- DL manuals
- Ezgo
- Golf Cars
- 605586
- Repair And Service Manual
Ezgo 605586 Repair And Service Manual
Summary of 605586
Page 1
Gasoline powered golf cars revised date : january 2007 technician’s repair and service manual 605586.
Page 2: Safety
Safety (notes, cautions and warnings continued on inside of back cover) safety 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...
Page 3: Technician’S
Page i repair and service manual technician’s repair and service manual gasoline powered txt golf cars & personal vehicles fleet golf car (9 hp, ce, carb) freedom ™ (9 hp, ce, carb, se, le, hp) shuttle 2 + 2 ( 9 hp, ce, carb) starting model year 2007 textron golf, turf & specialty products reserves ...
Page 4: Notes
Notes page ii repair and service manual to obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized branch or the warranty department with vehicle serial number and manufacturer code. The use of non original equipment manufacturer (oem) parts may...
Page 5: Table of Contents
Page iii repair and service manual table of contents title page safety ........................................................................................................................... Inside covers notes ........................................................................................
Page 6: Table of Contents
Page iv repair and service manual table of contents notes:.
Page 7: Safety Information
Repair and service manual page v safety information safety information this manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the...
Page 8: Safety Information
Repair and service manual page vi safety information this vehicle conforms to the current applicable standard(s) for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to federal motor vehicle safety standards of the united states ...
Page 9: Safety Information
Repair and service manual page vii safety information • insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. • use spec...
Page 10: Safety Information
Repair and service manual page viii safety information notes:.
Page 11
Page a-i repair and service manual general information & routine maintenance table of contents for section ’a’ section title page no. Serial number plate and location ............................................................................................................. A - 1 starting the vehi...
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 notes, cautions and warnings..
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 notes, cautions and warnings. Serial number plate and location the serial number and manufacture date code label are on...
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 notes, cautions and warnings. B from the batteries before removing any heavy gauge battery wires. To prevent the possib...
Page 15
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 notes, cautions and warnings. B b spring loaded mechanism. To prevent possi- bility of fingers becoming pinched in the ...
Page 16
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 notes, cautions and warnings. B care and cleaning of the vehicle when pressure washing vehicle, do not use pressure in ...
Page 17
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 notes, cautions and warnings. B b trailering to prevent personal injury to occupants of oth- er highway vehicles, be su...
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 notes, cautions and warnings. B periodic service schedule 3 check clean, adjust, etc. S replace note : some maintenance...
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 notes, cautions and warnings. B b semi-annual - 125 hours (includes items listed in previous tables & the following) di...
Page 20
Page a-8 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 notes, cautions and warnings..
Page 21: Safety
Page b-i repair and service manual safety table of contents section title page no. General (asme/ansi) ........................................................................................................................................... B - 1 general (asme/ngcma) .................................
Page 22: 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 notes, cautions and warnings..
Page 23: Safety
Page b-1 repair and service manual safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. General the following text is provided as recommended by part ii of american society of mechanical engineers / american nati...
Page 24: 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 notes, cautions and warnings. B 4.5.2 the user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of an...
Page 25: Safety
Page b-3 repair and service manual safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. (a) operational performance tests and evaluations during, and at completion of, the program. 5.1 personnel and burden carrie...
Page 26: Safety
Page b-4 safety repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 5.5.12 do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and then...
Page 27: Safety
Page b-5 repair and service manual safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. (a) before disconnecting any part of the engine fuel system of lp gas powered carriers, close the lp gas cylinder valve and ...
Page 28: Safety
Page b-6 repair and service manual notes: safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 29: Safety
Page b-7 repair and service manual safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. General the following text is provided as recommended by part ii of ansi/ngcma 130.1-2004. Ezgo, as a member of the national...
Page 30: Safety
Page b-8 safety repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B 5.2.5 golf car/pedestrian interaction areas areas where pedestrians and golf cars could interact should be avoided by rero...
Page 31: Safety
Page b-9 repair and service manual safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. 6.2.6 as required in 6.2.4, the manufacturer shall be contacted to secure new nameplates, warnings, or safety labels, as nec...
Page 32: Safety
Page b-10 repair and service manual notes: safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 33: Safety
Safety page b-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b notes, cautions and warnings throughout this manual, the following notes, cau- tions and warnings are used. For the pro...
