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E-Z-GO RXV - Gas Owner Manual - Page 35

Fig. 22, Torque Specifications and Bolt Grades

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B OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with this vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. HARDWARE Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref. Fig. 22). Use care when tightening fasteners and refer to the Technician's Repair and Service Manual for specific torque values. B Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head and grade 8 hardware is identified by 6 marks on the head. Unmarked hardware is Grade 2 (Ref. Fig. 22). ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners. BOLT SIZE 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1" Grade 2 4 8 15 24 35 55 75 130 125 190 (5) (11) (20) (33) (47) (75) (102) (176) (169) (258) Grade 5 6 13 23 35 55 80 110 200 320 480 (8) (18) (31) (47) (75) (108) (149) (271) (434) (651) Grade 8 6 18 35 55 80 110 170 280 460 680 (8) (24) (47) (75) (108) (149) (230) (380) (624) (922) BOLT SIZE M4 Class 5.8 1 (Grade 2) 5.8 (2) Class 8.8 2 (Grade 5) 8.8 (3) Class 10.9 3 (Grade 8) 10.9 (4) M5 M6 M8 M10 M12 M14 2 4 10 20 35 55 (3) (6) (14) (27) (47) (76.4) 4 7 18 35 61 97 (6) (10) (24) (47) (83) (131) 6 10 25 49 86 136 (8) (14) (34) (66) (117) (184) Fig. 22 Torque Specifications and Bolt Grades To reduce the possibility of severe injury or death from improper servicing techniques: DO NOT attempt any type of servicing operations before reading and understanding all notes, cautions and warnings in this manual. Any servicing requiring adjustments to be made to the powertrain while the motor is running must be made with both drive wheels raised and vehicle properly supported on jack stands. To reduce the possibility of motor damage, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a 'no load' condition. Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or compressed air. To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the battery before removing battery wires. explosion. Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench 'shorting out' a battery, which could result in an Reduce the possibility of accidental starting by removing and grounding spark plug wires and disconnecting battery at negative terminal before servicing. The electrolyte in a battery is an acid solution which can cause severe burns to the Owner's Guide Page 15

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

OPERATION AND SERVICE INFORMATION

Page 15

Owner’s Guide

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

HARDWARE

Periodically, the vehicle should be inspected for loose

fasteners. Fasteners should be tightened in accordance

with the Torque Specifications table (Ref. Fig. 22).

Use care when tightening fasteners and refer to the

Technician’s Repair and Service Manual for specific

torque values.

Generally, three grades of hardware are used in the ve-

hicle. Grade 5 hardware can be identified by the three

marks on the hexagonal head and grade 8 hardware is

identified by 6 marks on the head. Unmarked hardware

is Grade 2 (Ref. Fig. 22).

Fig. 22

Torque Specifications and Bolt Grades

To reduce the possibility of severe injury or

death from improper servicing techniques:

DO NOT attempt any type of servicing

operations before reading and understand-

ing all notes, cautions and warnings in this

manual.

Any servicing requiring adjustments to be

made to the powertrain while the motor is

running must be made with both drive

wheels raised and vehicle properly support-

ed on jack stands.

To reduce the possibility of motor damage,

never operate vehicle at full throttle for

more than 4 - 5 seconds while vehicle is in

a ‘no load’ condition.

Wear eye protection when

working on the vehicle.

Use extra care when

working around batteries,

or using solvents or com-

pressed air.

To reduce the possibility of causing an

electrical arc, which could result in a battery

explosion, turn off all electrical loads from

the battery before removing battery wires.

Wrap wrenches with vinyl

tape to reduce the possibil-

ity of a dropped wrench

‘shorting out’ a battery,

which could result in an

explosion.

Reduce the possibility of accidental starting

by removing and grounding spark plug

wires and disconnecting battery at negative

terminal before servicing.

The electrolyte in a battery is an acid solu-

tion which can cause severe burns to the

ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)

BOLT SIZE

Grade 2

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

Unless otherwise noted in text, tighten all hardware in accordance with this chart.

This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when

installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.

(5)

(11)

(20)

(33)

(47)

(75)

(102)

130

(176)

125

(169)

190

(258)

Grade 5

Grade 8

(8)

(18)

(31)

(47)

(75)

(108)

110

(149)

200

(271)

320

(434)

480

(651)

(8)

(24)

(47)

(75)

(108)

110

(149)

170

(230)

280

(380)

460

(624)

680

(922)

BOLT SIZE

Class 5.8

(Grade 2)

M10

M12

M14

(2)

(3)

(6)

(14)

(27)

(47)

(76.4)

Class 8.8

(Grade 5)

(3)

(6)

(10)

(24)

(47)

(83)

(131)

Class 10.9

(Grade 8)

(4)

(8)

(14)

(34)

(66)

(117)

136

(184)

5.8

8.8

10.9