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Textron EZGO RXV 2016 User Manual

Textron EZGO RXV 2016
168 pages
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TECHNICIAN’S REPAIR AND SERVICE MANUAL
RXV
647701-A
Gasoline Powered Vehicle
REVISED JANUARY 2016ISSUED OCTOBER 2015

Table of Contents

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Textron EZGO RXV 2016 Specifications

General IconGeneral
Model Year2016
TypeGolf Car
Motor Power3.5 kW
Horsepower (kW)3.5 kW
Seating Capacity2
Top Speed19 mph
Battery TypeFlooded Lead-Acid or Lithium-Ion
Electrical System48V DC
BrakesRegenerative and hydraulic disc
SteeringRack and pinion
Front SuspensionIndependent A-Arms
Tires18 x 8.5-8
Braking SystemHydraulic disc

Summary

SAFETY INFORMATION

NOTICES, CAUTIONS, WARNINGS AND DANGERS

Defines hazard symbols and their implications for safety.

GENERAL SAFETY GUIDELINES

Provides overarching safety advice for vehicle operation and servicing.

VEHICLE MODIFICATIONS WARNING

Warns against modifying the vehicle's weight distribution or stability.

BEFORE SERVICING VEHICLE PRECAUTIONS

Lists essential precautions and warnings before starting any service work.

LIFTING THE VEHICLE SAFELY

Provides detailed steps and safety measures for lifting the vehicle.

GENERAL INFORMATION AND ROUTINE MAINTENANCE

SERIAL NUMBER LABEL LOCATION

Identifies the location of vehicle serial number and manufacture date code labels.

VEHICLE WITH A DISCHARGED BATTERY

Explains how to safely charge a discharged battery and avoid jump starting.

STARTING VEHICLE ON A HILL

Details the safe procedure for starting the vehicle on an incline.

SERVICING THE VEHICLE AND FUEL SAFETY

Outlines general warnings, precautions for servicing, and fuel handling safety.

FUEL TANK TYPES AND BATTERY CARE

Differentiates fuel tank designs and covers battery usage and charging.

ROUTINE MAINTENANCE AND POWERTRAIN SERVICE

Emphasizes regular maintenance and guides on powertrain and brake system.

VEHICLE TRANSPORT, STORAGE, AND CLEANING

Provides instructions for transport, storage, cleaning, and care products.

HARDWARE AND TORQUE SPECIFICATIONS

Lists hardware types and provides torque values for fasteners.

BODY COMPONENTS AND SERVICE

BODY COMPONENT REPLACEMENT OVERVIEW

Introduces procedures for replacing various body parts.

FRONT BUMPER AND ROCKER PANEL REPLACEMENT

Details the removal and installation of front bumper and rocker panels.

FLOORMAT AND COWL/INSTRUMENT PANEL REPLACEMENT

Covers replacement procedures for the floormat and cowl/instrument panel.

FRONT SPLASH GUARD AND SWEATER BASKET REPLACEMENT

Details replacing the front splash guard and sweater basket.

SEAT BACK ASSEMBLY AND REAR BODY REPLACEMENT

Explains procedures for replacing seat back assembly and rear body panel.

REAR BUMPER AND 2+2 SEAT REPLACEMENT

Details replacing the rear bumper and the 2+2 rear facing seat.

FLOORBOARD REPLACEMENT AND BODY CARE

Covers floorboard replacement, body care, cleaning, and painting.

WHEELS AND TIRES SERVICE

WHEEL AND TIRE SERVICE PROCEDURES

Covers general procedures for wheel and tire maintenance.

TIRE REPAIR AND REPLACEMENT METHODS

Details methods for repairing tire punctures and replacing tires.

WHEEL INSTALLATION AND TORQUE

Explains the correct procedure for installing wheels and lug nut torque.

FRONT SUSPENSION AND STEERING

MAINTENANCE AND TIRE WEAR DIAGNOSIS

Covers routine maintenance and diagnosing tire wear patterns.

WHEEL ALIGNMENT PROCEDURE

Details the steps for adjusting and checking wheel alignment.

HUB, SPINDLE, AND STRUT ASSEMBLY SERVICE

Explains service procedures for hub, spindle, and strut components.

CONTROL ARM AND STEERING WHEEL SERVICE

Covers maintenance and replacement of control arm and steering wheel.

STEERING COLUMN, TIE ROD, AND STEERING BOX SERVICE

Provides procedures for steering column, tie rod, and steering box.

SPEED CONTROL SYSTEM

SYSTEM OPERATION AND PEDAL BOX FUNCTION

Explains how the accelerator, governor, and pedal box function together.

THROTTLE ROD AND GOVERNOR ADJUSTMENT

Details procedures for adjusting throttle rod and governor linkage.

ACCELERATOR CABLE AND PEDAL ASSEMBLY SERVICE

Covers removal, installation, and adjustment of accelerator cable and pedal.

ROAD TEST AND SPEED CALIBRATION

Explains how to perform a road test and calibrate governed speed.

ENGINE SERVICE AND MAINTENANCE

ENGINE SPECIFICATIONS AND DESCRIPTION

Lists engine model, type, displacement, and general description.

OIL LEVEL CHECK AND CHANGING THE OIL

Details procedures for checking and changing engine oil and filter.

AIR FILTER INSPECTION AND CLEANING

Covers inspection, cleaning, and replacement of the air filter element.

STARTER/GENERATOR BELT SERVICE AND REPLACEMENT

Explains belt tension adjustment and starter/generator replacement.

COOLING SYSTEM AND SPARK PLUG SERVICE

Covers cleaning the cooling system and servicing the spark plug.

