1992 EZGO 2Five Electric Repair & Service Manual 606779 – PDF DOWNLOAD
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1992 EZGO 2Five Electric Repair & Service Manual 606779 – PDF DOWNLOAD
Language : English
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1992 EZGO 2Five Electric Repair & Service Manual 606779 – PDF DOWNLOAD
I-BATTERY CHARGER-Jan2014pdf 0
CHARGER DESCRIPTION101
Fig 1 Charger Installation101
Looping the power cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging The plug can be damaged by driving over or catching the cord on the vehicle when driving away101
UNDERSTANDING THE CHARGER101
LED DISPLAY INFORMATION102
LED Operation Codes:102
LED Fault Code:102
MAINTENANCE INSTRUCTIONS102
1 For flooded lead-acid batteries, regularly check the water levels of each battery cell after charging and add distilled water as required to the level specified by the battery manufacturer Follow the safety instructions recommended by the battery102
2 Make sure the charger connections to the battery terminals are tight and clean Check for any deformations or cracks in the plastic parts Check the charger harness for chaffing and rubbing Inspect all wiring for fraying, loose terminals, chaffin102
3 Keep the cooling fins free of dirt and debris, do not expose the charger to oil, dirt, mud or to direct heavy water spray when cleaning equipment102
4 Inspect the plug of the vehicle charger receptacle for dirt or debris every time the power cord is connected102
REPLACING THE CHARGER/DC to DC CONVERTER102
Removal102
1 Turn the key switch to ’OFF’ and remove the key from the switch102
2 Raise and remove the seat bottom102
3 Unplug the cord (1) from the charger receptacle to the charger103
4 Unplug the Charger connectors (2, 3 and 4)103
5 Place a rubber mat over the exposed battery pack103
6 Remove the four flanged hex head bolts (5) and locking nuts (6) securing the charger to the charger brackets103
7 Lift the charger carefully and place it so the nut (7) securing the green ground wire to the charger can be removed103
Installation103
8 Connect the green ground wire to the stud on the front flange of the charger and secure with hex nut (7) Tighten to the specified torque103
9 Lower the charger down between the brackets and the battery pack, install four flanged hex head bolts (5) and secure with locking nuts (6) Tighten hardware to the specified torque103
10 Plug in the charger connectors (2, 3 and 4) as before103
11 Plug in the cord from the charger receptacle (1)103
12 Remove the protective rubber mat from the battery pack103
13 Install the seat bottom103
K-Electrical Wiring-Jan2014pdf 0
Fig 1 Electrical Harness119
MAIN WIRING HARNESS119
REPLACING THE MAIN WIRING HARNESS119
1 Disconnect the main wiring harness from the battery pack using an insulated wrench119
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, wait for the reverse warning indicator to become silent then turn the key switch to the off position and remove it fro119
3 Disconnect the rabbit/turtle switch in the cup holder from the wiring harness120
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with both hands and pull away from the instrument panel (13); move to the other side of the vehicle and grip the ball holder on 120
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel120
Fig 2 Instrument Panel & Trim120
6 Remove the wiring harness from the front splash shield retaining clips120
7 Disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder120
8 Remove the Diagnostic Plug from the bottom of the cup holder120
9 Disconnect the plug to the throttle enable switch120
10 Disconnect the plug from the rotary position sensor120
11 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard120
12 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support120
13 Remove two Torx head screws each side that secure the lower edge of the rear body to the floorboard120
14 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper120
15 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, move the splash shield out of the way120
16 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard120
17 Unplug the large 23 pin (35 pin for new controller) connector from the controller by lifting up on the locking tab and pulling the connector housing away from the controller120
Fig 3 Controller120
18 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through the splash shield CE vehicles will have a key switch in place of the toggle switch, unscrew the top ring to release the 121
Fig 4 Run / Tow Switch121
19 Remove the two Torx head screws (10) securing the reverse warning indicator (11) to the splash shield121
Fig 5 Reverse Warning Indicator121
20 OLD VEHICLES: Remove two larger hex nuts (16) from the larger terminal posts of solenoid and disconnect green wire from controller B+ terminal, green wire (20) from BL+, battery terminal, and yellow wire (21) from wire harness Remove two smaller121
21 NEW VEHICLES: Remove two larger hex nuts (16) from the larger terminal posts of solenoid and disconnect bus bar from controller B+ terminal, red wire from BL+, battery terminal, and yellow wire (21) from main wire harness Remove two smaller hex 121
Fig 6 Solenoid Connections121
22 Unplug the connectors from the motor brake (31), the motor temperature sensor (32) and the speed sensor (33)121
Fig 7 Motor Connections122
23 Remove main wiring harness from the vehicle122
24 Install new main wiring harness making sure that it follows the proper path122
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1 & 2)122
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels122
Fig 8 Harness Routing & Pedal Connections122
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4)122
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6)122
e) Connect the wires to the brake pedal rotary position sensor (8)122
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10)122
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel122
h) Feed the connectors for the key switch, the speedometer, the rabbit/turtle switch and the diagnostic plug through the opening in the cup holder base (12) Place the diagnostic plug (13) into the cup holder base and route the connectors for the key122
Fig 9 Cup Holder122
i) Route the wires (14) for the key switch and the speedometer through the guide (15) on the front splash shield and the connectors for the key switch and the speedometer through the opening (16) in the back of the instrument panel122
l122
Fig 10 Front Splash Shield122
j) Connect the wire harness to the key switch, the speedometer and the rabbit/turtle switch123
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side123
123
Fig 11 Solenoid Connections123
l) Reconnect the black wire (23) and red wire (24) to the solenoid as shown and secure in place with small hex nuts (28)123
m) OLD VEHICLES: Connect the green wire from the controller B+ to the back terminal of the solenoid and secure in place using a hex nut (16) Do not over tighten the nut123
n) OLD VEHICLES: Connect the green wire (20) from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to the front terminal on the solenoid, secure in place with hex nut (16) Be sure to place larger wire terminal123
123
Fig 12 Controller Connections123
o) NEW VEHICLES: Connect the bus bar from the controller B+ to the front terminal of the solenoid and secure in place using a hex nut (16) Do not over tighten the nut124
