Cushman HAULER 1200 Repair Manual
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Cushman HAULER 1200 Repair Manual

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HAULER 1200
Repair Manual
653045–

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Questions and answers

Harold Grubbs
March 20, 2025

Do you have this manual for a 2021 Cushman Hauler 1200X gas with electronic fuel injection illustrated?

0
1 comments:
Mr. Anderson
March 20, 2025

The context mentions that repair and service manuals are available from a local distributor or an authorized branch. However, it does not specifically confirm the availability of an illustrated manual for the 2021 Cushman Hauler 1200X gas with electronic fuel injection.

This answer is automatically generated

0
Mark Price
April 1, 2025

How to remove oil filler cap

0
1 comments:
Mr. Anderson
April 1, 2025

To remove the oil filler cap on a Cushman Hauler 1200:

1. Ensure the vehicle is on a level surface with the parking brake engaged.
2. Allow time for the oil to drain into the crankcase if the engine was recently running.
3. Clean the area around the oil fill cap.
4. Use a 19 mm socket with a ratchet and an 8" extension to loosen and remove the oil fill cap.

This answer is automatically generated

0
Bill Lynch
April 3, 2025

How do I get to the top nut on the front shock #30? Do I need to remove the front body?

0
2 comments:
Mr. Anderson
April 3, 2025

To access the top nut (#30) on the front shock of a Cushman Hauler 1200, you need to compress the shock absorber to clear the mounting bracket. Then, use a 9/16” wrench to loosen the nut while holding the shock absorber in place. There is no mention of needing to remove the front body, so it is not necessary.

This answer is automatically generated

0
Bill Lynch
April 3, 2025

@Mr. Anderson

-1
Bill Lynch
April 3, 2025

Thank you Mr Anderson. I thought I cannot access the nut #30. Will do what you said

0
Daniel Melvin Hastings
April 17, 2025

How do I remove the shaft Governor on a Cushman 1200

0
Daniel Melvin Hastings
April 17, 2025

How do I remove the shaft Governor from a Cushman 1200 golf cart

0

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Summary of Contents for Cushman HAULER 1200

