Cushman HAULER 800X Technician's Repair And Service Manual
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Cushman HAULER 800X Technician's Repair And Service Manual

Gasoline powered utility vehicle
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TECHNICIAN'S REPAIR AND SERVICE MANUAL
GASOLINE POWERED UTILITY VEHICLE
625609
ISSUED APRIL 2012
REVISED MAY 2014

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Do you have a question about the HAULER 800X and is the answer not in the manual?

Questions and answers

steve
April 8, 2025

crank no start just turns over but will not stay ruuning when you take your foot off gas peddle , fuel pump is good , relays and fuses are good need answer,

0
1 comments:
Mr. Anderson
April 9, 2025

A Cushman HAULER 800X that cranks but does not stay running when the gas pedal is released could be caused by poor low-speed performance. Possible causes include:

- Clogged pilot port
- Clogged low-speed jet
- Loose low-speed jet

These issues affect fuel delivery at low speeds and should be cleaned or tightened as needed.

This answer is automatically generated

0
Glenn
April 24, 2025

is it necessary to prime? I removed float switch to verify the float is functioning

0

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Summary of Contents for Cushman HAULER 800X

  • Page 1 TECHNICIAN’S REPAIR AND SERVICE MANUAL GASOLINE POWERED UTILITY VEHICLE 625609 ISSUED APRIL 2012 REVISED MAY 2014...

  • Page 2: Safety

    SAFETY 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 hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 SERVICE AND REPAIR MANUAL GASOLINE POWERED UTILITY VEHICLES SHUTTLE 4X HAULER 800X HAULER 1200X STARTING MODEL YEAR 2012 The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously.

  • Page 4: General Information

    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 Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ......................... INSIDE COVERS GENERAL INFORMATION ......................II SAFETY INFORMATION ......................... V TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D FRONT SUSPENSION AND STEERING ..................E SPEED CONTROL...........................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specification.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated. •...
  • Page 10 SAFETY INFORMATION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page viii...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LOCATION ................. A - 1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY ........ A - 1 SERVICING THE VEHICLE ..................A - 1 FUEL .........................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-ii...

  • Page 13: General Information & Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERIAL NUMBER LOCATION Observe all instructions provided by the manufacturer of the charger. Three serial number and manufacture date code labels SERVICING THE VEHICLE are on the vehicle.

  • Page 14: Fuel

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. sider the safety of yourself and those around you, should the component move unexpectedly. Some components are heavy, spring loaded, highly cor- FUEL Leave 1”...

  • Page 15: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use extra caution when towing vehicle. Do not tow a sin- To activate the direction selector, pull the neutral lock pin gle vehicle at speeds in excess of 12 mph (19 kph).

  • Page 16: Brakes

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For maintenance procedures relating to the engine, exceed the weight of the vehicle (see GENERAL SPEC- speed control, fuel system, transmission, and rear axle IFICATIONS for vehicle weight) and load.

  • Page 17: Care And Cleaning Of The Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. • Turn the Key Switch to OFF position, and leave Rubber parts should be cleaned with non-abrasive the Forward/Reverse switch in the NEUTRAL household cleaner.

  • Page 18: Torque Specifications

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.

  • Page 19: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • Page 20 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REMARKS Steering Assembly - excessive play, loose or missing hardware Tie Rods - excessive play, bent rods, loose or missing hardware Rear Axle - fluid level, oil leakage, noise, loose or missing hardware...
  • Page 21 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-9...
  • Page 22 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page A-10...
  • Page 23 SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTICES, CAUTIONS WARNINGS AND DANGERS ..........B - 1 IMPORTANT SAFETY WARNING ................B - 1 MODIFICATIONS TO VEHICLE................B - 1 GENERAL MAINTENANCE..................B - 1 BEFORE SERVICING THE VEHICLE............... B - 1 Battery Removal and Installation..............
  • Page 24 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-ii...

  • Page 25: Safety

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICES, CAUTIONS WARNINGS battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders AND DANGERS if not treated with utmost caution.
  • Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. could expose the body or eyes to potential Wrap wrenches with vinyl injury. In particular, use care when working tape to prevent the possi- with or around batteries, compressed air bility of a dropped wrench...
  • Page 27 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Battery Removal and Installation Some servicing operations may require the front, rear or the entire vehicle to be raised. Tool List Qty.
  • Page 28 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Center of Front Axle Flat Portion of Frame Outside End of Rear Axle View from Underside of Vehicle Fig.
  • Page 29 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-5...
  • Page 30 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page B-6...
  • Page 31 Fig. 4 Rear Body Components (Shuttle 4X) ............C - 4 FIg. 5 Body Components (Hauler 800X and Hauler 1200X) ........C - 5 FIg. 6 Rear Body Components (Hauler 800X and Hauler 1200X) ......C - 6 FIg. 7 Seating ....................... C - 7 FIg.