Page 34: Safety
Page b-12 safety repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B set the parking ‘park’ brake before per- forming any work on the vehicle. If repairs are to be made that will require wel...
Page 35: Safety
Safety page b-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 1 battery removal connect the positive (+) battery cable first. Connect negative (-) battery cable last. Be sure t...
Page 36: Safety
Page b-14 repair and service manual notes: safety read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 37: Body
Page c-i repair and service manual body table of contents for section ’c’ section title page no. Body ......................................................................................................................................................................... C - 1 general .................
Page 38: 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 notes, cautions and warnings..
Page 39: 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 notes, cautions and warnings. Body in the following text, there are references to removing/install- ing bolts etc. Additional hardware (nuts, washers etc.) ...
Page 40: 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 notes, cautions and warnings. B 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 41: 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 notes, cautions and warnings. B b fig. 3 body components (rear) 27 32 30 31 33 34 29 shuttle 2+2 model only 28 48 49 53 52 53 52 51 50
Page 42: 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 notes, cautions and warnings. B fig. 4 shuttle 2 + 2 components 36 37 38 40 41 42 43 44 45 46 47 39.
Page 43: 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 notes, cautions and warnings. B b to prevent the possibility of injury due to lack of vehicle information, the correct safety label must be on the instrumen...
Page 44: Body
Page c-6 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B body replacement tool list qty. Reqd. Electric/air drill ............................................................ 1 dril...
Page 45: Body
Body page c-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b . The foot rest is heavy and awkward to handle. To prevent possible personal injury, it is strongly recommended that adequ...
Page 46: Body
Page c-8 repair and service manual notes: body read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 47: Wheels and Tires
Page d-i repair and service manual wheels and tires table of contents for section ’d’ section title page no. Wheel and tire service .................................................................................................................................... D - 1 tire repair ....................
Page 48: 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 notes, cautions and warnings..
Page 49: Wheels and Tires
Page d-1 repair and service manual wheels and tires read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Wheel and tire service tools list qty. Required lug wrench, 3/4" ....................................................
Page 50: 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 notes, cautions and warnings. B it is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating o...
Page 51
Page e-i repair and service manual front suspension and steering table of contents for section ’e’ section title page no. Maintenance ......................................................................................................................................................... E - 2 lubric...
Page 52
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 notes, cautions and warnings..
Page 53
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 notes, cautions and warnings. Fig. 1 steering and front suspension part of frame part of frame wave washer bearing outer snap ring ...
Page 54
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 notes, cautions and warnings. B maintenance in the following text, there are references to removing/installing bolts etc. Additiona...
Page 55
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 notes, cautions and warnings. B b the bearing is removed for inspection. It is recom- mended that a bearing packer attached to a gr...
Page 56
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 notes, cautions and warnings. B fig. 4 wheel alignment to hold threaded tube while loosening jam nut, use a wrench on the center, f...
Page 57
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 notes, cautions and warnings. B b front suspension fig. 6 front suspension components front shock absorber replacement tool list qt...
Page 58
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 notes, cautions and warnings. B front axle replacement tool list qty. Required ratchet, 1/2" drive ...................................
Page 59
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 notes, cautions and warnings. B b loosen front wheels. Lift and support front of vehicle per safety section. In addition, support f...
Page 60
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 notes, cautions and warnings. B remove the dust cap (1), cotter pin (2) and castellated nut (3) (ref. Fig. 8 on page e-8). While ho...
Page 61
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 notes, cautions and warnings. B b steering fig. 11 steering components rack ball joint replacement tool list qty. Required needle n...
Page 62
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 notes, cautions and warnings. B to install new rack ball joint close to its correct position, measure amount of threads exposed fr...
Page 63
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 notes, cautions and warnings. B b remove cotter pin (9) and loosen castellated nut (10) until tie rod ball joint (6) threads are p...
Page 64
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 notes, cautions and warnings. B secure rack and pinion unit in vice by the mounting ears only. The rack and pinion unit is made of...
Page 65
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 notes, cautions and warnings. B b spindle installation is the reverse order of disassembly. The thrust washer (9) is located on to...
Page 66
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 notes, cautions and warnings. B after replacing or servicing steering components, always verify that an 1/8" gap exists between la...
