Transcript
INSTALLATION INSTRUCTIONS
TITLE
DRIVE CLUTCH 2-CYCLE(2-PASSENGER)-3PG INSTALLATION
DRAWING NO.
617619
REV
-
NOTICE Read all of the following safety and service instructions before attempting installation. Wear safety glasses during installation.
Tool List
Qty.
Tools List
Qty.
Hydraulic Floor Jack ................................................ 1
Jack Stands ............................................................. 4
Chocks..................................................................... 4 Impact Socket, 1 1/8", 1/2" drive ............................. 1
Plastic faced Hammer.............................................. 1 Clutch Puller, (P/N 19779-G2) ................................. 1
Impact Wrench, 1/2" drive (air or electric) .............. 1 Thread Locking sealant ....................................... A/R Socket, 5/8", 3/8" drive ........................................... 1
Ratchet, 3/8" drive ...................................................1 Torque Wrench, 1/2" drive, ft. lbs ............................1 Lug wrench, 5/8", 3/4" .............................................. 1
To prevent possible injury or death resulting 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 vehicle 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. Wear eye protection when working on or around vehicle. In particular use care when working around the batteries, or when using solvents or compressed air. INSTALLATION INSTRUCTIONS GAS MARATHON (2 CYCLE), GAS SHUTTLE 950s GAS REFRESHER, GAS WH 1200, GAS ST 350/SPORT. Center of front axle
When lifting the vehicle, position jack stands only in the areas indicated. To raise the entire vehicle, install chocks in front and behind each front wheel. Center jack under the rear frame crossmember. Raise vehicle Flat portion of frame
and locate a jack stand under outer ends of 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 and position jack stands under the inner frame member as indicated. Lower the jack and test the stability of the vehicle on the four jack stands. If only the front or rear of the vehicle is to be raised, place the chocks in front and
Outside end of rear axle View from Underside of Vehicle
behind each wheel not being raised in order to stabilize the vehicle. Lower the vehicle by reversing the lifting sequence.
E-Z-GO Division of Textron Inc., 3010 Perkins Rd., Augusta, GA. 30906-3852 Parts & Accessories (Consumers): 1-877-394-6727 / www.shopezgo.com Parts & Accessories (Commercial Accounts): 1-888-438-3946 / www.ezgo.com/gpaonline
INSTALLATION INSTRUCTIONS
TITLE
DRIVE CLUTCH 2-CYCLE(2-PASSENGER)-3PG INSTALLATION
DRAWING NO.
617619
REV
-
1. Turn key to "OFF" position and remove it from the switch. Make sure the vehicle is on level ground and parking brake is set. 2. To access Drive clutch assembly (6) raise and remove the seat bottom from car. Remove negative cable from battery. 3. To replace the Drive clutch assembly (6), follow the instructions mentioned in first sheet to lift the vehicle.
To prevent burns and other possible injuries: Disable the electrical system by disconnecting the negetive battery post wire, before attempting to remove the drive belt, to prevent the engine from inadvertently starting. Be sure that the engine and exhaust components have cooled before attempting any service. Do not allow fingers to become trapped between the belt and clutch sheave. Use only sockets designed for use with an impact wrench. Never use a socket intended for use with hand tools.
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1 Jam nut and adjusting nut 5 4 3 2
Driven Clutch
6
1
4. Remove the drive belt (1) by pulling the belt upwards and rotating the driven clutch simultaneously which will cause the driven clutch sheaves to open and loosen the belt tension. Refer to the figure. The belt may then be rolled off the driven clutch. 5. Remove the passenger side (rear) hub cap, (if equipped) wheel and tire assembly. Retain them for installation later. 6. Remove the starter belt (2) by loosening the jam nut and the adjusting nut securing the starter / generator adjuster until the starter belt (2) can be removed from the drive clutch (6). 7. Make sure the parking brake is set and toggle direction selector to "FORWARD" to put tension on clutches. 8. Remove the clutch bolt (3), lock washer (4) and pilot washer (5). E-Z-GO Division of Textron Inc., 3010 Perkins Rd., Augusta, GA. 30906-3852 Parts & Accessories (Consumers): 1-877-394-6727 / www.shopezgo.com Parts & Accessories (Commercial Accounts): 1-888-438-3946 / www.ezgo.com/gpaonline
INSTALLATION INSTRUCTIONS
TITLE
DRIVE CLUTCH 2-CYCLE(2-PASSENGER)-3PG INSTALLATION
DRAWING NO.
617619
REV
-
9. Insert a greased clutch puller and tighten (clockwise) using an impact wrench which will remove the drive clutch (6) from the engine crankshaft.
NOTICE Never beat on or hit the clutch to loosen or remove it. In some extreme cases, the clutch may not separate from the crankshaft. Remove the clutch puller and fill the cavity with grease. Replace the clutch puller and tighten it with the impact wrench. The combined mechanical and hydraulic effect will remove the clutch. Remove all excess grease.
10. Clean both the engine crankshaft and the drive clutch bore. Slide the clutch onto the engine crankshaft and rotate the clutch while lightly pushing the movable sheave in and out several times to seat the drive clutch (6) with the tapered crankshaft. 11. Install the lock washer (4) and the pilot washer (5) onto the clutch bolt (3). 12. Apply thread sealant to the threads of the clutch bolt (3). Install and tighten it to 40 - 44 ft. lbs (54 - 60 Nm) torque. 13. Installation of other parts are in the reverse order of disassembly.
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2 5
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“CROSS SEQUENCE” pattern tire style may vary in different vehicles
14. While installing the wheel make sure the valve stem is outside, mount the wheel onto the hub with lug nuts. Be sure to position the wheel on hub correctly with arrow indicating direction of rotation when moving forward. Finger tight lug nuts in a cross sequence patter. Then tighten lug nuts to 50 - 85 ft. lbs (70 -115 Nm) torque in 20 ft. lbs (30 Nm) increments following the same cross sequence pattern.
E-Z-GO Division of Textron Inc., 3010 Perkins Rd., Augusta, GA. 30906-3852 Parts & Accessories (Consumers): 1-877-394-6727 / www.shopezgo.com Parts & Accessories (Commercial Accounts): 1-888-438-3946 / www.ezgo.com/gpaonline