  • Page 32: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers Notes: Page C-ii Repair and Service Manual...
  • Page 33 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY metal between the surface being drilled and components directly behind it. Drill out rivet Pop Rivet head only In the following text, there are references to removing/installing bolts etc.
  • Page 34 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Glove Box Door Splash Panel Cowl Instrumental Panel Fender Flare Front Basket Floorpan Brush Guard Fig. 2. Front Body Components Repair and Service Manual Page C-2...
  • Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For Vechicle Models Shuttle 4X, Hauler 800X and Hauler 1200X ASHTRAY Gun Holder Floor Mat FLOOR MOUNT GUN HOLDER...
  • Page 36 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Access Panel Cover Rear Bumper Splash panel Battery Tray Fender Liner Fender Liner Fig. 4. Rear Body Components (SHUTTLE 4X) Repair and Service Manual Page C-4...
  • Page 37 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Floor Mat Splash Panel Seat Wrap W/Louvers Battery Tray Rocker Panel Side Panel Fig. 5 Body Components (HAULER 800X and 1200X) Repair and Service Manual Page C-5...
  • Page 38 Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HAULER 1200X Rear Panel Rear Fender HAULER 800X Seat Hinge Plate Rear Panel Rear Fender Fig. 6 Rear Body Components (HAULER 800X and 1200X) Repair and Service Manual Page C-6...
  • Page 39 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Vinyl Seat bottom cover Form Padding Seat Bottom wood Vinyl Trim Vinyl Seat back cover Seat Hinge Form Padding Seat Back wood Seat Back Support Bracket...
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Plastic Bed Latch Handle Heat Shield Latch Plate Rubber Bumper Fig. 8 Plastic Bed Components (Manual Lift) Repair and Service Manual Page C-8...
  • Page 41 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Plastic Bed Electric Actuator Actuator may be rotated 90° on some models Front of Vehicle ELECTRIC DUMP DOWN WHT from Actuator BLK from Battery RED from Battery...
  • Page 42 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING 2. Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type touch- Follow the paint manufacturer’s recommendations for up paint.
  • Page 43 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page C-11...
  • Page 44 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page C-12 Repair and Service Manual...
  • Page 45 WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ................... D - 1 Tire Repair ....................... D - 1 Wheel Installation..................... D - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheel and Tire Installation ................D - 2 Repair and Service Manual Page D-i...
  • Page 46 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-ii...

  • Page 47: Wheel And Tire Service

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL AND TIRE SERVICE rate from the rim or cause the tire to explode, either of which could cause personal injury.

  • Page 48: Wheel Installation

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Finger tighten lug nuts as shown. Then, tighten lug nuts to 50 - 85 ft.
  • Page 49 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-3...
  • Page 50 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page D-4...
  • Page 51 FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. FRONT SUSPENSION AND STEERING ..............E - 1 FRONT SUSPENSION....................E - 1 Front Shock Absorber Replacement ..............E - 1 Shock Boot Removal and Replacement ............E - 1 Front Axle Replacement...................
  • Page 52 FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘E’ (CONT.) PAGE NO. SECTION TITLE FRONT SUSPENSION ....................E - 15 Front Shock Absorber Replacement..............E - 15 Front Axle Replacement ..................E - 16 Front Spring Replacement..................E - 16 Hub Replacement ....................E - 17 Wheel Bearing and Race Replacement..............E - 18 STEERING ........................E - 20 Rack Ball Joint Replacement................E - 20...

