page 73: Engine

    ENGINE Table OF CONTENTS FOR Section 'G' Department TITLE PAGE NO. POWERTRAIN MAINTENANCE ................G - 1 Checking the Oil Level ..................G - ane Changing the Oil ....................G - 1 AIR FILTER INSPECTION/REPLACEMENT ............G - 3 Cleaning the Air Filter Chemical element................. G - 3 STARTER/GENERATOR BELT TENSION ...............
  • Page 74 ENGINE Read all of Section B and this section before attempting any process. Pay item attention to all Notices, Cautions, Warnings and Dangers. NOTES: Folio Thousand-ii Repair and Service Manual...

  • Page 75: Checking The Oil Level

    ENGINE Read all of Section B and this department before attempting whatsoever procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers For further engine information, encounter Engine Shop The engine can be operated safely equally long as oil is Rebuild and Service Parts Manual.
  • Page 76 ENGINE Read all of Section B and this section before attempting whatsoever procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers Before installing the drain plug make clean the area around Observe the drain plug mountain with a lint free cloth and inspect the drain plug (1) for damage;...

  • Page 77: Air Filter Inspection/Replacement

    ENGINE Read all of Section B and this section before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers Inspect the new oil filter for whatever defects, apply engine oil AIR FILTER INSPECTION/REPLACE- to the 'O' ring seal and install the new oil filter onto the MENT engine until the seal contacts mounting surface of the engine.

  • Folio 78: Starter/Generator Belt Tension

    ENGINE Read all of Section B and this section earlier attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers STARTER/GENERATOR Chugalug TEN- Re-tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique. A maximum deflec- SION tion of i/2"...
  • Page 79 ENGINE Read all of Section B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Using a socket and open finish wrench, tighten the starter/generator pivot bolts (xiii) and nuts (xiv) to the specified torque value.

  • Page lxxx: Cooling System Cleaning

    ENGINE Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers COOLING Organization CLEANING Spark Plug At least once a year, or more frequently nether adverse condi- tions the cooling system should be cleaned. Cleaning volition assure an adequate supply of air to the cooling fins.

  • Folio 81: Cylinder Head

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers CYLINDER Caput Using the starter motor, turn the engine over with the throttle fully open until the pinch guess stops ris- ing.

  • Page 82: Valve Clearance Inspection

    ENGINE Read all of Section B and this department before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers Valve Clearance Adjustment Turn the crankshaft to the proper management until the pis- ton is at TDC of the compression stroke. Fig.

  • Folio 83: Engine Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers ENGINE REMOVAL 6. Remove the ground strap from the Starter/Generator using a 10 mm socket. Tool Listing Qty.

  • Page 84: Controls And Wiring

    ENGINE Read all of Section B and this department before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers 23. Enhance the powertrain with the floor jack so that the Tighten the bottom and horizontal mounting bolts to 45 clutch puller bolt clears the spring hanger.

  • Page 85: Fuel Organization

    FUEL SYSTEM Table OF CONTENTS FOR SECTION 'H' SECTION Championship PAGE NO. GENERAL......................... H - 1 CARBURETOR Operation ................... H - 2 Float System ....................H - 2 Pilot Jet System ....................H - 2 Main Jet System....................H - 2 Carburetor Service ...................
  • Folio 86 FUEL System Read all of Section B and this section earlier attempting whatever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page H-2 Repair and Service Manual...

  • Page 87: Full general

    FUEL Organisation Read all of Section B and this section earlier attempting whatever process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CARB Canister Fuel Filter Fuel Line to Fuel Tank Carburetor Fuel Gauge Sending Unit of measurement Pulse Line to Crankcase Line Fig.

  • Page 88: Carburetor Operation

    FUEL SYSTEM Read all of Section B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CARBURETOR OPERATION Choke Performance (Ref. Fig. three) The carburetor consists of 4 different systems: • bladder Pull the choke knob (10) out to operate the asphyxiate (Ref.

  • Page 89: Fuel System Component Service And Replacement

    FUEL SYSTEM Read all of Section B and this section before attempting whatsoever procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. FUEL SYSTEM COMPONENT SER- unless otherwise specified. Not-specified torque specifica- tions are as shown in the table contained in Department 'A'. VICE AND REPLACEMENT Feed the choke cable assembly (eight) through the pigsty in the bezel (8) (Ref.
  • Page 90 FUEL System Read all of Department B and this department before attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. Fig. v Carburetor Performance Carburetor Removal Straight blade screwdriver, (narrow) ......1 (Ref. Fig. v) Tool List Qty.