Page 67
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 notes, cautions and warnings. B b fig. 18 spindle contact with front axle with spindle arm resting against front axle, cut wire ti...
Page 68
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 notes, cautions and warnings. B loosen the steering wheel retaining nut (6) two to three turns (ref. Fig. 21 on page e-15). Do not...
Page 69
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 notes, cautions and warnings. B b fig. 23 small retaining ring orientation slide wave washer into base of steering column. To inst...
Page 70
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 notes, cautions and warnings..
Page 71: Speed Control - All Cables
Page f-i repair and service manual speed control - all cables table of contents for section ’f’ section title page no. Accelerator, governor and carburetor linkage .............................................................................. F - 1 system operation .....................................
Page 72: Speed Control - All Cables
Page f-ii repair and service manual notes: speed control - all cables read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 73: Speed Control - All Cables
Page f-1 repair and service manual speed control - all cables read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Fig. 1 accelerator and governor system accelerator, governor and carburetor linkage system operation the...
Page 74: Speed Control - All Cables
Page f-2 speed control - all cables repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B governor operation until the vehicle reaches its governed speed, the vehi- cle will continue to accele...
Page 75: Speed Control - All Cables
Speed control - all cables page f-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b throttle cable installation to install the throttle cable, proceed in reverse order. Throttle cable ...
Page 76: Speed Control - All Cables
Page f-4 speed control - all cables repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B micro switch adjustment when the system is in correct adjustment, the micro switch in the accelerator ...
Page 77: Speed Control - All Cables
Speed control - all cables page f-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 5 accelerator linkage 2 1/2 " (63.5 mm) to governor accelerator cable accelerator cable throttl...
Page 78: Speed Control - All Cables
Page f-6 repair and service manual notes: speed control - all cables read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 79: Engine
Page g-i repair and service manual engine table of contents for section ’g’ section title page no. Powertrain maintenance ................................................................................................................................G - 1 checking the oil level ........................
Page 80: Engine
Page g-ii repair and service manual engine table of contents for section ’g’ section title page no. Fig. 17 overhead valve/cam system .......................................................................................................................... G - 7 fig. 18 four cycle operation ...........
Page 81: 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 notes, cautions and warnings. For further engine information, see four cycle engine shop rebuild and service parts manual, p/n 27615- g01. Powertrain main...
Page 82: 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 notes, cautions and warnings. B be aware that engine fluids may be hot and contact to the skin may cause severe burns. Wear rubber gloves to protect skin ...
Page 83: 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 notes, cautions and warnings. B b fig. 8 add engine oil both the oil dipstick and fill cap must be in place before operat- ing the engine. Failure to inst...
Page 84: 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 notes, cautions and warnings. B although not as accurate, a new belt may be depressed with a finger. A maximum deflection of 3/8" (10 mm) is acceptable (r...
Page 85: 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 notes, cautions and warnings. B b allow the water to flow freely over the cooling fins and through the blower housing. After flushing, dry with low pressu...
Page 86: 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 notes, cautions and warnings. B third, or power stroke by the expanding gases. As the piston reaches bdc it enters the fourth cycle. The exhaust valve ope...
Page 87: Engine
Page g-7 repair and service manual engine read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Fig. 17 overhead valve/cam system valve operation valve cover camshaft cam lobe cylinder head cylinder piston timing belt sc...
Page 88: 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 notes, cautions and warnings. B fig. 18 four cycle operation first revolution second revolution compression intake intake exhaust exhaust power note: this...
Page 89: 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 notes, cautions and warnings. B b fig. 19 overhead valve adjustment fig. 20 valve cover tightening sequence at yearly intervals, the timing belt tension s...
Page 90: 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 notes, cautions and warnings. B fig. 21 timing belt adjustment compression tests tool list qty. Required compression gauge .................................
Page 91: Engine
Engine page g-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b all readings should be compared with the engine manu- factures specification. Engine cylinder specifications are usuall...
Page 92: Engine
Page g-12 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 23 engine assembly controls and wiring unplug the wiring harness from the engine and cut the wire tie securing the a...
Page 93: Engine
Engine page g-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b fig. 24 engine mounting drive clutch removal tool list qty. Required socket, 5/8", 3/8" drive ............................