  • Page 1 HAULER 1200 Repair Manual 653045–...
  • Page 2 For any questions on material contained in this manual, MANUFACTURER’S INTENDED USE contact an authorized representative for clarification. This vehicle is designed and manufactured in the United States of America (USA). The standards and specifications listed in the following text originate in the USA unless oth- Read and understand all labels located on the vehicle.
  • Page 3 REPAIR AND SERVICE MANUAL GAS POWERED VEHICLES Hauler 1200 STARTING MODEL YEAR 2017 CALIFORNIA Proposition 65 Warning WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects and other reproductive harm.
  • Page 4 Overfilling battery may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate above factory specifications will void the vehicle warranty. When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manu- facture.
  • Page 5 SAFETY INFORMATION This manual has been designed to assist in the maintenance of the vehicle in accordance with procedures developed by the manufacturer. Following these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Certain replacement parts can be used independently and/or in combination with other accessories to modify a TSV (AUGUSTA) manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph.
  • Page 6 GENERAL OPERATION ALWAYS: • Use the vehicle in a responsible manner. • Read and observe all warnings and operation instruction labels affixed to the vehicle. • Follow all safety rules in the area where the vehicle is being operated. • When there is a risk of lightning, leave the vehicle and look for a safe location to wait until the lightning has stopped.
  • Page 7 TABLE OF CONTENTS SAFETY INFORMATION GENERAL ........................III GENERAL OPERATION....................IV MAINTENANCE ....................... IV VENTILATION........................IV GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION ................1 VEHICLE WITH A DISCHARGED BATTERY..............1 STARTING VEHICLE ON A HILL ..................1 SERVICING THE VEHICLE....................
  • Page 8 TABLE OF CONTENTS Lifting Front of Vehicle ..................9 Lifting Rear of Vehicle ...................9 Lowering Vehicle ....................10 BODY GENERAL........................13 BODY COMPONENT REPLACEMENT ................13 Front Body Components ..................14 Instrument Panel Replacement ................14 Brush Guard Replacement .................15 Cowl Replacement ....................15 Front Bumper Replacement ................16 Rocker Panel Replacement ................16 Side Panel Replacement ..................16 Seat Filler Panel Replacement ................17...
  • Page 9 TABLE OF CONTENTS PEDAL BOX ADJUSTMENTS ..................27 Accelerator Pedal Arm Adjustment ..............27 Micro Switch Adjustment ..................28 Road Test ......................28 WEATHER PROTECTION GENERAL ........................31 Transporting Vehicle ..................31 CANOPY TOP......................... 31 Front Strut Installation ..................31 Rear Support Installation ..................
  • Page 10 TABLE OF CONTENTS Daily Brake Performance Test ................49 Brake System Inspection ..................49 Wheel Brake Inspection ..................49 MAINTENANCE AND REPAIRS ..................51 Adjusting Brake Pedal Free Travel ..............52 Brake Drum Removal and Installation ..............53 Wheel Brake Service ..................53 Backing Plate/Entire Wheel Brake Assembly Removal and Installation .....54 Brake Shoe Removal ..................55 Brake Shoe Installation ..................57 Brake Cable and Equalizer Assembly Removal and Installation ......58...
  • Page 11 TABLE OF CONTENTS Brake Bleeding Procedure ................. 66 REAR HYDRAULIC BRAKES SYSTEM DESCRIPTION....................69 Daily Brake Performance Test ................69 Brake System Inspection ................... 69 BRAKE DRUM REMOVAL AND INSTALLATION ............69 WHEEL BRAKE SERVICE ..................... 71 Cleaning and Inspection ..................71 Reassembly .......................
  • Page 12 TABLE OF CONTENTS Rack and Pinion Unit Replacement ..............93 Checking/Adjusting Rack Extension-to-Rack and Pinion Unit Clearance ...93 Steering Wheel Replacement ................94 Steering Shaft and Column Replacement ............95 REAR AXLE NEUTRAL LOCK ......................99 Checking the Lubricant Level ................99 REAR AXLE DISASSEMBLY ..................100 Axle Shaft Removal and Disassembly ..............100 Axle Shaft Seal Removal and Replacement .............100 Axle Shaft Replacement ...................101...
  • Page 13 TABLE OF CONTENTS FOUR CYCLE ENGINE ....................113 Engine Specifications ..................113 Engine Description ................... 113 POWERTRAIN MAINTENANCE................... 113 Checking the Oil Level ..................113 Changing the Oil ....................114 AIR FILTER INSPECTION/REPLACEMENT ..............116 Clean the Air Filter Element ................116 STARTER/GENERATOR BELT TENSION..............
  • Page 14 TABLE OF CONTENTS Choke Cable and Housing Installation ..............128 Carburetor Removal ..................128 Carburetor Disassembly ...................128 Float Level Alignment ..................129 Carburetor Installation ..................129 FUEL PUMP ........................130 Fuel Pump Replacement ..................130 Fuel Lines and Filter ..................130 FUEL TANK REMOVAL....................130 CARBON CANISTER ....................131 ELECTRICAL CIRCUITS AND CONTROLS ..................
