EZGO RXV GOLF CAR FREEDOM SHUTTLE 2+2 SERVICE MANUAL (GASOLINE) – PDF DOWNLOAD
DESCRIPTION:
EZGO RXV GOLF CAR FREEDOM SHUTTLE 2+2 SERVICE MANUAL (GASOLINE) – PDF DOWNLOAD
REPAIR AND SERVICE MANUAL GASOLINE POWERED GOLF CARS AND PERSONAL VEHICLES RXV GOLF CAR RXV FREEDOM™ RXV SHUTTLE 2+2
- This vehicle has been designed and manufactured in the United States of America (USA). The standards and specifications listed in the following text originate in the USA unless otherwise indicated. The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.
- 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 manufacture.
- Many vehicles are used for a variety of tasks beyond their original intended use; therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur. Warnings cannot replace good common sense and prudent driving practices.
- Common sense and prudent driving practices do more to decrease the risk of accidents and injury than warnings and instructions can provide. The manufacturer strongly suggests anyone operating the vehicle read the entire owner’s guide provided with the purchase of the vehicle, paying particular attention to the CAUTIONS, WARNINGS and DANGERS within.
- For any questions or concerns, contact the closest representative, or write to the address on the back cover of this publication, Attention: Customer Care Department. Textron Specialized Vehicles (TSV) reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice.
- TSV is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. This vehicle conforms to the current applicable standard for safety and performance requirements. This vehicle is designed and manufactured for off-road use.
- It does not conform to Federal Motor Vehicle Safety Standards and is not equipped for operation on public streets. Some communities may permit these types of vehicles to be operated on their streets on a limited basis and in accordance with local ordinances. Ensure all electrical accessories are grounded directly to the battery (-) post. Never use the chassis or body as a ground connection.
TABLE OF CONTENTS:
EZGO RXV GOLF CAR FREEDOM SHUTTLE 2+2 SERVICE MANUAL (GASOLINE) – PDF DOWNLOAD
SAFETY INFORMATION
GENERAL iii
GENERAL OPERATION iii
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 2
FUEL 2
FUEL TANK 3
Early Production Fuel Tank 3
Late Production Fuel Tank 3
BATTERY 3
ROUTINE MAINTENANCE 4
POWERTRAIN MAINTENANCE 4
BRAKES 4
TIRES 4
LIGHT BULB REPLACEMENT 4
TRANSPORTING VEHICLE 4
Towing 4
Neutral Lock 4
Hauling 5
CANOPY AND WINDSHIELD 5
WINTER OR PROLONGED STORAGE 5
VEHICLE CLEANING AND CARE 6
VEHICLE CARE PRODUCTS 6
HARDWARE 7
TORQUE SPECIFICATIONS 7
SAFETY
NOTICES, CAUTIONS, WARNINGS AND DANGERS 9
IMPORTANT SAFETY WARNING 9
MODIFICATIONS TO VEHICLE 9
GENERAL MAINTENANCE
BEFORE SERVICING VEHICLE 9
Battery Removal and Installation 10
LIFTING THE VEHICLE 11
How to lift the entire vehicle: 11
How to lift the rear of the vehicle only: 12
How to Lift the Front of the Vehicle Only: 12
Lower the Vehicle: 12
BODY
GENERAL 15
BODY COMPONENT REPLACEMENT 16
Front Bumper 16
Rocker Panels 16
Floormat 16
Cowl and Instrument Panel 17
Front Splash Guard 18
Sweater Basket 19
Seat Back Assembly 19
Fender Liner 19
Rear Body 19
Rear Bumper 20
2 + 2 REAR FACING SEAT AND FOOT REST 21
FLOORBOARD 22
Bagwell Closeout 23
BODY CARE MAINTENANCE 23
Cleaning 23
PAINTING 23
Minor Scratches 24
Larger Scratches 24
Complete Panel Repair 24
WHEELS AND TIRES
WHEEL AND TIRE SERVICE 27
Tire Repair 27
Wheel Installation
FRONT SUSPENSION AND STEERING
MAINTENANCE 31
Tire Wear Diagnosis 31
Wheel Alignment 32
Hub Assembly 33
Spindle Assembly 33
Struts 33
Control Arm Assembly 34
Clipboard and Steering Wheel 35
Installation 35
Steering Column Assembly and Yoke 36
Tie Rod End / Ball Joint 37
Steering Box 37
SPEED CONTROL
SYSTEM OPERATION 41
Pedal Box Operation 41
Governor Operation 41
FAULT TESTING 42
SPEED CONTROL 42
Throttle Rod Removal 42
Throttle Rod Adjustment 42
Accelerator Cable Removal at Governor 43
Accelerator Cable Removal and Installation at Pedal 43
Accelerator Pedal Arm Adjustment 43
Road Test 43
Accelerator Pedal Assembly 44
ENGINE
GENERAL 47
FOUR CYCLE ENGINE 47