  • Page 53: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Front Axle Replacement NOTICE Tool List Qty. In the following text, there are references to removing/installing Wheel chocks ..............4 bolts etc.
  • Page 54 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten the shock absorber mounting hardware until the rubber bushings expand to the diameter of the shock ITEM TORQUE SPECIFICATION absorber washer.
  • Page 55 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pliers................1 NOTICE Impact wrench .............1 Impact socket, 3/4" ............1 Failure of a single spring will result in overstressing the other Impact socket, 11/16"...........1 spring, therefore it is good practice to replace the front springs as a set.
  • Page 56 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. When steering wheel is loosened, remove retaining nut and remove steering wheel. NOTICE Replace steering wheel by first lightly coating the splines To maintain correct orientation when replacing steering wheel, of the steering shaft with a commercially available anti- first turn wheels straight ahead.
  • Page 57 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bolts (9) should be tightened to a light drag between shaft (12) and coupling (11). Do not over tighten. ITEM TORQUE SPECIFICATION Bolts (6) must be replaced with new bolts.
  • Page 58 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To remove the tensioner, remove the bolts (31), the cover plate (32) and gasket (33) that secures the rack ITEM TORQUE SPECIFICATION tensioner in the steering housing.
  • Page 59 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE and removing the ball joint (21) from the rack (Ref Fig. 7). Good routine maintenance of the front suspension and Rack Ball Joint Installation steering consists of routine lubrication (See Lubrication Chart and the Periodic Service Schedule in Section ‘A’).
  • Page 60 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove the dust cap (14), cotter pin (15) castellated nut and washer (16), outer roller bearing (18) and hub assembly (17) from the spindle (Ref Fig.
  • Page 61 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Sizing reamer, .875" ............ 1 tern. Lower the vehicle and roll it forward approximately Socket, 15/16" ............. 1 five feet in order to allow the tires to take their normal Torque wrench, ft.
  • Page 62 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. INDICATES AREAS OF EXCESSIVE TIRE WEAR NOTES: ILLUSTRATIONS ARE DISTORTED FOR CLARITY. DUE TO LOW WEIGHT OF VEHICLE &...
  • Page 63 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wave Washer Bearing Outer Snap Ring Inner Snap Ring Front of Vehicle Intermediate Rack &...
  • Page 64 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE NOTICE Do not use more than three (3) pumps of grease in any In the following text, there are references to removing/ grease fitting at any one time.
  • Page 65 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove hub from spindle and disassemble. See Illus- slight resistance is felt. If the cotter pin hole in the spin- tration “Seal Installation”...
  • Page 66 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. tern. Lower vehicle and, with tires in the straight ahead Fig. 18). Reconnect intermediate shaft and tighten bolt position, roll it forward approximately five feet in order to to 155 - 215 in.
  • Page 67 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.
  • Page 68 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Installation of shock absorber is reverse of disassembly. (17). Secure rack and pinion unit to spring with wire to Mounting nuts should be tightened until rubber bushings prevent pulling apart intermediate shaft.
  • Page 69 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pull upper passenger side of floor mat out of plastic trim retainer and away from floor. Locate and remove hard- NOTICE ware (25 - 27) securing rear of spring (17) to vehicle frame and discard lock nuts (27).
  • Page 70 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Ball Peen Hammer ............1 Lower vehicle per SAFETY section and tighten front Needle Nose Pliers............
  • Page 71 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Fig. 23 Wheel Bearing Replacement Install inner wheel bearing (4) and new grease seal in hub and mount hub to spindle.
  • Page 72 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STEERING Front of Vehicle Flat Section Fig. 24 Steering Components Rack Ball Joint Replacement Remove passenger side front wheel and turn steering wheel fully to the left.
  • Page 73 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tie Rod Inspection/Replacement To install new rack ball joint close to its correct position, measure amount of threads exposed from jam nut Tool List Qty.
  • Page 74 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cut wire ties (5,6) and slide bellows off rack extension. Install new bellows aligning small end over groove in Remove lock nut (10) until tie rod ball joint (6) threads rack extension and secure with new wire tie (5).
  • Page 75 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Secure rack and pinion unit in vice by the mounting ears Socket, 11/16"..............1 only.
  • Page 76 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. wire ties (8, 14) securing bellows (9) and slide bellows off rack extension. Pull rack (3) from unit (1). Remove NOTICE pinion seal (10).
  • Page 77 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque and continue to tighten as needed to insert new cotter pin.
  • Page 78 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. joint. This will provide more travel for the steering wheel to be turned to the right. Steering Wheel Replacement Front Tool List...
  • Page 79 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bearing Separator............1 Gear Puller..............1 Arbor Press..............1 Bearing Driver Set ............1 Torque Wrench, ft. lbs..........1 Torque Wrench, in.
  • Page 80 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. as far as possible using snap ring pliers (Ref Fig. 36). Use fingers to push retaining ring fully into groove. Slide wave washer into base of steering column.
  • Page 81 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Page E-29 Repair and Service Manual...
  • Page 82 FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page E-30...

  • Page 83: Speed Control

    SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. SYSTEM OPERATION ..................F - 1 Pedal Box Operation ..................F - 1 Governor Operation ..................F - 2 TROUBLESHOOTING ....................F - 2 SPEED CONTROL....................F - 2 Accelerator Cable Removal at Governor ............
  • Page 84 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page F-ii...

  • Page 85: System Operation

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Governor Lever - Upper Governor Lever - Lower Governor Spring Accelerator Compression Spring Fig. 1 Accelerator and Speed Control System SYSTEM OPERATION NOTICE Pedal Box Operation...

  • Page 86: Governor Operation

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Governor Operation Tool List Qty. Socket, 15 mm .............1 Until the vehicle reaches its governed speed, the vehicle will continue to accelerate in relation to the accelerator Torque Wrench, in.