  • Folio 91: Float Level Alignment

    FUEL System Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. Float Bedchamber Stem Bladder Valve Float Carburetor Body Float should be aligned so that its top is parallel or "slightly above"...

  • Page 92: Fuel Lines And Filter

    FUEL SYSTEM Read all of Section B and this section before attempting any process. Pay particular attending to all Notices, Cautions, Warnings and Dangers. fuel pump (1) (Ref. Fig. 8). This motion draws fuel the fuel tank on the passenger side of the vehicle from the fuel tank into the fuel pump chamber.

  • Page 93: Fuel Tank Removal

    FUEL SYSTEM Read all of Department B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. take become clogged. The filter should be replaced equally CARB CANISTER (Ref. Fig. 11) required. See 'Periodic Service Schedule' in Department 'A'. Tool List Qty.
  • Page 94 FUEL System Read all of Department B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page H-8 Repair and Service Manual...

  • Page 95: Continuously Variable Transmission (Cvt)

    CONTINUOUSLY VARIABLE Manual (CVT) Tabular array OF CONTENTS FOR SECTION 'J' Department Title PAGE NO. Full general........................J - one CLUTCHES ........................J - 1 Bulldoze Clutch ......................J - one Driven Clutch ....................J - 2 Increased Load ....................J - two Equilibrium ......................J - two Removing the Bulldoze Belt ...................J - 2 Drive Belt Service .....................J - 2 Bulldoze Clutch Removal ..................J - 2...
  • Page 96 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Department B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers NOTES: Page J-ii Repair and Service Manual...

  • Folio 97: General

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section earlier attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. Driven Clutch Drive Belt Drive Clutch Fig. ane Continuously Variable Manual System (CVT) General moveable sheave inwards.

  • Page 98: Drive Clutch

    CONTINUOUSLY VARIABLE Manual (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Driven Clutch The driven clutch sheaves are closed at rest which results in the drive belt existence held at the outer diameter of the driven clutch.
  • Folio 99 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. Apply only sockets designed for utilize with an the bound hanger. Remove the forepart eyebolt from the impact wrench.

  • Page 100: Drive Clutch Installation

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Department B and this section before attempting whatsoever process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Drive Clutch Installation Driven Clutch Repair (Ref. Fig. three) Make clean both the engine crankshaft and the drive clutch NOTICE diameter.
  • Folio 101 CONTINUOUSLY VARIABLE Transmission (CVT) Read all of Department B and this section earlier attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Folio J-five...
  • Page 102 CONTINUOUSLY VARIABLE Transmission (CVT) Read all of Department B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page J-6 Repair and Service Manual...

  • Page 103: Direction Selector

    Management SELECTOR TABLE OF CONTENTS FOR SECTION 'One thousand' Section TITLE Folio NO. DIRECTION SELECTOR ..................K - 2 Removing Direction Selector ................K - 2 Replacing a Micro Switch ................. K - 2 Shift Cable Adjustment..................K - 2 Neutral Lock Operation ..................Chiliad - two List OF ILLUSTRATIONS Fig.
  • Page 104 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Folio Thousand-ii Repair and Service Manual...
  • Folio 105 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers Fig. 1 Direction Selector Repair and Service Manual Folio 1000-1...
  • Page 106 DIRECTION SELECTOR Read all of Section B and this section before attempting whatever procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers DIRECTION SELECTOR Replacing a Micro Switch To replace a micro switch (v), remove the attaching Before removing a suspected faulty micro switch, hardware (Ref.
  • Page 107 Direction SELECTOR Read all of Section B and this section before attempting any procedure. Pay detail attending to all Notices, Cautions, Warnings and Dangers Spring loaded mechanism. To foreclose possibil- ity of fingers becoming pinched in the direction selector machinery, hold direction selector lever when releasing neutral lock pin handle.
  • Page 108 DIRECTION SELECTOR Read all of Section B and this section earlier attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers NOTES: Folio One thousand-4 Repair and Service Manual...
  • Folio 109 Electric Tabular array OF CONTENTS FOR SECTION 'L' SECTION Title PAGE NO. CIRCUITS AND CONTROLS ..................50 - ane STARTER ......................... L - 1 GENERATOR ......................50 - i WIRING ........................L - i TESTING IGNITION CIRCUIT................... L - i Testing the Magneto ..................L - 5 TESTING STARTING Excursion ................
  • Folio 110 Electrical Read all of Section B and this section before attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. Notes: Folio Fifty-two Repair and Service Manual...