  • Page 15 Testing Fuses ....................143 POWERTRAIN PERFORMANCE ................. 144 STARTER FAULT TESTING ..................146 SUSPENSION AND STEERING FAULT TESTING............146 GENERAL SPECIFICATIONS HAULER 1200- GENERAL SPECIFICATIONS ............149 SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE..................153 Initial Service Requirements ................153 Severe Use Conditions ..................153 SCHEDULED MAINTENANCE CHART ...............
  • Page 16 TABLE OF CONTENTS Repair and Service Manual 653045...
  • Page 17 TABLE OF CONTENTS 653045 Repair and Service Manual...
  • Page 18 TABLE OF CONTENTS Repair and Service Manual 653045...
  • Page 19 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL INFORMATION AND ROUTINE MAINTENANCE SERIAL NUMBER LABEL LOCATION the body panel below the driver seat. PART D is found on the frame tube below the floorboard.
  • Page 20 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SERVICING THE VEHICLE To decrease the risk of severe Item Service Operation injury or death, resulting from improper servicing techniques, Battery Charge battery...
  • Page 21 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. be lifted. Refer to LIFTING THE VEHICLE in the SAFETY section for proper lifting procedure and safety information. For maintenance procedures relating to the engine, speed control, fuel system, transmission, and rear axle or suspension refer to the particular section.
  • Page 22 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRANSPORTING VEHICLE HAULING Make sure you secure the vehicle Towing and all items before you transport a vehicle on a trailer.
  • Page 23 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always wear safety glasses while refueling to • Do not engage the park brake, but secure the car decrease the risk of possible eye injury from gaso- from rolling.
  • Page 24 GENERAL INFORMATION AND ROUTINE MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. VEHICLE CARE PRODUCTS TORQUE SPECIFICATIONS To help maintain the vehicle, the manufacturer has sev- eral products, available through a local Distributor, an HARDWARE authorized Branch, or the Service Parts Department, among them are:...
  • Page 25 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SAFETY NOTICES, CAUTIONS, WARNINGS MODIFICATIONS TO VEHICLE AND DANGERS Do not modify the vehicle in any manner that will change the weight distribution of the vehicle.
  • Page 26 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The shifter must always be placed in the P (park) ing with clear water. Contact a physician immedi- position, except for cases where the powertrain ately.
  • Page 27 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BATTERY REMOVAL AND INSTALLA- LIFTING THE VEHICLE TION Tool List Qty. Tool List Qty. Floor Jack ..............1 Jack Stand ..............4 Insulated Wrench, 1/2”...
  • Page 28 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Confirm that the vehicle is stable on the jack stands before proceeding with any service. Lowering Vehicle Make sure chocks are still in place on any wheels that remain on the ground.
  • Page 29 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 30 SAFETY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 31 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BODY BODY COMPONENT REPLACEMENT NOTICE: Hardware that is removed must always be installed in its original position unless otherwise specified.
  • Page 32 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Body Components Front of Vehicle Figure 4 Front Body Components Instrument Panel Replacement NOTICE: The instrument panel can be removed with- out removing the cowl, or may be removed as part Tool List Quantity...
  • Page 33 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ment panel to the frame. Remove the two bolts (7), wash- Cowl Replacement ers (8) and spacers that secure instrument panel (1) to Tool List Quantity vehicle.
  • Page 34 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front Bumper Replacement Rocker Panel Replacement Tool List Quantity Tool List Quantity Drill ................1 Phillips Screwdriver............1 Drill Bit ................. 1 Socket, 3/8”..............1 Punch, Small ...............
  • Page 35 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. rear fender (Figure 9). Remove the hardware (28) from five clips that secure the side panel to the front panel and rear fender.
  • Page 36 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PAINTING Rear Fender Replacement Tool List Quantity Follow the paint manufacturer’s recommendations for specific painting procedures and information. Socket, 7/16” ............... 1 Ratchet ................
  • Page 37 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use 400 grit “wet” sand paper to blend painted area level with the surface of the part being repaired. Use a polishing compound (3M Finesse or automo- tive grade) to renew gloss and to further blend and transition newly painted surface.
  • Page 38 BODY Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 39 TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCK BED Front of Vehicle Figure 1 Truck Bed Replacement Electric lift assembly Figure 2 Truck Bed Replacement (Optional Electric Lift) 653045 Repair and Service Manual...
  • Page 40 TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TRUCK BED REMOVAL NOTICE: Make sure the pivot bushings are in place before installing the bed. Tool List Quantity Bed Assembly (Plastic) Back Brace ..............