  • Page 87: Accelerator Cable Removal At Pedal Box

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Accelerator Cable Installation To install the accelerator cable, proceed in reverse order (Ref Fig. 3)(Ref Fig. 4)(Ref Fig. 5). ITEM TORQUE SPECIFICATION 30 - 33 ft.

  • Page 88: Pedal Box Adjustments

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE Note that the factory applies a thread sealant to the accelera- tor rod threads before threading the rod into the clevis. Fig.

  • Page 89: Road Test

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Loosen the setscrew (9) in cam (10) using an 1/8" Allen wrench. Loosen the jam nut (12) and move the cam to adjust as needed (Ref Fig.
  • Page 90 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page F-6...

  • Page 91: Engine

    ENGINE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE ................G - 1 Checking the Oil Level ..................G - 1 Changing the Oil ....................G - 1 AIR FILTER INSPECTION/REPLACEMENT ............G - 3 Cleaning the Air Filter Element.................G - 3 STARTER/GENERATOR BELT TENSION ...............G - 4 Adjusting the Belt .....................G - 4 STARTER/GENERATOR REPLACEMENT ..............G - 5...
  • Page 92 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page G-ii...

  • Page 93: Powertrain Maintenance

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. For further engine information, see Engine Shop Rebuild and Service Parts Manual. Maximum Oil Level POWERTRAIN MAINTENANCE Fill Cold Engine For Hot Engine To This Point Do Not Overfill...
  • Page 94 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. HEAVY DUTY WORK 10W-40 10W-30 Be careful of hot oil when drained. It may be hot enough to burn you severely LIGHT DUTY WORK Place the oil drain pan under the oil drain plug (1) found 10W-30...

  • Page 95: Air Filter Inspection/Replacement

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. from the engine and allow the oil to drain into the oil drain pan (Ref. Fig. 6). The ‘O’ ring (5) may remain on engine (6) or filter (7) (Ref.

  • Page 96: Cleaning The Air Filter Element

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE NOTICE A loose belt can cause audible vibration and squeal. The air filter assembly on the vehicle is a dry unit. Do not use oil on the filter element or any part of the unit.

  • Page 97: Starter/Generator Replacement

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Move the lower nut (11) up or down the adjustment bolt until proper belt tension is achieved. Hold the lower nut (11) in place and tighten the upper jam nut (12) against it the lower nut to the specified torque value (Ref.

  • Page 98: Cooling System Cleaning

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. COOLING SYSTEM CLEANING Remove the wiring from the starter/generator. Loosen the jam nut (11) and the adjusting nut (12) securing the starter/generator adjuster until the starter/generator belt At least once a year, or more often under adverse condi- can be removed from the drive clutch.

  • Page 99: Four Cycle Engine

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CYLINDER HEAD Spark Plug Compression Measurement Tool List Qty. Ratchet ................1 Spark Plug Socket ............1 Extension 6"..............1 0.7 - 0.8 mm Compression Gauge &...

  • Page 100: Rocker Cover Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Cylinder Compression should be between 9 - 11 kgf/ Valve Clearance Inspection (128-156 psi) Tool List Qty. If the compression is higher than 9 kgf/cm (128 psi) the Allen Bit, 3 mm.............1 piston rings, cylinder and valves are probably in good...

  • Page 101: Engine Removal

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wrench, 14 mm ............2 Wrench, 15 mm ............1 Wrench, 19 mm ............1 Combo Wrench, 19 mm..........1 Pliers................1 Extension 6"..............1 Ratchet ................1 Flat Ratchet ..............1 Impact Tool ..............1...

  • Page 102: Controls And Wiring

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Controls and Wiring 11. Disconnect the pulse line from the fuel pump using pli- ers. Unplug the wiring harness from the engine and cut the 12.
  • Page 103 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. driving it off with the impact wrench and the clutch puller bolt. NOTICE In some extreme cases, the clutch will be resistant to removal In stubborn cases the clutch removal tool should be removed and the cavity filled with grease.
  • Page 104 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page G-12...
  • Page 105 FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. GENERAL ......................... H - 1 CARBURETOR OPERATION ................... H - 2 Float System ....................H - 2 Pilot Jet System ....................H - 2 Main Jet System....................H - 2 Carburetor Service ...................

  • Page 106: Fuel System

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page H-ii...

  • Page 107: General

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CARB Canister Fuel Filter Shut Off Valve Fuel Line to Fuel Pump Fuel Tank Carburetor Fuel Gauge Sending Unit Fig.

  • Page 108: Carburetor Operation

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Carburetor Service Be sure that the ignition system is functioning correctly FUEL Leave 1” airspace before determining that servicing the carburetor is for ventilation required.

  • Page 109: Fuel System Component Service And Replacement

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 4 Choke Cable and Housing At the seat panel, remove the nut (6) and lock washer (7) securing the outer cable to the bezel (8).