  • Page 111: Circuits And Controls

    ELECTRICAL Read all of Section B and this section before attempting whatever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CIRCUITS AND CONTROLS WIRING The electrical system is a 12 volt negative footing sys- tem (Ref. Fig. 1) (Ref. Fig. three) consisting of a: •...
  • Page 112 Electrical Read all of Department B and this section before attempting whatever procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. Fig. ane Electrical Arrangement Wiring Diagram Repair and Service Transmission Page L-2...
  • Page 113 Electric Read all of Department B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. two Electrical System Wiring Diagram Repair and Service Transmission Page L-3...
  • Page 114 Electrical Read all of Department B and this section earlier attempting any procedure. Pay detail attending to all Notices, Cautions, Warnings and Dangers. Electrical Controller Voltage Starter/Generator Regulator Reverse Buzzer Solenoid Relay Frame Battery Frame To Magneto Direction Selector Hour Meter Accelerator Pedal...

  • Folio 115: Testing The Magneto

    ELECTRICAL Read all of Section B and this section earlier attempting whatever procedure. Pay item attending to all Notices, Cautions, Warnings and Dangers. cylinder, etc.). Turn over the engine with the starter. Look for a blue electric arc at the spark plug elec- trode.

  • Folio 116: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section earlier attempting any process. Pay particular attending to all Notices, Cautions, Warnings and Dangers. TESTING STARTING CIRCUIT (c) If "0" voltage is not indicated while the accelerator pedal is pressed, replace the solenoid. TESTING CHARGING Excursion To foreclose the possibility of injury resulting Tool List...

  • Page 117: Inspection

    ELECTRICAL Read all of Department B and this section earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. prior reading, supplant the regulator. ii. Audit the brush assembly for habiliment and damage to the brush holder insulators. Bank check the brushes for 9) If the above procedures practise non correct the length, approximately 11/16"...

  • Page 118: Battery Voltage Test

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. brushes worn to less than 11/16" (17 mm) in length or Discover to the line marked on the brush. In general, starter/generator service is best performed by 3.

  • Page 119: Storage Of Battery

    Electric Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. STORAGE OF Battery The wiring diagram shows the path followed past a volt- age or betoken from its origination point to its destination. Each wire is indicated past colour and is divided into the A battery that is removed from service for storage must main harness and the dash harness (Ref.
  • Page 120 Electric Read all of Section B and this section before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. battery voltage indicates that the ability wire is in good Notice status. If any DVOM readings indicate a faulty wire, it is recommended Observe that the condition of the terminals and wire junction exist exam- ined.
  • Page 121 Electrical Read all of Section B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. WHITE BROWN GRAY GRAY BLACK Blackness GRAY BLACK BLACK BLACK Bluish Bluish/WHITE Blackness BLACK WHITE Fig. xi Accessory Wiring Diagram Repair and Service Manual Page L-11...
  • Page 122 ELECTRICAL Read all of Section B and this section before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Folio Fifty-12 Repair and Service Manual...