Engine Specifications 47
Engine Description 47
POWERTRAIN MAINTENANCE 47
Checking the Oil Level 47
Changing the Oil 48
AIR FILTER INSPECTION/REPLACEMENT
Clean the Air Filter Element 50
STARTER/GENERATOR BELT TENSION 50
Adjusting the Belt 51
STARTER/GENERATOR REPLACEMENT 51
COOLING SYSTEM CLEANING 52
SPARK PLUG 52
CYLINDER HEAD 53
Compression Leak Down Test 53
Rocker Cover Removal 53
Valve Clearance Inspection 53
Valve Clearance Adjustment 54
ENGINE REMOVAL 54
Controls and Wiring 55
Removing the Engine from the Vehicle 55
Engine Installation 55
DRIVE CLUTCH REMOVAL 56
FUEL SYSTEM
GENERAL 61
Early Production Fuel Tank 61
Late Production Fuel Tank 62
CARBURETOR OPERATION 62
Float System 62
Pilot Jet System 62
Main Jet System 62
Choke System 62
Carburetor Service 62
Choke Operation 62
Choke Adapter Installation 63
FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT 63
Choke Cable and Housing Removal 63
Choke Cable and Housing Installation 63
Carburetor Removal 64
Carburetor Disassembly 64
Float Level Alignment 65
Carburetor Installation 65
FUEL PUMP 66
Fuel Pump Replacement 66
Fuel Lines and Filter 66
Early Production Vehicles 66
Late Production Vehicles 66
FUEL TANK REMOVAL 69
CARBON CANISTER 69
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
GENERAL 73
CLUTCHES 73
Primary Clutch 73
Secondary Clutch 74
Increased Load 74
Equilibrium 74
Removing the Transmission Belt 74
Transmission Belt Service 74
Primary Clutch Removal 74
Primary Clutch Installation 76
Secondary Clutch Removal 76
Secondary Clutch Repair 76
Secondary Clutch Assembly 76
Secondary Clutch Installation 76
STORAGE 76
DIRECTION SELECTOR
DIRECTION SELECTOR 79
Removing Direction Selector 79
Replacing a Micro Switch 80
Shift Cable Adjustment 80
Neutral Lock Operation 80
ELECTRICAL
CIRCUITS AND CONTROLS 83
STARTER 83
GENERATOR 83
WIRING
TESTING THE IGNITION CIRCUIT 83
Testing the Magneto 86
TESTING THE STARTING CIRCUIT 87
TESTING THE CHARGING CIRCUIT 87
INSPECTION 88
STARTER/GENERATOR 89
Starter/Generator Removal 89
Disassembly 89
Repair and Replacement 89
VOLTAGE TEST FOR BATTERY 89
STORAGE OF BATTERY 90
DVOM (DIGITAL VOLT OHM METER) 90
FAULT TESTING 90
POWER SUPPLY 91
ACCESSORY WIRING 91
LIGHT BULB REPLACEMENT 91
Headlight (if equipped) 91
Turn Signal (if equipped) 92
Taillight (if equipped) 92
BRAKES
BRAKE SYSTEM OVERVIEW 96
General Description 96
How the Service Brake Works 96
Equalizer Link 96
Automatic Adjuster Mechanism 96
How the Parking Brake Works 97
Kick-Off Actuating Linkage 97
FAULT TESTING AND INSPECTION 97
New Vehicles 97
Fault Testing and Inspection Procedures 97
Brake Pedal and Linkage Inspection 97
Periodic Brake Performance Test (PBPT) 98
Aggressive Stop Test 99
Wheel Brake Inspection 100
MAINTENANCE AND REPAIRS
Parts Replacement vs Repair 102
Adjusting Brake Pedal Free Travel 102
Brake Drum Removal and Installation 103
Wheel Brake Service 104
Backing Plate/Entire Wheel Brake Assembly Removal and Installation 105
Brake Shoe and Adjuster Replacement 106
Brake Cable Snap Ring Removal 107
Brake Cable and Equalizer Assembly Removal and Installation 107
Brake Pedal Assembly Replacement 107
BRAKE FAULT TESTING 108
REAR SUSPENSION
REAR SUSPENSION 111
General 111
Shock Absorber 111
Rear Leaf Spring 112
Removal 112
Installation 112
REAR AXLE
NEUTRAL LOCK 115
Checking the Lubricant Level 115
REAR AXLE DISASSEMBLY 116
Axle Shaft Removal and Disassembly 116
Axle Shaft Seal Removal and Replacement 117
Axle Shaft Replacement 117
WEATHER PROTECTION
CANOPY AND WINDSHIELD 119
Transporting the Vehicle 119
WINDSHIELD 120
GOLF CAR TOP 120
Removal 120
Installation 120
2 + 2 CANOPY 122
Removal 122
Installation
REAR VIEW MIRROR WITH CANOPY 124
Mirror Bracket Installation 124
Mounting Mirror to Bracket 124
REAR VIEW MIRROR WITHOUT CANOPY 125
FAULT TESTING
GASOLINE VEHICLE PERFORMANCE 129
FUEL ACCUMULATION IN THE CRANKCASE 133
CARBURETOR 134
STARTER / GENERATOR 135
SUSPENSION AND STEERING 136
BRAKE SYSTEM 136
GENERAL SPECIFICATIONS
APPROXIMATE VEHICLE DIMENSIONS 145
TURNING DIAMETER AND INCLINE INFORMATION 147
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE 149
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