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- RXV SHUTTLE 2+2
- Service & Repair Manual
Ezgo RXV SHUTTLE 2+2 Service & Repair Manual
Summary of RXV SHUTTLE 2+2
Page 1
Rxv electric service & repair issued february 2009 revised july 2010 611103.
Page 2: S A F E T Y
(notes, cautions and warnings continued on inside of back cover) 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 h...
Page 3: Service and Repair Manual
Page i repair and service manual service and repair manual electric powered golf cars & personal vehicles rxv fleet golf car rxv freedom golf car rxv shuttle 2+2 starting mid-model year 2009 (manufactured beginning february 23, 2009) e-z-go division of textron inc. Reserves the right to make design ...
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 models ...........................................................................................
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 manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings this manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with proce- dures...
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 and warnings. B always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed...
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 and warnings. B b ventilation hydrogen gas is generated in the charging cycle of batteries and is explosive in concentration...
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 and warnings..
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 towing ...................................................
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 and warnings..
Page 13: Serial Number Location
General information & routine maintenance page a-1 repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. B b thank you for purchasing this vehicle. This repair man- ual contains information t...
Page 14: Towing
Page a-2 general information & routine maintenance repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. B towing to reduce the possibility of severe injury or death: use extra caution when t...
Page 15: Parking Brake
General information & routine maintenance page a-3 repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. B b with the switch in the ‘tow’ or (on ce vehicles) position and the key in ’n’. • th...
Page 16: Rear Axle
Page a-4 general information & routine maintenance repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. B rear axle the only maintenance required for the first five years or 1000 hours of op...
Page 17: Hardware
General information & routine maintenance page a-5 repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. B b when transporting vehicle below highway speeds, check for tightness of hardware an...
Page 18
Page a-6 general information & routine maintenance repair and service manual read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. B periodic service schedule 3 - check c&a - check & adjust cl - clean r - replace *use...
Page 19
Page a-7 repair and service manual notes: read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings. General information & routine maintenance.
Page 20
Page a-8 repair and service manual notes: general information & routine maintenance read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all notices, cautions and warnings..
Page 21: 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 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 notices, cautions and warnings..
Page 23: Safety
Safety page b-1 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b notices, cautions, warnings and dangers throughout this manual, the following notices, cau- tions, warnings and danger...
Page 24: Safety
Page b-2 safety repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B always turn the key switch to ‘off’ and remove the key before disconnecting a live circuit. When connecting battery cabl...
Page 25: Safety
Safety page b-3 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 attach accessory wires to battery pack accessories connected to this vehicle that do not use the accessory harn...
Page 26: Safety
Page b-4 safety repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 2 batteries, charger receptacle & controller battery removal & installa- tion tool list qty. Insulated wrench, 9/16...
Page 27: Safety
Safety page b-5 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b 2. Using an insulated wrench, disconnect the main nega- tive (-) battery cable, bl-. 3. Using an insulated wrench, dis...
Page 28: Safety
Page b-6 safety repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 5 battery hold down fig. 6 battery connections 14. Tighten all battery terminal hardware to 98 - 105 in. Lbs. (11 -...
Page 29: Safety
Safety page b-7 repair and service manual read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b to raise only the front or rear of the vehicle, place the wheel chocks in front and behind the rear wheels. The jack m...
Page 30: Safety
Page b-8 repair and service manual notes: safety read all of section a and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 31: Body
Table of contents for section ‘c’ section title page no. Body page c-i repair and service manual body........................................................................................................................ C - 1 general ...................................................................
Page 32: 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 and warnings..
Page 33: Body
Body page c-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 body general vehicle accessories, such as the sun top and windshield, need to be removed before removing many bod...
Page 34: 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 and warnings. B body component replace- ment the body components can be replaced by removing the securing hardware, replacing the componen...
Page 35: 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 and warnings. B b i fig. 5 floor mat fastener removal installation of the floor mat will require new christmas tree rivets — install the s...
Page 36: 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 and warnings. B 5. Remove three self threading nuts (20) securing the cup holder assembly (15) to the instrument panel. Remove the cup hol...