p) NEW VEHICLES: Connect the red wire from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to the rear terminal on the solenoid, secure in place with hex nut (16) Be sure to place larger wire terminals on the124
q) Plug the 23 pin (35 pin for new controller) connector from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched124
r) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the speed sensor (33) into the connectors on the motor and motor brake124
124
Fig 13 Motor Connections124
29 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10)124
30 Press the fuse holder (12) into the hole on the controller splash shield124
Fig 14 Reverse Warning Indicator & Fuse124
31 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notch towards the RUN direction Install the upper nut (5) finger tight and torque as specified in the torque table, install t124
Fig 15 Run / Tow Switch124
32 Replace the controller splash shield and secure it to the body with three christmas tree rivets124
33 Install the top portion of the cup holder and secure with the speed nuts124
34 Connect the negative battery wires using an insulated wrench124
35 Connect the positive battery wires using an insulated wrench124
36 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness124
REPLACING ELECTRICAL COMPONENTS125
Run / Tow Switch (Ref Fig 16 on page K-7)125
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench125
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires125
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts125
4 Cut the wires from the existing run/tow switch close to the switch125
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness125
6 Remove the upper nut and seal (7) from the new switch (8)125
7 Install the switch (8) with the notch towards the RUN direction125
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table125
Fig 16 Run / Tow Switch125
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller125
Reverse Warning Indicator (Ref Fig 17 on page K-8)125
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench125
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires125
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield126
4 Cut the wires close to the reverse warning indicator (11)126
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness126
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10)126
7 Reinstall the splash shield126
Fig 17 Reverse Warning Indicator126
Speedometer126
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel126
Fig 18 Trim Panel Hardware126
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20)126
3 Depress the tabs on the speedometer (20) and push the unit out of the trim panel (11)126
126
Fig 19 Speedometer126
4 Insert the speedometer (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place126
5 Connect the main harness (21) to the fuel gage/state of charge meter (20)126
6 Push the instrument panel trim (11) into place making sure that no wires are pinched126
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl126
Fig 20 Main Wiring Harness127
Fig 21 Accessory Wiring Harness129
Fig 21 Accessory Wiring Harness (AFTER 1 AUGUST 2013)130
Fig 22 Accessory Wiring Harness131
ACCESSORY WIRING HARNESS131
REPLACING THE ACCESSORY WIRING HARNESS131
1 Using an insulated wrench disconnect the accessory harness from the battery pack, both positive (+) and negative (-) terminals132
2 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn and the brake lights132
3 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder132
4 Unplug the accessory harness from the main harness132
5 Remove the fuse holder from the controller splash shield132
6 Disconnect the Fan and the Fan Relay132
7 Disconnect wires from the Fuse Block132
8 Disconnect the green ground wire by removing the torx head bolt that secures the fuse holder bracket to the battery tray132
9 Disconnect the DC to DC connector and the Charger Connector132
10 Remove the screw securing the green wire to the on board charger132
11 Disconnect the taillight wiring connectors132
12 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard132
13 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support132
14 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard132
15 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper132
16 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard132
17 Remove the accessory wiring harness from the vehicle132
18 Install new accessory wiring harness making sure that it follows the proper path132
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that the wires tagged ’Driver Side’ are routed to the driver’s side of the vehicle and the wires tagged ’Passenger Sid132
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch132
c) route the wires for the 12 Volt Outlet through the opening in the upper part of the cup holder132
d) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle132
e) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn132
f) Connect the horn button connector to the accessory harness under the cup holder132
g) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2)132
132
Fig 23 Brake Light Relay132
h) Route the rest of the harness down through the cup holder, in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor132
i) Route the wires and connector for the fuse block, DC to DC converter, on-board battery charger and the driver side brake light between the rear body and the battery pack and around the driver’s side of the battery pack to the splash shield Secu133
j) Install the fuse holder bracket and the green ground wire133
k) Route the connection to the main electric harness, one fuse, fan relay, fan connector and the passenger side brake light wires between the rear body and the battery pack133
l) Install the fan relay onto the controller heat sink133
m) Connect the connector to the cooling fan133
n) Snap the fuse holder into the hole on the controller splash shield133
o) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light133
p) Connect the DC to DC converter and on-board battery charger connectors133
q) Install the single fuse holder on the driver’s side on the underside of the fuse block bracket133
r) Connect the wires with push on connectors to the fuse block and attach the red wire with ring terminal to the post on the fuse block133
Fig 24 Fuse Block133
19 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness133
REPLACING ELECTRICAL ACCESSORIES133
Headlight Replacement133
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward133
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward133
3 Disconnect the accessory harness connector (5) from the headlight (3)133
133
Fig 25 Headlight Assembly133
4 To install the headlight assembly, connect the accessory harness connection (5) to the headlight bulb (3)133
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position133
Headlight Bulb Replacement134
1 Turn the headlight bulb (3) clockwise and pull to remove134
2 Disconnect the accessory harness from the light bulb134
3 Connect the accessory harness to the light bulb134
4 Align the bulb with the opening in the back of the headlight assembly134
5 Turn the bulb (3) counter clockwise until it stops134
Turn signal Bulb Replacement134
1 Remove two phillips head screws (8), pull turn signal lens (7) away from the housing to access the bulb134
Fig 26 Front Turn Signal Bulb Replacement134