  • Page 41 TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 42 TRUCK BED Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 43 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPEED CONTROL Accelerator Cable Governor Lever - Upper Governor Lever - Lower Accelerator Governor Compression Spring Spring Fig. 1 Accelerator and Speed Control System NOTICE: The linkages that control the accelerator The rear end of the accelerator rod is joined to the micro mechanism, governor and carburetor are designed...
  • Page 44 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. power transmission. Driving above governed speed could cause a loss of vehicle control and possible injury or death. Tampering with or adjusting the governor or other speed control components will void the warranty.
  • Page 45 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Throttle Rod Adjustment To adjust the throttle rod (17), loosen the bolt (18) between the two governor levers and rotate lower gover- nor lever (19) counter-clockwise until the carburetor throt- tle plate is fully open.
  • Page 46 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Note that the factory applies a thread seal- ant to the accelerator rod threads before threading the rod into the clevis. Fig.
  • Page 47 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. speed specified in the GENERAL SPECIFICATIONS sec- tion. Determine the speed by measuring the time it takes to travel a known set distance with the vehicle at maximum speed.
  • Page 48 SPEED CONTROL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 49 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WEATHER PROTECTION GENERAL Lower Hole: Install the strut with bolt (2), lock washer (3), and flat washer (4) outside of the strut with the a The canopy does not provide pro- flat washer (4) between the front cowl and strut.
  • Page 50 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Figure 1 Canopy Top Repair and Service Manual 653045...
  • Page 51 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FLAT WINDSHIELD Orient the windshield assembly (17). Align each windshield fastener grommet (19) with the mounting Tool List Quantity hole in each strut, and clip the sashes (18) to the canopy struts.
  • Page 52 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SPLIT WINDSHIELD Orient the windshield assembly (23). Align each windshield fastener grommet (25) with the mounting Tool List Quantity hole in each strut, and clip the sashes (24) to the canopy struts.
  • Page 53 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 54 WEATHER PROTECTION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 55 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEELS AND TIRES WHEEL AND TIRE SERVICE Tool List Quantity Tire Terrain Lug Wrench, 3/4”............1 Pressure Condi- Recommendation Impact Wrench ............
  • Page 56 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Installation Finger tighten lug nuts (1) in the cross-sequence pattern as shown (Figure 1). Continue to tighten the lug nuts in 20 To decrease the risk of compo- ft.
  • Page 57 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 58 WHEELS AND TIRES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 59 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. BRAKES Torsion Springs Park Brake Pedal Push Nut Identification Hinge Pin Hole* Service Brake Pedal Pedal Latch Arm Spacer Catch Bracket Cap Screw Kick Off Cam...
  • Page 60 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the front shoe, pushing it against the brake drum. The force applied to the front and rear shoes is approximately equal.
  • Page 61 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING FLOWCHART Remove B Don't Dist Mecha Adjust External Correct ection Visually Replace udes Good Overh Worn (L Spline, Crac Grease Con Adjust...
  • Page 62 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure. Replace Free Movement of Torque Lug Nuts.
  • Page 63 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING TABLE thorough visual inspection, Daily Brake Performance Test has been performed (Figure 6). Refer to the following fault diagnosis table only after the Condition Possible Cause Correction...
  • Page 64 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Condition Possible Cause Correction Moisture has caused surface rust on Apply moderate force to pedal while at Grabbing brakes (oversensitive) drums maximum level ground speed to remove rust until condition is relieved.
  • Page 65 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The parking brake lock force can be checked for verifica- tion after setting brake pedal free travel. The recom- mended method of checking parking brake lock force is to place a ‘bathroom’...
  • Page 66 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Not to exceed 1/8" (3 mm) in either Front direction Normal Position Check for loose clevis pin Spherical Nut Lock Nut View From Below NOTE: This dimension is factory pre-set with the...
  • Page 67 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. parts to lose their hardness properties. Always use in braking effect from the disc pads wearing away, a loss new parts.
  • Page 68 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. If one wheel brake assembly is be replaced with a new wheel brake assembly. replaced, the one on the other side Always replace wheel brake assemblies in pairs.