  • Folio 123: Mechanical Brakes

    MECHANICAL BRAKES TABLE OF CONTENTS FOR Department 'G' Department TITLE Folio NO. BRAKE SYSTEM OVERVIEW ...........................M - 1 General Description ............................Chiliad - 1 How the Service Restriction Works ........................Thousand - 2 Equalizer Link ..............................Thou - ii Automatic Adjuster Machinery ........................M - ii How the Parking Restriction Works ........................M - 2 Compensator Associates ..........................One thousand - 3 Kick-Off Actuating Linkage ..........................M - iii...
  • Page 124 MECHANICAL BRAKES TABLE OF CONTENTS FOR Section 'M' SECTION Title PAGE NO. Fig. 15 Adjuster Mechanism ............................K - 12 Fig. 16 Brake Shoe Clothing ............................K - xiii Fig. 17 Orientation of Brake Shoe Springs ......................M - thirteen Fig. eighteen Free Travel Aligning ..........................M - 14 Fig.
  • Page 125 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Identification Hole Hinge Pin Pedal Latch Service Brake Pedal Kicking Off Spacer Catch Subclass...
  • Folio 126 MECHANICAL BRAKES Read all of Section B and this department before attempting any procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers. How the Service Brake Works Depressing the service restriction pedal pulls the compensa- tor assembly and equalizer link, which are connected to the brake cables (Ref.
  • Page 127 MECHANICAL BRAKES Read all of Section B and this section before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Compensator Assembly The compensator assembly contains a leap, which is compressed until the stop tube inside the bound is engaged and the linkage becomes solid (Ref.
  • Folio 128 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Machinery Adjust Visual External Visually Cheque Correct Inspection Visually Inspect Supercede Condition of:...
  • Page 129 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Adjuster Tries Detach Restriction, to Move Star Bicycle? Install Wheel and Tire, Make clean, Lube. Star Bike Rotates? Check Tire Pressure.
  • Page 130 MECHANICAL BRAKES Read all of Section B and this section before attempting whatsoever procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING Tabular array Test (PBPT), and Aggressive Terminate Test is performed (Ref. Fig. six on Page K-6). Refer to the following troubleshooting tabular array only after the thorough visual inspection, Periodic Restriction Performance Condition...
  • Page 131 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Condition Possible Crusade Correction Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification ment is latched.
  • Page 132 MECHANICAL BRAKES Read all of Department B and this section before attempting whatever procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPEC- TION New Vehicles A new vehicle will undergo an initial interruption-in of compo- nents including restriction cables and brake shoes.
  • Page 133 MECHANICAL BRAKES Read all of Section B and this section before attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. cables and linkages or initial burglary of components. brake lever. They must be loose when the brake pedal Not enough pedal gratuitous travel may betoken improper has been released (Ref.
  • Page 134 MECHANICAL BRAKES Read all of Department B and this department earlier attempting any process. Pay particular attending to all Notices, Cautions, Warnings and Dangers. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Confronting Latch Arm At This Point 0.0" Gap Button (0.0 mm) Catch...
  • Page 135 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. ping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle should cease within the "normal"...
  • Page 136 MECHANICAL BRAKES Read all of Department B and this section before attempting any procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. found, the pulsate must be replaced. NOTICE iii. Remove any accumulated brake dust from the bike The brake adjuster mechanism must expand and release fully brake associates with a brush.
  • Page 137 MECHANICAL BRAKES Read all of Department B and this section earlier attempting whatsoever process. Pay item attending to all Notices, Cautions, Warnings and Dangers. seven. Bank check the condition and operation of the moving The pattern of normal restriction shoe wear is anchor assembly (Ref.
  • Page 138 MECHANICAL BRAKES Read all of Department B and this department earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. MAINTENANCE AND REPAIRS travel volition limit braking adequacy. Too footling pedal gratuitous travel may crusade the brakes to drag (non fully released). Tool Listing Qty.
  • Page 139 MECHANICAL BRAKES Read all of Section B and this section before attempting whatever procedure. Pay item attending to all Notices, Cautions, Warnings and Dangers. Cheque to encounter that the clevis pins attaching the brake cables to the brake levers are loose (Ref. Fig. 19 on Page K-15).
  • Page 140 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. i boosted inner brake drum washer (full of 2) to shoes or the friction surface of the brake drum. Use just obtain required spacing.
  • Page 141 MECHANICAL BRAKES Read all of Section B and this section before attempting whatsoever procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. Backing Plate/Entire Cycle Brake Assembly accumulated brake grit from the bankroll plate and adjuster mechanism using a castor or air hose. Removal and Installation If the brake is being removed for an axle bearing and Remove the four bolts (1) and lock nuts (2) securing the...
  • Page 142 MECHANICAL BRAKES Read all of Section B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. The brake shoe end is squared off and engages the the hole in the axle. Maximum torque 140 ft. lbs. (190 screw end of the adjuster.
  • Folio 143 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Summit PULL ADJUSTER ASSEMBLY Fig. 27 Restriction shoes and Springs Compensator Associates, Removal and with restriction lights. Unhook the torsion spring (iv) past insert- ing a thin blade screwdriver betwixt the small hook and Installation the bracket.
  • Page 144 MECHANICAL BRAKES Read all of Section B and this department before attempting whatsoever procedure. Pay detail attending to all Notices, Cautions, Warnings and Dangers. Remove the ii bolts (1) and nuts (2) which secure the catch subclass. Supercede the grab bracket with a new 1, supplant and tighten the hardware to 85 - 95 in.
  • Folio 145 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. setscrew heads in the kick-off cam should be approxi- Parking Brake Boot-Off Cam Removal, mately 1/iv" - 3/8" (6 - 9.five mm). Replacement and Installation.
  • Page 146 MECHANICAL BRAKES Read all of Section B and this department before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page M-22 Repair and Service Manual...