2 Remove bulb from socket and replace with a new one134
3 Replace the lens (7) and secure in place with the two phillips head screws (8)134
Headlight Switch Replacement134
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel134
Fig 27 Trim Panel Hardware134
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the headlight switch (13)134
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11)134
Fig 28 Headlight Switch134
4 Insert the new headlight switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place134
5 Connect the accessory harness (12) to the headlight switch (13)134
6 Push the instrument panel trim into place making sure that no wires are pinched134
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl134
Turn Signal Switch Replacement135
1 Remove the top part of the cup holder (ref Section B)135
2 Unplug the connector from the turn signal switch harness to the main electrical harness135
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder135
4 Remove the plastic cover from the steering column135
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw135
6 Remove the turn signal switch assembly including the clamp135
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column135
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape135
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column135
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove135
11 Route the wire harness under the floor mat to the cupholder135
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet135
13 Plug the turn signal wire harness connector into the accessory wire harness135
Turn signal Flasher Unit Replacement135
1 Remove the top part of the cup holder (ref Section B)135
2 Unplug the flasher unit from the turn signal wire harness135
3 Install the new flasher unit in the wire harness receptacle135
4 Replace the top part of the cup holder (ref Section B)135
Taillight Assembly Replacement135
1 Remove the four Torx head screws (15) that secure the taillight assembly (16) to the rear body135
2 Pull the taillight (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17)135
Fig 29 Taillight Assembly135
3 Plug the new taillight assembly (15) into the accessory wire harness connector (16) and push the taillight assembly (16) into the opening135
4 Install the four Torx head screws (15)135
Taillight Lens Replacement135
1 Remove the two phillips head screws that secure the lens to the taillight assembly135
2 Install the new lens and secure in place with the two phillips head screws135
Taillight Bulb Replacement135
1 Remove the two phillips head screws that secure the lens to the taillight assembly135
2 Remove the light bulb135
3 Install the new light bulb135
4 Install the lens and secure in place with the two phillips head screws135
Horn Button Replacement136
1 Remove the horn button cover using a flat blade to work the cover off of the switch136
2 Pull the upper corner of the floormat down to expose the switch retaining nut136
3 Remove the nut that secures the horn button136
4 Remove the horn button switch from the floor1board136
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch136
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder136
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame136
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness136
9 Replace the floormat and install the horn button cover136
Horn Replacement136
1 Disconnect the accessory wire harness from the horn136
2 Remove the hex head bolt that secures the horn to the mounting bracket136
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt136
4 Connect the accessory wire harness to the horn136
Top Mounted Brake Light Replacement136
1 Remove two torx head screws that secure the brake light assembly to the top136
2 Pull the brake light out away from the vehicle top, disconnect the wires from the wire harness136
3 Connect the wires from the new brake light to the wire harness136
4 Install the light assembly into the opening in the top, making sure that the wires are not pinched between the the light housing and the top openeing136
5 Install two torx head screws and tighten to 13 – 22 in lbs (15 – 25 Nm) of torque136
Top Mounted Brake Light Bulb Replacement136
1 Remove two phillips head screws136
2 Remove red lens136
3 Pull straight out on the bad light bulb136
4 Install a new #921 wedge base bulb136
5 Replace red lens and secure with phillips head screws136
Fig 20 Main Wiring Harness (AFTER 1 FEBRUARY 2012)128
12-BRAKES-AUG2014pdf 0
Fig 1 Brake System107
GENERAL107
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, washers, etc) that are removed must always be installed in their original positions unless otherwise specified Non-specifie107
ROUTINE MAINTENANCE107
Fig 2 Christmas Tree Rivet Removal107
Hydraulic brake systems must be totally flushed if the fluid becomes contaminated with water, dirt or other corrosive chemicals To flush, bleed the entire system until all brake fluid has been replaced with fresh DOT 3 standard automotive brake fluid107
Check Brake Fluid107
Fig 3 Master Cylinder Fill Line108
Brake Cable Adjustment108
1 Check the brake pads; are they worn, in need of replacement? If the pads need to be replaced see Brake Pad Replacement under REPLACEMENT OF WEAR ITEMS in this section of the manual108
2 Bleed the brake lines to be sure that they are free of trapped air For detailed instructions on bleeding the brakes see BLEEDING BRAKES in this section of the manual108
1 Remove the driver side rear wheel108
2 Remove the christmas tree rivets on the lower edge of the fender liner Pull the fender liner out away from the body to access the adjustment nut (16)108
Fig 4 Cable Adjusting Nut108
3 Using locking pliers to hold the knurled end of the brake cable adjust the nut on the end of the cable 1/8 – 1/4 of a turn at a time Check the pedal for free play before each adjustment DO NOT over adjust the brake cable With no pressure on the108
Fig 5 Brake Cable Adjustment108
REPLACEMENT OF WEAR ITEMS109
Brake Pad Replacement109
1 Remove the wheel109
2 Remove the brake line (1) from the carrier (2) Front wheels only, rear wheels proceed to step 3109
3 Remove both of the flanged hex head bolts (3) securing the caliper (4) to the spindle or axle109
Fig 6 Caliper Removal109
4 Swing the caliper (4) free from the rotor (5) and remove both anti-rattle springs (6)109
Fig 7 Anti-Rattle Springs109
5 Using channel lock pliers compress the side with the O Ring Remove the brake pads (7) one at a time109
Fig 8 Compress O Ring Side109
6 Compress the caliper piston, once the piston is compressed it will stay in position until the brake pedal is pressed109
7 Compress the side with the O Ring and hold while installing the new pads (7) Once both pads are installed release pressure on the O Ring109
8 Install both anti-rattle springs (6)109
9 Separate pads (7) and place caliper (4) over the rear flange of the rotor(5)109
10 Install both flanged hex head bolts (3) finger tight Tighten both bolts to specified torque value109
11 Replace wheel and tighten lug nuts as specified in the Wheels and Tires section of this manual109
Rotor Replacement109
The rotor (disc brake hub) is not designed to be turned to eliminate grooves or high spots109
Spindle Replacement110
Brake Pedal Assembly110
1 Remove four christmas tree rivets (20) securing pedal cover (21) to floorboard110
2 Remove pedal cover (21)110
Fig 9 Pedal Cover110