Page 37: 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 and warnings. B b fig. 10 golf car rear body, sweater basket, rear bumper & fender liner sweater basket (ref. Fig. 10) tool list qty. Torx...
Page 38: 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 notices, cautions and warnings. B fender liner (ref. Fig. 2)(ref. Fig. 10) tool list qty. Notched pry bar .....................................................
Page 39: 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 notices, cautions and warnings. B b installation is in the reverse order of removal. Replace any worn or damaged hardware with new as required. Fig. 11 2 + ...
Page 40: Body
Page c-8 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 3. Loosen the torx head bolts (23) and nuts (22) (ref. Fig. 15) that secure the seat back mounting brackets and hip restra...
Page 41: Body
Body page c-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b rear of the vehicle completely. Once the bolts are removed the foot rest assembly (29) may be removed from the vehicle b...
Page 42: Body
Page c-10 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B floorboard tool list qty. Torx bit, t-50 ............................................................... 1 ratchet .........
Page 43: Body
Body page c-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b body care maintenance cleaning tools & supplies list soft clean cotton cloth mild soap the body panels are painted and ...
Page 44: Body
Page c-12 body repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B sandpaper, 1500 grit wet or dry.................................. 1 wet sanding block ......................................
Page 45: Body
Page c-13 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. Body.
Page 46: Body
Page c-14 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 and warnings..
Page 47: 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 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 notices, cautions and warnings..
Page 49: 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 and warnings. B b wheel and tire service tools list qty. 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 notices, cautions and warnings. B wheel installation do not tighten lug nuts to more than 85 ft. Lbs. (115 nm) torque. It is important to follow...
Page 51: 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 and warnings. Wheels and tires.
Page 52: 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 and warnings..
Page 53
Table of contents for section ‘e’ section title page no. Electronic speed contorl (ac motor) page e-i repair and service manual general................................................................................................................. E - 1 accelerator pedal assembly .....................
Page 54
Page e-ii repair and service manual notes: electronic speed control (ac motor) read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 55
Electronic speed control (ac motor) page e-1 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 electronic speed control general in the following text, there are references to remo...
Page 56
Page e-2 electronic speed control (ac motor) 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. 3 pedal cover accelerator pedal assembly tool list qty. Ratchet ...........................
Page 57
Electronic speed control (ac motor) 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 fig. 4 accelerator pedal 10. Install the pedal cover, using new christmas tree riv- ets, re...
Page 58
Page e-4 electronic speed control (ac motor) 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 ring terminals and crimp both ends. Fig. 5 old style rectangular solenoid round solenoid ...
Page 59
Electronic speed control (ac motor) 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 the back terminal of the solenoid (4) and the white wire (12) to the resistor, secure in pl...
Page 60
Page e-6 electronic speed control (ac motor) 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. Disconnect the red wire from the controller b+ termi- nal to the back terminal of the sole...
Page 61
Electronic speed control (ac motor) 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 make sure that the red wire (17) and black wire (18) from the wire harness to the solenoid ...
Page 62
Page e-8 repair and service manual notes: electronic speed control (ac motor) read all of section b and this section before attempting any procedure. Pay particular attention to all notes, cautions and warnings..
Page 63
Table of contents for section ‘f’ section title page no. Front suspension and steering page f-i repair and service manual maintenance ........................................................................................................ F - 1 tire wear diagnosis.......................................
Page 64
Page f-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 and warnings..
Page 65: Notice
Front suspension and steering 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 and warnings. B b fig. 1 front suspension and steering in the following text, there are references to removing an...
Page 66
Page f-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 and warnings. B of the tread. Wear on either side of a correctly inflated tire indicates a tire that is out of al...
Page 67
Front suspension and steering 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 and warnings. B b 6. To adjust the wheel alignment, loosen the tie rod jam nut (1) and turn the tie rods and equa...
Page 68
Page f-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 and warnings. B struts (ref fig. 5) tool list qty. Wrench, 15mm ....................................................
Page 69
Front suspension and steering 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 and warnings. B b fig. 5 hub, spindle, strut and a-arm assemblies a-arm assembly (ref fig. 5) tool list qty. Wren...
