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TXT Fleet Gas 04-07 owners guide

1. E iue n eR Fer eee STARTING AND DRIVING STARTING THE VEHICLE ON A HILL essseeeeeeeeeneeennen eene nennen nenne nret retener eren enne innt 4 COASTING iii E teehee ee reeves ay 5 BATTERY redana ate EAN a M LABELS AND PICTOGRAMS SUN TFOP AND WINDSHIELD risin i ct itt dee ened honed cane RI ade VEHICLE CLEANING AND CARE 4 04221 6 VEHIGEE SEEANING 52 5 tas east then ee a Tea epee lm Ae me aD M 6 ect REA 7 LIFTING THE VEHICLE erecto cereal eine ae 7 FIGs Ge LAMING INO Vehicle 7 WHEELS AND TIRES MICHI Wheel InstallatiOH 2 trot Pret D coe n et dev t t A dd tutore teas Fig 10 Wheel Installation LIGHT BULB REPLACEMENT te e tr ete eR e e dE ert Fig 11 Headlight Turn Signal amp Marker Light Bulb Replacement 9 Fig 12 Tail and Brake Light Bulb Replacement FUSE REPLACEMENT rapti efe Meetic ete tent ett ute tain eed dedi A VEHICLE WITH DISCHARGED BATTERY 222 2 2 2 4 000000000 0000000 000000000 e ert t
2. LUBRIGATIONS cede re wes M paren dE 21 Fig 35 Lubrication Points Early Production eene tente 21 Fig 36 Lubrication Points Late Production 21 SPARK PLUGS sitio otto d ara Bd nig dad ceat en ce dte d Riv dale d 21 DIRECTION SELECTOR Dual Cable system sese nnne 22 Fig 37 Shift Cable Adjusimelt ir rette n P pin nr ere rra en PROLONGED STORAGE aded ee ae Li oh IER ia en ene ot diete HARDWARE ct di Fig 38 Torque Specifications CAPACITIES AND REPLACEMENT PARTS 2 Fig 39 Capacities and Replacement Parts 2 022000000 0 0000000 0000000 23 GENERAL SPECIFICATIONS TXT GASOLINE FLEET TAT GASOLINE FREEDOM M p 7 1 ce a aa a e detti debiera te i MEL ie 27 TXT GASOLINE FREEDOMTM SE tte pe aeaa eh ho e De 28 TXT GASOLINE FREEDOM LE TXTXGASOLINE FREEDOM M FIP b toit tet te re ee ense eR EXT GASOLINE FREEDOM HP SE cii Lore e er er e bp e Ee ener RENT cct dem preso TXT GASOLINE FREEDOM HP LE TXT GASOLINE SHUTTLE 20 dir cere epa D ake MEE KD RO AE A Re A Ee cue Fig 36 Vehicle Dimensions ioter rtr e En envia nein agent 34 Fig 37 Ve
3. Do not tow more than three vehicles at a time Do not exceed 5 mph 8 kph while towing multi ple vehicles Place direction selector in neutral The CAUTION neutral lock should be used to lock the direction selector in position This will reduce the possibility of it moving into F forward R reverse while being towed causing possible damage to the rear axle Do not tow a single vehicle at speeds in excess of 12 mph 19 kph Do not tow more than three vehicles at a time Do not exceed 5 mph 8 kph while towing multiple vehicles Towing the vehicle at above recommended speed may result in severe injury and or damage to vehicle and other property Tow bars are not intended for road use Never use ropes or chains to tow vehicle s Tow bars are available from the Service Parts Department Tow bars are not intended for highway use Before tow ing place direction selector in neutral and engage neu tral lock Do not ride on vehicle being towed Tow bars are designed to tow only one vehicle at a maximum Page 9 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings speed of 12 mph 19 kph and up to three vehicles at a maximum speed of 5 mph 8 kph NEUTRAL LOCK To prevent the driven clutch from turning the rear wheels during service operations and to prevent wear to the belt while being towed a
4. Individually Keyed Long Fender Liners Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Sand Bottle Kit Seating Special Color Cooler Jug No Side Basket Divot Repair Sand Container amp Scoop Requires Side Basket Divot Repair Sand Bottle No Side Basket Full Sound Control Package Hour Meter Key Switch Custom Page 32 Tow Bar Detachable Tow Bar Permanent Weather Protection Enclosure Windshield One Piece Top Required Windshield Rear Owner s Manual and Service Guide GENERAL SPECIFICATIONS STANDARD EQUIPMENT TXT GASOLINE SHUTTLE 2 2 BATTERY One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve ENGINE 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump TRANSAXLE 13 32 1 Helical Geared with Neutral Lock amp Ground Speed Governor TRANSMISSION Automatic Continuously Variable Transmission CVT FUEL TANK 6 Gallon 23 Liters Tank 36 Ibs 16 kg Fuel Weight BRAKES Dual Rear Wheel Self Adjusting Mechanical Drum Brakes PARKING BRAKE Automatic Parking Brake Release with Self Compensating System FRONT SUSPENSION Leaf Springs with Hydraulic Shock Absorbers REAR SUSPENSI
5. WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED DANGER OF EXPLOSION DO NOT FILL GAS CAN IN LOAD BED 14 25 WARNING MAXIMUM CROSS HILL RAMP WARNING ANGLE AS MAXIMUM LOAD BPECIDIEB amp CENTER OF GRAVITY KEEP LOAD LOAD WITH AS FAR HIGH CENTER FORWARD AS OF GRAVITY POSSIBLE COULD RESULT DO NOT RIDE IN TIP OVER IN LOAD BED LOAD KEEP HANDS amp CENTER FINGERS AWAY OF GRAVITY 1 4 ee sat EE DUMP Ref Pic 1 1 Appendix A 4 Owner s Manual and Service Guide LABELS AND PICTOGRAMS 1 3 CLEAN UP GASOLINE 4 15 22 HO SPILLS WITHWATER 27 TT EXPOSE 5 e BEFORE STARTING EN TO FLAME cr ENGINE 16 UNLEADED GASOLINE DISPOSE BATTERIES DO NOT 17 m PME SPILL FUEL IN LANDFILL D AQ ON AHOT ENGINE 18 GROUND DRIVE ON MES FUEL PUMP HIGHWAY 19 rovs LOW OIL PRESSURE PROVIDE 20 Aa GROUND Spadin FLYING OBJECTS DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND 1 i SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION E ad EI z 23 2 TAMPERING 5 OUT WARNING CORROSIVE N gt WARNING EXPLOSIVE WARNING LETHAL VOLTAGE N e N m Ref Pic 1 2 BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS WEAR EYE PROTECTION NO SMOKING HOT SURFACE Owner s Manual and Service Gu
6. WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION TXT GASOLINE FLEET One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump 13 32 1 Helical Geared with Neutral Lock amp Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 Gallon 23 Liters Tank 36 lbs 16 kg Fuel Weight Dual Rear Wheel Self Adjusting Mechanical Drum Brakes Automatic Parking Brake Release with Self Compensating System Leaf Springs with Hydraulic Shock Absorbers Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack amp Pinion Dual Handgrips Pencil Holder amp Scorecard Holder Cushion Foam Vinyl Cover Hip Restraint Hand Hold Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 12 14 mph 19 23 kph Welded Tubular Steel Powder Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with Base Coat Clear Coat Champagne Hunter Green Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders Tee amp Ball Storage 18 x 8 50 8 4 Ply Rated Load Range B 18 22 psi 124
7. birth defects or other reproductive harm NOTE The exhaust emissions of this vehicles engine complies with regulations set forth by the Envi ronmental Protection Agency EPA of the United States of America USA at time of manufacture Significant fines could result from modifications or tampering with the engine fuel ignition or air intake systems Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling NOTE This spark ignition system meets all require ments of the Canadian Interference Causing Equipment Regulations AWARNING A syst me d allumage par tincelle de v hicule respecte toutes les exigences R glement sur le mat riel brouilleur du Canada NOTES CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER OWNER S MANUAL AND SERVICE GUIDE GASOLINE POWERED FLEET GOLF CARS amp PERSONAL VEHICLES FLEET GOLF CAR FREEDOM FREEDOM SE FREEDOM LE FREEDOM HP FREEDOM HP SE FREEDOM HP LE SHUTTLE 242 STARTING MODEL YEAR 2002 E Z GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the infor mation contained in this manual is subject to change without notice 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 TO CON
8. 152 kPa 669 Ibs 304 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Caddy Kit Accent Stripes Analog Fuel Gauge Ash Tray Bag Cover Basket Center Basket Side Bunker Rake with Holder CE Package Cooler Jug No Side Basket Divot Repair Sand Container amp Scoop Requires Side Basket Divot Repair Sand Bottle No Side Basket Page 26 Freedom Package Headlights Taillights Brake Lights Horn Full Sound Control Package Hour Meter Key Switch Custom Key Switch Individually Keyed Long Fender Liners Low Oil Pressure Light Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Sand Bottle Kit Seating Special Color Owner s Manual and Service Guide Tires Turf Glide Turf Saver Fairway USA Trail Top Sun Canopy Tow Bar Detachable Tow Bar Permanent Turn Signal with 4 Way Flasher Weather Protection Enclosure Wheel Covers 8 Chrome Wheel Covers 6 Moon Wheel Covers Spoke Silver and Black Wheel Covers Spoke Gold and Black Windshield One Piece Top Required Windshield Fold Down Top Requ
9. AL LOWING THE VEHICLE TO OPERATE BEYOND TGTSP S SPECIFICATIONS SHOWS INDICATIONS THAT IT HAS BEEN ALTERED OR MODIFIED IN ANY WAY FROM TGTSP SPECIFICATIONS INCLUDING BUT NOT LIMITED TO ALTERATIONS TO THE SPEED BRAKING SYSTEM ELECTRICAL SYSTEM STEERING OR OTH ER OPERATING SYSTEMS OF THE VEHICLE OR SHOWS INDICATIONS THAT ROUTINE MAINTENANCE WAS NOT PERFORMED WHEN AND IN THE MANNER SPECIFIED IN THE TGTSP MAINTENANCE MANUAL THIS WARRANTY SHALL BE VOID WITH RESPECT TO ANY DEFECT OR DAMAGE CAUSED BY OR AS A RE SULT OF OR RELATED TO PARTS OR ACCESSORIES WHICH ARE NOT MANUFACTURED OR AUTHO RIZED BY TGTSP OR WERE NOT INSTALLED PER TGTSP S INSTRUCTIONS OR FOR GASOLINE VEHI CLES THE USE OF NON RECOMMENDED FUELS AND LUBRICANTS FOR FURTHER INFORMATION CALL 1 706 798 4311 OR WRITE TO TEXTRON GOLF TURF amp SPECIALTY PRODUCTS ATTENTION WARRANTY DEPARTMENT P O BOX 388 AUGUSTA GEORGIA 30903 0388 Page 40 Owner s Manual and Service Guide EMISSION WARRANTY FEDERAL UNITED STATES FEDERAL EMISSION CONTROL WARRANTY STATEMENT EMISSION COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all states except the State of California Fuji Heavy Industries Ltd and Textron Golf Turf amp Specialty Products Augusta Georgia herein Textron Golf Turf amp Specialty Products warrant s to the initial retail purchaser and each subsequent owner that this Nonroad engine herein has been design
10. Base Coat Clear Coat Champagne Hunter Green DASH PANEL Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders Tee amp Ball Storage LIGHTING HORN None TIRES 18 x 8 50 8 4 Ply Rated Load Range B TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION FEATURES 18 22 psi 124 152 kPa 679 Ibs 308 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator Center Basket WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Caddy Kit Accent Stripes Ash Tray Bag Cover Basket Side Horn USA Trail Hour Meter Top Sun Canopy Key Switch Custom Tow Bar Detachable Key Switch Individually Keyed Tow Bar Permanent Long Fender Liners Turn Signal with 4 Way Flasher Message Holder Weather Protection Enclosure Paint Color Custom Wheel Covers 8 Chrome Bunker Rake with Holder CE Package Cooler Jug No Side Basket Divot Repair Sand Container amp Scoop Requires Side Basket Divot Repair Sand Bottle No Side Basket Full Sound Control Package Headlights and Taillights Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirr
11. Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with Base Coat Clear Coat Champagne Hunter Green Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders Tee amp Ball Storage Single Halogen Light Bar Tail amp Brake Lights Horn 18 x 8 50 8 4 Ply Rated Load Range B 18 22 psi 124 152 kPa 679 Ibs 308 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator Center Basket WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Caddy Kit Accent Stripes Ash Tray Bag Cover Basket Side Bunker Rake with Holder CE Package Cooler Jug No Side Basket Divot Repair Sand Container amp Scoop Tires Requires Side Basket Divot Repair Sand Bottle No Side Basket Full Sound Control Package Hour Meter Key Switch Custom Key Switch Individually Keyed Long Fender Liners Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Sand Bottle Kit Seating Special Color Tow Bar Detachable Tow Bar Permanent Turn Signal with 4
12. Gallon 23 Liters Tank 36 Ibs 16 kg Fuel Weight BRAKES Dual Rear Wheel Self Adjusting Mechanical Drum Brakes PARKING BRAKE Automatic Parking Brake Release with Self Compensating System FRONT SUSPENSION Leaf Springs with Hydraulic Shock Absorbers REAR SUSPENSION Leaf Springs with Hydraulic Shock Absorbers STEERING Single Reduction Rack amp Pinion STEERING WHEEL Dual Handgrips Pencil Holder amp Scorecard Holder SEATING Cushion Foam Vinyl Cover Hip Restraint Hand Hold SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 15 mph 23 kph Welded Tubular Steel Powder Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with Base Coat Clear Coat Champagne Hunter Green Cloud Gray Bright Silver Metallic Flame Red Dark Garnet Patriot Blue Pearl Black Steel Blue Pearl DASH PANEL Wood Grain with 4 Drink Holders LIGHTING HORN Single Halogen Light Bar Tail amp Brake Lights Horn TIRES 18 x 8 00 10 4 Ply Rated Load Range B TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION FEATURES 20 25 psi 140 170 kPa 679 Ibs 308 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator Sun Top Fold Down Windshield Center Basket Tur
13. Manual and Service Guide TABLE CONTENTS Ly dz EET Inside covers NOTES ccc cc E ii SAFETY INFORMATION iro cO e UE V BEFORE INITIAL USE reet ee tie tet A E eate Fig 1 Initial Service Chart CONTROLS AND INDICATORS 1 KEY EIGEET SWLETGRL ai eet ea ie iin ac SA GEN 1 Fig 2 Key Light Switch Low Oil Pressure Light and Fuel Gauge 2 DIRECTION SELECTOR Fig 3 Direction Selector oue ener e 2 eve decer e ese e ote per 2 Fig 4 Choke tieni ET eene 2 F EL GAUGE eR e AT b di AI ede bnc ivt aed bete tu uL dde b ud eh ae 2 LOW OIL PRESSURE INDICATOR 2 ACCELERATOR PEDAL zr 2 Fig 5 Accelerator and Brake Controls 3 COMBINATION BRAKE AND PARK BRAKE PEDAL sees nnrn nr en rennen enne 3 HORN ies aee en ea Te pte Cao e ob Na ad did Last MS 3 Figs 6 cien Mn 3 OPERATING THE VEHICLE oic cra nunc D Fan peer 3 RB EU RE 4 Fig 7 Check Oil Level on Dipstick nnns 4 COLD STARTING
14. OUTSIDE THE U S AND CANADA TEXTRON GOLF TURF amp SPECIALTY PRODUCTS TGTSP warrants to the Original Retail Purchaser or the Original Retail Lessee that any 2003 TGTSP vehicle and or Battery Charger shall be free from any defects in material or workmanship for one year from the date of installation at the customer s location with respect to parts and labor EXCLUSIONS Specifically excluded from any TGTSP warranty are adjustments repairs made due to normal wear beyond the first 180 days routine maintenance items cosmetic deterioration and electrical components which are susceptible to fluctuations in current beyond the control of TGTSP This warranty also does not apply to Acts of God or other events over which TGTSP has no control Transportation charges for warranty service as well as freight charges to receive warranty parts are excluded from this warranty and all replaced parts shall become the property of TGTSP This warranty also excludes batteries tires and Lester battery chargers which are warranted by their respective manufacturer REMEDY The sole remedy under this warranty and TGTSP s only obligation in the event of a defect in the vehicle battery charger is that TGTSP will at its sole option repair or replace any defective parts This remedy precludes all other remedies including any lawsuits claims or other proceedings alleging strict liability negligence of contract or any cause of action TGTSP reserves the right to
15. SEATING Cushion Foam Vinyl Cover Hip Restraint Hand Hold SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 16 18 mph 26 29 kph Welded Tubular Steel Powder Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with Base Coat Clear Coat Champagne Hunter Green Cloud Gray Bright Silver Metallic Flame Red Dark Garnet Patriot Blue Pearl Black Steel Blue Pearl DASH PANEL Wood Grain with 4 Drink Holders LIGHTING HORN Single Halogen Light Bar Tail amp Brake Lights Horn TIRES 18 x 8 00 10 4 Ply Rated Load Range B TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION FEATURES 20 25 psi 140 170 kPa 679 Ibs 308 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator Sun Top Windshield Fold Down Center Basket Turn Signal with 4 Way Flasher Glove Box Doors WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Cadgy Kit Accent Stripes Ash Tray Bag Cover Basket Side Bunker Rake with Holder CE Package Key Switch
16. Tighten an existing belt to 75 80 lbs 34 36 kg ten sion using the same technique and inspect for cracking Page 17 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings or wear A maximum deflection of 1 2 13 mm is accept able Adjusting the Belt Loosen the starter generator pivot bolt While holding the lower adjusting nut with a wrench loosen the upper jam nut with another 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 Ref Fig 28 on page 18 Ref Abt 1 Fig 28 Adjusting Belt Tension Tighten the starter generator pivot bolt BATTERY CLEANING To reduce the possibility of damage to CAUTION vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical components while cleaning do not use a pressure washer Cleaning should take place per the Periodic Service Schedule Ref Fig 17 on page 13 When cleaning the outside of the battery and terminals first spray with a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the top of the battery to another area of the vehicle or storage facility w
17. allowed to operate golf cars except those persons who posses a valid motor vehicle driver s license 8 1 2 The controlling party shall display the operation and safety instructions as recommended by the golf car manufacturers and the golf course safety rules in a con spicuous place near the golf car rental area or golf car pick up area It is also recommended as with all motor vehicles that the warning Do not operate golf cars when under the influence of alcohol or drugs be posted in a conspicuous location Page xvii SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes Page xviii Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Thank you for purchasing this vehicle Before driving the vehicle we ask you to spend some time reading this Owner s Manual and Service Guide This guide contains the information that will assist you in maintaining this highly reliable vehicle Some illustrations may show items that are optional for your vehicle This guide covers the operation of several vehicles therefore some picto rial views may not represent your vehicle Physical differ ences in contro
