- DL manuals
- E-Z-GO
- Utility Vehicle
- TXT FREEDOM
- Technician's repair and service manual
E-Z-GO TXT FREEDOM Technician's repair and service manual
Summary of TXT FREEDOM
Page 1
Gasoline powered personnel carriers issued february 2010 technician’s repair and service manual 614276.
Page 2: S A F E T Y
S a f e t y for any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal ...
Page 3: Service and Repair Manual
Page i repair and service manual service and repair manual gasoline powered golf car txt fleet txt freedom txt valor starting model year 2010 e-z-go division of textron inc. Reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include the...
Page 4: General Information
Page ii repair and service manual general information this vehicle has been designed and manufactured in the united states of america (usa) as a ‘world vehicle’. The standards and specifications listed in the following text originate in the usa unless otherwise indicated. The use of non original equ...
Page 5: Table Of Contents
Page iii repair and service manual table of contents title page safety ........................................................................................................................... Inside covers general information...........................................................................
Page 6: Table of Contents
Page iv repair and service manual table of contents notes:.
Page 7: Safety Information
Safety information page v repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions,warnings and dangers this manual has been designed to assist in maintaining the vehicle in accordance with procedures develope...
Page 8: Safety Information
Page vi safety information repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions warnings and dangers never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its...
Page 9: Safety Information
Safety information page vii repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions,warnings and dangers • insulate any tools used within the battery area in order to prevent sparks or battery explosion cause...
Page 10: Safety Information
Page viii repair and service manual notes: safety information read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions warnings and dangers.
Page 11
Table of contents for section ‘a’ section title page no. General information & routine maintenance page a-i repair and service manual serial number location ................................................................................. A - 1 starting the vehicle with a discharged battery ...........
Page 12
Page a-ii repair and service manual notes: general information & routine maintenance read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 13
Page a-1 repair and service manual general information & routine maintenance read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Serial number plate and location two serial number and manufacture date code l...
Page 14
Page a-2 general information & routine maintenance repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. The safety of yourself and those around you, should the component move unexpec...
Page 15: Notice
General information & routine maintenance page a-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Ward) or ‘r’ (reverse) while being towed, causing possible damage to the rear ...
Page 16: Notice
Page a-4 general information & routine maintenance repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Brakes after the vehicle has been put into service, it is recom- mended that t...
Page 17: Notice
General information & routine maintenance page a-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Removal of oil, tar, asphalt, shoe polish, etc. Will require the use of a comm...
Page 18
Page a-6 general information & routine maintenance repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Torque specifications fig. 6 torque specifications all torque figures are in f...
Page 19
General information & routine maintenance page a-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Periodic service schedule * - check c&a - check & adjust cl - clean r - replac...
Page 20
Page a-8 general information & routine maintenance repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Tie rods - excessive play, bent rods, loose or missing hardware * * * * rear a...
Page 21
Page a-9 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. General information & routine maintenance.
Page 22
Page a-10 repair and service manual notes: general information & routine maintenance read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 23: Safety
Table of contents for section ‘b’ section title page no. Safety page b-i repair and service manual notes, cautions and warnings .................................................................... B - 1 important safety warning ...........................................................................
Page 24: Safety
Page b-ii repair and service manual notes: safety read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 25: Safety
Safety page b-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Notice, cautions and warnings throughout this manual, the following notice, cautions, warnings and dangers are us...
Page 26: Safety
Page b-2 safety repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Set the parking ‘park’ brake before per- forming any work on the vehicle. If repairs are to be made that will req...
Page 27: Safety
Safety page b-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 battery removal connect the positive (+) battery cable first. Connect negative (-) battery cable last. Be ...
Page 28: Safety
Page b-4 repair and service manual notes: safety read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 29: Body
Page c-i repair and service manual body table of contents for section ’c’ section title page no. Body ......................................................................................................................................................................... C - 1 general .................
Page 30: Body
Page c-ii repair and service manual notes: body read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 31: Body
Page c-1 repair and service manual body read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Body in the following text, there are references to removing/install- ing bolts etc. Additional hardware (nuts, was...
Page 32: Body
Page c-2 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 2 body components (front) 1 4 5 6 7 8 9 10 11 14 15 16 12 17 18 19 20 6 frame 22 23 24 25 26 11.
Page 33: Body
Body page c-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 3 body components (rear) 27 32 30 31 33 34 29 28 48 49 53 52.
Page 34: Body
Page c-4 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. To prevent the possibility of injury due to lack of vehicle information, the correct safety label must be on the in...