Page 70: Notice
Page f-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 and warnings. B clipboard and steering wheel (ref fig. 6) (ref fig. 7) (ref fig. 8) tool list qty. Socket, 24 mm....
Page 71
Front suspension and steering page f-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b clipboard with a new one. 11. Carefully press the top two tabs into the matching slots in the s...
Page 72
Page f-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 and warnings. B yoke onto the shaft. Do not tighten the upper cross bolt and nut. 8. To install the steering colu...
Page 73
Front suspension and steering page f-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b spindle arm. 4. Repeat steps 3 through 5 for the remaining tie rod end. 5. Remove the lower cro...
Page 74
Page f-10 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 and warnings..
Page 75: Motor & Motor Brake
Table of contents for section ‘g’ section title page no. Motor & motor brake page g-i repair and service manual general.................................................................................................................G - 1 motor............................................................
Page 76: Motor & Motor Brake
Page g-ii repair and service manual notes: motor & motor brake read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 77: Motor & Motor Brake
Motor & motor brake page g-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b o fig. 1 motor general the only serviceable items for the electric motor is the entire motor brake. Motor...
Page 78: Motor & Motor Brake
Page g-2 motor & motor brake repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B recent motor has only one set of wires routed from under the housing. If the vehicle has the early motor pr...
Page 79: Motor & Motor Brake
Motor & motor brake 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 and warnings. B b fig. 5 motor bolt tightening sequence 16. Connect the wires from the main harness to the motor brake (31)...
Page 80: Motor & Motor Brake
Page g-4 motor & motor brake repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 7 motor brake do not drop the brake assembly. Dropping or hitting the brake assembly will damage it. I...
Page 81: Motor & Motor Brake
Motor & motor brake 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 and warnings. B b bearing encoder motor brake and motor need to be removed from the axle shaft before removing the encoder ...
Page 82: Motor & Motor Brake
Page g-6 motor & motor brake repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B shown below. 5. Tighten all the hardware to the specified torque value. 6. Re-install motor end cap back to...
Page 83: Motor & Motor Brake
Page g-7 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. Motor & motor brake.
Page 84: Motor & Motor Brake
Page g-8 repair and service manual notes: motor & motor brake read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 85: Batteries & Charging
Table of contents for section ‘h’ section title page no. Batteries & charging page h-i repair and service manual safety .................................................................................................................... H - 1 battery ....................................................
Page 86: Notes:
Page h-ii repair and service manual notes: batteries & charging read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 87: Batteries & Charging
Batteries & charging page h-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 batteries and charging receptacle safety always observe the following warnings when working on or...
Page 88: Batteries & Charging
Page h-2 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B always wear a safety shield or approved safety goggles when adding water or charging batteries. Any electr...
Page 89: Batteries & Charging
Batteries & charging 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 and warnings. B b this level will leave approximately 1/4" - 3/8" (6 - 10 mm) of space between the electrolyte and the ven...
Page 90: Batteries & Charging
Page h-4 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B tion to the batteries special attention should be paid to metallic components adjacent to the batteries wh...
Page 91: Batteries & Charging
Batteries & charging 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 and warnings. B b 8. Check the area surrounding the battery tray for corro- sion. If any corrosion is found, it should be ...
Page 92: Batteries & Charging
Page h-6 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B . Fig. 9 battery connections to prevent battery explosion that could result in severe personal injury or d...
Page 93: Batteries & Charging
Batteries & charging 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 and warnings. B b fig. 10 freezing point of electrolyte battery charging the battery charger is designed to fully charge t...
Page 94: Batteries & Charging
Page h-8 batteries & charging repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B specific gravity of the electrolyte. The greater the con- centration of sulfuric acid, the more dense the ...
Page 95: Batteries & Charging
Batteries & charging page h-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 12 hydrometer temperature correction.
Page 96: Batteries & Charging
Page h-10 repair and service manual notes: batteries & charging read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 97: Battery Charger
Table of contents for section ‘i’ section title page no. Battery charger page i-i repair and service manual charger description .........................................................................................I - 1 portable charger installation ..................................................
Page 98: Battery Charger
Page i-ii repair and service manual notes: battery charger read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 99: Battery Charger
Battery charger page i-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b charger description the powerwise qe 48v charger is automatic and is designed specifically for charging elect...
