Textron EZGO RXV 2016

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Repair and Service Manual

BODY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

647701

Main Page

Safety Information5
General5
General Operation5
Ventilation6
Table of Contents7
General Information and Routine Maintenance15
Serial Number Label Location15
Vehicle with a Discharged Battery15
Starting Vehicle on a Hill15
Servicing the Vehicle16
Fuel16
Fuel Tank17
Early Production Fuel Tank17
Late Production Fuel Tank17
Battery17
Routine Maintenance18
Powertrain Maintenance18
Brakes18
Tires18
Light Bulb Replacement18
Transporting Vehicle18
Towing18
Neutral Lock18
Hauling19
Canopy and Windshield19
Winter or Prolonged Storage19
Vehicle Cleaning and Care20
Vehicle Care Products20
Hardware21
Torque Specifications21
Safety23
Notices, Cautions, Warnings and Dangers23
Important Safety Warning23
Modifications to Vehicle23
General Maintenance23
Before Servicing Vehicle23
Battery Removal and Installation24
Lifting the Vehicle25
How to Lift the Entire Vehicle25
How to Lift the Rear of the Vehicle Only26
How to Lift the Front of the Vehicle Only26
Lower the Vehicle26
Body29
General29
Body Component Replacement30
Front Bumper30
Rocker Panels30
Floormat30
Cowl and Instrument Panel31
Front Splash Guard32
Sweater Basket33
Seat Back Assembly33
Fender Liner33
Rear Body33
Rear Bumper34
Rear Facing Seat and Foot Rest35
Floorboard36
Bagwell Closeout37
Body Care Maintenance37
Cleaning37
Painting37
Minor Scratches38
Larger Scratches38
Complete Panel Repair38
Wheels and Tires41
Wheel and Tire Service41
Tire Repair41
Wheel Installation41
Front Suspension and Steering45
Maintenance45
Tire Wear Diagnosis45
Wheel Alignment46
Hub Assembly47
Spindle Assembly47
Struts47
Control Arm Assembly48
Clipboard and Steering Wheel49
Installation49
Steering Column Assembly and Yoke50
Tie Rod End / Ball Joint51
Steering Box51
Speed Control55
System Operation55
Pedal Box Operation55
Governor Operation55
Fault Testing56
Speed Control56
Throttle Rod Removal56
Throttle Rod Adjustment56
Accelerator Cable Removal at Governor57
Accelerator Cable Removal and Installation at Pedal57
Accelerator Pedal Arm Adjustment57
Road Test57
Accelerator Pedal Assembly58
Engine61
General61
Four Cycle Engine61
Engine Specifications61
Engine Description61
Powertrain Maintenance61
Checking the Oil Level61
Changing the Oil62
Air Filter Inspection/Replacement63
Clean the Air Filter Element64
Starter/Generator Belt Tension64
Adjusting the Belt65
Starter/Generator Replacement65
Cooling System Cleaning66
Spark Plug66
Cylinder Head67
Compression Leak down Test67
Rocker Cover Removal67
Valve Clearance Inspection67
Valve Clearance Adjustment68
Engine Removal68
Controls and Wiring69
Removing the Engine from the Vehicle69
Engine Installation69
Drive Clutch Removal70
Fuel System73
General75
Early Production Fuel Tank75
Late Production Fuel Tank76
Carburetor Operation76
Float System76
Pilot Jet System76
Main Jet System76
Choke System76
Carburetor Service76
Choke Operation76
Choke Adapter Installation77
Fuel System Component Service and Replacement77
Choke Cable and Housing Removal77
Choke Cable and Housing Installation77
Carburetor Removal78
Carburetor Disassembly78
Float Level Alignment79
Carburetor Installation79
Fuel Pump80
Fuel Pump Replacement80
Fuel Lines and Filter80
Early Production Vehicles80
Late Production Vehicles80
Fuel Tank Removal83
Carbon Canister83
Continuously Variable Transmission (Cvt)87
General87
Clutches87
Primary Clutch87
Secondary Clutch88
Increased Load88
Equilibrium88
Removing the Transmission Belt88
Transmission Belt Service88
Primary Clutch Removal88
Primary Clutch Installation90
Secondary Clutch Removal90
Secondary Clutch Repair90
Secondary Clutch Assembly90
Secondary Clutch Installation90
Storage90
Direction Selector93
Removing Direction Selector93
Replacing a Micro Switch94
Shift Cable Adjustment94
Neutral Lock Operation94
Circuits and Controls97
Starter97
Generator97
Wiring97
Testing the Ignition Circuit97
Testing the Magneto100
Testing the Starting Circuit101
Testing the Charging Circuit101
Inspection102
Starter/Generator103
Starter/Generator Removal103
Disassembly103
Repair and Replacement103
Voltage Test for Battery103
Storage of Battery104
Dvom (Digital Volt Ohm Meter)104
Fault Testing104
Power Supply105
Accessory Wiring105
Light Bulb Replacement105
Headlight (if Equipped)105
Turn Signal (if Equipped)106
Taillight (if Equipped)106
Brake System Overview110
General Description110
How the Service Brake Works110
Equalizer Link110
Automatic Adjuster Mechanism110
How the Parking Brake Works111
Kick-Off Actuating Linkage111
Fault Testing and Inspection111
New Vehicles111
Fault Testing and Inspection Procedures111
Brake Pedal and Linkage Inspection111
Periodic Brake Performance Test (PBPT)112
Aggressive Stop Test113
Wheel Brake Inspection114
Maintenance and Repairs116
Parts Replacement Vs. Repair116
Adjusting Brake Pedal Free Travel116
Brake Drum Removal and Installation117
Wheel Brake Service118
Backing Plate/Entire Wheel Brake Assembly Removal and Installation119
Brake Shoe and Adjuster Replacement120
Brake Cable Snap Ring Removal121
Brake Cable and Equalizer Assembly Removal and Installation121
Brake Pedal Assembly Replacement121
Brake Fault Testing122
Rear Suspension125
General125
Shock Absorber125
Rear Leaf Spring126
Removal126
Installation126
Rear Axle129
Neutral Lock129
Checking the Lubricant Level129
Rear Axle Disassembly130
Axle Shaft Removal and Disassembly130
Axle Shaft Seal Removal and Replacement131
Axle Shaft Replacement131
Weather Protection133
Canopy and Windshield133
Transporting the Vehicle133
Windshield134
Golf Car Top134
Removal134
Installation134
2 + 2 Canopy136
Removal136
Installation136
Rear View Mirror with Canopy138
Mirror Bracket Installation138
Mounting Mirror to Bracket138
Rear View Mirror Without Canopy139
Fault Testing143
Gasoline Vehicle Performance143
Fuel Accumulation in the Crankcase147
Carburetor148
Starter / Generator149
Suspension and Steering150
Brake System150
General Specifications155
Approximate Vehicle Dimensions159
Turning Diameter and Incline Information161
Periodic Service Schedule163

Textron EZGO RXV 2016 - Page 40

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