18. and then enter squarely after the elevator car is properly leveled Once on the elevator neutralize the controls shut off power and set parking brakes lt is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit Owner s Manual and Service Guide 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arranged loads When handling off center loads which cannot be cen tered operate with extra caution 5 6 2 Handle only loads within the capacity of the carrier as specified on the nameplate 5 6 3 Handle loads exceeding the dimensions used to establish carrier capacity with extra caution Stability and maneuverability may be adversely affected 5 7 Operator Care of Personnel and Burden Carriers 5 7 1 At the beginning of each shift during which the carrier will be used the operator shall check the carrier condition and inspect the tires warning devices lights battery s speed and directional controllers brakes and steering mechanism If the carrier is found to be in need of repair or in any way unsafe the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating condition 5 7 2 f during operation th
19. at the time of manufacture with the applicable regulations of the California Air Re Sources Board and 2 is free from defects in materials and workmanship which could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below A WARRANTY COMMENCEMENT DATE The warranty period begins on the date the engine is delivered to a first retail purchaser B LENGTH OF COVERAGE FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which could cause the failure of a warranted emission related part for a pe riod of two 2 years after the date of delivery to the first retail purchaser C WHAT IS COVERED 1 REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part will be performed at no charge to you by an au thorized dealer distributor or a service provider You may contact the Textron Golf Turf amp Spe cialty Products Warranty Department at 1 800 241 5855 to get the nearest appropriate location where your warranty repairs are performed 2 WARRANTY PERIOD This warranty continues for a period of two 2 years and shall apply only to the repair replace ment or adjustment of the component parts which are not scheduled for replacement as required maintenance Further component parts which are scheduled only for regular inspection to the ef fect of repair or replace as necessary shall be warranted fo
20. brake and remove the key Place a drain pan under the engine Wipe the top of the engine clean with a cloth Ref Fig 21 on page 16 Remove the oil fill cap Ref Cte 1 Fig 21 Clean Top of Engine Clean the area around the filter Oil drainage is accom plished by removing the three bolts securing the oil filter to the engine Remove the filter by pulling it from the engine and allow the oil to drain The O rings may remain on the engine or the filter Ref Fig 22 on page 16 At each oil change thoroughly inspect filter before clean ing At the first oil change metal chips and lint may be found This is normal resulting from engine run in At subsequent oil changes the presence of metal chips may indicate possible engine damage Page 16 Large O Ring O Small O Ring Inside Ref Rof 1 End Of Oil Filter Fig 22 Remove Oil Filter Wear eye protection to reduce the possi bility of splashed solvent contacting the 5 eyes when cleaning oil filter Clean the filter by washing in any shop degreaser and brushing the metal screen clean with a soft brush Ref Fig 23 on page 16 Ref Cof 1 Fig 23 Clean Oil Filter Blow out the filter with low pressure air 30 psi 210 kPa or less from no closer than 3 8 cm and allow to air dry Ref Fig 24 on page 16 3 8 cm Minimum 30 psi 210 kPa Maximum Fig 24 Blowing Out Oil Filter Owner s Manual and Service Guide
21. can cause serious personal injury or death Modifications that increase the speed and or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle Do not make any such modifications or changes The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition Read and observe all warnings and operation instruction labels affixed to the vehicle Follow all safety rules established in the area where the vehicle is being operated Reduce speed to compensate for poor terrain or conditions Apply service brake to control speed on steep grades Maintain adequate distance between vehicles Reduce speed in wet areas Use extreme caution when approaching sharp or blind turns Use extreme caution when driving over loose terrain Use extreme caution in areas where pedestrians are present MAINTENANCE Always Maintain the vehicle in accordance with the manufacturer s periodic service schedule Ensure that repairs are perfor
22. carrier opera tors to comply with additional specific safety practices 4 3 Nameplates Markings Capacity and Modifica tions 4 3 4 The user shall maintain in a legible condition all nameplates warnings and instructions which are supplied by the manufacturer 4 3 2 user shall not perform any modification or Owner s Manual and Service Guide addition which affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 4 3 3 As required under paras 4 3 1 or 4 3 2 the manufacturer shall be contacted to secure new name plates warnings or instructions which shall then be affixed in their proper place on the carrier 4 4 Fuel Handling and Storage 4 4 4 user shall supervise the storage and han dling of liquid fuels when used to be certain that it is in accordance with appropriate paragraphs of American National Standards Institute National Fire Protection Association ANSI NFPA 505 and ANSI NFPA 30 4 4 2 Storage and handling of liquefied petroleum gas fuels shall be in accordance with appropriate para graphs of ANSI NFPA 505 and ANSI NFPA 58 If such storage or handling is not in compliance with these stan dards the user shall prevent
23. located on the driver side at the rear of the housing Ref Fig 33 on page 20 Unless leakage of rear axle lubricant is evident an annual lubricant check is sufficient Page 20 v4 Ref Raf 2 Drain Plug Fig 33 Add Check and Drain Rear Axle Lubricant Checking the Lubricant Level Tool List Qty Required Socket 13 mm 3 8 1 Ratchet 3 8 drive 2 1 1 Clean the area around the check fill plugs Remove the check plug The correct lubricant level is just below the bottom of the threaded hole Ref Fig 39 on page 23 If lubricant is to be added remove the fill plug and add lubricant using a funnel Add lubricant slowly until lubricant starts to seep from the check plug hole Install the check plug and the fill plug In the event that the lubri cant is to be replaced a drain plug is provided at the bot tom of the differential housing AIR CLEANER INSPECTION AND REPLACEMENT To reduce the possibility of engine CAUTION damage be sure that bottom tabs of cover are installed in enclosure and top of cover is installed under top tabs Secure all spring clips NOTE 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 To aide installation and sealing petroleum jelly may be applied to back side of cover tabs and each side of filter seal The air cleaner is attach
24. nician s Repair and Service Manual Some service procedures may require the vehicle to be lifted Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information Page 12 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings PERIODIC SERVICE SCHEDULE Check Clean Adjust etc A Replace To perform service that is listed in this schedule but not described in this manual contact a local Service Representative or see the Repair and Service Manual for this vehicle NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions BEFORE USE Check service brake general operation Check park brake function Check warning device function in reverse Check tire condition Check overall vehicle condition WEEKLY TIRES for cuts excessive wear and pressure See GENERAL SPECIFICA TIONS WHEELS Check for bent rims missing or loose lug nuts FUEL GAUGE Check for proper operation at fueling and fuel cap vent is free of dirt ENGINE OIL Check and add if required DO NOT OVERFILL STARTER GENERATOR BELT V Check for tension wear cracks MONTHLY 20 HOURS includes items listed in previous table amp the following WIRING Check all wirin
25. range Ref Dsk 1 Fig 19 Check Oil Level on Dipstick Oil should be added to bring the level into the safe oper ating range Do not overfill Check that the oil fill cap and dipstick are firmly in place CHANGING THE OIL Tool List Qty Required Socket 10 mm 3 8 drive 1 Ratchet 3 8 1 Extension 8 3 8 drive esses 1 Oll drain pari uit 1 For maximum performance and longevity the engine oil should be replaced every 125 hours of operation or semi annually whichever comes first The selection of oil is dependent upon the service that the vehicle will perform Most vehicles require 10W 30 oil whereas vehicles used at capacity or near capacity load applications will require 10W 40 oil after run in Ref Fig 20 on page 16 To reduce the possibility of severe injury wear rubber gloves to protect skin from exposure to hot used oil and degreaser These fluids contain chemicals known to cause can cer Page 15 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings HEAVY DUTY WORK 10W 40 LIGHT DUTY WORK C 30 10 20 AIR TEMPERATURE Ref Ove 1 Fig 20 Oil Viscosity Chart The oil should be changed with the engine warm Park the vehi cle on a level surface engage the park
26. service brake when engine starts When the accelerator pedal is released the igni tion circuit is de energized and the engine stops To stop the vehicle more quickly depress the ser vice brake pedal When the direction selector is in the reverse NOTE position a warning signal will sound to indicate that the vehicle is ready to run in reverse STARTING THE VEHICLE ON A HILL To reduce the possibility of roll back which could result in severe injury or vehicle damage do not release service brake until engine has started Do not hold vehicle on hill by using CAUTION accelerator and engine This will cause premature and excessive wear to drive train components Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings To reduce the possibility of permanent damage to the drive system it is important to prevent excessive roll back when starting the vehicle on a hill Place left foot on service brake and release the park brake Depress accelerator with right foot and release the service brake by lifting left foot COASTING To reduce the possibility of severe injury or death from coasting at above recommended speeds limit speed with service brake On steep hills it is possible for the vehicle to coast at greater than normal
27. should keep all receipts and mainte nance records covering the performance of regular maintenance in the event questions arise These receipts and maintenance records should be transferred to each subsequent owner of the engine Textron Golf Turf amp Specialty Products reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep mainte nance records MAINTENANCE REPLACEMENT OR REPAIR OF EMISSSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALER OR SERVICE PROVIDER AUTHO RIZED BY TEXTRON GOLF TURF amp SPECIALTY PRODUCTS THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EF FECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUT COME OF A WARRANTY CLAIM If other than the parts authorized by Textron Golf Turf amp Specialty Products are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by Textron Golf Turf amp Specialty Products in their performance and durability HOW TO MAKE A CLAIM All repairs qualifying under this limited warranty must be perfor
28. station G MAINTENANCE REPLACEMENT AND REPAIR OF EMISSION RELATED PARTS Only warranted engine replacement parts approved by FUJI should be used in the performance of any war ranty maintenance or repairs on emission related parts If other than authorized parts are used for mainte nance replacement or repair of components affecting emission control you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability however assumes no liability under this warranty with respect to parts other than autho rized parts The use of non authorized replacement parts does not invalidate the warranty on other com ponents unless the non authorized parts cause damage to warranted parts H PARTS COVERED UNDER THE CALIFORNIA EMISSIONS WARRANTY 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system il Air fuel ration feedback and control system if applicable iil Cold start enrichment system if applicable iv Regulator assembly gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable 1 Air filter 3 Ignition System i Spark plugs il Magneto or electronic ignition system Page 44 Owner s Manual and Service Guide EMISSION WARRANTY CALIFORNIA iii Spark advance retard system if applicable 4 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Syst
29. that meets or exceeds SF SG CC oil ENGINE OIL DO NOT OVERFILL DRIVE BELT V Check for cracks fraying and excessive wear ANNUAL 250 300 HOURS includes items listed in previous tables amp the following FRONT WHEEL BEARINGS V Check and adjust as required see Technician s Repair and Service Manual REAR AXLE V Check lubricant add lubricant Ref Fig 39 on page 23 as required Clean and adjust see Technician s Repair and Service Manual ERVICE BRAKES 2 amp Check brake shoe linings see 5 Repair and Service Manual FUEL FILTER A Replace SPARK PLUGS A Replace gap new plugs Ref Fig 39 on page 23 MUFFLER EXHAUST V Check mounting hardware check for leaks at head and muffler gaskets VALVES V Check cold intake exhaust per Technician s Repair and Service Manual Fig 17 Periodic Service Schedule Page 14 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 500 HOURS includes items listed in previous tables amp the following TIMING BELT Check tension and for signs of wear damage replace if worn or damaged CARBURETOR Clean CYLINDER HEAD AND PISTONS Remove carbon from cylinder head and pistons Check valve seats for carbon buildup and clean as required Fig 17 Periodic Service Sche
30. when charging batteries Do not charge batteries without adequate ventilation Do not permit open flame or anyone to smoke in an area that is being used for charging batteries A concentration of 4 hydrogen gas or more is explosive Engine exhaust gas carbon monoxide is deadly Carbon monoxide is an odorless colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal The following are symptoms of carbon monoxide inhalation Dizziness Vomiting Intense headache Muscular twitching Weakness and sleepiness Throbbing in temples If any of these symptoms are experienced get fresh air immediately Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance amp Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 International Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
31. years If any emission related part on your engine is defective the part will be repaired or replaced by OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual FUJI recommends that you retain all receipts covering maintenance on your engine but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a dealer distributor or service provider authorized by Textron Golf Turf amp Specialty Products Augusta Georgia herein Textron Golf Turf amp Specialty Prod ucts to which FUJI supplies the engine as soon as a problem exists The warranty repairs should be com pleted in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 LIMITED WARRANTY on Emission Control Systems California Only FUJI Tokyo Japan warrants to the owner of the 2001 and later engine that the engine 1 has been designed built and equipped so as to conform
32. 28681 G01 A Textron Company 5 MANUAL AND SERVICE GUIDE GASOLINE POWERED FLEET GOLF CARS amp PERSONAL VEHICLES REVISED 05 05 SAFETY For any questions on material contained in this manual contact an authorized representative for clarification Read and understand all labels located on the vehicle Always replace any damaged or missing labels On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface To pre vent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying the service brake Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may cause a loss of vehicle control is costly is considered abuse and will not be covered under warranty Use extra caution when towing the vehicle s Do not tow a single vehicle at speeds in excess of 12 mph 19 kph Do not tow more than three vehicles at a time Do not exceed 5 mph 8 kph while towing multiple vehicles Towing the vehicle at above the recommended speed may result in personal injury and or damage to the vehicle and other prop erty Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition BATTERY WARNING BATTERIE
33. 875E 48 35751 Shuttle 954E 34731 Industrial 875PE 48 35752 Shuttle 956E 34732 Industrial 875AE 48 35753 Shuttle 955 35501 Industrial 881 35500 Shuttle 957 35502 Industrial 640 33601 Shuttle 952G 34733 Shuttle 954G 34734 Shuttle 956G 34735 Product Description Off Road Personnel Burden Carrier Serial Number 1400000 and above Vehicles in the above series which bear the CE mark on the serial plate conforms with the essential health and safety requirements of the following directives Machinery Directive 98 37 EC Battery and Accumulator Directive 91 157 EEC Electromagnetic Compatibility Directive 89 336 EEC 92 31 Location Augusta GA U S A Date September 19 2002 p ae Anil V Kulkarni Vice President of Engineering E Z GO Textron Golf Turf amp Specialty Products 1451 Marvin Griffin Road Augusta 30906 U S A SYSTEMS 150 2001 Bob Cat Brouwer Bunton e Cushman 2 eJacobsen Ransomes Ryan Steiner 034103822 Owner s Manual and Service Guide Page 53 DECLARATION OF CONFORMITY Notes Page 54 Owner s Manual and Service Guide LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner s Manual and Service Guide Appendix A 1 LABELS PICTOGRAMS See Following Pages For Explanation Of These Operate from the driver s side only For golf course a