  • Folio 147: Rear Break

    REAR Interruption Tabular array OF CONTENTS FOR Department 'P' SECTION TITLE PAGE NO. REAR SUSPENSION ....................P - 1 Full general ......................P - 1 Stupor Absorber Removal................. P - 1 Stupor Absorber Installation ................P - ane Rear Leap Removal ..................P - i Rear Jump Installation..................
  • Page 148 REAR SUSPENSION Read all of Section B and this section before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page P-ii Repair and Service Manual...

  • Page 149: Full general

    REAR SUSPENSION Read all of Department B and this section earlier attempting any procedure. Pay item attending to all Notices, Cautions, Warnings and Dangers. REAR SUSPENSION Daze Absorber Installation Stupor absorber installation is in the opposite order of dis- Observe assembly except that the shock cushion nuts (one,three) must be tightened until the stupor absorber bushings (4) In the following text, there are references to removing/installing...
  • Folio 150 REAR Pause Read all of Section B and this department earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Vinyl Cap Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual Folio P-two...
  • Page 151 REAR SUSPENSION Read all of Section B and this section earlier attempting whatsoever procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REAR AXLE REMOVAL Remove the accelerator cablevision from the accelerator bracket and take off the button nut holding the cable on Tool List Qty.
  • Page 152 REAR SUSPENSION Read all of Section B and this section before attempting any process. Pay detail attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page P-4 Repair and Service Transmission...

  • Page 153: Rear Axle

    REAR Beam Table OF CONTENTS FOR SECTION 'Q' Section Championship PAGE NO. NEUTRAL LOCK ............................... Q - 1 REAR AXLE ................................Q - ane Checking the Lubricant Level ........................Q - ane REAR Axle DISASSEMBLY ............................ Q - ii Axle Shaft Removal and Disassembly ......................Q - 2 Axle Shaft Seal Removal and Replacement ....................Q - 3 Axle Shaft Replacement ..........................
  • Page 154 REAR AXLE Read all of Department B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page Q-ii Repair and Service Manual...

  • Page 155: Neutral Lock

    REAR Beam Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers For farther axle information, see Four Bicycle Transaxle REAR AXLE Shop Rebuild and Service Parts Manual. The rear axle is provided with a lubricant level check Refer to REAR SUSPENSION section for axle removal.
  • Page 156 REAR Axle Read all of Section B and this section before attempting whatever process. Pay particular attention to all Notices, Cautions, Warnings and Dangers REAR AXLE DISASSEMBLY The rear beam is a precision assembly, and therefore whatever repair or replacement of parts must exist washed with extreme care in a clean environment.
  • Page 157 REAR AXLE Read all of Section B and this department before attempting any process. Pay particular attention to all Notices, Cautions, Warnings and Dangers Beam Shaft Seal Removal and Replacement Tools List Qty. Internal Snap Band Pliers ..........1 Seal Puller ..............1 Plastic Faced Hammer ..........one Ratchet ................one Torque Wrench, ft.
  • Page 158 REAR Beam Read all of Section B and this department before attempting any process. Pay particular attending to all Notices, Cautions, Warnings and Dangers Notes: Page Q-4 Repair and Service Manual...