Page 35: Body
Body page c-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Body replacement tool list qty. Electric/air drill ............................................................ 1 d...
Page 36: Body
Page c-6 repair and service manual notes: body read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 37: Body-Paint
Body-paint page c-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers painting follow the paint manufacturer’s recommendations for specific painting procedures and information. All...
Page 38: Body-Paint
Page c-8 repair and service manual notes: body-paint read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions, warnings and dangers.
Page 39: Wheels And Tires
Table of contents for section ‘d’ section title page no. Wheels and tires page d-i repair and service manual wheel and tire service ................................................................................... D - 1 tire repair .....................................................................
Page 40: Wheels and Tires
Page d-ii repair and service manual notes: wheels and tires read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 41: Wheels And Tires
Wheels and tires page d-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Wheel and tire service tools list qty. Lug wrench, 3/4"...................................................
Page 42: Wheels and Tires
Page d-2 wheels and tires repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Wheel installation do not tighten lug nuts to more than 85 ft. Lbs. (115 nm) torque. It is important to...
Page 43: Wheels And Tires
Page d-3 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Wheels and tires.
Page 44: Wheels and Tires
Page d-4 repair and service manual notes: wheels and tires read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 45
Table of contents for section ‘e’ section title page no. Page e-i repair and service manual front suspension and steering maintenance ............................................................................................................ E - 2 lubrication ..........................................
Page 46
Page e-ii repair and service manual notes: front suspension and steering read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 47
Page e-1 repair and service manual front suspension and steering read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 steering and front suspension part of frame part of frame wave washer bearing outer...
Page 48: Notice
Page e-2 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Maintenance in the following text, there are references to removing/installing bolts etc. ...
Page 49: Notice
Front suspension and steering page e-3 repair and service manual 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- mended that a bearing packer attached ...
Page 50: Notice
Page e-4 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 4 wheel alignment to hold threaded tube while loosening jam nut, use a wrench on the ...
Page 51
Front suspension and steering page e-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Front suspension fig. 6 front suspension components front shock absorber replacement tool ...
Page 52: Notice
Page e-6 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Front axle replacement tool list qty. Required ratchet, 1/2" drive ..........................
Page 53: Notice
Front suspension and steering page e-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Loosen front wheels. Lift and support front of vehicle per safety section. In addition, su...
Page 54
Page e-8 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Remove the dust cap (1), cotter pin (2) and castellated nut (3) (ref. Fig. 8). While holdi...
Page 55
Front suspension and steering page e-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Steering fig. 11 steering components rack ball joint replacement tool list qty. Required n...
Page 56: Notice
Page e-10 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. To install new rack ball joint close to its correct position, measure amount of threads e...
Page 57: Notice
Front suspension and steering page e-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Remove cotter pin (9) and loosen castellated nut (10) until tie rod ball joint (6) thread...
Page 58: Notice
Page e-12 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Secure rack and pinion unit in vice by the mounting ears only. The rack and pinion unit i...
Page 59: Notice
Front suspension and steering page e-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Spindle installation is the reverse order of disassembly. The thrust washer (9) is locate...
Page 60
Page e-14 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. After replacing or servicing steering components, always verify that an 1/8" gap exists b...
Page 61: Notice
Front suspension and steering page e-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 18 spindle contact with front axle with spindle arm resting against front axle, cut ...
Page 62
Page e-16 front suspension and steering repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Loosen the steering wheel retaining nut (6) two to three turns (ref. Fig. 21). Do not rem...
Page 63
Front suspension and steering page e-17 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 23 small retaining ring orientation slide wave washer into base of steering column. ...
Page 64
Page e-18 repair and service manual notes: front suspension and steering read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 65: Speed Control
Table of contents for section ‘f’ section title page no. Speed control page f-i repair and service manual system operation ......................................................................................... F - 1 pedal box operation ................................................................
Page 66: Speed Control
Page f-ii repair and service manual notes: speed control read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 67: Speed Control
Speed control page f-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 accelerator and speed control system the linkages that control the accelerator mechanism, governor ...
Page 68: Speed Control
Page f-2 speed control repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Governor operation until the vehicle reaches its governed speed, the vehicle will continue to accelerate i...
Page 69: Speed Control
Speed control page f-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Accelerator cable removal at pedal box to access the micro switch, remove the rocker panel (4), lift the f...
Page 70: Speed Control
Page f-4 speed control repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Pedal box adjustments tool list qty. Needle nose pliers......................................................