3 Mark the position of the retaining nut (12) on the threaded portion of the pedal return spring rod (13)110
4 Loosen the retaining nut (12) to release the spring tension110
Fig 10 Pedal Return Spring110
5 Disconnect the wires from the rotary position sensor (18)110
6 Remove four socket head hex screws (17) securing the brake pedal assembly to the floorboard110
Fig 11 Brake Pedal Cable and Return Spring110
7 Disconnect the brake cable (14) and the brake pedal return spring (13) by removing the retaining ring (15), spacer (24) and the clevis pin (16)110
8 Remove the two Torx screws (19) from the rotary position sensor (18) and remove sensor110
Fig 12 Rotary Position Sensor111
9 Install the rotary position sensor (18) Align the slot in the rotary position sensor (18) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (19) Use Loctite® 242, according to product instructions, with 111
10 Reconnect electrical harness to rotary position sensor (18)111
11 Install the clevis pin (16) through the brake cable end, the pedal assembly arm, spacer (24) and the brake pedal return spring arm (13) and secure with the E-clip (15)111
12 Position the pedal assembly in the floorboard recess and secure with four socket head cap screws (17)111
13 Tighten the return spring retaining nut (12) to the position marked111
14 Install the pedal cover (21), using new christmas tree rivets (20), replace the floormat and rocker panels‘111
Bell Crank Bushings111
1 Hold brake cable with pliers and remove the nut (16) from the end of the brake cable and pull cable free of the bell crank111
Fig 13 Clevis Pin Removal111
2 Remove the three pan head torx bolts (18) that secure the master cylinder bracket to the floorboard111
Fig 14 Master Cylinder Bracket111
3 Rock the master cylinder assembly and bracket to remove the E-clip (20) from the bottom of the bell crank shaft111
4 Remove the bell crank shaft (23) from the top of the mounting bracket111
Fig 15 Bell Crank Bushings112
5 Pivot the bell crank (21) until it is clear of the bracket and the flanged bushings (22) can be removed112
6 Install new bushings (22) into the bell crank (21) and pivot the three items back into the bracket112
7 Install the pivot shaft (23) with one E-clip down through the bushings (22) and the bell crank (21)112
8 Install the E-clip (20) into the groove of the bell crank shaft (23)112
9 Reposition the master cylinder bracket with the master cylinder attached and install the three pan head torx screws (18) that secure the bracket to the floorboard When installing the pan head torx screws (18) make sure that the screw threads go i112
MASTER CYLINDER REPLACEMENT112
1 OPTIONAL: Remove the on-board battery charger from mounting brackets to gain better access to the master cylinder For removal instructions refer to the ’Battery Charger’ section of this manual112
2 Remove the driver side fender liner; this will give better access to the bell crank112
3 Remove the cotter pin (10) and the clevis pin (11) joining the master cylinder clevis and the bell crank112
Fig 16 Clevis Pin Removal112
4 Remove the two hex head bolts (12) and nuts (13) that secure the master cylinder to the mounting bracket112
Fig 17 Master Cylinder113
5 Remove the banjo bolts (15) that secure the braided brake lines (14) to the master cylinder and allow brake fluid to drain into a container Do not reuse old brake fluid113
1 Use a new copper crush washer on each side of the banjo bolt (15) and connect the brake line from the rear wheels to the front port of the master cylinder Tighten the banjo bolt (15) to the specified torque value113
2 Use a new copper crush washer on each side of the banjo bolt (15) and connect the brake line from the front wheels to the rear port on the master cylinder Tighten the banjo bolt (15) to the specified torque value113
3 Install the two hex head bolts (12) and nuts (13) that secure the master cylinder to the mounting bracket Tighten the nuts to the specified torque value113
4 Align the master cylinder rod clevis with the hole in the bell crank arm and install the clevis pin (10)113
5 Install a new cotter pin through the clevis bolt, separate the legs of the clevis pin and bend legs in opposite directions113
6 Add clean fresh DOT 3 brake fluid into reservoir and bleed system per ‘BLEEDING BRAKES’113
‘113
BLEEDING BRAKES113
An assistant will be necessary to perform this procedure113
1 Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves Clean each fitting before opening to prevent contaminating the system113
2 Open the master cylinder reservoir and top off with standard automotive DOT 3 brake fluid113
3 Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean container containing fresh, clean brake fluid113
Fig 18 Bleeding Brakes114
4 Starting with the passenger side rear brake , then driver side rear brake, driver side front brake and passenger side front brake last Bleeding the brakes requires an assistant to pump the brake pedal and keep pressure on the pedal Bleed the bra114
a) Build pressure in the brake system, if possible, by slowly pumping the brake pedal114
b) Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal slowly goes through the full stroke114
c) Close the bleeder valve and have the assistant slowly release the brake pedal114
d) Repeat the process until no bubbles can be seen leaving the bleeder valve114
e) Close the valve and move to the next brake114I-BATTERY CHARGER-Jan2014pdf 0
CHARGER DESCRIPTION101
Fig 1 Charger Installation101
Looping the power cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging The plug can be damaged by driving over or catching the cord on the vehicle when driving away101
UNDERSTANDING THE CHARGER101
LED DISPLAY INFORMATION102
LED Operation Codes:102
LED Fault Code:102
MAINTENANCE INSTRUCTIONS102
1 For flooded lead-acid batteries, regularly check the water levels of each battery cell after charging and add distilled water as required to the level specified by the battery manufacturer Follow the safety instructions recommended by the battery102
2 Make sure the charger connections to the battery terminals are tight and clean Check for any deformations or cracks in the plastic parts Check the charger harness for chaffing and rubbing Inspect all wiring for fraying, loose terminals, chaffin102
3 Keep the cooling fins free of dirt and debris, do not expose the charger to oil, dirt, mud or to direct heavy water spray when cleaning equipment102
4 Inspect the plug of the vehicle charger receptacle for dirt or debris every time the power cord is connected102
REPLACING THE CHARGER/DC to DC CONVERTER102
Removal102
1 Turn the key switch to ’OFF’ and remove the key from the switch102
2 Raise and remove the seat bottom102
3 Unplug the cord (1) from the charger receptacle to the charger103
4 Unplug the Charger connectors (2, 3 and 4)103
5 Place a rubber mat over the exposed battery pack103
6 Remove the four flanged hex head bolts (5) and locking nuts (6) securing the charger to the charger brackets103
7 Lift the charger carefully and place it so the nut (7) securing the green ground wire to the charger can be removed103
Installation103
8 Connect the green ground wire to the stud on the front flange of the charger and secure with hex nut (7) Tighten to the specified torque103
9 Lower the charger down between the brackets and the battery pack, install four flanged hex head bolts (5) and secure with locking nuts (6) Tighten hardware to the specified torque103