Page 100: Battery Charger
Page i-2 battery charger repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B looping the dc cord through the steering wheel when charg- ing serves as a good reminder to store the cord out ...
Page 101: Battery Charger
Page i-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 and warnings. Battery charger.
Page 102: Battery Charger
Page i-4 repair and service manual notes: battery charger read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 103: Brakes
Table of contents for section ‘j’ section title page no. Brakes page j-i repair and service manual general..................................................................................................................J - 1 brake pedal assembly ........................................................
Page 104: Brakes
Page j-ii repair and service manual notes: brakes read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 105: Brakes
Brakes page j-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 brake pedal general for information on the motor brake see the motor sec- tion of this manual, section g. In th...
Page 106: Brakes
Page j-2 brakes repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B using an insulated wrench, disconnect the bat- tery cable at the negative (-), bl-, battery ter- minal. To access the pe...
Page 107: Brakes
Brakes 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 and warnings. B b 12. Reconnect electrical harness to rotary position sensor (8) and to the brake switch (10). 13. Place pedal assembly ...
Page 108: Brakes
Page j-4 repair and service manual notes: brakes read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 109
Table of contents for section ‘k’ section title page no. Electrical components & wiring page k-i repair and service manual main wiring harness......................................................................................... K - 1 replacing the main wiring harness ...............................
Page 110
Table of contents for section ‘k’ (cont.) section title page no. Electrical components & wiring page k-ii repair and service manual fig. 27 turn signal bulb replacement .................................................................K - 14 fig. 28 trim panel hardware ..................................
Page 111
Electrical components & wiring page k-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 main electrical harness main wiring harness the main electrical harness for the vehicle...
Page 112
Page k-2 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B instrument panel along the upper edge then grip the ball holder with both hands and pull away fr...
Page 113
Electrical components & wiring 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 and warnings. B b fig. 5 reverse warning indicator 23. Determine which solenoid is installed. Two types of solen...
Page 114
Page k-4 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 28. New wire harness: disconnect the connectors of motor brake (31), the temperature sensor (32)...
Page 115
Electrical components & wiring page k-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 11 harness routing & pedal connections c) connect the wires to the accelerator rotary pos...
Page 116
Page k-6 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 14 charger receptacle. M) a new solenoid will only be installed if the old one was connecte...
Page 117
Electrical components & wiring page k-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b . Fig. 17 motor connections (early vehicles) t) new style wire harness: plug male con- nector ...
Page 118
Page k-8 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 34. Replace the controller splash shield and secure it to the body with two torx head screws. 35...
Page 119
Electrical components & wiring page k-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b battery terminal using an insulated wrench. 2. Remove three plastic rivets securing the contro...
Page 120
Page k-10 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B c b a 4 3 2 1 a b 3 2 1 4 5 6 9 8 7 b a 1 2 9 3 4 5 6 7 8 15 14 13 12 11 10 16 17 18 19 20 21 2...
Page 121
Electrical components & wiring page k-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 25 main wiring harness c b a d c b a a b 3 2 1 4 5 6 9 8 7 b a 1 2 9 3 4 5 6 7 8 15 14 1...
Page 122
Page k-12 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 26 accessory wiring harness turn signal ps turn l t. Black ba ds turn l t. Ps headlight ds...
Page 123
Electrical components & wiring page k-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 27 accessory wiring harness and accessories accessory wiring harness the accessory wirin...
Page 124
Page k-14 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 5. Remove the three fuse holders from the controller splash shield. 6. Disconnect the tail ligh...
Page 125
Electrical components & wiring page k-15 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b replacing electrical accesso- ries using an insulated wrench, disconnect the bat- tery cable ...
Page 126
Page k-16 electrical components & wiring repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 31 trim panel hardware 2. Pull the top of the trim panel (11) away from the instru- ment p...
Page 127
Electrical components & wiring page k-17 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b tail light assembly replacement make sure that the vehicle key switch is in the ’off’ positio...
Page 128
Page k-18 repair and service manual notes: electrical components & wiring read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 129
Page k-19 repair and service manual notes: read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. Electrical components & wiring.