Page 71: Speed Control
Speed control page f-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Speed specified in the general specifications section. Determine speed by measuring the time it takes to t...
Page 72: Speed Control
Page f-6 repair and service manual speed control read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Notes:.
Page 73: Engine
Table of contents for section ‘g’ section title page no. Engine page g-i repair and service manual powertrain maintenance ............................................................................... G - 1 checking the oil level ........................................................................
Page 74: Engine
Page g-ii repair and service manual notes: engine read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 75: Engine
Page g-1 repair and service manual engine read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers for further engine information, see engine shop rebuild and service parts manual. Powertrain maintenance access th...
Page 76: Engine
Page g-2 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers if vehicle is to be stored over winter months, it can be stored with old oil left in engine. The oil should be cha...
Page 77: Engine
Engine page g-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers inspect the new oil filter for any defects, apply engine oil to the ’o’ ring seal and install the new oil filter o...
Page 78: Engine
Page g-4 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers starter/generator belt ten- sion tool list qty. Belt tension gauge ..................................................
Page 79: Engine
Engine page g-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers using a socket and open end wrench, tighten the starter/generator pivot bolts (13) and nuts (14) to the specified ...
Page 80: Engine
Page g-6 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers cooling system cleaning at least once a year, or more often under adverse condi- tions the cooling system should b...
Page 81: Engine
Engine page g-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers cylinder head compression measurement tool list qty. Ratchet ........................................................
Page 82: Engine
Page g-8 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers fig. 19 rocker cover valve clearance inspection tool list qty. Allen bit, 3 mm ......................................
Page 83: Engine
Engine page g-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers engine removal tool list qty. Socket, 10 mm ............................................................ 1 socket,...
Page 84: Engine
Page g-10 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers 23. Raise the powertrain with the floor jack so that the clutch puller bolt clears the spring hanger. Remove the ...
Page 85: Fuel System
Table of contents for section ‘h’ section title page no. Fuel system page h-i repair and service manual general ................................................................................................................. H - 1 carburetor operation ..................................................
Page 86: Fuel System
Page h-ii repair and service manual notes: fuel system read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 87: Fuel System
Page h-1 repair and service manual fuel system read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 fuel system general illustrations in this section may include components used on vehicles that comply...
Page 88: Fuel System
Page h-2 fuel system repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Carburetor operation the carburetor consists of four different systems: • float • pilot jet • main jet • cho...
Page 89: Fuel System
Fuel system page h-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fuel system component ser- vice and replacement choke cable and housing removal (ref. Fig. 3) (ref. Fig. 4) ...
Page 90: Fuel System
Page h-4 fuel system repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 5 carburetor operation carburetor removal (ref. Fig. 5) tool list qty. Socket, 10 mm .....................
Page 91: Fuel System
Fuel system page h-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 6 carburetor disassembly float level alignment (ref. Fig. 7) the float level cannot be adjusted but sho...
Page 92: Fuel System
Page h-6 fuel system repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fuel pump (1) (ref. Fig. 8). This movement draws fuel from the fuel tank into the fuel pump chamber. This ac...
Page 93: Fuel System
Fuel system page h-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Have become clogged. The filter should be replaced as required. See ‘periodic service schedule’ in section ‘...
Page 94: Fuel System
Page h-8 repair and service manual notes: fuel system read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 95
Table of contents for section ‘j’ section title page no. Continuously variable transmission (cvt) page j-i repair and service manual general ..................................................................................................................J - 1 clutches .................................
Page 96: Notes:
Page j-ii repair and service manual notes: continuously variable transmission (cvt) read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers.
Page 97
Page j-1 repair and service manual continuously variable transmission (cvt) read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 continuously variable transmission system (cvt) general power transmissi...
Page 98
Page j-2 continuously variable transmission (cvt) repair and service manual 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...
Page 99: Notice
Continuously variable transmission (cvt) page j-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Use only sockets designed for use with an impact wrench. Never use a socket int...
Page 100: Notice
Page j-4 continuously variable transmission (cvt) repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Drive clutch installation (ref. Fig. 3) clean both the engine crankshaft and th...
Page 101
Page j-5 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Continuously variable transmission (cvt).
Page 102
Page j-6 repair and service manual notes: continuously variable transmission (cvt) read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 103: Direction Selector
Table of contents for section ‘k’ section title page no. Direction selector page k-i repair and service manual direction selector .......................................................................................... K - 2 removing direction selector ................................................