  • Page 110: Carburetor Removal

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 5 Carburetor Operation Carburetor Removal (Ref. Fig. 5) NOTICE Tool List Qty. Socket, 10 mm ............1 Before disassembling the carburetor, drain the fuel bowl and Ratchet ................

  • Page 111: Float Level Alignment

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Float Chamber Stem Float Valve Float Carburetor Body Float should be aligned so that its top is parallel or “slightly above”...

  • Page 112: Fuel Pump Replacement

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. a negative pressure moves the diaphragm within the fuel pump (1) (Ref. Fig. 8). This movement draws fuel NOTICE from the fuel tank into the fuel pump chamber.

  • Page 113: Fuel Tank Removal

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To prevent possibility of personal injury, tests that involve fuel flow should be avoided if at all possible.
  • Page 114 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 11 CARB Canister Fig. 12 CARB Hoses Repair and Service Manual Page H-8...
  • Page 115 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-9...
  • Page 116 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page H-10...

  • Page 117: Continuously Variable Transmission (Cvt)

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL ........................J - 1 CLUTCHES ........................J - 1 Drive Clutch ......................J - 1 Driven Clutch ....................J - 2 Increased Load ....................J - 2 Equilibrium ......................J - 2 Removing the Drive Belt..................J - 2 Drive Belt Service....................J - 2 Drive Clutch Removal ..................J - 2...
  • Page 118 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page J-ii...
  • Page 119 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driven Clutch Drive Belt Drive Clutch Fig. 1 Continuously Variable Transmission System (CVT) GENERAL moveable sheave inwards. The drive belt is engaged by the clutch sheaves and begins to rotate.
  • Page 120 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driven Clutch The driven clutch sheaves are closed at rest which results in the drive belt being held at the outer diameter of the driven clutch.
  • Page 121 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use only sockets designed for use with an spring hanger using a 15 mm socket and a 15 mm impact wrench.
  • Page 122 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Drive Clutch Installation Driven Clutch Repair (Ref. Fig. 3) Clean both the engine crankshaft and the drive clutch bore.
  • Page 123 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-5...
  • Page 124 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page J-6...

  • Page 125: Direction Selector

    DIRECTION SELECTOR TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. DIRECTION SELECTOR ..................K - 2 Removing Direction Selector ................K - 2 Replacing a Micro Switch ................. K - 2 Shift Cable Adjustment..................K - 2 Neutral Lock Operation ..................K - 2 LIST OF ILLUSTRATIONS Fig.
  • Page 126 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page K-ii...
  • Page 127 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FOR VEHICLES MANUFACTURED FROM APRIL 2014 Fig. 1 Direction Selector Repair and Service Manual Page K-1...
  • Page 128 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. DIRECTION SELECTOR Replacing a Micro Switch Before removing a suspected faulty micro switch, To replace a micro switch (5), remove the attaching ensure the electrical wires are firmly attached and the hardware (Ref.
  • Page 129 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To activate the direction selector, pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole (3) in the direction selector cam.
  • Page 130 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page K-4...
  • Page 131 ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS ..................L - 1 STARTER ......................... L - 1 GENERATOR......................L - 1 WIRING ........................L - 1 TESTING IGNITION CIRCUIT................... L - 1 Testing the Magneto ..................L - 4 TESTING STARTING CIRCUIT ................
  • Page 132 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page L-ii...

  • Page 133: Circuits And Controls

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CIRCUITS AND CONTROLS WIRING The electrical system is a 12 volt negative ground sys- tem (Ref. Fig. 1) (Ref. Fig. 2) consisting of a: •...
  • Page 134 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Electrical System Wiring Diagram Repair and Service Manual Page L-2...
  • Page 135 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Electrical Controller Starter/Generator Voltage Regulator Reverse Solenoid Buzzer Relay Frame Battery Frame To Magneto Direction Selector Hour Meter Accelerator Pedal Fuel Gauge...

  • Page 136: Testing The Magneto

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. good, and with a spark plug installed in the cylinder, place on a clean grounded engine surface, (muffler, cylinder, etc.).

  • Page 137: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TESTING STARTING CIRCUIT (b) Press the accelerator pedal. The DVOM will indi- cate “0” voltage if the solenoid contacts are closed. (c) If “0”...

  • Page 138: Starter/Generator

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. winding (green lead) is not grounded. If it is not, Inspection replace the regulator. 1. Inspect the commutator for wear or damage. 8) If the reading is below 14 volts, disconnect the 2.

  • Page 139: Disassembly

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. brushes worn to less than 11/16" (17 mm) in length or NOTICE to the line marked on the brush. In general, starter/generator service is best performed by 3.