Page 94: Engine
Page g-14 engine repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B page g-13). Tighten a new starter/generator belt per ‘starter/generator belt tension’ earlier in this section. Tighten ja...
Page 95: Fuel System
Page h-i repair and service manual fuel system table of contents for section ’h’ section title page no. General .................................................................................................................................................................. H - 1 carburetor operatio...
Page 96: 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 notes, cautions and warnings..
Page 97: 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 notes, cautions and warnings. General in the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washer...
Page 98: 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 notes, cautions and warnings. B fig. 2 fuel system choke operation pull the choke knob out to operate the choke (ref. Fig. 3 on page h-2). Check that...
Page 99: 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 notes, cautions and warnings. B b choke cable and housing installation in the following text, there are references to removing/install- ing bolts etc...
Page 100: 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 notes, cautions and warnings. B fig. 4 air cleaner do not tamper with the pilot screw (7) or plastic cover. Remove the pilot jet (8). Wash all parts ...
Page 101: 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 notes, cautions and warnings. B b fig. 5 carburetor.
Page 102: 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 notes, cautions and warnings. B do not let the carburetor vent hoses become clogged or kinked. Engine heat will cause the fuel in the carburetor bowl...
Page 103: 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 notes, cautions and warnings. B b the length of the pulse hose from the fuel pump is important for efficient pump operation. If the hose is to be rep...
Page 104: Fuel System
Page h-8 fuel system repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 9 california emission requirement fuel lines & filter - california emission requirement tool list qty. Required ...
Page 105: Fuel System
Fuel system page h-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b care should be taken while installing new hos- es onto the plastic receptacles of the fuel tank and the fuel pump. ...
Page 106: Fuel System
Page h-10 fuel system repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B poor fuel economy fuel level too high adjust float loose jets tighten jets choke not opening fully adjust choke dirt...
Page 107
Page j- i repair and service manual continuously variable transmission (cvt) table of contents for section ’j’ section title page no. General .................................................................................................................................................................
Page 108
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 notes, cautions and warnings..
Page 109
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 notes, cautions and warnings. Fig. 1 continuously variable transmission system (cvt) general power transmission from the...
Page 110
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 notes, cautions and warnings. B conditions, the drive belt friction is overcome by the additional load and the belt seek...
Page 111
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 notes, cautions and warnings. B b to prevent burns and other possible injuries: disable the electrical system before att...
Page 112
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 notes, cautions and warnings. B drive belt removing the drive belt with the vehicle on level ground, remove the drive be...
Page 113: Direction Selector
Page k-i repair and service manual direction selector table of contents for section ’k’ section title page no. Direction selector ........................................................................................................................................... K - 1 removing direction selec...
Page 114: Direction Selector
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 notes, cautions and warnings..
Page 115: 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 notes, cautions and warnings. Direction selector before removing direction selector and replacing the buzzer or a micro switch, ensure the ele...
Page 116: 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 notes, cautions and warnings. B fig. 1 direction selector reverse warning buzzer micro switch shift cable adjustment shift cable adjustment di...
Page 117: Electrical
Page l- i repair and service manual electrical table of contents for section ’l’ section title page no. Circuits and controls ......................................................................................................................................L - 1 starter .............................
Page 118: 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 notes, cautions and warnings..
Page 119: 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 notes, cautions and warnings. Circuits and controls the electrical system is a 12 volt negative ground sys- tem (ref. Fig. 1 on page l-2) (ref. Fig. 2...
Page 120: 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 notes, cautions and warnings. B fig. 1 electrical system wiring diagram + - fuse 7 amp red blk reverse warning battery blk solenoid a b red blk blk ig...
Page 121: 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 notes, cautions and warnings. B b fig. 2 electrical system (physical location) starter/ generator battery ignition coil grn f2 a2 a1 f1 df 25 26 24 fr...
Page 122: 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 notes, cautions and warnings. B do not arc spark plug wire to ground. Connect to a known good spark plug and ground plug to a clean metal surface (muf...
Page 123: 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 notes, cautions and warnings. B b (b) press the accelerator pedal. The dvom will indi- cate “0” voltage if the solenoid contacts are closed. (c) if “0...
Page 124: 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 notes, cautions and warnings. B testing charging circuit tool list qty. Required dvom....................................................................