  • Page 159: Troubleshooting

    TROUBLESHOOTING Table OF CONTENTS FOR Department 'R' Department TITLE PAGE NO. TROUBLESHOOTING ....................R - 1 Gasoline Vehicle Performance ................R - 1 Starter Does Non Turn ..................R - one Starter Turns Slowly..................R - 1 Starter Rotates but Vehicle Doesn't Start or Hard to Get-go ....... R - 1 Engine Runs Rough or Loss of Power .............
  • Page 160 TROUBLESHOOTING Read all of Department B and this section before attempting whatever procedure. Pay item attention to all Notices, Cautions, Warnings and Dangers. Notes: Page R-ii Repair and Service Manual...
  • Page 161 TROUBLESHOOTING Read all of Department B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers GASOLINE VEHICLE Performance Status Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace every bit necessary Terminals are loose or corroded Clean and retighten Poor wiring connections...
  • Page 162 TROUBLESHOOTING Read all of Section B and this department before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction Fuel pump faulty Repair or supercede Fuel line chock-full or clamp loose Clean or replace if required Croaky or broken fuel line Supercede with new hose Principal jet blocked...
  • Page 163 TROUBLESHOOTING Read all of Section B and this section before attempting whatever process. Pay particular attending to all Notices, Cautions, Warnings and Dangers Status Possible Cause Correction POOR LOW SPEED Plugged gas tank vent Clean or repair Functioning Asphyxiate on Push asphyxiate in Carburetor float level incorrect Check/Replace float...
  • Page 164 TROUBLESHOOTING Read all of Department B and this section before attempting whatever procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers Condition Possible Crusade Correction REPEATED SPARK PLUG Wrong spark plug type Supercede with correct spark plug FOULING Wrong spark plug gap Check and adjust if required Faulty magneto...
  • Page 165 TROUBLESHOOTING Read all of Section B and this section before attempting whatever procedure. Pay particular attending to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction ERRATIC, SURGING, OR SUDDEN Damaged governor leap Replace Change IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm...
  • Page 166 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction Operation AND APPLICATION Engine non reaching total temperature Increase run time intervals to build higher cylinder temperature Continuous use at 1/4 throttle or less at depression Instruct operator...
  • Page 167 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Status Possible Crusade Correction POOR High SPEED OPERATION Fuel pump faulty Replace fuel pump Loose main jet Tighten master jet Incorrect fuel level in float bowl Adjust float...

  • Folio 168: Interruption And Steering

    TROUBLESHOOTING Read all of Section B and this department before attempting any procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers Condition Possible Cause Correction RECTIFICATION IS IMPERFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn across limits Replace Commutator is excessively rough...

  • Folio 169: Brake System

    TROUBLESHOOTING Read all of Section B and this department before attempting whatsoever procedure. Pay detail attention to all Notices, Cautions, Warnings and Dangers Condition Possible Crusade Correction STEERING PULLS TO 1 SIDE Wrong tire pressure Inflate to recommended pressure level Dragging wheel brakes Service brake system Suspension component failure Repair...
  • Page 170 TROUBLESHOOTING Read all of Section B and this section before attempting whatever process. Pay item attention to all Notices, Cautions, Warnings and Dangers Status Possible Crusade Correction NEITHER Bicycle LOCKS WHEN Incorrect cable adjustment Render to factory specification PARK Restriction IS LATCHED. (NOTE: Excessive restriction pedal free travel Adjust per manual AT Full SPEED THE WHEELS MAY...
  • Page 171 TROUBLESHOOTING Read all of Section B and this section earlier attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers Notes: Repair and Service Manual Page R-eleven...
  • Page 172 TROUBLESHOOTING Read all of Department B and this section before attempting any procedure. Pay item attending to all Notices, Cautions, Warnings and Dangers Notes: Page R-12 Repair and Service Manual...