34. CE Package USA Trail Hour Meter Top Sun Canopy Key Switch Custom Key Switch Individually Keyed Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Seating Special Color Tow Bar Detachable Tow Bar Permanent Turn Signal with 4 Way Flasher Weather Protection Enclosure Wheel Covers 8 Chrome Wheel Covers 6 Moon Wheel Covers Spoke Silver and Black Wheel Covers Spoke Gold and Black Windshield One Piece Top Required Windshield Fold Down Top Required Owner s Manual and Service Guide Page 33 GENERAL SPECIFICATIONS Page 34 Front 33 5 85 i Rear Clearance 38 in 97 cm 65 5 in 166 cm 4 92 5 in 235 cm gt 105 in 267 cm NOTE Shaded Area Indicates SHUTTLE 2 2 Ref Dim 1 1 Fig 36 Vehicle Dimensions Owner s Manual and Service Guide GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP RECOMMENDED SIDE TILT 25 GRADE or 14 MAX 25 GRADE or 14 MAX TURNING CLEARANCE DIAMETER 19 ft 5 8 m Fig 37 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter Owner s Manual and Service Guide Page 35 GENERAL SPECIFICATIONS Notes Page 36 Owner s Man
35. DO NOT MAKE ANY SUCH MODIFICATION OR CHANGE TGTSP PROHIBITS AND DISCLAIMS RE SPONSIBILITY FOR ANY SUCH MODIFICATIONS OR ANY OTHER ALTERATION WHICH WOULD ADVERSE LY AFFECT THE SAFETY OF VEHICLE OR BATTERY CHARGER VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR BAT TERY CHARGER IS ABUSED OR OTHERWISE NOT USED IN ITS INTENDED MANNER IS IN AN ACCIDENT OR COLLISION SHOWS INDICATIONS THAT THE SPEED GOVERNOR WAS ADJUSTED OR MODIFIED AL LOWING THE VEHICLE TO OPERATE BEYOND TGTSP S SPECIFICATIONS SHOWS INDICATIONS THAT IT HAS BEEN ALTERED OR MODIFIED IN ANY WAY FROM TGTSP SPECIFICATIONS INCLUDING BUT NOT LIMITED TO ALTERATIONS TO THE SPEED BRAKING SYSTEM STEERING OR OTHER OPERATING SYS TEMS OF THE VEHICLE OR SHOWS INDICATIONS THAT ROUTINE MAINTENANCE WAS NOT PERFORMED WHEN AND IN THE MANNER SPECIFIED IN THE TGTSP MAINTENANCE MANUAL THIS WARRANTY SHALL BE VOID WITH RESPECT TO ANY DEFECT OR DAMAGE CAUSED BY OR AS A RESULT OF OR RELATED TO PARTS OR ACCESSORIES WHICH ARE NOT MANUFACTURED OR AUTHORIZED BY TGTSP OR WERE NOT INSTALLED PER TGTSP S INSTRUCTIONS OR FOR GASOLINE VEHICLES THE USE OF NON RECOM MENDED FUELS AND LUBRICANTS FOR FURTHER INFORMATION CALL 1 706 798 4311 OR WRITE TO TEXTRON GOLF TURF amp SPECIALTY PRODUCTS ATTENTION WARRANTY DEPARTMENT P O BOX 388 AUGUSTA GEORGIA 30903 0388 Owner s Manual and Service Guide Page 39 2003 INTERNATIONAL WARRANTY ALL COUNTRIES
36. DS 76113 Freedom TXT HP 76103 Product Description Off Road Golf Car Serial Number 1400000 and above Vehicles in the above series which bear the CE mark on the serial plate conforms with the essential health and safety requirements of the following directives Machinery Directive 98 37 EC Battery and Accumulator Directive 91 157 EEC Electromagnetic Compatibility Directive 89 336 EEC 92 31 EEC Location Augusta GA U S A Date September 19 2002 IER a Anil V Kulkarni Vice President of Engineering E Z GO Textron Golf Turf amp Specialty Products 1451 Marvin Griffin Road Augusta GA 30906 U S A SYSTEMS Iso 9001 431103423 QUALITY Bob Cat Brouwer Bunton Cushman E Z GO eJacobsen Ransomes Ryan Steiner Page 52 Owner s Manual and Service Guide DECLARATION OF CONFORMITY 22451 EEE Company 1451 Marvin Griffin Road Vice President of Engineering Augusta GA 30906 706 798 4311 Textron Golf Turf amp Specialty Products 706 771 4602 Fax DECLARATION OF CONFORMITY MODEL NAME MODEL MODEL NAME MODEL NUMBER NUMBER Industrial 875E 34301 Shuttle 2 2 Freedom TXT G 76106 Industrial 875PE 34500 Shuttle 2 2 Freedom TXT E 76105 Industrial 875AE 34501 Shuttle 4 6E 76126 Industrial 875G 34300 Shuttle 4 6G 76129 Industrial 875PG 34502 Shuttle 4 6 GM 76104 Industrial 875AG 34503 Shuttle 952E 34730 Industrial
37. HANGING Fig 20 Viscosity Chart Fig 21 Clean Top of Engine Fig 22 Remove Qil Filt r s i eee es eee eee Fig 23 Clean Oll Filter 2 5 NE at oA De its ede Saleh d ole cee ses Fig 24 Blowing Out Oil Filter Fig 25 Add Engine Ol 7 ore pi p ERE XE Syene STARTER GENERATOR BELT Fig 26 Checking Belt Tension with Gauge Fig 27 Checking Belt Tension Manually Adjusting the Belt Fig 28 Adjusting Belt Tension BATTERY CLEANING 5 a A Fig 29 Preparing Acid Neutralizing Solution 18 BRAKES Periodic Brake Test for Mechanical Brakes 19 Fig 30 Typical Brake Performance Test sessi enne 19 AIR INTAKE AND COOLING FINS Fig 31 Cleaning Air Intake ode e 20 Fig 32 Cleaning the Cooling Fins sss 92 20 REAR AXLE Checking the Lubricant Level rr etre tnr rhet E ee e enean 20 Fig 33 Add Check and Drain Rear Axle Lubricant sees 20 AIR CLEANER INSPECTION AND 20 Cleaning the Air Filter Element 21 Ig EXKL Air 21
38. NOT approve Distributor Dealer or customer modifications converting E Z GO products into LSV s The Company in addition recommends that all E Z GO products sold as personal transportation vehicles BE OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product On behalf of E Z GO am directing that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the Distributor or Dealer has rea son to believe may be operated in personal transportation applications Information on FMVSS 571 500 can be obtained at Title 49 of the Code of Federal Regulations section 571 500 or through the Internet at the website for the U S Department of Transportation at Dockets and Regulation then to Title 49 of the Code of Federal Regulations Transportation GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur No warnings can take the place of good common sense and prudent driving practices Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined The manufacturer strongly suggests t
39. ON Leaf Springs with Hydraulic Shock Absorbers STEERING Single Reduction Rack amp Pinion STEERING WHEEL Dual Handgrips Pencil Holder amp Scorecard Holder SEATING Cushion Foam Vinyl Cover Hip Restraint Hand Hold Fold Down Rear Facing Seat SEATING CAPACITY TOTAL LOAD CAPACITY Operator amp 3 Passengers 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo SPEED 12 14 mph 19 23 kph CHASSIS Welded Tubular Steel Powder Coated DuraShield BODY Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer STANDARD COLORS with Base Coat Clear Coat Champagne Hunter Green DASH PANEL Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders Tee amp Ball Storage LIGHTING HORN Single Halogen Light Bar Tail amp Brake Lights Horn TIRES 18 x 8 50 8 4 Ply Rated Load Range B TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION 18 22 psi 124 152 kPa 765 Ibs 347 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment Tires Accent Stripes Turf Glide Ash Tray Turf Saver CC Retro Kit Fairway
40. OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Wipe the area around the filter mount with a clean lint free cloth and inspect both filter O rings for damage replace if necessary Install the filter into the engine The filter engages over a short nipple in the engine The filter should slide easily onto the nipple and seat against the engine using light hand pressure only Align the holes in the filter mounting plate with the holes in the engine Install and hand tighten the bolts before tightening them firmly Add slightly less than 1 1 2 quarts 1 4 liters to allow for possible residual oil left in engine Ref Fig 25 on page 17 The oil must be high quality oil that meets or exceeds API SF SG CC standards Ref Fig 39 on page 23 Check oil level on dipstick If necessary continue to add oil slowly and allow time for oil to flow down into engine Check oil level on dipstick Do not overfill CAUTION Do not overfill engine Too much oil may cause smoking or allow oil to enter the air filter enclosure NOTE Both the oil dipstick and fill must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil being discharged into the engine compartment Ref Aco 1 Fig 25 Add Engine Oil Inspect oil fill cap O ring and replace if necessary Install the
41. Product Engineering Augusta GA 30903 0388 et 706 798 4311 E Z GO Division of Textron Inc Fax 706 771 4602 Email charris ezgo textron com DECLARATION OF CONFORMITY We hereby declare that Produc Number Shuttle 2 2 Medalist Electric 76009G01 76017001 76016601 Shuttle 48 Cargo and 6 Passenger 76026G01 Shuttle Gas Cargo and 6 Passenger 76015G01 Shuttle Gas Cargo and 6 Passenger Hyd 76041G01 Product description 4 Wheel off road utility truck Serial number 453900 499999 800 000 9 999 999 conforms with the essential health and safety requirements of the following Directives Machinery Directive 98 37 EC Battery and Accumulator Directive 91 157 EEC Electromagnetic Compatibility Directive 89 336 EEC 92 31 Location Augusta Georgia U S A Date 3 2945 2 o0 Connie Harris V P Product Engineering E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 U S A World s Finest Utility Vehicles for Sports and Industry Owner s Manual and Service Guide Page 51 DECLARATION OF CONFORMITY BAA EE Company 1451 Marvin Griffin Road Vice President of Engineering Augusta GA 30906 706 798 4311 Textron Golf Turf amp Specialty Products 706 771 4602 Fax DECLARATION OF CONFORMITY MODEL NAME F A MODEL NAME F A NUMBER NUMBER 76101 Freedom TXT 76102 TXTE 76080 Freedom TXT E 76100 TXT PDS 76112 Freedom TXT P
42. Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings by a broken socket when removing wheels use only sockets designed for impact wrench use Use caution when inflating tires Overinflation could cause the tire to separate from the wheel or cause the tire to explode either of which could cause severe injury Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seconds Over inflation could cause the tire to separate from the wheel or cause the tire to explode Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor appli cations with major use on grassy areas the following should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower pressure reduces the possibility of tires cutting into the turf For vehicles being used on paved or hard sur faces tire inflation pressure should be in the higher allowable range but under no condition should inflation pressure be higher than recommended on tire sidewall All four tires should have the same pressure for opti mum handling characteristics Be sure to install the valve dust cap after checking or inflating The vehicle is fitted with low pressure tubeless tires mounted on one piece rims therefore the m
43. S AND RELATED PARTS CONTAIN LEAD Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WASH HANDS AFTER HANDLING NING Battery posts terminals and related WASH HANDS AFTER HANDLING accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WARNING WARNING WARNING WARNING SHARP TURN SHARP TURN STEEP HILL APPLY BRAKE TO LIMIT SPEED e gh elg M 14 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 14 APPLY BRAKE TO LIMIT SPEED APPLY BRAKE TO LIMIT SPEED Be sure that this manual remains as part of the permanent service record should the vehicle be sold NOTES CAUTIONS AND WARNINGS Throughout this guide NOTE CAUTION and WARNING will be used NOTE A NOTE indicates a condition that should be observed CAUTION A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a hazardous condition that could result in severe injury or death Observe these NOTES CAUTIONS and WARNINGS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe Engine exhaust from this PNE NE product contains chemi cals known in certain quantities to cause cancer
44. SPECIFICATIONS STANDARD EQUIPMENT BATTERY ENGINE TRANSAXLE TRANSMISSION FUEL TANK BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS DASH PANEL LIGHTING HORN TIRES TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION FEATURES TXT GASOLINE FREEDOM HP SE One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump 10 67 1 Helical Geared with Neutral Lock amp Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 Gallon 23 Liters Tank 36 Ibs 16 kg Fuel Weight Dual Rear Wheel Self Adjusting Mechanical Drum Brakes Automatic Parking Brake Release with Self Compensating System Leaf Springs with Hydraulic Shock Absorbers Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack amp Pinion Dual Handgrips Pencil Holder amp Scorecard Holder Cushion Foam Vinyl Cover Hip Restraint Hand Hold Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 16 18 mph 26 29 kph Welded Tubular Steel Powder
45. TACT US NORTH AMERICA TECHNICAL ASSISTANCE amp WARRANTY PHONE 1 800 774 3946 FAX 1 800 448 8124 SERVICE PARTS PHONE 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 INTERNATIONAL PHONE 010 1 706 798 4311 FAX 010 1 706 771 4609 E Z GO DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN ROAD AUGUSTA GEORGIA USA 30906 3852 Owner s Manual and Service Guide Page i GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America USA as a World Vehicle 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 at 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 BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C Page ii Owner s
46. Way Flasher Weather Protection Enclosure Wheel Covers 8 Chrome Wheel Covers 6 Moon Wheel Covers Spoke Silver and Black Wheel Covers Spoke Gold and Black Wheels 10 Alloy with Pro Tour Tires Windshield One Piece Top Required Windshield Fold Down Top Required Turf Glide Windshield Rear Turf Saver Wood Grain Dash with Locking Glove Box Fairway Doors USA Trail Top Sun Canopy Owner s Manual and Service Guide Page 31 GENERAL SPECIFICATIONS STANDARD EQUIPMENT TXT GASOLINE FREEDOM HP LE 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve BATTERY One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve ENGINE Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump TRANSAXLE 10 67 1 Helical Geared with Neutral Lock amp Ground Speed Governor TRANSMISSION Automatic Continuously Variable Transmission CVT FUEL TANK 6 Gallon 23 Liters Tank 36 1 5 16 kg Fuel Weight BRAKES Dual Rear Wheel Self Adjusting Mechanical Drum Brakes PARKING BRAKE Automatic Parking Brake Release with Self Compensating System FRONT SUSPENSION Leaf Springs with Hydraulic Shock Absorbers REAR SUSPENSION Leaf Springs with Hydraulic Shock Absorbers STEERING Single Reduction Rack amp Pinion STEERING WHEEL Dual Handgrips Pencil Holder amp Scorecard Holder
47. a that is not adequate ly ventilated Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark Store vehicle in a clean dry area Do not store in same area as a Stove furnace water heater or other appliance that uses a pilot light or has a device that can create a spark When refueling inspect the fuel cap for leaks or breaks that could result in fuel spillage Always wear safety glasses while refueling to pre Page 22 vent possible eye injury from gasoline or gasoline vapor Keep hands clothing and jewelry away from mov ing parts Use care not to contact hot objects Raise the rear of the vehicle and support on jack stands before attempting to run the engine Preparing the engine for a prolonged storage period 30 days or more calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corro sion in the engine Raise the rear of the vehicle and support on jack stands Refer to Lifting the Vehicle for proper lift ing procedure and safety information e Disconnect the fuel hose at the fuel tank and plug hose With proper ventilation depress the accelerator pedal and allow engine to run until it stops due to lack of fuel Remove spark plugs Refer to SPARK PLUGS on page 21 and pour about 1 oz 30 ml of engine oil into each cylinder Replace spark plugs ground spark plug wires and use starter to turn engine over a few s
48. ad all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings SUN TOP AND WINDSHIELD The sun top does not 1 provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects The sun top and windshield provide some protection from the elements however they will not keep the opera tor and passenger dry in a downpour This vehicle is not equipped with seat belts and the sun top has not been designed to provide roll over protection In addition the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs Keep arms and legs inside of vehicle while it is moving VEHICLE CLEANING AND CARE VEHICLE CLEANING To reduce the possibility AWARNINGA of severe injury or vehi cle damage read and understand all instructions supplied by manufacturer of pressure washer CAUTION When pressure washing exterior of vehicle do not use pressure in excess of 700 psi To reduce the possibility of cosmetic damage do not use any abrasive or reactive solvents to clean plastic parts It is important that proper techniques and cleaning mate rials be used Using excessive water pressure may cause severe injury to operator or bystander damage to seals plastics seat material body finish or electrical sys tem Do not use pressure in excess of 700 ps
49. affic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the car rier under control at all times 5 5 2 Yield the right of way to pedestrians ambu lances fire trucks or other carriers or vehicles in emer gency situations 5 5 3 Do not pass another carrier or vehicle travel ing in the same direction at intersections blind spots or at other dangerous locations 5 5 4 Keep a clear view of the path of travel observe other traffic and personnel and maintain a safe clearance 5 5 5 Slow down or stop as conditions dictate and activate the sound producing warning device at cross aisles and when visibility is obstructed at other locations 5 5 6 Ascend or descend grades slowly 5 5 7 Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up and down 5 5 8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in a safe manner 5 5 9 Make starts stops turns or direction rever sals in a smooth manner so as not to shift the load endanger passengers or overturn the carrier 5 5 10 Do not indulge in dangerous activities such as stunt driving or horseplay 5 5 11 Slow down when approaching or on wet or slippery surfaces 5 5 12 Do not drive carrier onto any elevator unless specifically authorized to do so Approach elevators slowly
