Name: E-Z-GO FLEET 1999
Brand: E-Z-GO
Rating: 5 (1 reviews)

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TECHNICIAN'S

REPAIR AND SERVICE MANUAL

GASOLINE POWERED GOLF CARS

AND PERSONAL VEHICLES

MODEL YEARS: 1999/2000

REVISED: 12/2000

Table of Contents5
Notes6
Safety Information7
Serial Number Plate Location13
Starting the Vehicle with Adischarged Battery13
Fig. 2 Fuel Tank13
Servicing the Vehicle14
Neutral Lock14
Fig. 3 Initial Service Chart14
Routine Maintenance15
Powertrain Maintenance15
Checking the Oil Level15
Fig. 5 Lubrication Points15
Fig. 6 Clean Entire Dipstick15
Changing the Oil16
Fig. 7 Check Oil Level on Dipstick16
Fig. 8 Oil Viscosity Chart16
Fig. 9 Cleaning the Top of the Engine17
Fig. 11 Blowing out Oil Filter17
Fig. 12 Adding Engine Oil17
Air Cleaner Inspection/Replacement18
Checking the Lubricant Level18
Fig. 14 Add, Check and Drain Rear Axle Lubricant18
Starter/Generator Belt Tension19
Adjusting the Belt19
Air Intake and Cooling Fins19
Fig. 15 Checking Belt Tension with Gauge19
Fig. 16 Checking Belt Tension with Finger19
Fig. 17 Adjusting the Belt Tension19
Fig. 18 Cleaning Air Intake19
Spark Plugs20
Care and Cleaning of the Vehicle20
Fig. 19 Cleaning the Cooling Fins20
Fig. 20 Gapping the Spark Plug20
Vehicle Care Products21
Top and Windshield (if Equipped21
Winter or Prolonged Storage22
Torque Specifications22
Fig. 21 Bolt Grades22
Periodic Service Schedule23
Fig. 23 Periodic Service Schedule24
Safety25
General27
Notes, Cautions and Warnings34
Important Safety Warning34
Modifications to Vehicle34
General Maintenance34
Before Servicing the Vehicle34
Battery Removal and Lnstallation35
Lifting the Vehicle36
Neutral Lock36
Body47
Wheels and Tires55
Front Suspension and Steering59
Hardware62
Speed Control71
Accelerator, Governor and Carburetor Linkage73
System Operation73
Governor Operation74
Troubleshooting74
General Linkage Adjustment Procedure74
Linkage Removal74
Linkage Adjustment74
Linkage Installation74
Pedal Box Adjustments76
Accelerator Pedal Arm Adjustment76
Micro Switch Adjustment76
Control Arm Link76
Governor Compression Spring Adjustment78
Road Test78
Engine79
Engine Specifications81
Engine Description81
Engine Operation81
Valve Adjustment81
Adjustment Procedure81
Valve Cover Installation84
Tim16Ing Belt Adjustment85
Compression Tests85
Compression Test Readings86
Engine Removal87
Skid Plate Removal87
Controls and Wiring88
Removing the Engine from the Vehicle88
Engine Installation88
Drive Clutch Removal88
Cooling System Cleaning88
Starter/Generator Installation90
Engine Isolation Mount Removal91
Muffler Removal91
Muffler Installation91
Fuel93
Fuel System94
General95
Carburetor Operation95
Float System95
Pilot Jet System95
Main Jet System95
Choke System96
Choke Operation96
Fuel System Component Service and Replacement96
Choke Cable and Housing Removal96
Choke Cable and Housing Installation96
Carburetor Service96
Carburetor Removal96
Carburetor Installation97
Carburetor Disassembly98
Float Level Adjustment98
Throttle Shaft Adjustment99
Carburetor Installation99
Fuel Pump99
Fuel Pump Replacement100
Fuel Lines and Filter100
Fuel and Storage100
Prolonged Storage101
Carburetor Troubleshooting101
Continuously Variable Transmission (CVT)103
Electrical109
Circuits and Controls111
Starter111
Generator111
Wiring111
Testing Ignition Circuit111
Testing the Ignition Coil114
Testing the Pulser Coil114
Testing Starting Circuit114
Testing Charging Circuit114
Starter/Generator116
Starter/Generator Removal116
Starter/Generator Disassembly116
Starter/Generator Inspection116
Starter/Generator Repair and Replacement118
Battery Voltage Test118
Storage of Battery118
Accessory Wiring119
Mechanical Brakes125
Brake System Overview127
General Description127
Equalizer Link127
Automatic Adjuster Mechanism128
How the Parking Brake Works128
Compensator Assembly129
Kick-Off Actuating Linkage129
Troubleshooting Flowchart130
Brake Test131
Troubleshooting Table132
Troubleshooting and Inspection134
New Vehicles134
Troubleshooting and Inspection Procedures134
Brake Pedal and Linkage Inspection134
Periodic Brake Performance Test (PBPT)136
Aggressive Stop Test137
Wheel Brake Inspection138
Adjusting Brake Pedal Free Travel140
Brake Drum Removal and Installation141
Wheel Brake Service142
Backing Plate/Entire Wheel Brake Assembly Removal and Installation142
Rear Suspension147
Rear Axle153
Paint157
Troubleshooting161
Limited Warranty169
General Specifications177
Tires180

Brand	E-Z-GO
Model	FLEET 1999
Category	Golf Cars
Language	English

E-Z-GO FLEET 1999 User Manual

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E-Z-GO FLEET 1999 Specifications

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