  • Page 69 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PASSENGER Forward SIDE Drum Rotation Heavy Shoe Spring Forward DRIVER Drum Rotation Light Shoe SIDE Spring Figure 17 Orientation of Brake Shoe Springs MAINTENANCE AND REPAIRS Tool List Quantity...
  • Page 70 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Adjusting Brake Pedal Free Travel All brake tests must be done in a safe location with regard for the Brake pedal free travel must be safety of all personnel.
  • Page 71 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. hole in the drum is directly over the brake mechanism. Use a small straight blade screwdriver to raise the adjuster arm just above the star wheel.
  • Page 72 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wear eye protection and a mask when cleaning brake components. Backing Plate Do not use compressed air to remove brake dust from the brake assembly.
  • Page 73 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. cable to the wheel brake with clevis pin (installed from the top downward) and a new cotter pin. Install the brake assembly or backing plate to the axle Wear a dust mask and eye protec- tube flange.
  • Page 74 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP PULL ADJUSTER ASSEMBLY Figure 24 Brake Shoes and Springs Repair and Service Manual 653045...
  • Page 75 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Shoe Installation The leading brake shoe (marked 17L) is angled to a nar- row end and engages the backside of the adjuster (Figure 25).
  • Page 76 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repeat on other side of vehicle. Adjust the brake pedal Loosen and remove the jam nut and the spherical nut free travel.
  • Page 77 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Catch Bracket Removal and Installation Part of Frame Remove the driver side front wheel to access the brake pedal release mechanism.
  • Page 78 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. file it, as doing so will cause the part to lose its hardness characteristics. Always use a new park- ing brake arm latch.
  • Page 79 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 80 BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 81 FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT HYDRAULIC BRAKE Front of Vehicle Figure 1 Master Cylinder Replacement Front hydraulic brakes are optional, therefore may not be the brake pedal released, the upper actuator pivot and present on all vehicles.
  • Page 82 FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ROUTINE MAINTENANCE from the master cylinder (1) and allow brake fluid to drain into a container. Discard fluid. Do not reuse old brake Tool List Quantity fluid.
  • Page 83 FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. dle but only remove one. Swing the caliper free from the Reconnect the actuator linkage using washer and a new rotor.
  • Page 84 FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Never reuse any excess fluid or After bleeding, check fluid level using a mechanics return to original container. Dispose mirror and a flashlight.
  • Page 85 FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 86 FRONT HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 87 REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR HYDRAULIC BRAKES SYSTEM DESCRIPTION Check for leaks along all lines and at brake assembly. If no external leaks are apparent, the problem is inside the NOTICE: To ensure correct braking performance, all master cylinder.
  • Page 88 REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove brake drum washer. spacing, the brake drum is incorrect and must be replaced with a new drum. Slide the brake drum and hub assembly from the axle shaft.
  • Page 89 REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. WHEEL BRAKE SERVICE Cleaning and Inspection The drum must not be machined to Tool List Quantity remove grooves.
  • Page 90 REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disassemble by removing the C-clip. Wire brush contact surfaces to remove any corrosion and contaminants. Lightly grease the pin and contact surfaces before re- assembly.
  • Page 91 REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 92 REAR HYDRAULIC REAR HYDRAULIC BRAKES Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 93 PARK BRAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PARK BRAKE Front of Vehicle Shown Partially for Clarity Figure 1 Park Brake Cable 653045 Repair and Service Manual...
  • Page 94 PARK BRAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. PARK BRAKE The rear brake includes a park brake consisting of a wheel brake lever. The wheel brake lever is controlled by a cable that is attached to the hand operated lever.
  • Page 95 PARK BRAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 96 PARK BRAKE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 97 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION AND STEERING Scorecard Holder Steering Wheel Cover Steering Wheel Steering Shaft Wave Washer Bearing Steering Column Outer Snap Ring...
  • Page 98 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. MAINTENANCE can cause grease seals to fail, or grease to move into areas that could damage components. NOTICE: Hardware that is removed must always be installed in its original position unless otherwise Wheel Bearing and King Pin Bushing...
  • Page 99 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. It is recommended that a bearing packer attached to a excess grease. If required, tighten the castellated nut (3) grease pump be used;...