Page 125: 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 notes, cautions and warnings. B b fig. 5 starter/generator fig. 6 starter/generator brush removal fig. 7 bearing removal 7 6 8 2 4 9 1 3 brush brush s...
Page 126: 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 notes, cautions and warnings. B starter/generator inspection 1. Inspect the commutator for wear or damage. 2. Inspect the brush assembly for wear and ...
Page 127: 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 notes, cautions and warnings. B b the make and model. Always follow the meter manufac- turer’s recommendations and instructions for the use and care o...
Page 128: 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 notes, cautions and warnings. B ing indicates (a) a poor connection between the probes and the battery terminals; (b) a faulty dvom. A voltage readin...
Page 129: 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 notes, cautions and warnings. B b fig. 9 accessory wiring diagram driver side marker turn turn headlight headlight blk blk blk blk blk red red grn bl...
Page 130: 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 notes, cautions and warnings..
Page 131: 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 132: Mechanical Brakes
Page m- ii repair and service manual mechanical brakes table of contents for section ’m’ section title page no. Fig. 20 checking parking brake latching pressure ............................................................................................... M - 15 fig. 21 brake assembly ................
Page 133: 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 notes, cautions and warnings. Fig. 1 mechanical brake system brake system overview general description this vehicle is equipped with a mechanic...
Page 134: 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 notes, cautions and warnings. B closely related. It is very important to maintain the proper relationships to assure braking performance and th...
Page 135: 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 notes, cautions and warnings. B b fig. 3 parking brake and kick-off mechanism depressing the parking brake pedal moves the latch arm against th...
Page 136: 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 notes, cautions and warnings. B troubleshooting flowchart fig. 5 troubleshooting flowchart do steps through to one side at a time 1 bad visuall...
Page 137: 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 notes, cautions and warnings. B b fig. 5 troubleshooting flowchart adjuster tries to move star wheel? Star wheel rotates? Free movement of slid...
Page 138: 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 notes, cautions and warnings. B troubleshooting table refer to the following troubleshooting table only after the thorough visual inspection, p...
Page 139: 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 notes, cautions and warnings. B b neither wheel locks when park brake is latched. (note: at full speed the wheels may not lock, but should brak...
Page 140: 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 notes, cautions and warnings. B troubleshooting and inspection new vehicles a new vehicle will undergo an initial break-in of compo- nents incl...
Page 141: 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 notes, cautions and warnings. B b may indicate wheel brakes not adjusting, wear in the cables and linkages or initial break-in of components. N...
Page 142: 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 notes, cautions and warnings. B fig. 11 parking brake pedal hinge inspection 9. Check the condition and operation of the parking brake latchin...
Page 143: 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 notes, cautions and warnings. B b fig. 13 periodic brake performance test over time, a subtle loss of performance may take place; there- fore,...
Page 144: 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 notes, cautions and warnings. B the brake adjuster mechanism must expand and release fully to function. Under light usage this may not occur, ...
Page 145: 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 notes, cautions and warnings. B b if adjuster arm engages star wheel but fails to rotate it , the adjuster assemblies must be replaced with ne...
Page 146: 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 notes, cautions and warnings. B fig. 17 orientation of brake shoe springs 11. Repeat procedure at the opposite wheel brake. 12. Check/adjust b...
Page 147: 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 notes, cautions and warnings. B b fig. 18 free travel adjustment the correct brake pedal free travel should be set to 7/8" - 1 1/8" (2.2 - 2.9...
Page 148: 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 notes, cautions and warnings. B brake drum removal and installation remove the dust cap (1) to gain access to the castel- lated nut (2) and th...
Page 149: 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 notes, cautions and warnings. B b . Do not use a commercial brake cleaner unless the entire brake has been disassembled. Remove any accumulate...
Page 150: 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 notes, cautions and warnings. B brake shoe and adjuster replacement it is recommended that when brake shoes are replaced, the adjusters and sp...
Page 151: 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 notes, cautions and warnings. B b adjust the brake pedal free travel. “adjusting brake pedal free travel” on page m 14 brake cable and equaliz...
Page 152: 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 notes, cautions and warnings. B inspect the shoulder bolt for corrosion that could cause binding. This bolt and both bushings (7) must be repl...
Page 153: 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 notes, cautions and warnings. B b parking brake release linkage removal and replacement remove the cotter pin (2), washers (3) and bushings (4...