Page 130
Page k-20 repair and service manual notes: electrical components & wiring read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 131: Rear Suspension
Table of contents for section ‘l’ section title page no. Rear suspension page l-i repair and service manual general ..................................................................................................................L - 1 shock absorber ....................................................
Page 132: Rear Suspension
Page l-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 and warnings..
Page 133: Rear Suspension
Rear suspension page l-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 rear suspension general in the following text, there are references to removing/installing hardware (n...
Page 134: Rear Suspension
Page l-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 and warnings. B ing any repair procedure. Never work on a vehicle that is supported by a jack alone. Using an insulated wrench,...
Page 135: Rear Suspension
Rear suspension 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 and warnings. B b (16) can now be removed from the vehicle. 6. Remove the flanged urethane bushings (6) and the spacer (5) from...
Page 136: Rear Suspension
Page l-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 and warnings..
Page 137: Rear Axle
Table of contents for section ‘m’ section title page no. Rear axle page m-i repair and service manual rear axle maintenance...................................................................................M - 1 checking torque to rotate .................................................................
Page 138: Rear Axle
Page m-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 and warnings..
Page 139: Rear Axle
Rear axle page m-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 rear axle rear axle maintenance the only maintenance required for the first five years or 1000 hours of oper...
Page 140: Rear Axle
Page m-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 and warnings. B to reduce the possibility of personal injury, fol- low the lifting procedure in section b of this manual. Place wheel...
Page 141: Rear Axle
Rear axle 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 and warnings. B b behind the front wheels and check the stability of the vehicle on the jack stands before start- ing any repair proc...
Page 142: Rear Axle
Page m-4 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 and warnings. B fig. 6 press bearing from shaft 4. Remove the inner snap ring. Use care to prevent damage to the inner surface of the...
Page 143: Rear Axle
Page m-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 and warnings. Rear axle.
Page 144: Rear Axle
Page m-6 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 and warnings..
Page 145: Weather Protection
Table of contents for section ‘n’ section title page no. Weather protection page n-i repair and service manual top and windshield........................................................................................... N - 1 windshield..................................................................
Page 146: Weather Protection
Page n-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 notices, cautions and warnings..
Page 147: Weather Protection
Weather protection page n-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 1 top and windshield top and windshield the top does not provide protection from roll over or falling...
Page 148: Weather Protection
Page n-2 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B windshield tool list qty. Torx bit, 50 ip .............................................................. 1 r...
Page 149: Weather Protection
Weather protection page n-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b the vehicle. Align the mounting holes in each strut with the matching holes in the sweater basket and seat...
Page 150: Weather Protection
Page n-4 weather protection repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 2 + 2 top tool list qty. Socket, 15 mm.............................................................1 ratchet...
Page 151: Weather Protection
Weather protection page n-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b 3. Lift the top (3) off of the struts and set it aside. 4. Remove the access cover (1) by sliding a flat s...
Page 152: Weather Protection
Page n-6 repair and service manual notes: weather protection read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 153
Table of contents for section ‘o’ section title page no. Troubleshooting and diagnostics page o-i repair and service manual troubleshooting and diagnostics how to use the hand held diagnostic unit .............................................O - 1 menus .................................................
Page 154
Page o-ii repair and service manual notes: troubleshooting and diagnostics read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 155
Troubleshooting and diagnostics page o-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b how to use the hand held diag- nostic unit the e-z-go hand held diagnostic unit, p/n 606215 i...
Page 156
Page o-2 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B . 2. Calculated battery current: displayed as ’current’, the next line displays calculated curr...
Page 157
Troubleshooting and diagnostics page o-3 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b 16. Solenoid: displayed as ’solenoid’, the next line displays the solenoid state as ’on’ or ’...
Page 158
Page o-4 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B error messages 1. Current error message is displayed on the error status screen 2. Past 7 error...
Page 159
Troubleshooting and diagnostics page o-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b code description possible causes diagnostic step action (post diagnos- tics) 8976 ac over cur...
Page 160
Page o-6 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 12818 dc bus high - hardware detected 1. Battery pack voltage is over 67 volts. Note: it is unl...