  • Page 100 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lower vehicle and, with tires in the straight ahead posi- tion, roll it forward approximately five feet in order to allow the tires to take their normal running position.
  • Page 101 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FRONT SUSPENSION Part of Frame Front of Vehicle Part of Frame *NOTE: Tie Rod Not Shown for Clarity Figure 7 Front Suspension Components Front Shock Absorber Replacement Compress shock absorber to clear the mounting bracket.
  • Page 102 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Install the new shock absorber in the reverse order of Remove three bolts (18), two bolts (28), spring plate (24) removal.
  • Page 103 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. View from Underside of Vehicle Equal Distance Figure 8 Axle Linkage Rod Replacement Check the axle alignment. The distance from the center Figure 9 Front Axle Alignment bolt at the rear left spring to the center bolt at the front right spring, must be equal distance as the center bolt at...
  • Page 104 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. locations. Pull the driver side of the floor mat out of the plastic trim View from Underside retainer and away from the floor.
  • Page 105 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lower the vehicle per the SAFETY section. Tighten the front wheel(s) per WHEELS AND TIRES section. Wheel Bearing and Race Replacement Front of Vehicle Tool List...
  • Page 106 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Replace the dust cap (7). Lower the vehicle per the SAFETY section. Tighten the front wheel(s) per the WHEELS AND TIRES section. STEERING Front of Vehicle Axle shown for...
  • Page 107 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. steering wheel fully to the left. Remove the cotter pin (2) and loosen the castellated nut (3) until the rack ball joint (1) threads are protected.
  • Page 108 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the end without the flat has conventional right hand Remove the rack ball joint (2) and jam nut (3) from the threads (counter-clockwise to loosen) (Figure 16).
  • Page 109 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To avoid damage to the aluminum attracts dirt and will ruin the bearings. Do not apply rack and pinion unit, secure unit in grease to the spindle bearings.
  • Page 110 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. See Rack and Pinion Unit Replacement. Rack and Pinion Unit Disassembly and Inspection Tool List Quantity Vice................
  • Page 111 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ing is turned fully to the right forcing passenger Tighten the bolt (13) securing the intermediate shaft to the spindle arm against front axle.
  • Page 112 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Wheel Replacement Tool List Quantity Socket, 15/16”..............1 Front of Vehicle Ratchet, 1/2” drive............1 Plastic Faced Hammer..........1 Ball Peen Hammer............1 Anti-seize Compound...........1 Torque Wrench, ft.
  • Page 113 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Torque Wrench, in. lbs..........1 Wheel Bearing Grease ..........AR To remove the steering shaft (4) (Figure 24), remove the steering wheel.
  • Page 114 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. seated in the groove of the column. Place the steering column on the vehicle and tighten the column bolts (5) to the torque value specified below.
  • Page 115 SUSPENSION AND SFRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 116 FRONT SUSPENSION AND STEERING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 117 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE For further axle information, see the Four Cycle Trans- handle fits into the hole (3) in the direction selector cam. axle Shop Rebuild and Service Parts Manual.
  • Page 118 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR AXLE DISASSEMBLY Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube (Ref. The rear axle is a precision assem- Fig.
  • Page 119 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use care to decrease the risk of NOTICE: Tighten the castellated axle nut to 70 ft. damage to the inner surface of axle lbs.
  • Page 120 REAR AXLE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 121 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. REAR SUSPENSION General Rear Leaf Spring Removal To decrease the possibility of per- NOTICE: Hardware that is removed must be sonal injury, follow the lifting proce- installed in its original position unless otherwise dure in SAFETY section of this...
  • Page 122 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of the Vehicle Fig. 1 Rear Suspension Repair and Service Manual 653045...
  • Page 123 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 124 REAR SUSPENSION Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 125 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Secondary Clutch Transmission Belt Primary Clutch Fig. 1 Continuously Variable Transmission System (CVT) GENERAL As the engine speed continues to increase, the primary clutch sheave continues to move inwards forcing the...
  • Page 126 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Secondary Clutch The secondary clutch sheaves are closed at rest which results in the transmission belt being held at the outer diameter of the secondary clutch.