50. age 13 as an evalua tion of braking system performance It is useful as a method of identifying subtle loss of performance over time Periodic Brake Test for Mechanical Brakes The purpose of this test is to compare the braking perfor mance of the vehicle to the braking performance of new or known to be good vehicles or to an established acceptable stopping distance Actual stopping distances will be influenced by weather conditions terrain road surface condition actual vehicle weight accessories installed and vehicle speed No specific braking distance can be reliably specified The test is conducted by latch ing the parking brake to eliminate different pedal pres sures and to include the affects of linkage mis adjustment Establish the acceptable stopping distance by testing a new or known to be good vehicle and recording the stopping location or stopping distance For fleets of vehi cles several vehicles should be tested when new and the range of stopping locations or distances recorded Over time a subtle loss of performance may NOTE take place therefore it is important to establish the standard with a new vehicle Drive the vehicle at maximum speed on a flat dry clean paved surface Ref Fig 30 on page 19 Quickly depress the brake pedal to latch the parking brake at the line or marker in the test area and remove foot from pedal The vehicle should stop aggressively The wheel brakes may or may not lo
51. aged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic VENTILATION Always store gasoline vehicles in a well ventilated area Ventilation prevents gasoline fumes from accumulating Never fuel a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furnaces Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal Owner s Manual and Service Guide Page ix SAFETY INFORMATION Notes Page x Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings GENERAL The following text is provided as recommended by part Il of American Society of Mecha
52. ands under the frame crossmember as indicated Lower the jack and test the stability of the vehicle on all four jack stands If only the front or rear of the vehicle is to be raised place the chocks in front and behind each wheel not being raised to stabilize the vehicle Lower the vehicle by reversing the lifting sequence Owner s Manual and Service Guide Center of 5544 Pd Front Axle NOE Flat Portion of Frame Outside End of Rear Axle as Ref Liv 1 View from Underside of Vehicle Fig 9 Lifting the Vehicle WHEELS AND TIRES Tire Repair Tool List Qty Required LUG 1 Impact socket 3 4 1 2 1 Impact wrench 1 2 1 Torque wrench 1 2 1 A tire explosion can AWARNING A cause severe injury or death Never exceed inflation pressure rating on tire sidewall To reduce the possibility of tire explosion pres surize tire with small amount of air applied inter mittently to seat beads Due to the low volume of the small tires overinflation can occur in sec onds Never exceed the tire manufacturer s rec ommendation when seating a bead Protect face and eyes from escaping air when removing valve core To reduce the possibility of severe injury caused Page 7 OPERATION AND SERVICE INFORMATION
53. as the atmo sphere shall be maintained within limits specified in the American Conference of Governmental Industrial Hygienists publication Threshold Limit Values for Chemical Substances and Physical Agents in the Work room Environment This shall be accomplished by venti lation provided by the user and or the installation use and proper maintenance of emission control equipment recommended or provided by the manufacturer of the equipment 4 9 Warning Device s 4 9 1 The user shall make periodic inspections of the carrier to be certain that the sound producing and or visual device s are maintained in good operating condi tion 4 9 2 The user shall determine if operating condi tions require the carrier to be equipped with additional sound producing and or visual devices and be responsi ble for providing and maintaining such devices in accor dance with the manufacturer s recommendations 5 OPERATING SAFETY RULES AND PRACTICES 5 1 Personnel and Burden Carrier Operator Qualifications 5 1 1 Only persons who are trained in the proper operation of the carrier shall be authorized to operate the carrier Operators shall be qualified as to visual auditory physical and mental ability to safely operate the equip ment according to Section 5 and all other applicable parts of this Standard 5 2 Personnel and Burden Carrier Operators Training 5 2 1 The user shall conduct an operators training program 5 2 2 Successfu
54. ator light is located on the dash panel Ref Fig 2 on page 2 The light illuminates when the oil pressure is low Check oil level If oil level is between ADD and FULL mark on dipstick a mechanical problem exists within the engine and the vehicle must Page 2 Ref Chk 1 Fig 4 Choke not be driven Contact a local distributor or authorized branch CAUTION To prevent engine damage do not oper ate engine until oil pressure is correct ed Do not overfill engine Too much oil may cause smoking or allow oil to enter the air filter enclosure If oil level is below ADD mark on dipstick add oil to bring level to FULL mark Drive vehicle a short distance and check oil pressure If oil light does not come on continue to use vehicle ACCELERATOR PEDAL Unintentional movement AWARNINGA of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death With the key switch ON depressing the accelerator pedal starts the engine When the pedal is released the engine will stop Ref Fig 5 on page 3 To stop the vehi cle more quickly depress the service brake If key switch is ON and park brake is set depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death Depressing the accelerator pedal will release the park brake if it is engaged T
55. be permitted to maintain repair adjust and inspect carriers c Before undertaking maintenance or repair follow the manufacturer s recommendations for immobilizing the carrier d Block chassis before working underneath it e Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with grav ity feed fuel systems be sure shutoff valve is closed and run engine until fuel system is depleted and engine stops running f Before disconnecting any part of the engine fuel system of LP gas powered carriers close the LP gas inder valve and run the engine until fuel in the system is depleted and the engine stops running g Operation to check performance of the carrier shall be conducted in an authorized area where safe clear ance exists h Before commencing operation of the carrier follow the manufacturer s instructions and recommended pro cedures i Avoid fire hazards and have fire protection equip ment present in the work area Do not use an open flame to check level or leakage of fuel battery electrolyte or coolant Do not use open pans of fuel or flammable cleaning fluids for cleaning parts j Properly ventilate the work area k Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use I Brakes steering mechanisms speed and direc tional control mechanisms wa
56. c tions with forced air Reinstall the wires Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings REPAIR LIFTING THE VEHICLE Tool List Qty Required Floor 1 SEIo gri c 4 4 Some servicing operations may require the front wheels the rear wheels or the entire vehicle be raised To reduce the possibility IW of severe injury or death from a vehicle falling from a jack Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test the stability of the vehi cle on the stands Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process CAUTION When lifting vehicle position jacks and jack stands at the areas indicated only To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 9 on page 7 Center the jack under the rear frame crossmember Raise the vehicle enough to place a jack stand under the outer ends of the rear axle Lower the jack and test the stability of the vehicle on the two jack stands Place the jack at the center of the front axle Raise the vehicle enough to place jack st
57. ccordance with the Peri odic Service Schedule while the engine is warm See SERVICE AND MAINTENANCE for checking oil level and changing oil procedures Maximum oil level DO NOT OVERFILL Full operating range Ref Dsk 1 Fig 7 Check Oil Level on Dipstick Page 4 COLD STARTING Starting a cold engine may require use of the choke Depress the accelerator approximately 1 2 5 cm or until the starter just begins to operate Pull the choke out if required Accelerate slowly and push the choke in com pletely when the engine runs smoothly Do not allow the starter to operate con CAUTION tinuously for more than 10 seconds Allow 30 seconds between starting attempts If the vehicle does not start on the third attempt turn the key switch off set the park brake and determine the cause of the problem If the vehicle had been running and the engine does not start within 10 seconds use the choke STARTING AND DRIVING To reduce the possibility ZN EIN EY INL of roll back which could result in severe injury or vehicle damage do not release service brake until engine has started To operate vehicle Apply the service brake place the key in the key switch and turn it to the ON position Move the direction selector to the direction desired Release the park brake by depressing the service brake pedal until the park brake releases Slowly depress the accelerator pedal to start the engine Release
58. ck Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched The vehicle should stop within the normal range of stopping distances If the vehicle stops more than 4 ft 1 2 m beyond the accept able stopping distance or pulls to one side the vehicle has failed the test and should be tested again If the vehicle fails the second test it should immediately be removed from service The vehicle must be inspected by a qualified mechanic who should refer to the TROU BLESHOOTING section in the Technicain s Repair and Service Manual Page 19 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings AIR INTAKE AND COOLING FINS To prevent possible P ANINE burns engine parts should be kept clean to reduce risk of overheating and ignition of accumulat ed debris After every off road use allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins Dirt and debris may clog the engine s air cooling system Clean areas shown to prevent engine damage Ref Fig 31 on page 20 Ref Fig 32 on page 20 Keep linkages springs and controls clean Keep area around muffler free of any combustible material Fig 32 Cleaning the Cooling Fins REAR AXLE The rear axle is provided with a lubricant level check plug
59. dule TIRE INSPECTION Tire condition should be inspected per the Periodic Ser vice Schedule Ref Fig 17 on page 13 Inflation pres sures should be checked when the tires are cool Be sure to install the valve dust cap after checking or inflating CHECKING THE OIL LEVEL Do not overfill engine Too much oil CAUTION may cause engine to smoke or spark plug fouling When adding oil between oil changes do not NOTE mix brands and viscosity grades of oil Both the oil dipstick and fill cap must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil becoming contaminated and or oil being discharged into the engine compartment The oil should be checked with the engine warm The vehicle must be on a level surface with the park brake engaged Allow adequate time for oil to drain into the crankcase before checking Remove the dipstick and wipe off the entire area indi cated with a lint free cloth Ref Fig 18 on page 15 Ref Ced 1 Fig 18 Clean Entire Dipstick Insert the dipstick fully into the dipstick hole and remove Examine the level of oil on the dipstick Owner s Manual and Service Guide The engine can be operated safely as long as oil is within the safe operating range as indicated on the dipstick Do not operate vehicle if oil level is below the safe area indicated on the dipstick Ref Fig 19 on page 15 Maximum oil level DO NOT OVERFILL Full operating
60. e On aHill Froma Brake With Release Releasing Service Brake As Stopped Position Left Foot Park Brake Vehicle Starts 74443G01 See Following 74443G01 Pages For Explanation Of These Pictograms 1 2 Ref Lal 2 1 Appendix A 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms 23 27 18 20 22 17 15 74093G01 THIS VEHICLE IS EQUIPPED WITH A NEGATIVE GROUND SYSTEM NEVER ALLOW THE POSITIVE BATTERY POST OR CABLE TO CONTACT THE FRAME AS THIS COULD RESULT IN A BATTERY EXPLOSION AND SERIOUS PERSONAL INJURY 24876G01 DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE GOVERNOR FAILURE TO COMPLY COULD RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY 24880G01 See Following Pages For Explanation Of Pictogram 49 A WARNING A 27653G01 Ref Lal 2 2 Raise Seat To Find These Labels Located On The Air Cleaner And Chassis Owner s Manual and Service Guide See Following Pages For Explanation Of Pictogram 30 AWARNING A Windshields do not provide protection from golf balls or other flying objects EGWHL14 Appendix A 3 LABELS AND PICTOGRAMS WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL READ MANUAL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED
61. e Pay particular attention to all Notes Cautions and Warnings Make sure that the direction selector is in correct position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operat ing in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehicle is in motion RUN IN Check for oil or fuel leaks that could have developed in shipment from the factory Avoid full throttle starts and rapid acceleration until the engine has achieved operat ing temperature All engines consume more oil than normal during the first hours of operation As internal moving parts are run in oil consumption should gradually decrease until the rate of consumption stabilizes Check the oil level per the Periodic Service Schedule Ref Fig 17 on page 13 Add oil if the level on the dip stick indicates that oil is in the add oil range Ref Fig 7 on page 4 Do not overfill engine Too much oil CAUTION may cause smoking or allow oil to enter the air filter enclosure Both the oil dipstick and fill cap must be in NOTE place before operating the engine Failure to install the dipstick and fill cap will result in oil becoming contam inated and or being discharged into the engine compartment The oil should be changed in a
62. e carrier becomes unsafe in any way the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating con dition 5 7 3 Do not make repairs or adjustments unless specifically authorized to do so 5 7 4 The engine shall be stopped and the operator shall leave the carrier while refueling 5 7 5 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before starting engine 5 7 6 not operate a carrier with a leak in the fuel System or battery s 5 7 7 not use open flames for checking electro lyte level in storage battery s or liquid level in fuel tanks 6 MAINTENANCE PRACTICES 6 1 Introduction Page xiii SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 6 1 1 Carriers may become hazardous if mainte nance is neglected Therefore maintenance facilities trained personnel and procedures shall be provided Such facilities may be on or off the premises 6 2 Maintenance Procedures 6 2 1 Maintenance and inspection of all carriers shall be performed in conformance with the manufac turer s recommendations and the following practices a A scheduled preventive maintenance lubrication and inspection system shall be followed b Only qualified and authorized personnel shall
63. econds to distribute oil e Add a gasoline additive to the tank in accordance with the manufacturer s recommendations e Reattach fuel line to tank and drive the vehicle for several minutes to circulate the additive through the carburetor While engine is still warm change oil Refer to CHANGING THE OIL on page 15 Clean body chassis and engine of debris mud chaff or grass Refer to AIR INTAKE AND COOL ING FINS on page 20 HARDWARE Periodically the vehicle should be inspected for loose fasteners Fasteners should be tightened in accordance with the Torque Specifications table Ref Fig 38 on page 23 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 vehi cle 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 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 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 o
64. ed built and equipped to conform at the time of initial sale to all applicable regu lations of the U S Environmental Protection Agency EPA and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period For the components listed under PARTS COVERED the distributor dealer or service provider authorized by Tex tron Golf Turf amp Specialty Products will at no cost to you make the necessary diagnosis repair or replacement necessary to ensure that the engine complies with applicable U S EPA regulations EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of 2 years PARTS COVERED Listed below are the parts covered by the Emission Component Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system ii Air fuel ration feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assembly gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spa
65. ed to the engine and may be accessed by raising the seat Inspect and replace air fil ter in accordance with the Periodic Service Schedule Ref Fig 17 on page 13 The air cleaner element is accessible by unsnapping top clips from the air box and swinging the cover open Remove cover and air filter ele ment Ref Fig 34 on page 21 Clean inside of cover and Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Front and back sides of air filter seal may be lubricated with petroleum jelly Front and back sides of tabs may be lubricated with petroleum jelly Ref Air 1 Fig 34 Air Cleaner enclosure Install the new element in the same way the old filter was removed being sure that the filter seal is correctly installed Insert cover into the lower portion of the enclosure and swing it up into place Squeeze hous ing together and secure with top clips Be sure cover fits under tabs and all clips are fastened securely Cleaning the Air Filter Element Do not use compressed air to clean the CAUTION air filter doing so will damage the filter which may result in damage to the engine 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 LUBRICATION Do not use more than t