Page 161
Troubleshooting and diagnostics page o-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b 20755 5v supply low or high voltage 1. Typically caused by a short in the 5 volt wire harness...
Page 162
Page o-8 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B 25106 reverse alarm test failed 1. Reverse warning alarm failed at startup check. The controlle...
Page 163
Troubleshooting and diagnostics page o-9 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b warning dc bus low dc bus voltage is less than 24 volts. 1. Verify that all battery wires are...
Page 164
Page o-10 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B warning heat sink temp high 1. Measured heat sink temper- ature is greater than 85°c (185°f) b...
Page 165
Troubleshooting and diagnostics page o-11 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b warning throttle switch closed (dump cir- cuit monitoring tim- eout) 1. If this occurs with ...
Page 166
Page o-12 troubleshooting and diagnostics repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B digital volt ohm meter a typical dvom (digital volt ohm meter) is shown. A rec- ommended model...
Page 167: Notice
Troubleshooting and diagnostics page o-13 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b power supply tool list qty. Dvom...............................................................
Page 168
Page o-14 repair and service manual notes: troubleshooting and diagnostics read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 169
Table of contents for section ‘p’ section title page no. Lightning protection and grounding page p-i repair and service manual grounding requirements............................................................................... P - 1 ground systems .....................................................
Page 170
Page p-ii repair and service manual notes: lightning protection and grounding read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 171
A lightning protection and grounding 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 and warnings. B b gs-726-006 effective: 10/19/92 revision: supercedes: rev -, ecn 027194 title : general s...
Page 172
Page p-2 lightning protection and grounding repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B gs-726-006 effective: 10/19/92 revision: a supercedes: title: general specification: lightni...
Page 173
A lightning protection and grounding 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 and warnings. B b gs-726-006 effective: 10/19/92 revision: supercedes: rev -, ecn 027194 title : general s...
Page 174
Page p-4 repair and service manual notes: lightning protection and grounding read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 175: Specifications
Table of contents for section ‘q’ section title page no. Specifications page q-i repair and service manual rxv electric fleet vehicle specifications .............................................Q - 1 rxv electric freedom vehicle specifications.......................................Q - 2 rxv electric...
Page 176: Specifications
Page q-ii repair and service manual notes: specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 177: Specifications
Specifications page q-1 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b rxv electric - fleet vehicle specifications ** do not use low inflation pressure tires on any e-z-go vehicle. ...
Page 178: Specifications
Page q-2 specifications repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B rxv electric - freedom vehicle specifications ** do not use low inflation pressure tires on any e-z-go vehicle. ...
Page 179: Specifications
Specifications 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 and warnings. B b rxv electric - shuttle 2 + 2 vehicle specifications ** do not use low inflation pressure tires on any e-z-go v...
Page 180: Specifications
Page q-4 specifications repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 1 fleet & freedom vehicle dimensions 65.7” (167 cm) 94.5” (240 cm) 35.5” (90 cm) 38” (97 cm) 45.7” (116 cm)...
Page 181: Specifications
Specifications page q-5 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 2 shuttle 2 + 2 vehicle dimensions 65.7” (167 cm) 105.5” (268 cm) 35.5” (90 cm) 38” (97 cm) 45.7” (116 cm...
Page 182: Specifications
Page q-6 specifications repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B fig. 3 vehicle incline specifications and turning diameter recommended max ramp 25% grade or 14° max recommended...
Page 183: Specifications
Specifications page q-7 repair and service manual read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings. B b fig. 4 powerwise qe 48v charger 3.5" (9cm) 4.5" (11.4cm) 10.5" (26.7cm) 7.25" (18.5cm) Ø .25'' (.65cm) 7.75" (...
Page 184: Specifications
Page q-8 repair and service manual notes: specifications read all of section b and this section before attempting any procedure. Pay particular attention to all notices, cautions and warnings..
Page 185: Notice
Read the following warnings before attempting to operate the vehicle : to prevent personal injury or death, ob- serve the following: when vehicle is to be left unattended, en- gage park brake, move direction selector to neutral, turn key to ‘off’ position and re- move key. Drive vehicle only as fast...
Page 186
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.