  • Page 140: Storage Of Battery

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. gauges, the technician must be able to use the wiring diagram and a DVOM. The wiring diagram shows the path followed by a volt- Do not overcharge battery.
  • Page 141 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use the wiring diagram (Ref. Fig. 10) to check correct NOTICE wiring and wire routing. If there is power at the fuse end of the wire, there must also be power at the other end of If any DVOM readings indicate a faulty wire, it is recommended the wire at the switch or electrical accessory, and even-...
  • Page 142 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Driver Side Passenger Side Turn Signal Headlight Headlight Turn Signal BLU/WHT BLU/WHT H/L Switch Fuel Gauge Oil Light Turn Signal Connector Brake...

  • Page 143: Section Title

    MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW ..................M - 1 General Description ..................M - 1 How the Service Brake Works................M - 1 Equalizer Link ....................M - 2 Automatic Adjuster Mechanism ................M - 2 How the Parking Brake Works .................M - 2 Compensator Assembly ...................M - 3 Kick-Off Actuating Linkage ................M - 3...
  • Page 144 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ‘M’ (CONT.) SECTION TITLE PAGE NO Fig. 19 Checking Parking Brake Latching Pressure ..........M - 13 Fig. 20 Brake Assembly ..................M - 14 Fig. 21 Wheel Brake Lubrication Points............... M - 15 Fig.

  • Page 145: Mechanical Brakes

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Hinge Pin Identification Hole* Service Brake Pedal Pedal Latch Spacer Kick Off Catch Bracket Cap Screw...

  • Page 146: Automatic Adjuster Mechanism

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Lever system. Continued motion of the brake pedal pulls both the left and right brake cables. Each brake cable pulls a brake lever which pushes the rear brake shoe against Brake the brake drum.

  • Page 147: Compensator Assembly

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Compensator Assembly Older Models The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.

  • Page 148: Troubleshooting Table

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING TABLE Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Test (PBPT), and Aggressive Stop Test is performed (Ref.
  • Page 149 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Unequal braking (one wheel locks Wheel not locking is not adjusting. Check brake operation of wheel that is not locking.

  • Page 150: Troubleshooting And Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TROUBLESHOOTING AND INSPECTION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this 1/4"...
  • Page 151 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Either condition can prevent the brakes from adjusting loose, but brake pedal free travel is correctly adjusted properly.

  • Page 152: Periodic Brake Performance Test (Pbpt)

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. soon as the accelerator pedal is depressed. Pedal Latch Arm Hinge Torsion Springs Cam Must Be Against Latch Arm At This Point 0.0"...

  • Page 153: Aggressive Stop Test

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cles, several vehicles should be tested when new and the range of stopping locations or distances recorded. NOTICE Over time, a subtle loss of performance may take place;...

  • Page 154: Wheel Brake Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To perform an Aggressive Stop Test, equally load both friction surface. Turning will make the drum too sides of the vehicle (Ref.
  • Page 155 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. brake adjusters be replaced when installing new brake shoes. Wheel Brake Lever 10. Inspect the brake shoe springs. Be sure that they are not broken or damaged and are correctly installed.

  • Page 156: Maintenance And Repairs

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tool List Qty. Pliers ................1 Heavy Shoe Spring Vernier/Dial Calipers ............1 Plastic Tipped Hammer..........1 Light Puller (P/N 15947-G1) ..........1 Shoe Pry Bar .................1 Spring...
  • Page 157 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. latches. The parking brake should latch between 65 and 7/8" - 1 1/8" (2.2 - 2.9 cm) 75 lbs.
  • Page 158 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. until a new cotter pin can be installed through the castel- lated nut and the hole in the axle. Maximum torque is 140 ft.
  • Page 159 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Backing Plate/Entire Wheel Brake Assembly Lubricate the backing plate friction points of the shoes and moving anchor with Multi Purpose Grease (MPG) Removal and Installation lubricant (Ref.
  • Page 160 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always replace both brake shoes on both wheels as a Heavy Shoe Spring set. Install the shoes as indicated and install the shoe Shoe Clamp clamp (5) over the shoe clamp pin (4) and rotate 90°...
  • Page 161 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. replace if needed. Remove the brake cable and equalizer the bracket. Move the hook back and to the side to assembly and discard.
  • Page 162 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Catch Bracket Removal and hardened part. Do not grind or file it as doing so will cause the part to lose its hardness char- Installation acteristics.
  • Page 163 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Inspect the bushings (9,10) and spacer. If they are worn, replace them with new ones. Accelerator Pedal Fig.
  • Page 164 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page M-20...