  • Page 127 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Removal in ENGINE section). NOTICE: In some cases the clutch cannot separate from the crankshaft. Remove the clutch puller and Remove the bolt (2) from the center of the primary clutch fill the cavity with grease.
  • Page 128 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Primary Clutch Installation Remove the clutch, then remove the clutch puller bolt and slide the clutch from the rear axle input shaft. To decrease the risk of damage to Secondary Clutch Repair the clutch, be sure to remove all...
  • Page 129 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 130 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 131 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ENGINE GENERAL For further engine information, see Engine Shop Rebuild and Service Parts Manual. FOUR CYCLE ENGINE Engine Specifications Engine Model ..........
  • Page 132 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Changing the Oil Tool List Qty. Oil Fill Cap Socket, 19 mm............. 1 Ratchet ................ 1 Extension, 8" ............... 1 Oil Filter Wrench............
  • Page 133 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. the engine. 16. Check the oil level on the dipstick. Do not overfill. Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.
  • Page 134 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. AIR FILTER INSPECTION/REPLACE- STARTER/GENERATOR BELT TEN- MENT SION Tool List Qty. Belt Tension Gauge............1 Wrench, 3/4” ..............1 Wrench, 9/16” ..............2 Ratchet.................1 Socket, 3/4”..............1 The starter/generator belt tension should be checked...
  • Page 135 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique and inspect for cracking or wear.
  • Page 136 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR REPLACE- MENT Tool List Qty. Wrench, 8 mm ............. 1 Wrench, 10 mm ............1 Wrench, 13 mm ............1 Wrench, 14 mm ............
  • Page 137 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Spark Plug 0.7 - 0.8 mm (.028” - .031”) Fig. 16 Gapping the Spark Plug A fouled spark plug is indicated by an electrode with a wet, black appearance.
  • Page 138 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Valve Clearance Inspection Rotate the crankshaft to position the cylinder to be tested 10°-15° past TDC so that the exhaust valve is Tool List Qty.
  • Page 139 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Loosen the lock screw (10) using the 3 mm Allen bit NOTICE: Hardware that is removed must be installed in its original position unless otherwise and the adjusting nut (11).
  • Page 140 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 19. Access the driven clutch from the passenger side of The remaining installation is in the reverse order of the vehicle and remove the bolt from the driven disassembly using standard torque specifications.
  • Page 141 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 142 ENGINE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 143 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL SYSTEM Front of Vehicle Carbon Canister Air Cleaner Fuel Pump To Carburetor To Crankcase Pulse Fuel Tank Fig.
  • Page 144 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL CARBURETOR OPERATION NOTICE: NOTICE: Hardware that is removed must The carburetor consists of four different systems: always be installed in its original position unless •...
  • Page 145 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FUEL SYSTEM COMPONENT SER- should be smooth throughout the operating range. If there is any binding or sharp bends, the choke cable assembly VICE AND REPLACEMENT must be replaced.
  • Page 146 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Choke Cable and Housing Installation tor mounted bracket (5) and attach the nuts (3) to the choke cable housing finger tight. Insert the choke cable NOTICE: Hardware that is removed must be bullet into the choke arm (1) hole and release.
  • Page 147 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Before you disassemble the carburetor, Float Level Alignment drain the fuel bowl and clean the outside of the car- NOTICE: The float level cannot be adjusted but buretor thoroughly.
  • Page 148 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. replace the hose, make sure to replace with a hose of the same length and approved material. Item Torque Specification Observe and identify the supply and pulse hoses.
  • Page 149 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. of spent fuel safely. Remove the forward hex nut (6), washer (1), and bolt. Remove the rear nut (7), washer (9) and spacer. Remove the tank from the engine compartment.
  • Page 150 FUEL SYSTEM Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 151 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ELECTRICAL CIRCUITS AND CONTROLS WIRING Before performing any test of wiring The electrical system is a 12 volt negative ground system components, disconnect the battery consisting of: cables from the battery to decrease...
  • Page 152 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fig. 1 Main Harness Wiring Diagram Repair and Service Manual 653045...
  • Page 153 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not arc spark plug wire to ground. Connect to a known good spark plug and ground plug to a clean metal surface (muffler, cylinder, etc.).
  • Page 154 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Turn the key switch to OFF. a. Place one probe of the DVOM (set to ohms scale) on the red wire at the solenoid. Place the C to B other probe on the key switch terminal with the blue wire.