10 Plug in the charger connectors (2, 3 and 4) as before103
11 Plug in the cord from the charger receptacle (1)103
12 Remove the protective rubber mat from the battery pack103
13 Install the seat bottom103
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Fig 1 Electrical Harness119
MAIN WIRING HARNESS119
REPLACING THE MAIN WIRING HARNESS119
1 Disconnect the main wiring harness from the battery pack using an insulated wrench119
2 Drain the stored energy from the controller Place the Run/Tow switch in the ’Run’ position, turn the key switch to reverse, wait for the reverse warning indicator to become silent then turn the key switch to the off position and remove it fro119
3 Disconnect the rabbit/turtle switch in the cup holder from the wiring harness120
4 Loosen the trim panel (12) by pulling it away from the instrument panel along the upper edge then grip the ball holder with both hands and pull away from the instrument panel (13); move to the other side of the vehicle and grip the ball holder on 120
5 Disconnect wires to the instruments located in the trim panel then remove the trim panel120
Fig 2 Instrument Panel & Trim120
6 Remove the wiring harness from the front splash shield retaining clips120
7 Disconnect the two wires to the brake light relay located on the front splash shield tab extending into the cup holder120
8 Remove the Diagnostic Plug from the bottom of the cup holder120
9 Disconnect the plug to the throttle enable switch120
10 Disconnect the plug from the rotary position sensor120
11 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard120
12 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support120
13 Remove two Torx head screws each side that secure the lower edge of the rear body to the floorboard120
14 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper120
15 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, move the splash shield out of the way120
16 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard120
17 Unplug the large 23 pin (35 pin for new controller) connector from the controller by lifting up on the locking tab and pulling the connector housing away from the controller120
Fig 3 Controller120
18 Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through the splash shield CE vehicles will have a key switch in place of the toggle switch, unscrew the top ring to release the 121
Fig 4 Run / Tow Switch121
19 Remove the two Torx head screws (10) securing the reverse warning indicator (11) to the splash shield121
Fig 5 Reverse Warning Indicator121
20 OLD VEHICLES: Remove two larger hex nuts (16) from the larger terminal posts of solenoid and disconnect green wire from controller B+ terminal, green wire (20) from BL+, battery terminal, and yellow wire (21) from wire harness Remove two smaller121
21 NEW VEHICLES: Remove two larger hex nuts (16) from the larger terminal posts of solenoid and disconnect bus bar from controller B+ terminal, red wire from BL+, battery terminal, and yellow wire (21) from main wire harness Remove two smaller hex 121
Fig 6 Solenoid Connections121
22 Unplug the connectors from the motor brake (31), the motor temperature sensor (32) and the speed sensor (33)121
Fig 7 Motor Connections122
23 Remove main wiring harness from the vehicle122
24 Install new main wiring harness making sure that it follows the proper path122
a) Starting in the middle of the vehicle, route the forward section of the harness under the rear body in the floorboard channels (1 & 2)122
b) Route the connections for the brake and accelerator pedals, making sure that the harness lays in the recessed floorboard channels122
Fig 8 Harness Routing & Pedal Connections122
c) Connect the wires to the accelerator rotary position sensor (5) and the throttle enable switch connector (4)122
d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6)122
e) Connect the wires to the brake pedal rotary position sensor (8)122
f) Place pedal assembly in position on the floorboard and secure with four socket head hex screws (10)122
g) Route the remaining wires in the floorboard channel that runs up under the instrument panel122
h) Feed the connectors for the key switch, the speedometer, the rabbit/turtle switch and the diagnostic plug through the opening in the cup holder base (12) Place the diagnostic plug (13) into the cup holder base and route the connectors for the key122
Fig 9 Cup Holder122
i) Route the wires (14) for the key switch and the speedometer through the guide (15) on the front splash shield and the connectors for the key switch and the speedometer through the opening (16) in the back of the instrument panel122
l122
Fig 10 Front Splash Shield122
j) Connect the wire harness to the key switch, the speedometer and the rabbit/turtle switch123
k) Route the two rear sections of the harness between the rear body and the battery pack making sure that the longer wires (21) are routed to the passenger side123
123
Fig 11 Solenoid Connections123
l) Reconnect the black wire (23) and red wire (24) to the solenoid as shown and secure in place with small hex nuts (28)123
m) OLD VEHICLES: Connect the green wire from the controller B+ to the back terminal of the solenoid and secure in place using a hex nut (16) Do not over tighten the nut123
n) OLD VEHICLES: Connect the green wire (20) from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to the front terminal on the solenoid, secure in place with hex nut (16) Be sure to place larger wire terminal123
123
Fig 12 Controller Connections123
o) NEW VEHICLES: Connect the bus bar from the controller B+ to the front terminal of the solenoid and secure in place using a hex nut (16) Do not over tighten the nut124
p) NEW VEHICLES: Connect the red wire from the positive (+), BL+, battery terminal and the yellow wire (21) from the wiring harness to the rear terminal on the solenoid, secure in place with hex nut (16) Be sure to place larger wire terminals on the124
q) Plug the 23 pin (35 pin for new controller) connector from the wire harness into the socket on the controller, push in firmly and make sure that the locking tab is latched124
r) Plug the connectors for the motor brake (31), the motor temperature sensor (32) and the speed sensor (33) into the connectors on the motor and motor brake124
124
Fig 13 Motor Connections124
29 Install the reverse warning indicator (11) onto the controller splash shield using two Torx head screws (10)124
30 Press the fuse holder (12) into the hole on the controller splash shield124
Fig 14 Reverse Warning Indicator & Fuse124
31 Install the Run/Tow switch (7) by removing the upper nut (5) and seal (4) from the switch Position the switch with the notch towards the RUN direction Install the upper nut (5) finger tight and torque as specified in the torque table, install t124
Fig 15 Run / Tow Switch124
32 Replace the controller splash shield and secure it to the body with three christmas tree rivets124
33 Install the top portion of the cup holder and secure with the speed nuts124
34 Connect the negative battery wires using an insulated wrench124
35 Connect the positive battery wires using an insulated wrench124
36 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness124
REPLACING ELECTRICAL COMPONENTS125
Run / Tow Switch (Ref Fig 16 on page K-7)125
1 Disconnect the battery cable at the negative (-) battery terminal using an insulated wrench125