66. ems i Electronic controls if applicable 1 Hoses belts connectors and assemblies iii Filter lock assembly gaseous fuel if applicable MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2001 and later Owner s Manual and to retain proof that inspection and maintenance services are performed at the times when recommended FUJI will not deny a warranty claim solely be cause you have no record of maintenance however FUJI may deny a warranty claim if your failure to per form required maintenance resulted in the failure of warranted part The proof which you maintain should be given to each subsequent owner of the engine You are responsible for performing the scheduled main tenance described in the Periodic Service Schedule of this manual The scheduled maintenance is based on the normal engine operating schedule Owner s Manual and Service Guide Page 45 EMISSION WARRANTY CALIFORNIA Notes Page 46 Owner s Manual and Service Guide DECLARATION CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY Owner s Manual and Service Guide Page 47 usus Company Connie S Harris P O Box 388 Vice President Product Engineering Augusta GA 30903 0388 706 798 4311 E Z GO Division of Textron Inc Fax 706 771 4602 Email charris ezgo textr
67. er to reduce the possibility of can contact ing battery terminals which could result in an explosion Owner s Manual and Service Guide It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recom mended in this manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle both dependable and economical This vehicle will give years of satisfactory service provid ing it receives regular maintenance Refer to the Periodic Service Schedule for appropriate service intervals Ref Fig 17 on page 13 Refer to Lubrication Points for appropriate lubrication locations Ref Fig 36 on page 21 SERIAL NUMBER PLATE LOCATION Early Production The serial number and manufacture date code are located on a plate on the passenger side of the dash housing of the vehicle Ref Fig 15 on page 11 Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manu facture date code serial number and vehicle model must be provided when ordering service parts Fig 15 Serial Number Plate Location Early Produc tion CAUTION To prolong vehicle life some mainte nance items must be serviced more fre quently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions fre quent use with maximum load To access powertrain for routine
68. erchangeable with the original parts and of a quality at least equal to that provided in the original equipment END OF ASME ANSI B56 8 1988 TEXT Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings GENERAL The following text is provided as recommended by part Il of American National Standards Institute National Golf Car Manufacturers Association ANSI NGCMA Z130 1 1993 The manufacturer as a member of the NGCMA strongly endorses the contents of this specification PART II MAINTENANCE AND OPERATIONS 5 GENERAL SAFETY PRACTICES 5 1 Introduction Like other machines golf cars can cause injury if improp erly used or maintained This section contains broad safety practices recommended for safe golf car opera tions Before operation the controlling party should establish such additional specific safety practices as may be reasonably required for safe operations Experience has shown that golf cars which comply with the provisions stated in Part Il of this Standard are safe when properly operated in accordance with the safety and operation warnings affixed to every golf car The safe operation is enhanced when the golf cars are operated within a specific set of operation instructions safety rules and practices established to meet actual operating ter rain and conditions The safety infor
69. ertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed Ref Fig 2 on page 2 If the vehicle is equipped with lights the key switch has a position to operate them indicated by the light icon If the vehicle is equipped with factory installed NOTE custom accessories some accessories remain operational with the key switch in the OFF position Page 1 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Low Oil Pressure RefKes2 Indicator Light Fig 2 Key Light Switch Low Oil Pressure Light and Fuel Gauge DIRECTION SELECTOR CAUTION To reduce the possibility of component damage the vehicle must be complete ly stopped before moving the direction selector Located on the seat support panel this lever permits the selection of either F forward or reverse Ref Fig 3 on page 2 Vehicle should be left in F when unat tended Reverse Forward Ref Dsl 2 Fig 3 Direction Selector CHOKE The choke is used to aid cold starting Ref Fig 4 on page 2 See COLD STARTING section for operating instructions FUEL GAUGE The fuel gauge if equipped will either be located on the dash panel electric Ref Fig 2 on page 2 or directly on the fuel tank mechanical LOW OIL PRESSURE INDICATOR LIGHT A low oil pressure indic
70. es Machinery Directive 98 37 EC Battery and Accumulator Directive 91 157 EEC Electromagnetic Compatibility Directive 89 336 EEC 92 31 Location Augusta Georgia U S A Date 3 23 2 7j Connie Harris V P Product Engineering E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 U S A World s Finest Utility Vehicles for Sports and Industry Owner s Manual and Service Guide Page 49 a Company Connie 5 Harris Box 388 Vice President Product Engineering Augusta GA 30903 0388 706 798 4311 E Z GO Division of Textron Inc Fax 706 771 4602 Email charris ezgo textron com DECLARATION OF CONFORMITY We hereby declare that Product name Freedom TXT HP Gas Product description Four wheeled fleet golf car Product number s 76011G01 Serial number 800 000 9 999 999 conforms with the essential health and safety requirements of the following Directives Machinery Directive 98 37 EC Battery and Accumulator Directive 91 157 Electromagnetic Compatibility Directive 89 336 EEC 92 31 Location Augusta Georgia U S A Date 3 2 1 2c00 ue oh Connie Harris V P Product Engineering E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 U S A World s Finest Utility Vehicles for Sports and Industry Page 50 Owner s Manual and Service Guide a Company Connie S Harris P O Box 388 Vice President
71. f cars or around batteries 6 2 5 7 Brakes steering mechanisms warning devices Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings governors and all other safety devices shall be inspected and maintained in a safe and proper operating condition and shall not be modified as supplied by the manufac turer 6 2 5 8 After each maintenance or repair the golf car shall be driven by qualified trained and authorized per sonnel to ensure proper operation and adjustment 6 2 5 9 Driving golf car to check for proper operation and adjustment after repair shall be performed in an area that is free of vehicular and pedestrian traffic 6 2 5 10 Record all maintenance performed in a mainte nance record log by date name of person performing maintenance and type of maintenance Controlling party management should periodically inspect maintenance log to ensure currency and completeness of entries 6 2 5 11 Provide operator comment cards to assist in identifying non periodic maintenance needs for specific golf cars 6 2 6 The controlling party shall maintain in a legible condition all nameplates warnings instructions which are supplied by the manufacturer 6 2 7 The controlling party shall not perform any modifi cation or addition which affects capacity or safe opera tion or make any change not
72. f the body shall remain within the plan view outline of the carrier 5 4 3 When a carrier is to be left unattended stop carrier apply the parking brake stop the engine or turn off power turn off the control or ignition circuit and remove the key if provided Block the wheels if machine is on an incline 5 4 4 carrier is considered unattended when the operator is 25 ft 7 6 m or more from the carrier which remains in his view or whenever the operator leaves the carrier and it is not within his view When the operator is dismounted and within 25 ft 7 6 m of the carrier still in his view he still must have controls neutralized and the parking brake s set to prevent movement 5 4 5 Maintain a safe distance from the edge of ramps and platforms 5 4 6 Use only approved carriers in hazardous loca tions as defined in the appropriate safety standards 5 4 7 Report all accidents involving personnel Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings building structures and equipment 5 4 8 Operators shall not add to or modify the car rier 5 4 9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles access to stairways or fire equipment 5 5 Traveling 5 5 1 Observe all traffic regulations including autho rized speed limits Under normal tr
73. f 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 4 8 15 24 35 55 75 130 125 Grade 2 11 20 33 47 75 102 176 169 13 23 35 55 80 110 200 320 18 31 47 75 108 149 271 434 18 35 55 80 110 170 280 460 24 75 149 230 380 624 BOLT SIZE Class 5 8 Grade 2 Ns 8 Class 8 8 Grade 5 Class 10 9 Grade 8 10 9 Ref Tsp 1 Fig 38 Torque Specifications CAPACITIES AND REPLACEMENT PARTS 6 0 gal 22 5 liters 87 Octane Spark Plugs BPRAES P N 25523 G3 020 030 71 76 mm Gap Ref Cap 2 Fig 39 Capacities and Replacement Parts Owner s Manual and Service Guide Page 23 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes Page 24 Owner s Manual and Service Guide GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner s Manual and Service Guide Page 25 GENERAL SPECIFICATIONS STANDARD EQUIPMENT BATTERY ENGINE TRANSAXLE TRANSMISSION FUEL TANK BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS DASH PANEL TIRES TIRE PRESSURE
74. g Brake Release with Self Compensating System Leaf Springs with Hydraulic Shock Absorbers Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack amp Pinion Dual Handgrips Pencil Holder amp Scorecard Holder Cushion Foam Vinyl Cover Hip Restraint Hand Hold Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 15 mph 23 kph Welded Tubular Steel Powder Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with Base Coat Clear Coat Champagne Hunter Green Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders Tee amp Ball Storage Single Halogen Light Bar Tail amp Brake Lights Horn 18 x 8 50 8 4 Ply Rated Load Range B 18 22 psi 124 152 kPa 679 Ibs 308 kg Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator Center Basket WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Caddy Kit Accent Stripes Ash Tray Bag Cover Basket Side Bunker Rake with Holder CE Package Cooler Jug No Side Basket i Divot Repair Sand Container amp Scoop Tires Requires Side Basket Di
75. g for loose connections and broken missing insulation ACCELERATOR V Check for smooth movement DO NOT LUBRICATE CABLE SERVICE BRAKE MECHANICAL BRAKES Conduct brake performance test PARK BRAKE Check brake performance and adjust if required CHOKE CABLE Check for smooth movement and adjustment DO NOT LUBRICATE CABLE CARBURETOR LINKAGE Check attachment adjust as required DIRECTION SELECTOR Check attachment adjust as required ENGINE V Check for unusual noise vibration acceleration oil leaks COOLING FAN X Check for build up of foreign matter inside blower housing and fins clean if required STEERING ASSEMBLY Check for abnormal play tightness of all hardware TIE ROD LINKAGES Check for excessive play bent components or loose connections REAR AXLE Check for leakage add SAE 30 oil as required QUARTERLY 50 HOURS includes items listed in previous tables amp the following FRONT AXLE Check for damage to axle and loose or missing hardware Fig 17 Periodic Service Schedule Owner s Manual and Service Guide Page 13 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings FRONT SHOCK ABSORBERS V Check for oil leakage and loose fasteners FRONT SPRINGS V Check for loose hardware cracks at attachment
76. ght Marker Turn Light Signal 9 a Ref Har 1 Fig 11 Headlight Turn Signal amp Marker Light Bulb Replacement Rear Fender Tail Light Lens Tail Ligh Ref Tlr 1 Bulb Fig 12 Tail and Brake Light Bulb Replacement do not attempt to jump start a vehicle The vehicle is equipped with a starter generator and does not idle When starting the engine the starter gen erator functions as a starter and with the engine running it functions as a generator With the short running times associated with this kind of vehicle the generator is more than adequate to maintain Owner s Manual and Service Guide the battery charge level The generator is not designed to charge a discharged battery When engine starts the clutches engage and cause vehicle to move making jump starting both dangerous and impractical If the vehicle battery has become discharged it must be charged using a 12 Volt charger that is rated at 10 amps or less Read and understand all instructions provided by the manufacturer of the charger TRANSPORTING VEHICLE TOWING To reduce the possibility of severe injury or death Use extra caution when towing a vehicle Do not ride on vehicle being towed Do not attempt to tow the vehicle with ropes chains or any device other than a factory approved tow bar Do not tow vehicle on highways Do not tow a single vehicle at speeds in excess of 12 mph 19 kph
77. hat all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein If you have any questions regarding this vehicle contact your closest representative or write to the address on the back cover of this publication Attention Product Service Department The manufacturer reserves the right to make design changes without obligation to make these changes on units previ ously sold and the information contained in this manual is subject to change without notice The manufacturer 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 s for safety and performance requirements These vehicles are designed and manufactured for off road use They do not conform to Federal Motor Vehicle Safety Owner s Manual and Service Guide Page vii SAFETY INFORMATION Standards of the United States of America USA and are not equipped for operation on public streets Some commu nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi nances Refer to GENERAL SPECIFICATIONS for vehicle seating capacity Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase the speed beyond the factory specification Such modifications
78. here it will attack the metal structure or the concrete asphalt floor Additionally a residue will be left on the battery which is conductive and will contribute to the discharge of the battery Page 18 To reduce the possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from the battery The correct cleaning technique is to spray the top and sides of the battery with a solution of sodium bicarbonate baking soda and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or a plastic spray bottle The solution should consist of the amounts of sodium bicarbonate baking soda and clear water shown below Ref Fig 29 on page 18 In addition to the battery special attention should be paid to metal components adjacent to the bat tery which should also be sprayed with the sodium bicar bonate baking soda solution 1 1 2 gallons 6 liters Clear Water C 1 quart lt _ gt 1 liter Clear Water 2 Teaspoons 10 ce Sodium Baking Soda 1 4 Cup 60 ml Sodium Bicarbonate Baking Soda Bicarbonate Plastic 2 Gallon Spray 7 5 liter Bottle Garden Sprayer Ref Pns 1 Fig 29 Preparing Acid Neutralizing Solution Allow the solution to sit for at least three minutes use a soft bristle brush or cloth to wipe
79. hicle Dimensions Incline Specifications and Turning Clearance Diameter 35 LIMITED WARRANTIES 5 2 37 DOMESTIC WARRANTY nente ene heec eb db 38 INTERNATIONAL WARRANTY 2002 2 22 4 2 00000000000000 00000 00 00 39 Owner s Manual and Service Guide TABLE CONTENTS INTERNATIONAL WARRANTY 2003 FEDERAL EMISSION COMPONENT DEFECT WARRANTY CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 43 DECLARATION OF CONFORMITY EUROPE 47 PIE GONE CAR 2000 o teh MS p I E OS UG E A FREEDOM GOLF FREEDOM GOLF CAR 2000 SHUTTLE 242 P000 a in nM le REN Aa etl shat eal Et als FLEET AND FREEDOM GOLF CAR 2002 52 SHUTTLES 2002A Eve een oes are M M M M LM 53 LABELS AND 5 Appendix A Owner s Manual and Service Guide Page v TABLE CONTENTS Notes Page vi Owner s Manual and Service Guide SAFETY INFORMATION This manual has been desig
80. his is a feature to assure the vehi Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Park Service Brake Brake Fig 5 Accelerator and Brake Controls cle is not driven with the park brake engaged Depress ing the accelerator pedal is not the preferred method of releasing the park brake NOTE Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest service life of brake compo nents COMBINATION BRAKE AND PARK BRAKE PEDAL The brake pedal incorporates a park brake feature Ref Fig 5 on page 3 To engage push down on the upper section of the pedal until it locks in place The park brake will release when the service brake pedal is depressed Use the lower section of the brake pedal to operate the service brake system HORN The horn is operated by pushing the horn button located on the floor to the left of the brake pedal Ref Fig 6 on page 3 Fig 6 Horn Button Owner s Manual and Service Guide OPERATING THE VEHICLE CAUTION Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance Read and understand the following warnings before attempting to operate the vehicle To reduce the possibility 19 of severe injury or death resul
81. hree 3 pumps CAUTION of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Putting more than three pumps of grease in a grease fit ting could damage grease seals and cause premature bearing failure Ref Fig 35 on page 21 Ref Fig 36 on page 21 Owner s Manual and Service Guide Ball Joints 2 and Idler Arm King Pin King Pin 0 i lt I o Ball Joint f 3 Ball Joint 4 E Ball Joint on i i 2 Steering Unit Tie Rod Ends Rack Ball Joint Ref Lub 3 View From Underside Of Vehicle Fig 35 Lubrication Points Early Production O Me Rack Ball Joint Ref Lub 1 View From Underside Of Vehicle Fig 36 Lubrication Points Late Production SPARK PLUGS Tool List Qty Required Spark plug socket 13 16 1 2 1 Ratchet 1 2 2 1 Plug gauge wire 1 Anti seize 0 0 00 AR Torque wrench 1 2 drive ft 165 1 Use care not to over tighten the plug CAUTION Over tightening can cau