  • Page 155 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. (+) probe on the positive (+) post of the battery. ness. Temporarily connect the green field wire to Note the reading. ground.
  • Page 156 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER/GENERATOR Puller Starter/Generator Removal Bearing Adapter (Puller) See ENGINE section. Disassembly Tool List Qty. DVOM................1 Wrench, 24 mm ............1 Wrench, 10 mm ............
  • Page 157 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hydrogen gas formed during bat- tery charging is explosive. Avoid any electrical spark or open flame near bat- Cover tery.
  • Page 158 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. fuses. is in good condition. No reading indicates a faulty fuse; replace with a good 15 amp fuse. When no battery voltage is found, the problem is between the point where no voltage is detected, and the last place that voltage was detected.
  • Page 159 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. remove the nuts securing the headlight assembly (5) and Taillight Replacement the front grille assembly (3). To replace the taillight bulb or the brake light bulb, roll the Remove the nuts allowing the LED headlight assembly rubber bezel from around the edge of the taillight and (5) to be removed from the outside of the cowl.
  • Page 160 ELECTRICAL Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 161 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. FAULT TESTING General To effectively troubleshoot the electrical circuits that include the headlights, brake light and the information dis- play, etc, the technician must be able to use the wiring diagram and a Digital Voltage Ohm Meter (DVOM).
  • Page 162 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. POWERTRAIN PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION STARTER DOES NOT Weak or bad battery Charge or replace as necessary TURN Terminals are loose or corroded Clean and tighten...
  • Page 163 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. CONDITION POSSIBLE CAUSE CORRECTION POOR MIDRANGE OR Spark plug fouled Clean or replace HIGH SPEED PERFOR- Dirty air filter Clean or replace MANCE Brake(s) dragging...
  • Page 164 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. STARTER FAULT TESTING CONDITION POSSIBLE CAUSE CORRECTION STARTER IS NOISY Bolts are loose Tighten to correct torque Starter has foreign matter inside Clean starter interior Bearings are faulty Replace...
  • Page 165 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 166 FAULT TESTING Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 653045...
  • Page 167 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. GENERAL SPECIFICATIONS HAULER 1200- GENERAL SPECIFICATIONS Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki •...
  • Page 168 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Fwd - 14.5 mph ± 0.5 mph (23.34 kph ± 0.80 kph) Speed (Level Ground) Rev - 11.6 mph ± 0.5 mph (18.67 kph ± 0.80 kph) Maximum Drawbar 720 lbs (3203 N) Towing Capacity...
  • Page 169 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 653045 Repair and Service Manual...
  • Page 170 GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 152653045 653045...
  • Page 171 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE initial service interval indicated, in addition to regular intervals. See SCHEDULED MAINTENANCE CHART. Consistent inspection, adjustment and lubrication of The initial service is required for optimum performance some components are necessary to maintain your vehicle and reliability.
  • Page 172 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Interval (perform at interval Item Remarks that comes first) Hours Calendar Fluid leakages Pre-ride Inspect entire vehicle for leaks CVT belt Pre-ride Check condition.
  • Page 173 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Interval (perform at interval Item Remarks that comes first) Hours Calendar Air filter 6 Months Inspect; clean or replace as necessary. Oil filter 6 Months Replace (with oil change).
  • Page 174 SCHEDULED MAINTENANCE Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Item Capacity Lubricants/Fluids Notes Brake fluid DOT 3 Fuel 6.0 gal. (22.7 L) Unleaded; 87 octane min 10% ethanol content max. Rear axle oil 51 oz.
  • Page 175 Normal use, age and wear on vehicle components can affect the safe operation and reliability of the vehicle. The recommended Inspection and maintenance procedures are crucial for safety, performance, reliability and maximum longevity of your vehicle. A damaged vehicle, or a vehicle that is not functioning properly is dangerous and must not be operated until repairs are made. NOTICE: Read the following operational warnings before driving the vehicle: Before you leave the vehicle, turn the key to the OFF position and remove the key from the vehicle to prevent unauthorized use.
  • Page 176 CONTACT INFORMATION: Textron Specialized Vehicles, Inc. 1451 Marvin Griffin Road Augusta, Georgia, USA 30906-3852 North America: Technical Assistance & Warranty PHONE: 1-800-774-3946 Service Parts PHONE: 1-888-438-3946 International PHONE: 001-706-798-4311 cushmancomm@textron.com Service Parts Manuals and Repair and Service Manuals are available from a local Distributor or an authorized Branch. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of...

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