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the switch and wires125
3 Remove the seal and upper nut to allow the switch to be removed from the splash shield Check the Run / Tow label, if it has become difficult to read replace it with a new one available from service parts125
4 Cut the wires from the existing run/tow switch close to the switch125
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the new run/tow switch to the wire harness125
6 Remove the upper nut and seal (7) from the new switch (8)125
7 Install the switch (8) with the notch towards the RUN direction125
8 Install the upper nut and seal (7) finger tight and torque as specified in the torque table125
Fig 16 Run / Tow Switch125
9 Install the splash shield using three plastic rivets to secure the shield to the body and the controller125
Reverse Warning Indicator (Ref Fig 17 on page K-8)125
1 Disconnect the battery cable at the negative (-), BL-, battery terminal using an insulated wrench125
2 Remove three plastic rivets securing the controller splash shield; two on the rear body and one from controller heat sink, raise splash shield and turn over to expose the reverse warning indicator and wires125
3 Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield126
4 Cut the wires close to the reverse warning indicator (11)126
5 Strip insulation from the end of each wire, using a butt splice connector and heat shrink tubing connect the wires from the replacement reverse warning indicator (11) to the wire harness126
6 Secure the new reverse warning indicator (11) to the splash shield with the torx head screws (10)126
7 Reinstall the splash shield126
Fig 17 Reverse Warning Indicator126
Speedometer126
1 Remove the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel126
Fig 18 Trim Panel Hardware126
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the harness (21) from the fuel gauge/state of charge meter (20)126
3 Depress the tabs on the speedometer (20) and push the unit out of the trim panel (11)126
126
Fig 19 Speedometer126
4 Insert the speedometer (20) into the opening in the instrument panel trim (11), making sure that the tabs all lock in place126
5 Connect the main harness (21) to the fuel gage/state of charge meter (20)126
6 Push the instrument panel trim (11) into place making sure that no wires are pinched126
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl126
Fig 20 Main Wiring Harness127
Fig 21 Accessory Wiring Harness129
Fig 21 Accessory Wiring Harness (AFTER 1 AUGUST 2013)130
Fig 22 Accessory Wiring Harness131
ACCESSORY WIRING HARNESS131
REPLACING THE ACCESSORY WIRING HARNESS131
1 Using an insulated wrench disconnect the accessory harness from the battery pack, both positive (+) and negative (-) terminals132
2 Unplug wires going to the headlights, turn signals, headlight switch, turn signal switch, horn and the brake lights132
3 Remove the christmas tree rivet holding the brake switch relay in place on the front splash shield tab that extends into the cup holder132
4 Unplug the accessory harness from the main harness132
5 Remove the fuse holder from the controller splash shield132
6 Disconnect the Fan and the Fan Relay132
7 Disconnect wires from the Fuse Block132
8 Disconnect the green ground wire by removing the torx head bolt that secures the fuse holder bracket to the battery tray132
9 Disconnect the DC to DC connector and the Charger Connector132
10 Remove the screw securing the green wire to the on board charger132
11 Disconnect the taillight wiring connectors132
12 Remove the two Torx head screws that secure the front edge of the rear body and seat support frame to the floorboard132
13 Remove the two Torx head screws along back edge of the seat opening that secure the rear body to the seat support132
14 Remove the four Torx head screws; two on each side that secure the lower edge of the rear body to the floorboard132
15 Remove the two Torx head screws from the bagwell that secure the rear body to the rear bumper132
16 Raise the front edge of the rear body several inches and support it with a block or piece of 2″ x 4″ wood This will allow the harness to be passed between the rear body and the floorboard132
17 Remove the accessory wiring harness from the vehicle132
18 Install new accessory wiring harness making sure that it follows the proper path132
a) Starting in the cup holder, route the forward section of the harness in the tabs on the front splash shield, making sure that the wires tagged ’Driver Side’ are routed to the driver’s side of the vehicle and the wires tagged ’Passenger Sid132
b) Route the wires for the headlight switch through the opening in the instrument panel for the headlight switch132
c) route the wires for the 12 Volt Outlet through the opening in the upper part of the cup holder132
d) Route the wires for the horn down through the flap in the front splash shield on the driver’s side of the vehicle132
e) Route the wires and connector for the horn between the frame and the under side of the front splash shield and connect to the horn132
f) Connect the horn button connector to the accessory harness under the cup holder132
g) Position the brake relay (1) on the front splash shield tab that extends into the cup holder base and secure with a christmas tree rivet (2)132
132
Fig 23 Brake Light Relay132
h) Route the rest of the harness down through the cup holder, in the floorboard channel and under the rear body in the floorboard channel along with the main wiring harness Make sure that the harness sets below the level of the floor132
i) Route the wires and connector for the fuse block, DC to DC converter, on-board battery charger and the driver side brake light between the rear body and the battery pack and around the driver’s side of the battery pack to the splash shield Secu133
j) Install the fuse holder bracket and the green ground wire133
k) Route the connection to the main electric harness, one fuse, fan relay, fan connector and the passenger side brake light wires between the rear body and the battery pack133
l) Install the fan relay onto the controller heat sink133
m) Connect the connector to the cooling fan133
n) Snap the fuse holder into the hole on the controller splash shield133
o) Route the wires and connector for the passenger side brake light around behind the controller, over the passenger side rear splash shield, through the guides and connect to the brake light133
p) Connect the DC to DC converter and on-board battery charger connectors133
q) Install the single fuse holder on the driver’s side on the underside of the fuse block bracket133
r) Connect the wires with push on connectors to the fuse block and attach the red wire with ring terminal to the post on the fuse block133
Fig 24 Fuse Block133
19 Be sure that all wires are connected properly before installing the body components that were removed to allow access to the wiring harness133
REPLACING ELECTRICAL ACCESSORIES133
Headlight Replacement133
1 Depress the two bottom tabs (1) on the back of the headlight assembly and push outward133
2 Depress the two top tabs (2) on the back of the headlight assembly and push outward133
3 Disconnect the accessory harness connector (5) from the headlight (3)133
133
Fig 25 Headlight Assembly133
4 To install the headlight assembly, connect the accessory harness connection (5) to the headlight bulb (3)133