82. i to wash exterior of vehicle Page 6 Clean windshield with lots of water and a clean cloth Minor scratches may be removed using a commercial plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces Occasional cleaning and waxing with non abrasive prod ucts designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle These mate rials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sedi ment packed in closed areas should be loosened to ease it s removal taking care not to chip or otherwise damage paint NOTE If the engine does not start or runs improperly after washing remove the spark plug wires by pulling the spark plug boots never the wires Dry all conne
83. ide Appendix A 5 LABELS AND PICTOGRAMS OPERATE FROM DRIVERS SIDE ONLY KEEP ARMS AND LEGS WITHIN VEHICLE TURN KEY TO ON MOVE DIRECTION SELECTOR TO FORWARD DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE TURN KEY TO ON MOVE DIRECTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL Ref Pic 1 3 Appendix A 6 TO OPERATE VEHICLE IN FORWARD KEEP CLEAR HAND OR FINGERS CAN BE TRAPPED 42 o NN OFF 44 gt 45 HEADLIGHTS ON POSITION UNLOCKED 46 LOCKED DIFFERENTIAL LOCKED WARNING KEEP ENTIRE BODY INSIDE CAR WARNING POSSIBILE ELECTRIC ARC OR BATTERY EXPLOSION WEAR EYE PROTECTION Owner s Manual and Service Guide Read and understand the following warnings before attempting to operate the vehicle To prevent personal injury or death observe the following When vehicle is to be left unattended engage parking brake move direction selector to F forward position turn key to OFF position and remove key NOTE Drive vehicle
84. ilures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment Before working on the FNIT vehicle remove jewelry rings watches necklaces etc Be sure that no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise rear of vehicle and support on jack stands before attempting to run or adjust powertrain Wear eye protection when working on or around vehicle In particular use care when working around batteries using solvents or compressed air Hydrogen gas is formed
85. improve or change the design of any TGTSP vehicle or battery charger without assuming any responsibility to modify previously manufactured vehicles or battery chargers DISCLAIMER THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES IMPLIED OR EXPRESSED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TGTSP WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISING FROM ANY DEFECT IN THE VEHICLE BATTERY CHARGER No agent employee or representative of TGTSP or any person has any authority to bind TGTSP to any other agree ment representation or warranty concerning the goods sold under this warranty WARNING ANY MODIFICATION OR CHANGE TO THE VEHICLE OR BATTERY CHARGER WHICH ALTERS THE WEIGHT DISTRIBUTION OF THE VEHICLE ITS STABILITY INCREASES THE SPEED OR ALTERS THE OUTPUT OF THE BATTERY CHARGER BEYOND THE FACTORY SPECIFICATION CAN CAUSE PERSONAL INJURY DO NOT MAKE ANY SUCH MODIFICATION OR CHANGE TGTSP PROHIBITS AND DISCLAIMS RE SPONSIBILITY FOR ANY SUCH MODIFICATIONS OR ANY OTHER ALTERATION WHICH WOULD ADVERSE LY AFFECT THE SAFETY OF VEHICLE OR BATTERY CHARGER VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR BAT TERY CHARGER IS ABUSED OR OTHERWISE NOT USED IN ITS INTENDED MANNER IS IN AN ACCIDENT OR COLLISION SHOWS INDICATIONS THAT THE SPEED GOVERNOR WAS ADJUSTED OR MODIFIED
86. in accordance with the owner s manual without the manufacturer s prior written authorization Where authorized modifications have been made the controlling party shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 6 2 8 As required under paragraphs 6 2 6 and 6 2 7 the manufacturer shall be contacted to secure new name plates warnings or instructions which shall then be affixed in their proper place on the golf car Owner s Manual and Service Guide 7 FUELS HANDLING AND STORAGE BATTERY CHARGING 7 1 The controlling party shall supervise the storage and handling of liquid fuels in accordance with applicable fire and safety requirements 7 2 Storage and handling of liquefied petroleum gas fuels shall be in accordance with American Gas Associa tion recommendations and applicable fire safety require ments 7 3 controlling party shall require battery chang ing and charging facilities and procedures to be in accor dance with applicable ordinances or regulations also see paragraph 6 2 3 2 7 4 controlling party shall periodically inspect facilities and review procedures to be certain that the procedures in paragraphs 6 2 3 2 and 7 3 are being fol lowed 8 OPERATING SAFETY RULES AND PRACTICES 8 1 Operator Qualifications 8 1 1 Only authorized persons shall be allowed to oper ate golf cars It is recommended that no persons be
87. ing Bracket Neutral Lock Pin Handle Ref NIk 2 Fig 14 Neutral Lock on Direction Selector HAULING To reduce the possibility AWARNINGA of severe injury or death while transporting vehi cle Secure the vehicle and contents Never ride on vehicle being transported Always remove windshield before transporting Maximum speed with sun top installed is 50 mph 80 kph If the vehicle is to be transported at highway speeds the sun top must be removed and the seat bottom secured When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mount ing points Always remove windshield when transporting Always check that the vehicle and contents are ade quately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehi cle see GENERAL SPECIFICATIONS for vehicle weight and load Lock the park brake and secure the vehicle using ratchet tie downs Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings SERVICE AND MAINTENANCE To reduce the possibility FIZ EW of severe injury or death from improper servicing techniques Do not attempt any type of servicing operations before reading and understanding all notes cau tions and warnings in this manual Any servicing requiring adjustme
88. ions by changing adding to or removing parts from the engine 3 Expenses incurred by processing warranty claims FUJI any authorized dealer distributors and service providers shall not be liable for any loss of use of the engine for any alternative usage for any damage to goods loss of time or inconve nience E HOW TO FILE A CLAIM All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or service providers authorized by Textron Golf Turf amp Specialty Products In the event that any emission related part is found to be defective during the warranty period you should notify Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 and you will be given the appro priate warranty service facilities where the warranty repair is performed F WHERE TO GET WARRANTY SERVICE It is recommended that warranty service be performed by the authorized dealer who sold you the engine although warranty service will be performed by any authorized dealers distributors and service providers anywhere in the United States When warranty repair is needed the engine must be brought to an autho rized dealer distributorship or service provider s place of business during normal business hours In all cas es areasonable time not to exceed 30 days must be allowed for the warranty repair to be completed after the engine is received by the authorized dealer distributor or service
89. ired Windshield Rear GENERAL SPECIFICATIONS STANDARD EQUIPMENT BATTERY ENGINE TRANSAXLE TRANSMISSION FUEL TANK BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS TXT GASOLINE FREEDOM One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump 13 32 1 Helical Geared with Neutral Lock amp Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 Gallon 23 Liters Tank 36 Ibs 16 kg Fuel Weight Dual Rear Wheel Self Adjusting Mechanical Drum Brakes Automatic Parking Brake Release with Self Compensating System Leaf Springs with Hydraulic Shock Absorbers Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack amp Pinion Dual Handgrips Pencil Holder amp Scorecard Holder Cushion Foam Vinyl Cover Hip Restraint Hand Hold Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 15 mph 23 kph Welded Tubular Steel Powder Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with
90. l completion of the operators train ing program shall be required by the user before opera tion of the carrier The program shall be presented in its entirety to all new operators and not condensed for those claiming previous experience Page xii 5 2 3 user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads carrier operator and other employees c general safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were for mulated d introduction of equipment control locations and functions and explanation of how they work when used properly and when used improperly and surface condi tions grade and other conditions of the environment in which the carrier is to be operated e operational performance tests and evaluations during and at completion of the program 5 3 Personnel and Burden Carrier Operator Responsibility 5 3 1 Operators shall abide by the following safety rules and practices in paras 5 4 5 5 5 6 and 5 7 5 4 General 5 4 1 Safeguard the pedestrians at all times Do not drive carrier in a manner that would endanger anyone 5 4 2 Riding on the carrier by persons other than the operator is authorized only on personnel seat s provided by the manufacturer All parts o
91. lame or electrical equipment that could cause an electrical arc Before a new vehicle is put into operation the items shown in the INITIAL SERVICE CHART must be per formed Ref Fig 1 on page 1 Vehicle battery must be fully charged before initial use Owner s Manual and Service Guide Check for correct tire inflation See GENERAL SPECIFI CATIONS Check for oil or fuel leaks that could have developed in shipment from the factory Determine and record braking distance required to stop vehicle for future brake performance tests Remove the protective clear plastic that protect the seat bottom and back rest during shipping before placing the vehicle in service SERVICE OPERATION Battery Charge battery Seats Remove protective plastic covering Brakes Check operation and adjust if necessary Establish acceptable stopping distance Tires Check air pressure see SPECIFICATIONS Fuel Fill tank with correct fuel Engine Check oil level Ref Isc 2 Fig 1 Initial Service Chart CONTROLS AND INDICATORS Vehicle controls and indicators consist of e key light switch direction selector choke e fuel gauge low oil pressure indicator light accelerator pedal combination service and park brake pedal horn KEY LIGHT SWITCH Located on the dash panel this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key To prevent inadv
92. ls will be illustrated This vehicle has been designed and manufactured as a World Vehicle Some countries have individual require ments to comply with their specifications therefore some sections may not apply in your country Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in accordance with the Periodic Service Sched ule Service Parts Manuals and Technician s Repair and Ser vice Manuals are available from a local Distributor an authorized Branch or the Service Parts Department When ordering parts or requesting information for your vehicle provide vehicle model serial number and manu facture date code BEFORE INITIAL USE Read understand and follow the safety label on the instrument panel Be sure you understand how to oper ate the vehicle its equipment and how to use it safely Maintaining good performance depends to a large extent on the operator Hydrogen gas is generat ed as a natural part of the lead acid battery charg ing process A 4 concentration of hydrogen gas is explosive and could cause severe injury or death Charging must take place in an area that is adequate ly ventilated minimum of 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open f
93. mainte nance program in accordance with the manufacturer s recommendations should be established Such a pro gram will be a valuable tool in providing the golfing patron with a safe properly operating golf car and thereby help to avoid accidents 6 2 1 Personnel Only qualified trained and authorized personnel shall be permitted to inspect adjust and maintain golf cars 6 2 2 Parts and Materials Only manufacturers recommended replacement parts and materials shall be used 6 2 3 Ventilation Maintenance and storage areas shall be properly venti lated to avoid fire hazards in accordance with applicable fire codes and ordinances 6 2 3 1 Ventilation for gasoline powered golf cars shall be provided to remove flammable vapors fumes and other flammable materials Consult applicable fire codes for specific levels of ventilation 6 2 3 2 Ventilation for electric powered golf cars shall be provided to remove the accumulation of flammable hydrogen gas emitted during the charging process The amount of hydrogen gas emitted depends upon a num ber of factors such as the condition of the batteries the output rate of the battery charger and the amount of time the batteries are on charge Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic Page xvi liters per car per charge Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets a mini
94. maintenance lift or remove seat For major repair refer to appropriate Tech nician s Repair and Service Manual Some service procedures may require the vehicle to be lifted Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information Late Production Two serial number and manufacture date code plates are on the vehicle One is placed on the body below the Page 11 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings front driver side of the seat The other is located on the chassis between the seat back supports To access it raise the seat and lift up the flap on the access panel Ref Fig 16 on page 12 Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manu facture date code serial number and vehicle model must be provided when ordering service parts Lift Flap on Access Panel Labels Serial Number Ref Spl 3 Fig 16 Serial Number Plate Location Late Produc tion CAUTION To prolong vehicle life some mainte nance items must be serviced more fre quently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions fre quent use with maximum load To access powertrain for routine maintenance lift or remove seat For major repair refer to appropriate Tech
95. mation contained in Part Il is intended to provide the controlling party with basic safety information and to encourage the controlling party to implement a golf car safety program It is suggested and recommended that Part Il be reprinted in the golf car manufacturer s operation and service manuals to encourage safe operations and prac tices at the controlling party s facility 5 2 Safety Survey The controlling party shall perform a safety survey odically and as conditions warrant to their premises to identify areas where golf cars should not be operated and to identify possible hazards Owner s Manual and Service Guide 5 2 1 Steep Grade In areas where steep grades exist golf car operations should be restricted to the designated golf car pathways where possible and shall be identified with a suitable warning giving the following information Warning steep grade descend slowly with one foot on brake 5 2 2 Wet Areas Wet grassy areas may cause a golf car to lose traction and may affect stability Wet areas shall be chained or roped off to prevent golf car operations or be identified by a suitable warning not to operate golf cars in this area due to wet terrain 5 2 3 Sharp Turns Approaches Blind Corners Bridge Sharp turns blind spots bridge approaches and other potentially hazardous areas shall be either chained or roped off to prevent golf car operations or identified with a Suitable warning
96. med by a distributor dealer or service provider au thorized by Textron Golf Turf amp Specialty Products In the event that any emission related part is found to be defec tive during the warranty period you shall notify Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 and you will be advised of the appropriate warranty service providers where the warranty repair can be performed Page 42 Owner s Manual and Service Guide EMISSION WARRANTY CALIFORNIA CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd herein FUJI are pleased to explain the emis sion control system warranty on your 2001 and later small off road engine herein engine In California the engine must be designed built and equipped to meet the State s stringent anti smog standards FUJI must warrant the emission control system on your engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor and the ignition system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists FUJI will repair your engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE The 2001 and later engines are warranted for two 2
97. med by those that are trained and qualified to do so Follow the manufacturer s maintenance procedures for the vehicle Be sure to disable the vehicle before performing any maintenance Disabling includes removing the key from the key switch and removal of a battery wire Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the battery or cover exposed terminals with an insulating material Use specified replacement parts Never use replacement parts of lesser quality Page viii Owner s Manual and Service Guide SAFETY INFORMATION Use recommended tools Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Support the vehicle using wheel chocks and jack stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Empty the fuel tank or plug fuel hoses to prevent fuel leakage Maintain the vehicle in an area away from exposed flame or persons who are smoking Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated Test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic Replace dam