Page 104: Notes:
Page k-ii repair and service manual notes: direction selector read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 105: Direction Selector
Page k-1 repair and service manual direction selector read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers fig. 1 direction selector 1 6 4 5 6 8 2 8 3 10 9 11.
Page 106: Direction Selector
Page k-2 direction selector repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers direction selector before removing a suspected faulty micro switch, ensure the electrical wires are fi...
Page 107: Direction Selector
Direction selector page k-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers spring loaded mechanism. To prevent possibil- ity of fingers becoming pinched in the direction selecto...
Page 108: Direction Selector
Page k-4 repair and service manual notes: direction selector read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers.
Page 109: Electrical
Table of contents for section ‘l’ section title page no. Electrical page l-i repair and service manual circuits and controls .................................................................................... L - 1 starter ...............................................................................
Page 110: Electrical
Page l-ii repair and service manual notes: electrical read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 111: Electrical
Page l-1 repair and service manual electrical read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Circuits and controls the electrical system is a 12 volt negative ground sys- tem (ref. Fig. 1) (ref. Fig. 3)...
Page 112: Electrical
Page l-2 electrical repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 electrical system wiring diagram fuel gage oil light f e fuel sending unit a b t o oil light switch on...
Page 113: Electrical
Electrical page l-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 2 electrical system wiring diagram f2 f1 a2 a1 df blk t o engine st ar ter/ genera t or grn a b 1 2 3 vo...
Page 114: Electrical
Page l-4 electrical repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 3 electrical system (physical location) do not arc spark plug wire to ground. Connect to a known good sp...
Page 115: Electrical
Electrical page l-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Cylinder, etc.). Turn over the engine with the starter. Look for a blue electrical arc at the spark plug elec...
Page 116: Electrical
Page l-6 electrical repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Testing starting circuit to prevent the possibility of injury resulting from vehicle inadvertently starting, ...
Page 117: Electrical
Electrical page l-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Prior reading, replace the regulator. 9) if the above procedures do not correct the problem, check for faults...
Page 118: Electrical
Page l-8 electrical repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. In general, starter/generator service is best performed by trained motor technicians who have the knowledge a...
Page 119: Electrical
Electrical page l-9 repair and service manual 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 a battery that is removed from service for storage must be cared for as follows: for batte...
Page 120: Electrical
Page l-10 electrical repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. If any dvom readings indicate a faulty wire, it is recommended that the condition of the terminals and wire ...
Page 121: Electrical
Electrical page l-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 11 accessory wiring diagram brake rela y 30 87a 87 86 85 brown brown gra y white brown cap hea t shrink...
Page 122: Electrical
Page l-12 repair and service manual notes: electrical read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 123: Mechanical Brakes
Page m-i repair and service manual mechanical brakes table of contents for section ’m’ section title page no. Brake system overview ...................................................................................................................................M - 1 general description ..............
Page 124: Mechanical Brakes
Page m-ii repair and service manual mechanical brakes table of contents for section ’m’ section title page no. Fig. 15 adjuster mechanism ....................................................................................................................................M - 12 fig. 16 brake shoe wear...
Page 125: Mechanical Brakes
Page m-1 repair and service manual mechanical brakes read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 mechanical brake system brake system overview general description this vehicle is equipped with...
Page 126: Mechanical Brakes
Page m-2 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. How the service brake works depressing the service brake pedal pulls the compensa- tor assembly and eq...
Page 127: Mechanical Brakes
Mechanical brakes page m-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Compensator assembly the compensator assembly contains a spring, which is compressed until the stop tu...
Page 128: Mechanical Brakes
Page m-4 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Troubleshooting flowchart fig. 4 troubleshooting flowchart do steps through to one side at a time 1 ba...
Page 129: Mechanical Brakes
Mechanical brakes page m-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 5 troubleshooting flowchart adjuster tries to move star wheel? Star wheel rotates? Free movement ...
Page 130: Mechanical Brakes
Page m-6 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Troubleshooting table refer to the following troubleshooting table only after the thorough visual insp...
Page 131: Mechanical Brakes
Mechanical brakes page m-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Neither wheel locks when park brake is latched. (note: at full speed the wheels may not lock, but shou...
Page 132: Mechanical Brakes
Page m-8 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Troubleshooting and inspec- tion new vehicles a new vehicle will undergo an initial break-in of compo-...
Page 133: Mechanical Brakes
Mechanical brakes page m-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Cables and linkages or initial break-in of components. Not enough pedal free travel may indicate impro...
Page 134: Mechanical Brakes
Page m-10 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 11 parking brake pedal hinge inspection 9. Check the condition and operation of the parking brak...