5 Position headlight assembly in the cowl opening and press in firmly making sure that all tabs are locked into position133
Headlight Bulb Replacement134
1 Turn the headlight bulb (3) clockwise and pull to remove134
2 Disconnect the accessory harness from the light bulb134
3 Connect the accessory harness to the light bulb134
4 Align the bulb with the opening in the back of the headlight assembly134
5 Turn the bulb (3) counter clockwise until it stops134
Turn signal Bulb Replacement134
1 Remove two phillips head screws (8), pull turn signal lens (7) away from the housing to access the bulb134
Fig 26 Front Turn Signal Bulb Replacement134
2 Remove bulb from socket and replace with a new one134
3 Replace the lens (7) and secure in place with the two phillips head screws (8)134
Headlight Switch Replacement134
1 Remove the four Torx head screws (10) that secure the instrument panel trim to the instrument panel134
Fig 27 Trim Panel Hardware134
2 Pull the top of the trim panel (11) away from the instrument panel and disconnect the accessory harness (12) from the headlight switch (13)134
3 Depress the tabs on the top and bottom of the headlight switch (13) and push the switch out of the trim panel (11)134
Fig 28 Headlight Switch134
4 Insert the new headlight switch into the opening in the instrument panel trim (11), making sure that the tabs all lock in place134
5 Connect the accessory harness (12) to the headlight switch (13)134
6 Push the instrument panel trim into place making sure that no wires are pinched134
7 Install the four Torx head screws (10) that secure the instrument panel trim (11) to the instrument panel and the front cowl134
Turn Signal Switch Replacement135
1 Remove the top part of the cup holder (ref Section B)135
2 Unplug the connector from the turn signal switch harness to the main electrical harness135
3 Feed the wires, connector and flasher unit down through the bottom of the cup holder135
4 Remove the plastic cover from the steering column135
5 Loosen the clamp that keeps the turn signal switch in place on the steering column Continue loosening the clamp until the end is free of the worm screw135
6 Remove the turn signal switch assembly including the clamp135
7 Inspect the black electrical tape on the steering column, if worn through, remove the old tape and replace it with new electrical tape to cushion the turn signal switch and improve the fit to the column135
8 Feed the end of the clamp through the turn signal switch housing and position the switch on the steering column over the electrical tape135
9 Start the end of the clamp into the worm screw, making sure that the turn signal switch is properly positioned and tighten securely on the steering column135
10 Snap the steering column cover in place making sure that the wire harness stays in the cover groove135
11 Route the wire harness under the floor mat to the cupholder135
12 Feed the flasher unit and the connector up through the bottom of the cup holder and secure the flasher unit to the center of the splash shield tab using a christmas tree rivet135
13 Plug the turn signal wire harness connector into the accessory wire harness135
Turn signal Flasher Unit Replacement135
1 Remove the top part of the cup holder (ref Section B)135
2 Unplug the flasher unit from the turn signal wire harness135
3 Install the new flasher unit in the wire harness receptacle135
4 Replace the top part of the cup holder (ref Section B)135
Taillight Assembly Replacement135
1 Remove the four Torx head screws (15) that secure the taillight assembly (16) to the rear body135
2 Pull the taillight (16) assembly away from the rear body and disconnect the assembly from the wire harness connector (17)135
Fig 29 Taillight Assembly135
3 Plug the new taillight assembly (15) into the accessory wire harness connector (16) and push the taillight assembly (16) into the opening135
4 Install the four Torx head screws (15)135
Taillight Lens Replacement135
1 Remove the two phillips head screws that secure the lens to the taillight assembly135
2 Install the new lens and secure in place with the two phillips head screws135
Taillight Bulb Replacement135
1 Remove the two phillips head screws that secure the lens to the taillight assembly135
2 Remove the light bulb135
3 Install the new light bulb135
4 Install the lens and secure in place with the two phillips head screws135
Horn Button Replacement136
1 Remove the horn button cover using a flat blade to work the cover off of the switch136
2 Pull the upper corner of the floormat down to expose the switch retaining nut136
3 Remove the nut that secures the horn button136
4 Remove the horn button switch from the floor1board136
5 Install the new horn button switch through the floorboard and secure in place with the hex nut supplied with the switch136
6 Disconnect the horn button wire harness from the accessory harness in the lower portion of the cup holder136
7 Before removing the old horn button wire harness route the new one along the same path, removing the old harness clips just before the new clips are placed on the frame136
8 Route the new horn button harness up through the flap in the front splash shield and connect it to the accessory harness136
9 Replace the floormat and install the horn button cover136
Horn Replacement136
1 Disconnect the accessory wire harness from the horn136
2 Remove the hex head bolt that secures the horn to the mounting bracket136
3 Position the new horn with the opening to the front of the vehicle and secure in place with the hex head bolt136
4 Connect the accessory wire harness to the horn136
Top Mounted Brake Light Replacement136
1 Remove two torx head screws that secure the brake light assembly to the top136
2 Pull the brake light out away from the vehicle top, disconnect the wires from the wire harness136
3 Connect the wires from the new brake light to the wire harness136
4 Install the light assembly into the opening in the top, making sure that the wires are not pinched between the the light housing and the top openeing136
5 Install two torx head screws and tighten to 13 – 22 in lbs (15 – 25 Nm) of torque136
Top Mounted Brake Light Bulb Replacement136
1 Remove two phillips head screws136
2 Remove red lens136
3 Pull straight out on the bad light bulb136
4 Install a new #921 wedge base bulb136
5 Replace red lens and secure with phillips head screws136
Fig 20 Main Wiring Harness (AFTER 1 FEBRUARY 2012)128
12-BRAKES-AUG2014pdf 0
Fig 1 Brake System107
GENERAL107
In the following text, there are references to removing and installing bolts and other fasteners Additional hardware (nuts, washers, etc) that are removed must always be installed in their original positions unless otherwise specified Non-specifie107
ROUTINE MAINTENANCE107
Fig 2 Christmas Tree Rivet Removal107
Hydraulic brake systems must be totally flushed if the fluid becomes contaminated with water, dirt or other corrosive chemicals To flush, bleed the entire system until all brake fluid has been replaced with fresh DOT 3 standard automotive brake fluid107
Check Brake Fluid107
Fig 3 Master Cylinder Fill Line108
Brake Cable Adjustment108
1 Check the brake pads; are they worn, in need of replacement? If the pads need to be replaced see Brake Pad Replacement under REPLACEMENT OF WEAR ITEMS in this section of the manual108
2 Bleed the brake lines to be sure that they are free of trapped air For detailed instructions on bleeding the brakes see BLEEDING BRAKES in this section of the manual108