CYLINDER HEAD AND VALVE CLEARANCE ADJUSTMENT

Details procedures for cylinder head inspection and valve clearance adjustment.

ENGINE REMOVAL AND INSTALLATION PROCEDURES

Outlines the complete process for removing and installing the engine.

DRIVE CLUTCH REMOVAL PROCEDURE

Explains the procedure for removing the drive clutch.

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

CVT GENERAL OPERATION AND CLUTCH FUNDAMENTALS

Explains the basic function of the CVT and its clutch components.

TRANSMISSION BELT SERVICE PROCEDURES

Details transmission belt inspection, washing, and replacement.

PRIMARY AND SECONDARY CLUTCH SERVICE

Covers removal, installation, repair, and assembly of primary and secondary clutches.

FUEL SYSTEM COMPONENTS AND SERVICE

FUEL SYSTEM OVERVIEW AND TANK TYPES

Describes the fuel system components and fuel tank variations.

CARBURETOR OPERATION AND SERVICE PROCEDURES

Explains carburetor systems, service, and choke operation.

CHOKE ADAPTER AND CABLE SERVICE

Covers installation of choke adapter and service of choke cable.

CARBURETOR REMOVAL AND DISASSEMBLY

Details procedures for carburetor removal and disassembly.

FUEL PUMP AND FUEL LINES/FILTER SERVICE

Covers fuel pump replacement and fuel line/filter maintenance.

DIRECTION SELECTOR SYSTEM

NEUTRAL LOCK OPERATION AND SAFETY PRECAUTIONS

Explains the neutral lock mechanism and its safety precautions.

MICRO SWITCH REPLACEMENT AND SHIFT CABLE ADJUSTMENT

Details replacing micro switch and adjusting shift cable.

DIRECTION SELECTOR COMPONENTS AND REMOVAL

Identifies direction selector parts and removal procedure.

ELECTRICAL SYSTEM AND TESTING

IGNITION AND MAGNETO TESTING PROCEDURES

Details procedures for testing the ignition circuit and magneto.

STARTING AND CHARGING CIRCUIT TESTING

Covers troubleshooting for starting and charging circuit faults.

STARTER/GENERATOR INSPECTION AND REPAIR

Provides guidance on inspecting, repairing, and replacing the starter/generator.

BATTERY TESTING, STORAGE, AND FAULT TESTING

Details battery testing, storage, fault testing methodology, and power supply checks.

LIGHT BULB REPLACEMENT PROCEDURES

Provides instructions for replacing headlights, turn signals, and taillights.

BRAKE SYSTEM OPERATION AND MAINTENANCE

BRAKE SYSTEM OVERVIEW AND ADJUSTMENT MECHANISMS

Describes the brake system and its automatic adjuster mechanism.

PARKING BRAKE OPERATION AND LINKAGE ADJUSTMENT

Explains parking brake function and kick-off linkage adjustments.

BRAKE TESTING AND INSPECTION PROCEDURES

Details fault testing, inspection, and performance tests for brakes.

WHEEL BRAKE INSPECTION AND SERVICE

Covers inspection of brake drums, shoes, springs, and adjuster mechanisms.

BRAKE CABLE AND PEDAL ASSEMBLY REPLACEMENT

Provides procedures for replacing brake cables, equalizer, and pedal assembly.

REAR SUSPENSION COMPONENTS AND SERVICE

REAR SUSPENSION GENERAL MAINTENANCE AND TOOLS

General information and tools required for rear suspension service.

SHOCK ABSORBER AND REAR LEAF SPRING REPLACEMENT

Details the procedure for replacing rear shock absorbers and leaf springs.

REAR AXLE SERVICE PROCEDURES

NEUTRAL LOCK OPERATION AND AXLE LUBRICATION

Covers neutral lock function and rear axle lubricant level checks.

REAR AXLE DISASSEMBLY AND SHAFT SERVICE

Details axle disassembly, shaft removal, and seal replacement.

WEATHER PROTECTION COMPONENTS AND INSTALLATION

CANOPY/WINDSHIELD SAFETY AND VEHICLE TRANSPORT

Covers safety aspects of canopy/windshield and vehicle transport procedures.

WINDSHIELD AND GOLF CAR TOP REPLACEMENT PROCEDURES

Details procedures for replacing windshield and golf car top.

2 + 2 CANOPY AND REAR VIEW MIRROR INSTALLATION

Explains canopy replacement and rear view mirror installation.

FAULT TESTING AND DIAGNOSIS

GASOLINE VEHICLE PERFORMANCE ISSUES

Lists conditions, causes, and corrections for vehicle performance problems.

ENGINE PERFORMANCE PROBLEMS AND FAULTS

Covers issues like rough running, loss of power, and overheating.

CARBURETOR, FUEL, STARTER/GENERATOR, AND BRAKE FAULTS

Details malfunctions and fixes for carburetor, fuel, starter/generator, and brake systems.

SUSPENSION, STEERING, AND BRAKE SYSTEM FAULTS

Lists common suspension, steering, and brake system issues and their solutions.

GENERAL VEHICLE SPECIFICATIONS

PRODUCT SPECIFICATIONS AND VEHICLE OVERVIEW

Provides detailed technical specifications and product highlights.

VEHICLE DIMENSIONS AND OPERATIONAL LIMITS

Lists approximate dimensions and turning/incline information for vehicles.

PERIODIC SERVICE SCHEDULE

VEHICLE MAINTENANCE SCHEDULE AND INTERVALS

Provides a checklist for routine maintenance tasks at various intervals.

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