Page 135: Mechanical Brakes
Mechanical brakes page m-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 13 periodic brake performance test over time, a subtle loss of performance may take place; there...
Page 136: Mechanical Brakes
Page m-12 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. The brake adjuster mechanism must expand and release fully to function. Under light usage this may no...
Page 137: Mechanical Brakes
Mechanical brakes page m-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. 7. Check the condition and operation of the moving anchor assembly (ref. Fig. 22 on page k-16). Opera...
Page 138: Mechanical Brakes
Page m-14 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Maintenance and repairs tool list qty. Required hydraulic floor jack ...................................
Page 139: Mechanical Brakes
Mechanical brakes page m-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Check to see that the clevis pins attaching the brake cables to the brake levers are loose (ref. Fig....
Page 140: Mechanical Brakes
Page m-16 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. One additional inner brake drum washer (total of 2) to obtain required spacing. Do not back off nut t...
Page 141: Mechanical Brakes
Mechanical brakes page m-17 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Backing plate/entire wheel brake assembly removal and installation remove the four bolts (1) and lock...
Page 142: Mechanical Brakes
Page m-18 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. The brake shoe end is squared off and engages the screw end of the adjuster. The brake shoe is stampe...
Page 143: Mechanical Brakes
Mechanical brakes page m-19 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 27 brake shoes and springs compensator assembly, removal and installation disconnect the compens...
Page 144: Mechanical Brakes
Page m-20 mechanical brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 28 brake pedal removal and installation parking brake catch bracket removal and installation rem...
Page 145: Mechanical Brakes
Mechanical brakes page m-21 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Setscrew heads in the kick-off cam should be approxi- mately 1/4" - 3/8” (6 - 9.5 mm). Tighten the lo...
Page 146: Mechanical Brakes
Page m-22 repair and service manual notes: mechanical brakes read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 147: Rear Suspension
Table of contents for section ‘p’ section title page no. Rear suspension page p-i repair and service manual rear suspension ................................................................................................ P - 1 general ....................................................................
Page 148: Rear Suspension
Page p-ii repair and service manual notes: rear suspension read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 149: Rear Suspension
Rear suspension page p-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Rear suspension in the following text, there are references to removing/installing bolts etc. Additional...
Page 150: Rear Suspension
Page p-2 rear suspension repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Fig. 1 rear suspension front of the vehicle 1 2 10 11 7 10 9 9 9 9 vinyl cap 3 5 5 6 4 4 8 8.
Page 151: Rear Suspension
Rear suspension page p-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers. Rear axle removal tool list qty. Lug wrench, 3/4"..........................................................
Page 152: Rear Suspension
Page p-4 repair and service manual notes: rear suspension read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 153: Rear Axle
Page q-i repair and service manual rear axle table of contents for section ’q’ section title page no. Neutral lock ....................................................................................................................................................... Q - 1 rear axle ....................
Page 154: Rear Axle
Page q-ii repair and service manual notes: rear axle read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 155: Rear Axle
Page q-1 repair and service manual rear axle read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers for further axle information, see four cycle transaxle shop rebuild and service parts manual. Refer to rear sus...
Page 156: Rear Axle
Page q-2 rear axle repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers rear axle disassembly the rear axle is a precision assembly, and therefore any repair or replacement of parts m...
Page 157: Rear Axle
Rear axle page q-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers axle shaft seal removal and replacement tools list qty. Internal snap ring pliers ................................
Page 158: Rear Axle
Page q-4 repair and service manual notes: rear axle read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers.
Page 159: Troubleshooting
Table of contents for section ‘r’ section title page no. Troubleshooting page r-i repair and service manual troubleshooting .............................................................................................. R - 1 gasoline vehicle performance .................................................
Page 160: Troubleshooting
Page r-ii repair and service manual notes: troubleshooting read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers..
Page 161: Troubleshooting
Page r-1 repair and service manual troubleshooting read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers gasoline vehicle performance condition possible cause correction starter does not turn weak or bad batter...
Page 162: Troubleshooting
Page r-2 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers fuel pump faulty repair or replace fuel line clogged or clamp loose clean or replace if required cracked ...
Page 163: Troubleshooting
Troubleshooting page r-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers poor low speed performance plugged gas tank vent clean or repair choke on push choke in carburetor float ...
Page 164: Troubleshooting
Page r-4 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers repeated spark plug fouling wrong spark plug type replace with correct spark plug wrong spark plug gap ch...