1 Remove the driver side rear wheel108
2 Remove the christmas tree rivets on the lower edge of the fender liner Pull the fender liner out away from the body to access the adjustment nut (16)108
Fig 4 Cable Adjusting Nut108
3 Using locking pliers to hold the knurled end of the brake cable adjust the nut on the end of the cable 1/8 – 1/4 of a turn at a time Check the pedal for free play before each adjustment DO NOT over adjust the brake cable With no pressure on the108
Fig 5 Brake Cable Adjustment108
REPLACEMENT OF WEAR ITEMS109
Brake Pad Replacement109
1 Remove the wheel109
2 Remove the brake line (1) from the carrier (2) Front wheels only, rear wheels proceed to step 3109
3 Remove both of the flanged hex head bolts (3) securing the caliper (4) to the spindle or axle109
Fig 6 Caliper Removal109
4 Swing the caliper (4) free from the rotor (5) and remove both anti-rattle springs (6)109
Fig 7 Anti-Rattle Springs109
5 Using channel lock pliers compress the side with the O Ring Remove the brake pads (7) one at a time109
Fig 8 Compress O Ring Side109
6 Compress the caliper piston, once the piston is compressed it will stay in position until the brake pedal is pressed109
7 Compress the side with the O Ring and hold while installing the new pads (7) Once both pads are installed release pressure on the O Ring109
8 Install both anti-rattle springs (6)109
9 Separate pads (7) and place caliper (4) over the rear flange of the rotor(5)109
10 Install both flanged hex head bolts (3) finger tight Tighten both bolts to specified torque value109
11 Replace wheel and tighten lug nuts as specified in the Wheels and Tires section of this manual109
Rotor Replacement109
The rotor (disc brake hub) is not designed to be turned to eliminate grooves or high spots109
Spindle Replacement110
Brake Pedal Assembly110
1 Remove four christmas tree rivets (20) securing pedal cover (21) to floorboard110
2 Remove pedal cover (21)110
Fig 9 Pedal Cover110
3 Mark the position of the retaining nut (12) on the threaded portion of the pedal return spring rod (13)110
4 Loosen the retaining nut (12) to release the spring tension110
Fig 10 Pedal Return Spring110
5 Disconnect the wires from the rotary position sensor (18)110
6 Remove four socket head hex screws (17) securing the brake pedal assembly to the floorboard110
Fig 11 Brake Pedal Cable and Return Spring110
7 Disconnect the brake cable (14) and the brake pedal return spring (13) by removing the retaining ring (15), spacer (24) and the clevis pin (16)110
8 Remove the two Torx screws (19) from the rotary position sensor (18) and remove sensor110
Fig 12 Rotary Position Sensor111
9 Install the rotary position sensor (18) Align the slot in the rotary position sensor (18) to the pivot shaft and rotate into position oriented as shown, secure with two Torx screws (19) Use Loctite® 242, according to product instructions, with 111
10 Reconnect electrical harness to rotary position sensor (18)111
11 Install the clevis pin (16) through the brake cable end, the pedal assembly arm, spacer (24) and the brake pedal return spring arm (13) and secure with the E-clip (15)111
12 Position the pedal assembly in the floorboard recess and secure with four socket head cap screws (17)111
13 Tighten the return spring retaining nut (12) to the position marked111
14 Install the pedal cover (21), using new christmas tree rivets (20), replace the floormat and rocker panels‘111
Bell Crank Bushings111
1 Hold brake cable with pliers and remove the nut (16) from the end of the brake cable and pull cable free of the bell crank111
Fig 13 Clevis Pin Removal111
2 Remove the three pan head torx bolts (18) that secure the master cylinder bracket to the floorboard111
Fig 14 Master Cylinder Bracket111
3 Rock the master cylinder assembly and bracket to remove the E-clip (20) from the bottom of the bell crank shaft111
4 Remove the bell crank shaft (23) from the top of the mounting bracket111
Fig 15 Bell Crank Bushings112
5 Pivot the bell crank (21) until it is clear of the bracket and the flanged bushings (22) can be removed112
6 Install new bushings (22) into the bell crank (21) and pivot the three items back into the bracket112
7 Install the pivot shaft (23) with one E-clip down through the bushings (22) and the bell crank (21)112
8 Install the E-clip (20) into the groove of the bell crank shaft (23)112
9 Reposition the master cylinder bracket with the master cylinder attached and install the three pan head torx screws (18) that secure the bracket to the floorboard When installing the pan head torx screws (18) make sure that the screw threads go i112
MASTER CYLINDER REPLACEMENT112
1 OPTIONAL: Remove the on-board battery charger from mounting brackets to gain better access to the master cylinder For removal instructions refer to the ’Battery Charger’ section of this manual112
2 Remove the driver side fender liner; this will give better access to the bell crank112
3 Remove the cotter pin (10) and the clevis pin (11) joining the master cylinder clevis and the bell crank112
Fig 16 Clevis Pin Removal112
4 Remove the two hex head bolts (12) and nuts (13) that secure the master cylinder to the mounting bracket112
Fig 17 Master Cylinder113
5 Remove the banjo bolts (15) that secure the braided brake lines (14) to the master cylinder and allow brake fluid to drain into a container Do not reuse old brake fluid113
1 Use a new copper crush washer on each side of the banjo bolt (15) and connect the brake line from the rear wheels to the front port of the master cylinder Tighten the banjo bolt (15) to the specified torque value113
2 Use a new copper crush washer on each side of the banjo bolt (15) and connect the brake line from the front wheels to the rear port on the master cylinder Tighten the banjo bolt (15) to the specified torque value113
3 Install the two hex head bolts (12) and nuts (13) that secure the master cylinder to the mounting bracket Tighten the nuts to the specified torque value113
4 Align the master cylinder rod clevis with the hole in the bell crank arm and install the clevis pin (10)113
5 Install a new cotter pin through the clevis bolt, separate the legs of the clevis pin and bend legs in opposite directions113
6 Add clean fresh DOT 3 brake fluid into reservoir and bleed system per ‘BLEEDING BRAKES’113
‘113
BLEEDING BRAKES113
An assistant will be necessary to perform this procedure113
1 Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves Clean each fitting before opening to prevent contaminating the system113
2 Open the master cylinder reservoir and top off with standard automotive DOT 3 brake fluid113
3 Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean container containing fresh, clean brake fluid113
Fig 18 Bleeding Brakes114
4 Starting with the passenger side rear brake , then driver side rear brake, driver side front brake and passenger side front brake last Bleeding the brakes requires an assistant to pump the brake pedal and keep pressure on the pedal Bleed the bra114
a) Build pressure in the brake system, if possible, by slowly pumping the brake pedal114
b) Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal slowly goes through the full stroke114
c) Close the bleeder valve and have the assistant slowly release the brake pedal114
d) Repeat the process until no bubbles can be seen leaving the bleeder valve114
e) Close the valve and move to the next brake114
S.M 11/24