98. ms occur use gasoline with a lower percentage of alcohol or ether Ref Fil 1 Fig 8 Fueling BATTERY CAUTION Excessive use of accessories may drain the battery and leave insufficient reserve to start the vehicle The vehicle uses a combination starter generator to both start the engine and charge the battery The engine will not idle therefore the battery cannot be charged while the vehicle is stopped Do not operate accessory items such as accessory lights radios winch etc exces sively while the vehicle is stopped The generator is capable of supplying 35 amps there fore operation of all accessories could result in the dis charge of the battery even though the engine is running and the generator operating Discharging the battery is known as deep cycling The battery is not a deep cycle model but is a starting battery Multiple deep cycling will result in the premature failure of the battery If the vehicle battery has become discharged it must be charged using a 12 Volt charger that is rated at 10 amps or less and in accordance with all instructions provided by the manufacturer of the charger LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appendix A illus trates and explains pictograms that may appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle Page 5 OPERATION AND SERVICE INFORMATION Re
99. mum of 5 air changes per hour is recommended The controlling party shall consult applicable fire and safety codes for the spe cific ventilation levels required as well as the use of explosion proof electrical apparatus 6 2 4 Maintenance Procedures All maintenance shall be performed in accordance with the manufacturer s recommended maintenance proce dures as outlined in the manufacturer s operation and service manuals 6 2 5 Maintenance Safety Procedures All maintenance shall be performed in accordance with the manufacturer s recommended safety procedures as outlined in the manufacturer s operation and service manuals The following list of recommended safety pro cedures are general in nature and in no way supersede the manufacturer s specific instructions 6 2 5 1 Follow manufacturer s instructions for immobi lizing golf car before beginning any maintenance 6 2 5 2 Block chassis before working underneath golf Car 6 2 5 3 Before disconnecting any part of the fuel sys tem drain the system and turn all shut off valves to the OFF position to prevent leakage or accumulation of flammable fuels in the work area 6 2 5 4 Avoid fire hazards and have fire protection equipment available 6 2 5 5 Before performing any maintenance on an elec tric golf car disable the electrical system in accordance with the manufacturer s instructions 6 2 5 6 Use only properly insulated tools when working on electrically powered gol
100. n Signal with 4 Way Flasher Wood Grain Locking Glove Box Doors WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Caddy Kit Accent Stripes Ash Tray Bag Cover Basket Side Bunker Rake with Holder CE Package Key Switch Custom Key Switch Individually Keyed Long Fender Liners Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Sand Bottle Kit Seating Special Color Cooler Jug No Side Basket Divot Repair Sand Container amp Scoop Requires Side Basket Divot Repair Sand Bottle No Side Basket Full Sound Control Package Hour Meter Owner s Manual and Service Guide Tow Bar Detachable Tow Bar Permanent Weather Protection Enclosure Windshield One Piece Top Required Windshield Rear Page 29 GENERAL SPECIFICATIONS STANDARD EQUIPMENT BATTERY ENGINE TRANSAXLE TRANSMISSION FUEL TANK BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS TXT GASOLINE FREEDOM HP One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled O
101. nd non highway use only Recommended to be operated only by authorized drivers with valid drivers license in 71 1 45G01 Pictograms designated areas All occupants must be seated keep entire body inside vehicle and hold on when vehicle is in motion 1 9 43 44 45 Maximum vehicle payload is 800 Ibs 363 kg including m of 2 persons golf bags options and or accessories sure occupants seated move direction selector to desired position apply service brake turn key accelerate smoothly To release parking PARK brake depress service lower brake pedal To stop release accelerator pedal and apply service brake Before leaving vehicle turn key OFF move the direction selector to forward position and engage parking PARK brake Drive slowly straight up and down slopes and in turns Use extreme care in reverse in congested areas or on wet or loose terrain Do not operate under the influence of drugs or alcohol Vehicle must be serviced by qualified personnel only See label below driver s side storage compartment 27826G01 Avoid standing in front of or behind vehicle No more than 2 occupants per seat Always remain seated and hold on while vehicle is in motion Keep feet legs hands and arms inside the vehicle at all times Do not leave children unattended on seat while vehicle is moving 74132001 74132G01 To Prevent Roll Back 2 Apply Service Fully Depress Accelerator Whil
102. ned to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product To reduce the chance of personal injury or property damage the following must be carefully observed CAUTION Certain replacement parts can be used independently and or in combination with other accessories to modify an E Z GO manufactured vehicle to permit the vehicle to operate at or in excess of 20mph When an E Z GO manufactured vehicle is modified an any way by the Distributor Dealer or customer to operate at or in excess of 20mph UNDER FERERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights rear lights turn signals seat belts top horn and all other modifications for LSV s mandated in FMVSS 571 500 and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571 565 Pursuant to FMVSS 571 500 and in accordance with the State laws applicable in the places of sale and use of the product the Distributor Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV and required to title or register the vehicle as mandated by State law E Z GO will
103. neutral lock is located at the direc tion selector or the rear axle On Rear Axle To operate Position direction selector lever between F and R Turn key switch to OFF Rotate pin on rear axle shift lever as shown Ref Fig 13 on page 10 The pin will snap into a cavity in the differential case When in this position the direction selector remains locked in the neutral position To unlock the direction selector pull the pin out and rotate until the pointed portion of the pin handle fits into the detent position in the rear axle shift lever Unlocked Position Pull out and rotate 180 to lock Pull out and rotate 180 to unlock Fig 13 Neutral Lock on Rear Axle On Direction Selector To operate Turn key switch to OFF and lift seat Pull out and rotate the neutral lock pin handle so that the pointed portion of the handle is to the side of the direction selector cam Ref Fig 14 on page 10 Move direction selector towards the area between F and R During that motion the pin will snap into the hole in the direction selector mounting bracket preventing any movement When in this position the direction selector remains locked in the neutral position To unlock the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction Page 10 Hole in Direction Selector Cam Hole in Direction Selector Mount
104. nical Engineers American National Standards Institute ASME ANSI B56 8 1988 The manufacturer strongly endorses the contents of this specification PART II FOR THE USER 4 GENERAL SAFETY PRACTICES 4 1 Introduction 4 1 1 Like other machines carriers can cause injury if improperly used or maintained Part Il contains broad safety practices applicable to carrier operations Before operation the user shall establish such additional spe cific safety practices as may reasonably be required for safe operation 4 2 Stability 4 2 1 Experience has shown that this vehicle which complies with this standard is stable when properly operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard Some of the conditions which may affect stability are failure of the user to follow safety practices also ground and floor conditions grade speed loading the operation of the carrier with improper loads battery weight dynamic and static forces and the judgement exercised by the carrier operator a The user shall train carrier operators to adhere strictly to the operating instructions stated in this Stan dard b The user shall survey specific operating conditions and environment and establish and train
105. nts to be made to the powertrain while the engine is running must be made with both drive wheels raised and vehicle properly supported on jack stands To reduce the possibility of engine 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 work ing around batteries or using sol vents 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 Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench short ing out a battery which could result in an explo sion 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 skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 sodium bicarbon ate baking soda dissolved in 1 quart 1 liters of water and flushed with water Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal contain
106. nty eligible service being performed Any non authorized replacement part or malfunction of authorized parts due to use of non authorized parts OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual Textron Golf Turf amp Specialty Products recommends that you retain all receipts covering maintenance on Owner s Manual and Service Guide Page 41 EMISSION WARRANTY FEDERAL your engine but Textron Golf Turf amp Specialty Products cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that Textron Golf Turf amp Specialty Products may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to the nearest distributor dealer or service provider authorized by Textron Golf Turf amp Specialty Products when a problem exists If you have any questions regarding your warranty rights and responsibilities you should contact the Textron Golf Turf amp Specialty Products Warranty Department at 1 800 241 5855 for the information THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper use and maintenance of the engine You
107. oil fill cap Run the vehicle for one or two minutes and check the filter for oil leaks Check the oil level again with the vehicle on level ground Oil should be added to bring the level into the safe oper ating range Do not overfill The engine can be operated safely as long as the oil is within the safe operating range as indicated on the dipstick Do not operate vehicle if Owner s Manual and Service Guide oil level is below the safe area indicated on the dip stick STARTER GENERATOR BELT TENSION Tool List Qty Required Belt tension 1 Wrench 9 45 0 1 Wrench 9 16 2 Ratchet 3 8 1 Socket 3 4 3 8 2 1 The starter generator belt tension should be checked after the first 15 20 hours and set to 75 80 Ibs 34 36 kg NOTE A loose belt can cause audible vibration and squeal Tighten a new starter generator belt Ref Fig 39 on page 23 to 90 110 lbs 41 50 kg tension when a gauge is applied half way between the two pulleys Ref Fig 26 on page 17 Ref Cbg 1 Fig 26 Checking Belt Tension with Gauge A new belt may be checked manually A maximum deflection of 3 8 10 mm is acceptable Ref Fig 27 on page 17 _ 3 8 1cm Max Deflection for New Belt 1 2 1 3 cm Max Deflection for Existing Belt Ref Cbm 1 Fig 27 Checking Belt Tension Manually
108. ol Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator Center Basket WARNING Europe Only This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures OPTIONS ACCESSORIES 2 Bag Attachment 4 Bag Attachment 4 Caddy Kit Accent Stripes Ash Tray Bag Cover Basket Side Bunker Rake with Holder CE Package Cooler Jug No Side Basket Divot Repair Sand Container amp Scoop Requires Side Basket Divot Repair Sand Bottle No Side Basket Full Sound Control Package Headlights and Taillights Page 30 Horn Hour Meter Key Switch Custom Key Switch Individually Keyed Long Fender Liners Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Sand Bottle Kit Seating Special Color Tires Turf Glide Turf Saver Fairway Owner s Manual and Service Guide USA Trail Top Sun Canopy Tow Bar Detachable Tow Bar Permanent Turn Signal with 4 Way Flasher Weather Protection Enclosure Wheel Covers 8 Chrome Wheel Covers 6 Moon Wheel Covers Spoke Silver and Black Wheel Covers Spoke Gold and Black Wheels 10 Alloy with Pro Tour Tires Windshield One Piece Top Required Windshield Fold Down Top Required Windshield Rear Wood Grain Dash with Locking Glove Box Doors GENERAL
109. on com DECLARATION OF CONFORMITY We hereby declare that Product name Medalist Gas Medalist Electric TXT Gas TXT Electric TXT PDS Product description Four wheeled fleet golf car Product number s 76007601 76005G01 76002G01 76000601 76059G01 Serial number 800 000 9 999 999 conforms with the essential health and safety requirements of the following Directives Machinery Directive 98 37 EC Battery and Accumulator Directive 91 157 Electromagnetic Compatibility Directive 89 336 EEC 92 3 1 EEC Location Augusta Georgia U S A Date 3 5 j 20606 Connie Harris V P Product Engineering E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 U S A World s Finest Utility Vehicles for Sports and Industry Page 48 Owner s Manual and Service Guide a Wim Company Connie S Harris P O Box 388 Vice President Product Engineering Augusta GA 30903 0388 706 798 4311 E Z GO Division of Textron Inc Fax 706 771 4602 Email charris ezgo textron com DECLARATION OF CONFORMITY We hereby declare that Product name Freedom Medalist Gas Freedom Medalist Electric Freedom TXT Gas Freedom TXT Electric Freedom TXT PDS Product description Four wheeled fleet golf car Product number s 76006601 76004G01 76003G01 76001G01 76060G01 Serial number 800 000 9 999 999 conforms with the essential health and safety requirements of the following Directiv
110. only as fast as terrain and safety considerations allow Consider the terrain and traffic conditions Consider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in a loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc All travel should be directly up or down hills Use extra care when driving the vehicle across an incline Stay in designated areas and avoid steep slopes Use the parking brake whenever the vehicle is parked Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure the direction selector is in correct position before attempting to start the vehicle Slow down before and during turns All turns should be executed at reduced speed Always bring vehicle to a complete stop before shifting the direction selector See GENERAL SPECIFICATIONS for vehicle load and seating capacity Read and understand the following text and NOTE warnings before attempting to service vehicle In any product components will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent fa
111. or Requires Top Sand Bottle Kit Seating Special Color Tires Turf Glide Turf Saver Fairway Owner s Manual and Service Guide Wheel Covers 6 Moon Wheel Covers Spoke Silver and Black Wheel Covers Spoke Gold and Black Wheels 10 Alloy with Pro Tour Tires Windshield One Piece Top Required Windshield Fold Down Top Required Windshield Rear Wood Grain Dash with Locking Glove Box Doors Page 27 GENERAL SPECIFICATIONS STANDARD EQUIPMENT BATTERY ENGINE TRANSAXLE TRANSMISSION FUEL TANK BRAKES PARKING BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING STEERING WHEEL SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED CHASSIS BODY STANDARD COLORS DASH PANEL LIGHTING HORN TIRES TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION FEATURES TXT GASOLINE FREEDOM SE One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump 13 32 1 Helical Geared with Neutral Lock amp Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 Gallon 23 Liters Tank 36 Ibs 16 kg Fuel Weight Dual Rear Wheel Self Adjusting Mechanical Drum Brakes Automatic Parkin
112. ost cost effective way to repair a puncture in the tread is to use a commercial tire plug NOTE Tire plug tools and plugs are available at most automotive parts outlets and have the advan tage of not requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manufacturer s instructions To reduce the possibility of severe injury be sure mounting demounting machine is anchored to floor Wear OSHA approved safety equipment when mounting demounting tires If the tire is to be removed or mounted the tire changing machine manufacturer s recommendations must be fol lowed in order to reduce possibility of severe injury Wheel Installation CAUTION To reduce the possibility of component Page 8 damage do not tighten lug nuts to more than 85 ft Ibs 115 Nm torque NOTE It is important to follow the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten lug nuts in a cross sequence pattern Ref Fig 10 on page 8 Tighten lug nuts to 50 85 ft Ibs 70 115 Nm torque in 20 ft Ibs 30 Nm increments following the cross sequence pat tern Cro
113. r the warranty period Any warranted Owner s Manual and Service Guide Page 43 EMISSION WARRANTY CALIFORNIA part which is scheduled for replacement as required maintenance shall be warranted for the pe riod of time up to the first scheduled replacement point for that part 3 DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective if the diagnostic work is performed at an authorized dealer distributor or service provider 4 CONSEQUENTIAL DAMAGES If a warranted part failed causing damages to other engine components consult a service provid er D WHAT IS NOT COVERED 1 This limited warranty does not cover any part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 2001 and later Owner s Manual in cluding 1 improper or inadequate scheduled engine inspection and maintenance 2 improper or inadequate maintenance of any warranted parts 3 improper installation adjustment or repair of the engine or of any warranted part unless per formed by an authorized dealer 4 failure to follow recommendations on fuel use contained in the 2001 and later Owner s Manual 5 repairs performed outside of the authorized warranty service facilities 6 use of parts which are not authorized by FUJI 2 Add on or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterat
