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FLEET 1999
E-Z-GO FLEET 1999 User Manual
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BODY
Page
C-2
kW
TYPE
KG
•
CE
•
Fig.
2
Body
Components
(Front)
Repair
and
Service
Manual
'
'
b
49
51
Table of Contents
Table of Contents
5
Notes
6
Safety Information
7
Serial Number Plate Location
13
Starting the Vehicle with Adischarged Battery
13
Fig. 2 Fuel Tank
13
Servicing the Vehicle
14
Neutral Lock
14
Fig. 3 Initial Service Chart
14
Routine Maintenance
15
Powertrain Maintenance
15
Checking the Oil Level
15
Fig. 5 Lubrication Points
15
Fig. 6 Clean Entire Dipstick
15
Changing the Oil
16
Fig. 7 Check Oil Level on Dipstick
16
Fig. 8 Oil Viscosity Chart
16
Fig. 9 Cleaning the Top of the Engine
17
Fig. 11 Blowing out Oil Filter
17
Fig. 12 Adding Engine Oil
17
Air Cleaner Inspection/Replacement
18
Checking the Lubricant Level
18
Fig. 14 Add, Check and Drain Rear Axle Lubricant
18
Starter/Generator Belt Tension
19
Adjusting the Belt
19
Air Intake and Cooling Fins
19
Fig. 15 Checking Belt Tension with Gauge
19
Fig. 16 Checking Belt Tension with Finger
19
Fig. 17 Adjusting the Belt Tension
19
Fig. 18 Cleaning Air Intake
19
Spark Plugs
20
Care and Cleaning of the Vehicle
20
Fig. 19 Cleaning the Cooling Fins
20
Fig. 20 Gapping the Spark Plug
20
Vehicle Care Products
21
Top and Windshield (if Equipped
21
Winter or Prolonged Storage
22
Torque Specifications
22
Fig. 21 Bolt Grades
22
Periodic Service Schedule
23
Fig. 23 Periodic Service Schedule
24
Safety
25
General
27
Notes, Cautions and Warnings
34
Important Safety Warning
34
Modifications to Vehicle
34
General Maintenance
34
Before Servicing the Vehicle
34
Battery Removal and Lnstallation
35
Lifting the Vehicle
36
Neutral Lock
36
Body
47
Wheels and Tires
55
Front Suspension and Steering
59
Hardware
62
Speed Control
71
Accelerator, Governor and Carburetor Linkage
73
System Operation
73
Governor Operation
74
Troubleshooting
74
General Linkage Adjustment Procedure
74
Linkage Removal
74
Linkage Adjustment
74
Linkage Installation
74
Pedal Box Adjustments
76
Accelerator Pedal Arm Adjustment
76
Micro Switch Adjustment
76
Control Arm Link
76
Governor Compression Spring Adjustment
78
Road Test
78
Engine
79
Engine Specifications
81
Engine Description
81
Engine Operation
81
Valve Adjustment
81
Adjustment Procedure
81
Valve Cover Installation
84
Tim16Ing Belt Adjustment
85
Compression Tests
85
Compression Test Readings
86
Engine Removal
87
Skid Plate Removal
87
Controls and Wiring
88
Removing the Engine from the Vehicle
88
Engine Installation
88
Drive Clutch Removal
88
Cooling System Cleaning
88
Starter/Generator Installation
90
Engine Isolation Mount Removal
91
Muffler Removal
91
Muffler Installation
91
Fuel
93
Fuel System
94
General
95
Carburetor Operation
95
Float System
95
Pilot Jet System
95
Main Jet System
95
Choke System
96
Choke Operation
96
Fuel System Component Service and Replacement
96
Choke Cable and Housing Removal
96
Choke Cable and Housing Installation
96
Carburetor Service
96
Carburetor Removal
96
Carburetor Installation
97
Carburetor Disassembly
98
Float Level Adjustment
98
Throttle Shaft Adjustment
99
Carburetor Installation
99
Fuel Pump
99
Fuel Pump Replacement
100
Fuel Lines and Filter
100
Fuel and Storage
100
Prolonged Storage
101
Carburetor Troubleshooting
101
Continuously Variable Transmission (CVT)
103
Electrical
109
Circuits and Controls
111
Starter
111
Generator
111
Wiring
111
Testing Ignition Circuit
111
Testing the Ignition Coil
114
Testing the Pulser Coil
114
Testing Starting Circuit
114
Testing Charging Circuit
114
Starter/Generator
116
Starter/Generator Removal
116
Starter/Generator Disassembly
116
Starter/Generator Inspection
116
Starter/Generator Repair and Replacement
118
Battery Voltage Test
118
Storage of Battery
118
Accessory Wiring
119
Mechanical Brakes
125
Brake System Overview
127
General Description
127
Equalizer Link
127
Automatic Adjuster Mechanism
128
How the Parking Brake Works
128
Compensator Assembly
129
Kick-Off Actuating Linkage
129
Troubleshooting Flowchart
130
Brake Test
131
Troubleshooting Table
132
Troubleshooting and Inspection
134
New Vehicles
134
Troubleshooting and Inspection Procedures
134
Brake Pedal and Linkage Inspection
134
Periodic Brake Performance Test (PBPT)
136
Aggressive Stop Test
137
Wheel Brake Inspection
138
Adjusting Brake Pedal Free Travel
140
Brake Drum Removal and Installation
141
Wheel Brake Service
142
Backing Plate/Entire Wheel Brake Assembly Removal and Installation
142
Rear Suspension
147
Rear Axle
153
Paint
157
Troubleshooting
161
Limited Warranty
169
General Specifications
177
Tires
180
5
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E-Z-GO FLEET 1999 Specifications
General
Brand
E-Z-GO
Model
FLEET 1999
Category
Golf Cars
Language
English
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