Page 154: 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 notes, cautions and warnings..
Page 155: Rear Suspension
Page n-i repair and service manual rear suspension table of contents for section ’n’ section title page no. Rear suspension ................................................................................................................................................. N - 1 general ...................
Page 156: Rear Suspension
Page n-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 notes, cautions and warnings..
Page 157: Rear Suspension
Page n-1 repair and service manual rear suspension read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Rear suspension in the following text, there are references to removing/install- ing bolts etc. Additional hardware...
Page 158: Rear Suspension
Page n-2 rear suspension repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 1 rear suspension 2 10 4 5 7 11 9 6 9 9 3 5 4 10 8 8 1 4 4 5 5.
Page 159: Rear Suspension
Rear suspension page n-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b rear axle removal tools list qty. Required lug wrench, 3/4" ......................................................
Page 160: Rear Suspension
Page n-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 notes, cautions and warnings..
Page 161: Rear Axle
Page p-i repair and service manual rear axle table of contents for section ’p’ section title page no. Neutral lock ........................................................................................................................................................ P - 1 rear axle ...................
Page 162: Rear Axle
Page p-iii repair and service manual notes: rear axle read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 163: Rear Axle
Page p-1 repair and service manual rear axle read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. For further axle information, see four cycle transaxle shop rebuild and service parts manual p/n 27660- g01. Refer to rea...
Page 164: Rear Axle
Page p-2 rear axle repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B handle all gears with extreme care since each is part of a matched set.Damage to one will require replacement of the en...
Page 165: Rear Axle
Rear axle page p-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b use care to prevent damage to the inner surface of axle tube at the sealing area. Replace the seal by lightly tapping...
Page 166: Rear Axle
Page p-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 notes, cautions and warnings..
Page 167: Weather Protection
Page q- i repair and service manual weather protection table of contents for section ’q’ section title page no. Top and windshield ............................................................................................................................................Q - 1 trailering ...............
Page 168: Weather Protection
Page q- ii repair and service manual notes: weather protection read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 169: Weather Protection
Page q-1 repair and service manual weather protection read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Top and windshield the top does not provide protection from roll over or falling objects. The windshield does no...
Page 170: Weather Protection
Page q-2 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 1 golf car sun top d a c b 6 2 3 5 3 4 detail a detail b 7 9 8 11 10 detail c 16 1, 18 13 7 14 15 (front)...
Page 171: Weather Protection
Weather protection page q-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b shuttle 2+2 sun top rear support installation 1. Tap end caps (item 7) into top of the rear support (items 1...
Page 172: Weather Protection
Page q-4 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B fig. 2 shuttle 2+2 sun top d c b a detail a 1,2 (driver's side shown) 3 4 5 4 6 detail b 9 11 10 13 12 detail ...
Page 173: Weather Protection
Weather protection page q-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b split windshield remove protective covering from the windshield (item 2) (ref. Fig. 3 on page q-5). Install ...
Page 174: Weather Protection
Page q-6 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B one-piece front windshield remove protective covering from the windshield (item 2) (ref. Fig. 4 on page q-6). ...
Page 175: Weather Protection
Weather protection page q-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b rear windshield remove protective covering from rear windshield (item 2) (ref. Fig. 5 on page q-7). Install ...
Page 176: Weather Protection
Page q-8 repair and service manual notes: weather protection read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 177: Paint
Page r-i repair and service manual paint table of contents for section ’r’ section title page no. Painting ................................................................................................................................................................... R - 1 minor scratches ..........
Page 178: Paint
Page r-ii repair and service manual notes: paint read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 179: Paint
Page r-1 repair and service manual paint read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Painting follow the paint manufacturer’s recommendations for specific painting procedures and information. All painting must ...
Page 180: Paint
Page r-2 repair and service manual notes: paint read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 181: Troubleshooting
Page s-i repair and service manual troubleshooting table of contents for section ’s’ section title page no. Gasoline vehicle performance .................................................................................................................... S - 1 starter / generator .......................
Page 182: Troubleshooting
Page s-ii repair and service manual notes: troubleshooting read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 183: Troubleshooting
Page s-1 repair and service manual troubleshooting read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. Gasoline vehicle performance condition possible cause correction starter does not turn weak or bad battery recharge...
