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E-Z-GO Freedom RXV - Gas Owner Manual - Page 40

Adjusting The Belt, Cooling System Cleaning

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OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. BIf the element is in acceptable condition, loose dirt may be removed by tapping the filter lightly. Do not use oil on the filter element or any part of the unit STARTER/GENERATOR BELT TENSION Tool List Qty. Belt tension gauge 1 Wrench, 13mm 1 Wrench, 14mm 2 Ratchet 1 Socket, 15mm 1 The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36 kg). Re-tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique. A maximum deflection of 1/2" (13 mm) is acceptable. ADJUSTING THE BELT Using a 15mm socket and a 13mm open end wrench, loosen the starter/generator pivot bolt. While holding the lower adjusting nut with a 14mm wrench, loosen the upper jam nut with another 14mm wrench. Move the lower nut up or down the adjustment bolt until proper belt tension is achieved. Hold the lower nut in place and tighten the upper jam nut against it. NOTICE A loose belt can cause audible vibration and squeal. Tighten a new starter/generator belt to 115 - 125 lbs. (52 - 57 kg) tension when a gauge is applied half way between the two pulleys. Fig. 34 Checking Belt Tension with Gauge Although not as accurate, a new belt may be depressed with a finger to check the belt tension. A maximum deflection of 3/8" (10 mm) is acceptable. 3/8" (1 cm) Maximum Deflection (New Belt) Fig. 36 Adjusting the Belt Tension Using a 15mm socket and a 13mm open end wrench, tighten the starter/generator pivot bolt. COOLING SYSTEM CLEANING At least once a year, or more often under adverse conditions, the cooling system should be cleaned. Cleaning will assure an adequate supply of air to the cooling fins. Compressed air may be used for routine cooling system maintenance. 1/2" (1.3 cm) Maximum Deflection (Existing Belt) Fig. 35 Checking Belt Tension with Finger Fig. 37 Cleaning Cooling System with Air Page 20 Owner's Guide

Section	Page
C_Model_Info-05Feb2010.pdf	3
E-Z-GO Division of TEXTRON Inc. 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.	3
These are the original instructions as defined by 2006/42/EC.	3
OWNER’S MANUAL AND SERVICE GUIDE	3
GASOLINE POWERED	3
FLEET GOLF CARS	3
RXV GOLF CAR	3
RXV FREEDOM™	3
RXV SHUTTLE 2 + 2	3
STARTING MODEL YEAR 2011	3
The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.	4
BATTERY PROLONGED STORAGE	4
E_Operation_Service_Info1-28APR10.pdf	21
In order to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must be provided when ordering service parts.	21
Fig. 1 Serial Number Location on Steering Column	21
Fig. 2 Serial Number on Front Frame	21
Fig. 3 Serial Number on Rear Frame	21
BEFORE INITIAL USE	22
.	22
Fig. 4 Initial Service Chart	22
CONTROLS AND INDICATORS	22
1. Key Switch	22
2. Fuel Gauge (optional)	22
3. Head Light Switch (optional)	22
4. Turn Signal Switch (optional)	22
5. Horn Button (optional)	22
6. Accelerator Pedal	22
7. Service Brake Pedal	22
8. Park Brake	22
Fig. 5 Operator Controls & Gauges	22
9. Hour Meter (optional)	22
10. Direction Selector	22
11. Choke	22
Fig. 6 Hour Meter	22
Key Switch	23
Direction Selector	23
Fig. 7 Direction Selector	23
Accelerator Pedal	23
Combination SERVICE Brake & Park Brake Pedal	23
Choke	23
Fig. 8 Choke	23
Fuel Gauge (IF SO EQUIPPED)	23
Low Oil Pressure Indicator (IF SO EQUIPPED)	23
Headlight Switch (IF SO EQUIPPED)	24
Turn Signal Switch (IF SO EQUIPPED)	24
Horn (IF SO EQUIPPED)	24
OPERATING THE VEHICLE	24
Run-In	24
The oil dipstick and cap must be in place before operating the engine. Failure to install the dipstick and cap will result in oil becoming contaminated and/or being discharged into the engine compartment.	25
Fig. 9 Oil Dipstick and Cap	25
Fig. 10 Check Oil Level	25
Cold Starting	25
Starting and Driving	25
Starting Vehicle On A Hill	26
Coasting	26
Fuel	26
Fig. 11 Fueling	26
Battery	27
Starting a Vehicle with a Discharged Battery	27
Labels and Pictograms	27
Sun Top And Windshield	27
VEHICLE CLEANING AND CARE	27
Vehicle Cleaning	27
REPAIR	28
Lifting The Vehicle	28
Fig. 12 Chock Wheels	28
T	29
Fig. 13 Lifting the Vehicle	29
WHEELS AND TIRES	29
Tire Repair	29
Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.	30
.	30
Wheel Installation	30
It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will assure even seating of the wheel against the hub.	30
Fig. 14 Wheel Installation	30
Light Bulb Replacement	30
Head Light Bulb Replacement	30
1. Turn the headlight bulb (3) clockwise and pull to remove.	30
2. Disconnect the accessory harness (5) from the light bulb.	30
Fig. 15 Head Light Bulb Replacement	31
3. Connect the accessory harness (5) to the light bulb (3).	31
4. Align the bulb with the opening in the back of the headlight assembly.	31
5. Turn the bulb (3) counter clockwise until it stops.	31
Turn signal Bulb Replacement	31
1. Remove the phillips head screw (7) and turn the retaining collar (8) to align with the turn signal bulb housing (9).	31
2. Grip the turn signal bulb housing (9) and pull backward to remove housing from the headlight assembly.	31
Fig. 16 Turn Signal Bulb Replacement	31
3. Remove the bulb from the housing and replace with a new one.	31
4. Push turn signal housing (9) into headlight assembly firmly, making sure that it is seated completely.	31
5. Turn the retaining collar (8) to secure the bulb housing and install the phillips head screw (7) to secure in place.	31
Tail Light/Brake Light Bulb Replacement	31
1. Remove the two phillips head screws (8) that secure the lens (9) to the tail light assembly.	31
2. Remove the light bulb.	31
3. Install the new light bulb.	31
4. Install the lens (9) and secure in place with the two phillips head screws. (8)	31
Fig. 17 Tail and Brake Light Bulb Replacement	31
TRANSPORTING VEHICLE	31
Towing	31
Neutral Lock	32
.	32
Fig. 18 Neutral Lock	32
Hauling	32
SERVICE AND MAINTENANCE	33
PERIODIC SERVICE SCHEDULE	33
P - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE	33
Fig. 19	33
CAPACITIES AND REPLACEMENT PARTS	35
Fig. 22 Torque Specifications and Bolt Grades	35
Tire Inspection	36
Rear Axle	36
Checking the Lubricant Level	36
Fig. 23 Add, Check and Drain Axle Lubricant	36
Checking the Oil Level	36
Fig. 24 Oil Dipstick & Cap	37
Fig. 25 Check Oil Level on Dipstick	37
When adding oil between oil changes, do not mix brands and viscosity grades of oil.	37
Changing the Oil	37
Fig. 26 Oil Viscosity Chart	37
Fig. 27 Cleaning Top of Engine	38
Fig. 28 Remove Oil Filter	38
Fig. 29 Inspect Oil Filter	38
Fig. 30 Oil Drain Plug	38
Fig. 31 Add Engine Oil	39
The oil dipstick and cap must be in place before operating the engine. Failure to install the dipstick and cap will result in oil being discharged into the engine compartment.	39
AIR CLEANER INSPECTION and REPLACEMENT	39
The air cleaner unit on the vehicle is a dry unit. DO NOT use oil on the filter element or any part of the unit.	39
Fig. 32 Air Cleaner	39
Cleaning the Air Filter Element	39
Fig. 33 .Air Cleaner Assembly	39
A loose belt can cause audible vibration and squeal.	40
Fig. 34 Checking Belt Tension with Gauge	40
Fig. 35 Checking Belt Tension with Finger	40
Adjusting the Belt	40
Fig. 36 Adjusting the Belt Tension	40
COOLING SYSTEM CLEANING	40
Fig. 37 Cleaning Cooling System with Air	40
SPARK PLUG	41
Fig. 38 Gapping the Spark Plug	41
Cleaning the Battery	41
Fig. 39 Preparing Acid Neutralizing Solution	41
Battery Removal and Installation	41
Fig. 40 Battery Removal	42
.	42
Periodic Brake Performance Test (PBPT)	42
Fig. 41 Periodic Brake Performance Test	43
Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.	43
PROLONGED STORAGE	43
F Specification--gas-10Feb10.pdf	48
RXV GAS - FREEDOM VEHICLE SPECIFICATIONS	49
RXV GAS - SHUTTLE 2 + 2 VEHICLE SPECIFICATIONS	50
Fig. 42 Flee & Freedom Vehicle Dimensions	51
Fig. 42 Shuttle 2 + 2 Vehicle Dimensions	52