  • Page 165: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. REAR SUSPENSION ....................N - 1 General ......................N - 1 Shock Absorber Removal................. N - 2 Shock Absorber Installation................N - 2 Rear Leaf Spring Removal ................N - 2 Rear Leaf Spring Installation ................
  • Page 166 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page N-ii...
  • Page 167 Rear Axle Bumper Stop Upper Spring Plate Upper Spring Front Plate & Bumper Mount Bushing For Hauler 800X Lower Spring Plate Fig. 1 Rear Suspension General Wrench, 1/2" ..............1 Insulated Wrench, 9/16"..........1 NOTICE Wrench, 3/4" ..............1 Socket, 1/2" ..............1 In the following text, there are references to removing/installing Socket, 9/16"...
  • Page 168 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ing any repair procedure. Never work on a Floor Jack ..............1 vehicle that is supported by a jack alone. Wrench,1/2"...
  • Page 169 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4. Position the shackle plates (12) over the bushings and Removal and installation of the leaf spring is the same install the hex head bolt (13) and nut (14).
  • Page 170 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page N-4...

  • Page 171: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. NEUTRAL LOCK ..........................P - 1 REAR AXLE ............................P - 1 Checking the Lubricant Level .....................P - 1 REAR AXLE DISASSEMBLY ......................P - 2 Axle Shaft Removal and Disassembly ................P - 2 Axle Shaft Seal Removal and Replacement ..............P - 3 Axle Shaft Replacement .....................P - 3 LIST OF ILLUSTRATIONS...
  • Page 172 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page P-ii...
  • Page 173 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE For further axle information, see Four Cycle Transaxle Shop Rebuild and Service Parts Manual. The rear axle is provided with a lubricant level check Refer to REAR SUSPENSION section for axle removal.
  • Page 174 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE DISASSEMBLY The rear axle is a precision assembly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment.
  • Page 175 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Axle Shaft Seal Removal and Replacement Tools List Qty. Internal Snap Ring Pliers..........1 Seal Puller ..............1 Plastic Faced Hammer ..........
  • Page 176 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page P-4...

  • Page 177: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. SUN TOP AND WINDSHIELD ..................Q - 1 Trailering ......................Q - 1 SUN TOP ........................Q - 1 Rear Support Installation..................Q - 1 Front Strut ......................Q - 1 Sun Top ......................Q - 1 SPLIT WINDSHIELD....................Q - 3 FULL WINDSHIELD....................Q - 4 SPLIT WINDSHIELD (CLIP-ON TYPE)..............Q - 5...
  • Page 178 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page Q-ii Repair and Service Manual...

  • Page 179: Sun Top And Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SUN TOP AND WINDSHIELD 3. Secure with washer (10) and lock nut (11) at outer side of rear strut as shown. Finger tighten hardware to allow for adjustment.
  • Page 180 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Front of Vehicle Vehicle seat back support Bumper Front of Front of Vehicle Vehicle seat Fig.

  • Page 181: Split Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD Position top grips (8) as shown (See Detail D) at top hole on each side of front strut. Secure with top grip fas- Tool List Qty.

  • Page 182: Full Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD Install sash (3) on each side of the windshield. Using a rubber mallet, gently tap sash to ensure windshield Tool List Qty.

  • Page 183: Split Windshield (Clip-On Type)

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD (CLIP-ON TYPE) the fastener grommet (9). Place grommet (13) at bottom of the windshield as shown and press the sleeve (14) Clip-on type windshield is used on vehicles with tubular starting at the grommet, onto the front strut so that it struts.

  • Page 184: Full Windshield (Clip-On Type)

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FULL WINDSHIELD (CLIP-ON TYPE) Insert fastener grommets (4) into large holes and insert sleeve into the grommets. Insert pan head bolt (5) Clip-on type windshield is used on vehicles with tubular through washer (7), fastener grommet (4) and existing struts.
  • Page 185 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page Q-7...
  • Page 186 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page Q-8 Repair and Service Manual...

  • Page 187: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. TROUBLESHOOTING ....................S - 1 Gasoline Vehicle Performance ................S - 1 Starter Does Not Turn ..................S - 1 Starter Turns Slowly..................S - 1 Starter Rotates but Vehicle Doesn’t Start or Hard to Start........ S - 1 Engine Runs Rough or Loss of Power .............
  • Page 188 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers NOTES: Repair and Service Manual Page S-ii...
  • Page 189 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GASOLINE VEHICLE PERFORMANCE Condition Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and retighten Poor wiring connections...
  • Page 190 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Fuel pump faulty Repair or replace Fuel line clogged or clamp loose Clean or replace if required Cracked or broken fuel line Replace with new hose Main jet blocked...

  • Page 191: Poor Low Speed Performance

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR LOW SPEED Plugged gas tank vent Clean or repair PERFORMANCE Choke on Push choke in Carburetor float level incorrect Check/Replace float Clutches not shifting out...