114. ret rre n etre TRANSPORTING VEHICLE 2 oem tenens docena 9 TOWING 9 NEUTRAL LOCK 2 10 On Rear Axle etre 2 10 Fig 13 Neutral Lock on Rear Axle 10 On Direction Selector 2 10 Fig 14 Neutral Lock Direction Selector 2 10 HAULING igiene eee e eu tel ER ee d E eet e 10 SERVICE AND MAINTENANCE sese asas seen errans 11 SERIAL NUMBER PEATEEOGATION 2 2322 ire ied on tende be e te b e adeb 11 Early Production MS 11 Owner s Manual and Service Guide Page iii TABLE CONTENTS Fig 15 Serial Number Plate Location Early Production 11 Late Production ne 11 Fig 16 Serial Number Plate Location Late Production 2 12 PERIODIC SERVICE SCHEDULE a a etur n erc EO e idl HEU Pura cedi see heel 13 Fig 17 Periodic Service Schedule esee nentes 13 TIRE INSPEGTION iiie te bee tene rabie Hae 15 CHECKING THE OIL LEVEL 5 irren reet rre eterne re re rri e er eee PE Pea 15 Fig 18 Glean Entir DIDSTICK i nen Ren ees sena 15 Fig 19 Check Oil Level on Dipstick eese eene ennt C
115. rk advance retard system if applicable 4 Exhaust Manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assembly gaseous fuel if applicable OBTAINING WARRANTY SERVICE To obtain warranty service take your engine to the nearest authorized Textron Golf Turf amp Specialty Products dis tributor dealer or service provider Bring your sales receipts indicating date of purchase for this engine The distrib utor dealer or service provider authorized by Textron Golf Turf amp Specialty Products will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order All parts and accessories replaced under this warranty become the property of Textron Golf Turf amp Specialty Products WHAT IS NOT COVERED Conditions resulting from tampering misuse improper adjustment unless they were made by the distributor dealer or service provider authorized by Textron Golf Turf amp Specialty Products during a warranty repair alter ation accident failure to use the recommended fuel and oil or not performing required maintenance services The replacement parts used for required maintenance services Consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc Diagnosis and inspection charges that do not result in warra
116. rning devices lights gov ernors guards and safety devices shall be inspected regularly and maintained in a safe operating condition m Special carriers or devices designed and approved for hazardous area operation shall be Page xiv inspected to ensure that maintenance preserves the orig inal approved safe operating features n Fuel systems shall be checked for leaks and condi tion of parts If a leak is found action shall be taken to prevent the use of the carrier until the leak has been eliminated o The carrier manufacturer s capacity operation and maintenance instruction plates tags or decals shall be maintained in legible condition p Batteries motors speed and directional control lers limit switches protective devices electrical conduc tors and connections shall be inspected and maintained in conformance with manufacturers recommended pro cedures q Carriers shall be kept in a clean condition to mini mize fire hazards and facilitate detection of loose or defective parts r Modifications and additions which affect capacity and safe machine operation shall not be performed by the customer or user without manufacturer s prior written authorization where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly s Care shall be taken to ensure that all replacement parts are int
117. s FRONT WHEEL ALIGNMENT V Check for unusual tire wear align if required Check for bent binding linkage rod PARK BRAKE V Check for damage or wear to latch arm or catch bracket Lubricate as required use light oil DO NOT LUBRICATE CABLES OR BRAKE LATCH REAR SHOCK ABSORBERS V Check for oil leakage loose mounting hardware ENGINE ELECTRICAL SYSTEM V Check coil spark plug wires for cracks loose connections Check for leaks at tank cap system lines filters pump carburetor V Check system lines for cracks deterioration THROTTLE GOVERNOR LINKAGE V Check operation and governed speed FUEL SYSTEM V Check for loose or missing hardware and components HARDWARE AND FASTENERS Tighten replace missing hardware SEMI ANNUAL 125 HOURS includes items listed in previous tables amp the following BATTERY Clean battery amp terminals DIRECTION SELECTOR V Check for wear and smooth movement lubricate shaft with light oil if required KING PINS V Check for excessive play and tightness of retaining nuts STEERING ASSEMBLY V Check bellows and pinion seal for damage or grease leakage RACK END BALL JOINT Lubricate use wheel bearing grease REAR AXLE v Check for unusual noise and loose or missing mounting hardware AIR FILTER ELEMENT V Check filter element clean replace as required OIL FILTER Clean in solvent at oil change replace O rings if required A Replace with SAE 10W 30 or 10W 40
118. se damage to the aluminum cylinder head threads Page 21 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Remove and inspect the spark plugs at intervals indi cated in the Periodic Service Schedule Ref Fig 17 on page 13 All new spark plugs should be properly gapped before installation Ref Fig 39 on page 23 Apply a light coat of anti seize compound and tighten to 18 ft Ibs 24 Nm torque Fouled spark plugs are indicated by a wet black appear ance This could be caused by a dirty air filter element or other restrictions in the air intake system Incorrectly adjusted valves spark plug wires which are in poor con dition or poor quality fuel could also contribute to the problem DIRECTION SELECTOR Dual Cable system The direction selector is a mechanical device that oper ates cables connected to the rear axle The cables are sealed and do not require lubrication but may require occasional adjustment Ref Fig 37 on page 22 The only other maintenance required is periodic lubrication of the linkage and related moving parts t Factory Installed Length 1 3 8 3 5 cm NEUTRAL Ref Sca 1 Fig 37 Shift Cable Adjustment PROLONGED STORAGE To reduce the possibility 1 severe injury or death resulting from a possi ble explosion Do not handle fuel in an are
119. speeds encountered on a flat sur face To reduce the possible loss of vehicle control and severe drivetrain damage speeds should be limited to no more than the maximum governed speed on level ground see GENERAL SPECIFICATIONS Limit speed by applying service brake FUEL To reduce the possibility INI of severe injury or death from improper fuel han dling Do not smoke near the fuel tank Do not refuel near open flame or electrical items which could produce a spark Always handle gasoline in a well ventilated area Always wear eye protection to protect against splashed fuel and fuel vapors Always allow adequate space for the expansion of gasoline Leave at least 1 2 5 cm space below bottom of filler neck Inspect fuel cap tank and other components for leaks or deterioration that could cause a hazard ous condition The fuel tank is located under the seat on the passenger side of the vehicle Ref Fig 8 on page 5 Fill the tank with fresh clean automotive grade gasoline Ref Fig 39 on page 23 High altitude or heavy use load applications may benefit from higher octane gasoline Do not use gasoline which contains Methanol CAUTION Some fuels called oxygenated or reformu lated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the Owner s Manual and Service Guide fuel system or cause performance problems If any undesirable operat ing sympto
120. ss Sequence 1 3 Tire style may vary Ref Whi 1 Fig 10 Wheel Installation LIGHT BULB REPLACEMENT To reduce the possibility of premature CAUTION bulb failure do not touch new bulbs with bare fingers Use clean dry tissue or paper towel to handle the glass portion of the bulb For vehicles equipped with lights mounted below cowl locate bulb socket on backside of light bar Ref Fig 11 on page 9 and turn bulb socket a quarter turn counter clockwise to unlock and pull out bulb Insert new bulb Ref Fig 39 on page 23 and rotate socket a quarter turn clockwise to secure To replace the tail and brake light bulb remove hardware securing lens and remove lens Ref Fig 12 on page 9 Install replacement bulb Ref Fig 39 on page 23 FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new auto motive type fuse Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department VEHICLE WITH A DISCHARGED BATTERY To reduce the possibility of severe injury or death from inadvertent motion Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Turn Signal Marker Light Li
121. the carrier from being used until such storage and handling is in compliance with these standards 4 5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 4 5 4 The user shall require battery changing and charging facilities and procedures to be in accordance with appropriate paragraphs of ANSI NFPA 505 4 5 2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI NFPA 505 are strictly complied with and shall familiarize carrier operators with it 4 6 Hazardous Locations 4 6 1 The user shall determine the hazard classifi cation of the particular atmosphere or location in which the carrier is to be used in accordance with ANSI NFPA 505 4 6 2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI NFPA 505 47 Lighting for Operating Areas 4 7 4 The user in accordance with his responsibility to survey the environment and operating conditions shall determine if the carrier requires lights and if so shall Page xi SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings equip the carrier with appropriate lights in accordance with the manufacturer s recommendations 4 8 Control of Noxious Gases and Fumes 481 When equipment powered by internal com bustion engines is used in enclosed are
122. the tops of the battery to remove any residue that could contribute to the self dis charge of the battery Rinse the entire area with low pres sure clear water Do not use a pressure washer Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BRAKES Dry Level Clean Paved Surface Accelerate To Maximum Speed Latch c Line or Marker Parking Brake and Take Foot Off Pedal Acceptable MA Line or Marker Stopping 4 ft 1 2 N Distance Normal Range of Stopping Distance Any vehicles that stop more than 4 ft 1 2 beyond the Acceptable Stopping Distance or pulls to one side should be removed from service and inspected by a qualified mechanic Ref Bpt 1 Fig 30 Typical Brake Performance Test To reduce the possibility FIZ injury or death always evaluate pedal travel before operating a vehicle to verify some brak ing function is present All driving brake tests must be done safe location Owner s Manual and Service Guide with regard for the safety of all personnel Over time a subtle loss of performance may NOTE take place therefore it is important to establish the standard with a new vehicle The Periodic Brake Performance Test should be per formed regularly Ref Fig 17 on p
123. ting from loss of vehicle control the following warnings must be observed When driving vehicle consider the terrain traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Stay in designated areas and avoid extremely rough terrain Maintain a safe speed when driving down hill Use service brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control Slow down before and during turns All turns should be made at reduced speed Never drive vehicle up down or across an incline that exceeds 14 25 grade To reduce the possibility INI of severe injury or death resulting from improper vehicle operation the following warnings must be observed Refer to GENERAL SPECIFICATIONS for seating capacily Depressing accelerator pedal will release foot operated park brake and may cause inadvertent vehicle movement Turn the key to the OFF posi tion whenever the vehicle is parked To prevent inadvertent movement when the vehi cle is to be left unattended engage the park brake move direction selector to forward posi tion turn key to OFF position and remove key Page OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicl
124. to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard 5 2 4 Loose Terrain Loose terrain may cause a golf car to lose traction and may affect stability Areas of loose terrain should be repaired if possible or chained or roped off to prevent golf car operation or identified by a suitable warning to operators not to operate golf cars in this area due to loose terrain or possible hazardous conditions 5 2 5 Golf Car Pedestrian Interference Areas Areas where pedestrians and golf cars interfere shall be avoided whenever possible by rerouting the golf car traf fic or the pedestrian traffic to eliminate the interference If elimination of the interference is not possible or is highly impractical signs shall be erected warning pedestrians of the golf car traffic and golf car operators of the pedes trian traffic and to drive slowly and use extreme caution Page xv SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 6 MAINTENANCE 6 1 Introduction 6 1 1 Golf cars may become hazardous if maintenance is neglected or improperly performed Therefore mainte nance facilities trained personnel and procedures in accordance with the manufacturers recommendations should be provided by the controlling party 6 2 Preventive Maintenance A regularly scheduled inspection and preventive
125. ttery chargers which are warranted by their respective manufacturer REMEDY The sole remedy under this warranty and TGTSP s only obligation in the event of a defect in the vehicle battery charger is that TGTSP will at its sole option repair or replace any defective parts This remedy precludes all other remedies including any lawsuits claims or other proceedings alleging strict liability negligence of contract or any cause of action TGTSP reserves the right to improve or change the design of any TGTSP vehicle or battery charger without assuming any responsibility to modify previously manufactured vehicles or battery chargers DISCLAIMER THIS WARRANTY IS MADE IN LIEU OF ALL OTHER WARRANTIES IMPLIED OR EXPRESSED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TGTSP WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISING FROM ANY DEFECT IN THE VEHICLE BATTERY CHARGER No agent employee or representative of TGTSP or any person has any authority to bind TGTSP to any other agree ment representation or warranty concerning the goods sold under this warranty WARNING ANY MODIFICATION OR CHANGE TO THE VEHICLE OR BATTERY CHARGER WHICH ALTERS THE WEIGHT DISTRIBUTION OF THE VEHICLE ITS STABILITY INCREASES THE SPEED OR ALTERS THE OUTPUT OF THE BATTERY CHARGER BEYOND THE FACTORY SPECIFICATION CAN CAUSE PERSONAL INJURY
126. ual and Service Guide LIMITED WARRANTIES Owner s Manual and Service Guide Page 37 WARRANTY DOMESTIC WARRANTY U S AND CANADA To obtain a copy of the limited warranty applicable to the vehicle call or write a local distributor authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code Page 38 Owner s Manual and Service Guide 2002 INTERNATIONAL WARRANTY ALL COUNTRIES OUTSIDE THE U S AND CANADA TEXTRON GOLF TURF amp SPECIALTY PRODUCTS TGTSP warrants to the Original Retail Pur chaser or the Original Retail Lessee that any 2002 TGTSP vehicle and or Battery Charger shall be free from any defects in material or workmanship for one year from the date of installation at the customer s location with respect to parts and labor EXCLUSIONS Specifically excluded from any TGTSP warranty are adjustments repairs made due to normal wear beyond the first 180 days routine maintenance items cosmetic deterioration and electrical components which are susceptible to fluctua tions in current beyond the control of TGTSP This warranty also does not apply to Acts of God or other events over which TGTSP has no control Transportation charges for warranty service as well as freight charges to receive warranty parts are excluded from this warranty and all replaced parts shall become the property of TGTSP This warranty also excludes batteries tires and Lester ba
127. verhead Cam Overhead Valve Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump 10 67 1 Helical Geared with Neutral Lock amp Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 Gallon 23 Liters Tank 36 1 5 16 kg Fuel Weight Dual Rear Wheel Self Adjusting Mechanical Drum Brakes Automatic Parking Brake Release with Self Compensating System Leaf Springs with Hydraulic Shock Absorbers Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack amp Pinion Dual Handgrips Pencil Holder amp Scorecard Holder Cushion Foam Vinyl Cover Hip Restraint Hand Hold Operator amp 1 Passenger 800 Ibs 360 kg Including Operator Passenger Accessories amp Cargo 16 18 mph 26 29 kph Welded Tubular Steel Powder Coated DuraShield Flexible Impact Resistant DuraShield Injection Molded TPE Thermoplastic Elastomer with Base Coat Clear Coat Champagne Hunter Green DASH PANEL Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders Tee amp Ball Storage LIGHTING HORN None TIRES 18 x 8 50 8 4 Ply Rated Load Range B TIRE PRESSURE WEIGHT Without Fuel OPERATING CONTROLS amp INSTRUMENTATION FEATURES 18 22 psi 124 152 kPa 679 Ibs 308 kg Removable Key Deadman Accelerator Contr
128. vot Repair Sand Bottle No Side Basket Full Sound Control Package Hour Meter Page 28 Key Switch Custom Key Switch Individually Keyed Long Fender Liners Message Holder Paint Color Custom Powertrain High Altitude 3000 6000 ft Powertrain High Altitude 6000 10000 ft Rear View Mirror Requires Top Sand Bottle Kit Seating Special Color Tow Bar Detachable Tow Bar Permanent Turn Signal with 4 Way Flasher Weather Protection Enclosure Wheel Covers 8 Chrome Wheel Covers 6 Moon Wheel Covers Spoke Silver and Black Wheel Covers Spoke Gold and Black Wheels 10 Alloy with Pro Tour Tires Windshield One Piece Top Required Windshield Fold Down Top Required Turf Glide Windshield Rear Turf Saver Wood Grain Dash with Locking Glove Box Fairway Doors USA Trail Top Sun Canopy Owner s Manual and Service Guide GENERAL SPECIFICATIONS STANDARD EQUIPMENT TXT GASOLINE FREEDOM LE 9 hp 6 7 kW 18 ci 295 cc Twin Cylinder Air Cooled Overhead Cam Overhead Valve BATTERY One 12 Volt Maintenance Free 430 CCA 60 Minute Reserve ENGINE Pressurized Lubrication with Washable Permanent Oil Filter Internal Balance Shaft Solid State Ignition with RPM Limiter Replaceable Dry Cartridge Air Filter Fixed Jet Bowl Carburetor Pulse Fuel Pump TRANSAXLE 13 32 1 Helical Geared with Neutral Lock amp Ground Speed Governor TRANSMISSION Automatic Continuously Variable Transmission CVT FUEL TANK 6

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