Page 184: Troubleshooting
Page s-2 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B starter rotates but vehicle will not start or hard to start weak battery recharge or replace as necessary corrode...
Page 185: Troubleshooting
Troubleshooting page s-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b engine runs rough or loss of power dirty or clogged air filter element wash or replace as required incorrect ch...
Page 186: Troubleshooting
Page s-4 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B poor midrange or high speed performance spark plug fouled clean or replace weak spark check ignition coil faulty ...
Page 187: Troubleshooting
Troubleshooting page s-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b excessive smoking wrong oil weight replace with recommended oil dirty oil change crankcase overfilled with oil ...
Page 188: Troubleshooting
Page s-6 troubleshooting repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B starter / generator condition possible cause correction starter is noisy bolts are loose retighten starter/genera...
Page 189: Troubleshooting
Troubleshooting page s-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings. B b suspension and steering condition possible cause correction uneven tire wear incorrect tire pressure inflate to...
Page 190: Troubleshooting
Page s-8 repair and service manual notes: troubleshooting read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 191: Limited Warranty
Page t-i repair and service manual limited warranty table of contents for section ’t’ section title page no. Federal emissions component defect warranty .................................................................... T - 1 california evaporative emission control warranty statement ................
Page 192: Limited Warranty
Page t-ii repair and service manual notes: limited warranty read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 193
Page t-1 owner’s manual and service guide vehicle warranties - federal (2006) federal emissions component defect warranty emissions component defect warranty coverage - this emission warranty is applicable in all states, except the state of california fuji heavy industries ltd. And e-z-go division o...
Page 194
Page t-2 owner’s manual and service guide vehicle warranties - federal (2006) deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance. As the engine owner, you should however be aware that e-z-go may deny warranty coverage if your en...
Page 195
Page t-3 owner’s manual and service guide vehicle warranties - california (2007) california evaporative emission control warranty statement 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 evaporativ...
Page 196
Page t-4 owner’s manual and service guide vehicle warranties - california (2007) maintenance, repair, and replacement of evaporative emission related parts: any e-z-go approved replacement part used in the performance of any warranted maintenance or repair on evaporative emission related parts will ...
Page 197: General Specifications
Page u-i repair and service manual general specifications table of contents for section ’u’ section title page no. Txt gasoline - fleet- car, ce, carb .............................................................................................................. U - 1 txt gasoline - freedom and freed...
Page 198: General Specifications
Page u-ii repair and service manual notes: general specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 199: General Specifications
Page u-1 repair and service manual general specifications txt gasoline - fleet car weight (dry fuel tank)............................................................ 669 lbs. (304 kg) fuel capacity 31 lbs. (14 kg) tires (4 ply rated) .....................................................................
Page 200: General Specifications
Page u-2 repair and service manual general specifications txt gasoline - freedom and freedom hp weight (dry fuel tank)............................................................679 lbs. (308 kg) fuel capacity 31 lbs. (14 kg) tires (4 ply rated) .........................................................
Page 201: General Specifications
Page u-3 repair and service manual general specifications txt gasoline - shuttle 2+2 weight (dry fuel tank)............................................................ 765 lbs. (347 kg) fuel capacity 31 lbs. (14 kg) tires (4 ply rated) ...................................................................
Page 202: General Specifications
Page u-4 repair and service manual general specifications fig. 1 vehicle dimensions note: shaded area indicates shuttle 2+2 65.5 in. (166 cm) 92.5 in. (235 cm) 105 in. (267 cm) 46.5 in. (118 cm) front 33.5 in. (85 cm) rear 38 in. (97 cm) 49 in. (124 cm) 67 in. (170 cm).
Page 203: General Specifications
Page u-5 repair and service manual general specifications fig. 2 vehicle dimensions, incline specifications and turning clearance diameter turning clearance diameter 19 ft. (5.8 m) recommended max ramp 25% grade or 14 o max recommended max side tilt 25% grade or 14 o max.
Page 204: General Specifications
Page u-6 repair and service manual general specifications notes:.
Page 205
Read and understand 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. ...
Page 206
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 textron golf, turf & specialty products p.O. Box 388 augusta, georgia 30906-3852 usa inside usa phone: 1-800-241-5855, fax:...