  • Folio 173: Limited Warranty

    Express WARRANTY - EMISSIONS Table OF CONTENTS FOR SECTION 'S' Department Championship PAGE NO. Federal Emission Component Defect Warranty (2004) ........Southward - 1 California Emission Control Warranty Statement (2004) .........S - 3 Repair and Service Manual Page Southward-i...
  • Page 174 LIMITED WARRANTY - EMISSIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page S-ii Owner'southward Guide...
  • Page 175 (ii) Hoses, belts, connectors, and assemblies. OBTAINING WARRANTY SERVICE To obtain warranty service, have your engine to the nearest authorized E-Z-GO benefactor, dealer, or service provid- er. Bring your sales receipts indicating engagement of purchase for this engine. The distributor, dealer, or service provider authorized by Due east-Z-GO will perform the necessary repairs or adjustments within a reasonable amount of time and replenish you with a re-create of the repair society.
  • Page 176 VEHICLE WARRANTIES - CALIFORNIA (2009) As the engine owner, you should however be aware that East-Z-Become may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by Due east-Z-GO when a trouble exists.
  • Page 177 Due east-Z-GO recommends that you retain all receipts covering maintenance on your vehicle, only Due east-Z-GO cannot deny warranty solely for the lack of receipts. As the vehicle owner, you should be aware that E-Z-GO may deny you warranty coverage if your vehicle or a covered part has failed due to abuse, fail, or improper maintenance, unapproved modifications, or the use of parts not made or canonical by Due east-Z-Go.
  • Page 178 VEHICLE WARRANTIES - CALIFORNIA (2009) NOTES: Repair and Service Manual Page S-4...

  • Page 179: Full general Specifications

    Tabular array OF CONTENTS FOR Section 'T' SECTION TITLE PAGE NO. TXT FLEET GASOLINE POWERED GOLF CAR ............. T - 1 TXT Liberty GASOLINE POWERED Golf CAR..........T - ii TXT VALOR GASOLINE POWERED Golf game CAR ............ T - 3 Listing OF ILLUSTRATIONS Fig.
  • Page 180 General SPECIFICATIONS Read all of this manual to go thoroughly familiar with this vehicle. Pay particular attending to all Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page T-two...
  • Page 181 11.42:1 (Forrard) 15.78:1 (Reverse) Specifications are subject to change without notice * Do not use low aggrandizement pressure tires on any Due east-Z-Get vehicle. Do not utilize any tire which has a recommended inflation pressure level less than the aggrandizement pressure recommended in Owner's Manual...
  • Page 182 xi.42:1 (Forward) 15.78:i (Opposite) Specifications are field of study to change without find * Do non use low inflation pressure level tires on any E-Z-GO vehicle. Do not use any tire which has a recommended aggrandizement force per unit area less than the inflation pressure recommended in Owner's Transmission...
  • Folio 183 11.42:1 (Forward) xv.78:ane (Reverse) Specifications are subject to change without notice * Do not use depression inflation force per unit area tires on any E-Z-Get vehicle. Do not utilise any tire which has a recommended aggrandizement force per unit area less than the inflation force per unit area recommended in Owner'south Manual...
  • Folio 184 Full general SPECIFICATIONS 68 in. (173 cm) 46.5 in. (118 cm) Forepart four.25 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance 38.5 in. (97 cm) 66.0 in. (168 cm) 91.0 in. (231 cm) 47.0 in. (119 cm) Fig. ane Vehicle Dimensions Repair and Service Manual Page T-4...
  • Page 185 GENERAL SPECIFICATIONS RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% Grade or 14 o MAX 25% Class or 14 o MAX TURNING CLEARANCE DIAMETER FREEDOM xix ft. (5.8 one thousand) FLEET 19 ft. (5.8 m) VALOR 19 ft. (5.eight m) Fig. ii Vehicle Turning Clearance Repair and Service Manual Page T-v...
  • Folio 186 Full general SPECIFICATIONS Read all of this transmission to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTES: Page T-vi Repair and Service Manual...
  • Page 187 Be aware that a vehicle requiring repair indicates that the vehi- Notice cle is no longer performance as designed and therefore should exist considered potentially hazardous. Apply farthermost care when Read the following warnings earlier attempting to operate the working on any vehicle. When diagnosing, removing or replac- ing any components that are not operating correctly, accept time vehicle: to consider the safety of yourself and others effectually you should...
  • Page 188 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Route, Augusta, Georgia 30906 - 3852 United states of america Copyrighted Material This manual may not be reproduced in whole or in part without the limited permission of E-Z-GO Sectionalisation of Textron, Inc. Technical Communications Department...

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Gear Selector Neutral Spring Adjustment 2003 Ezgo Txt UPDATED

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Gear Selector Neutral Spring Adjustment 2003 Ezgo Txt UPDATED. There are any Gear Selector Neutral Spring Adjustment 2003 Ezgo Txt UPDATED in here.