Match case Limit results 1 per page

Page 20

OPERATION AND SERVICE INFORMATION

Owner’s Guide

Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

If the element is in acceptable condition, loose dirt may

be removed by tapping the filter lightly. Do not use oil on

the filter element or any part of the unit

STARTER/GENERATOR BELT TENSION

Tool List

Qty.

Belt tension gauge

.......................................................

Wrench, 13mm

............................................................

Wrench, 14mm"

...........................................................

Ratchet

........................................................................

Socket, 15mm

..............................................................

The starter/generator belt tension should be checked af-

ter the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36

kg).

A loose belt can cause audible vibration and squeal.

Tighten a

new

starter/generator belt to 115 - 125 lbs. (52

- 57 kg) tension when a gauge is applied half way be-

tween the two pulleys.

Fig. 34

Checking Belt Tension with Gauge

Although not as accurate, a

new

belt may be depressed

with a finger to check the belt tension. A maximum de-

flection of 3/8" (10 mm) is acceptable.

Fig. 35

Checking Belt Tension with Finger

Re-tighten an

existing

belt to 75 - 80 lbs. (34 - 36 kg)

tension using the same technique. A maximum deflec-

tion of 1/2" (13 mm) is acceptable.

ADJUSTING THE BELT

Using a 15mm socket and a 13mm open end wrench,

loosen the starter/generator pivot bolt.

While holding the lower adjusting nut with a 14mm

wrench, loosen the upper jam nut with another 14mm

wrench. Move the lower nut up or down the adjustment

bolt until proper belt tension is achieved. Hold the lower

nut in place and tighten the upper jam nut against it.

Fig. 36

Adjusting the Belt Tension

Using a 15mm socket and a 13mm open end wrench,

tighten the starter/generator pivot bolt.

COOLING SYSTEM CLEANING

At least once a year, or more often under adverse condi-

tions, the cooling system should be cleaned. Cleaning

will assure an adequate supply of air to the cooling fins.

Compressed air may be used for routine cooling system

maintenance.

Fig. 37

Cleaning Cooling System with Air

NOTICE

3/8" (1 cm) Maximum

Deflection (New Belt)

1/2"

(1.3 cm) Maximum

Deflection (Existing Belt)