  • Page 192: Repeated Spark Plug Fouling

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction REPEATED SPARK PLUG Wrong spark plug type Replace with correct spark plug FOULING Wrong spark plug gap Check and adjust if required Faulty magneto Check and replace if required...

  • Page 193: Erratic, Surging, Or Sudden Change In Governed Speed

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction ERRATIC, SURGING, OR SUDDEN Damaged governor spring Replace CHANGE IN GOVERNED SPEED Problem with adjustment of accelerator, Adjust governor and carburetor linkage Bent governor arm...

  • Page 194: Overflow Leak

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction OPERATION AND APPLICATION Engine not reaching full temperature Increase run time intervals to build higher cylinder temperature Continuous use at 1/4 throttle or less at low Instruct operator...

  • Page 195: Abnormal Combustion (Fuel Mixture)

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction POOR HIGH SPEED OPERATION Fuel pump faulty Replace fuel pump Loose main jet Tighten main jet Incorrect fuel level in float bowl Adjust float Dirt in fuel tank or hoses...

  • Page 196: Stiff Steering

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction RECTIFICATION IS IMPERFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough...

  • Page 197: Brake System

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction STEERING PULLS TO ONE SIDE Incorrect tire pressure Inflate to recommended pressure Dragging wheel brakes Service brake system Suspension component failure Repair...

  • Page 198: Neither Wheel Locks When Park Brake Is Latched

    TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction NEITHER WHEEL LOCKS WHEN Incorrect cable adjustment Return to factory specification PARK BRAKE IS LATCHED. (NOTE: Excessive brake pedal free travel Adjust per manual AT FULL SPEED THE WHEELS MAY...
  • Page 199 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page S-11...
  • Page 200 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTES: Repair and Service Manual Page S-12...
  • Page 201 Fig. 2 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter (SHUTTLE 4X) ......V - 5 Fig. 3 Vehicle Dimensions (HAULER 800X) ......................... V - 6 Fig. 4 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter (HAULER 800X) ......V - 7 Fig. 5 Vehicle Dimensions (HAULER 1200X) ....................... V - 8 Fig.

  • Page 202: General Specifications

    GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Page V-ii Repair and Service Manual...
  • Page 203 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: SHUTTLE 4X TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2012 Part No:. 619213 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki z z Valve Train: z Fuel System:...
  • Page 204 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: HAULER 800X TYPE: GASOLINE POWERED TRUCK MODEL YEAR: 2012 Part No:. 618846 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine:  KS  N: ([FHHGV 6$( - 6WDQGDUG  F\FOH  FL  FF VLQJOH F\OLQGHU DLUFRROHG E\ .DZDVDNL...
  • Page 205 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MODEL: HAULER 1200X TYPE: GAS POWERED TRUCK MODEL YEAR: 2012 Part No:. 618847 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine:  KS  N: ([FHHGV 6$( - 6WDQGDUG  F\FOH  FL  FF VLQJOH F\OLQGHU DLUFRROHG E\ .DZDVDNL z Valve Train: z Fuel System:...
  • Page 206 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 52.4 in (133.0 cm) 5.5 in (14.0 cm) 74.5 in. 65.5 in (166.0 cm) (189.0 cm) 106.0 in (268.0 cm) Front 38.0 in.
  • Page 207 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER SHUTTLE 4X 20.5 ft (6.3 m) Fig.
  • Page 208 (Front) 65.5 in. (166.0 cm) 37.0 in. (94.0 cm) 103.5 in. (261.0 cm) (Rear) 38.0 in (97.0 cm) 46.5 in. HAULER 800X (118.0 cm) 36.0 in. (91.5 cm) Fig. 3 Vehicle Dimensions (HAULER 800X) Repair and Service Manual Page V-6...
  • Page 209 RECOMMENDED MAX SIDE TILT 25% or 14 ◦ MAX 25% or 14 ◦ MAX TURNING CLEARANCE DIA. 24 ft (7.3 m) HAULER 800X Fig. 4 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter (HAULER 800X) Repair and Service Manual Page V-7...
  • Page 210 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 111.5 in. (283.0 cm) 49.5 in. 10.5 in. (126.0 cm) (27.0 cm) 30.25 in. (76.8 cm) 77.0 in. (196.0 cm) 5.3 in.
  • Page 211 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14° MAX 25% or 14° MAX TURNING CLEARANCE DIAMETER HAULER 1200X 23.5 ft (7.2 m) Fig.
  • Page 212 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page V-10...
  • Page 213 Be aware that a vehicle requiring repair indicates that the vehi- NOTICE cle is no longer functioning as designed and therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, removing or replac- Read the following warnings before attempting to operate the ing any components that are not operating correctly, take time vehicle: to consider the safety of yourself and others around you should...
  • Page 214 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

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