Page 165: Troubleshooting
Troubleshooting page r-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers erratic, surging, or sudden change in governed speed damaged governor spring replace problem with adjustm...
Page 166: Troubleshooting
Page r-6 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers operation and application engine not reaching full temperature increase run time intervals to build highe...
Page 167: Troubleshooting
Troubleshooting page r-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers starter / generator poor high speed operation fuel pump faulty replace fuel pump loose main jet tighten m...
Page 168: Troubleshooting
Page r-8 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers suspension and steering rectification is imperfect load exceeds specification adjust load to specificatio...
Page 169: Troubleshooting
Troubleshooting page r-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers brake system steering pulls to one side incorrect tire pressure inflate to recommended pressure dragging ...
Page 170: Troubleshooting
Page r-10 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers neither wheel locks when park brake is latched. (note: at full speed the wheels may not lock, but should...
Page 171: Troubleshooting
Page r-11 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers troubleshooting.
Page 172: Troubleshooting
Page r-12 repair and service manual notes: troubleshooting read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions, warnings and dangers.
Page 173
Table of contents for section ‘s’ section title page no. Page s-i repair and service manual limited warranty - emissions federal emission component defect warranty (2004) ...................................S - 1 california emission control warranty statement (2004) .................................S...
Page 174: Limited Warranty - Emissions
Page s-ii owner’s guide notes: limited warranty - emissions read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions, warnings and dangers..
Page 175
Page s-1 repair and service manual vehicle warranties - california (2009) federal emissions component defect warranty emissions component defect warranty coverage - this emission warranty is applicable in all states, except the state of california kawasaki heavy industries ltd. And e-z-go division o...
Page 176
Page s-2 repair and service manual vehicle warranties - california (2009) as the engine owner, you should however be aware that e-z-go 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 prese...
Page 177
Page s-3 repair and service manual vehicle warranties - california (2009) california evapor ative emission control w arr anty statem ent your warranty rights and obligations: the california air resources board and the e-z-go division of textron inc. (e-z-go) are pleased to explain the evaporative em...
Page 178
Page s-4 repair and service manual vehicle warranties - california (2009) notes:.
Page 179: General Specifications
Table of contents for section ‘t’ section title page no. General specifications page t-i repair and service manual txt fleet gasoline powered golf car ..................................................... T - 1 txt freedom gasoline powered golf car............................................... T - ...
Page 180: General Specifications
Page t-ii repair and service manual general specifications notes: read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions, warnings and dangers..
Page 181: General Specifications
Page t-1 repair and service manual general specifications txt fleet model: txt fleet golf car type: gasoline powered fleet golf car model year: 2010 engine: 13 hp (9.7 kw) exceeds sae j1940 standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by kawasaki valve train: overhead valve fuel s...
Page 182: General Specifications
Page t-2 repair and service manual general specifications txt freedom model: txt freedom golf car type: gasoline powered freedom golf car model year: 2010 engine: 13 hp (9.7 kw) exceeds sae j1940 standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by kawasaki valve train: overhead valve ...
Page 183: General Specifications
Page t-3 repair and service manual general specifications txt valor model: txt valor golf car type: gasoline powered valor golf car model year: 2010 engine: 13 hp (9.7 kw) exceeds sae j1940 standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by kawasaki valve train: overhead valve fuel s...
Page 184: General Specifications
Page t-4 repair and service manual general specifications fig. 1 vehicle dimensions 47.0 in. (119 cm) front 34.0 in. (86 cm) rear 38.5 in. (97 cm) 46.5 in. (118 cm) 68 in. (173 cm) 66.0 in. (168 cm) 91.0 in. (231 cm) 4.25 in. (11.0 cm) ground clearance.
Page 185: General Specifications
Page t-5 repair and service manual general specifications fig. 2 vehicle turning clearance turning clearance diameter 19 ft. (5.8 m) recommended max ramp 25% grade or 14o max recommended max side tilt 25% grade or 14o max freedom 19 ft. (5.8 m) fleet 19 ft. (5.8 m) valor.
Page 186: General Specifications
Page t-6 repair and service manual notes: general specifications read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions, warnings and dangers..
Page 187: Notice
Read the following warnings before attempting to operate the vehicle: to prevent personal injury or death, observe the following: when vehicle is to be left unattended, engage parking brake, move direction selector to ‘f’ (forward) position, turn key to ‘off’ position and remove key. Drive vehicle o...
Page 188
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 e-z-go division of textron inc., 1451 marvin griffin road, augusta, georgia 30906 - 3852 usa.