FSB 3A-05 Carburetor Update_PREMCI.fm - E-Z-Go

Bulletin No.
3A-05
!
ACTION REQUIRED
INFORMATION ONLY
ROUTINE MAINTENANCE
!
IMMEDIATE ACTION REQUIRED
(FIELD CAMPAIGN)
REVISED 3A
Subject:
Carburetor Update - Pre MCI
Date:
11/29/2005
Units Affected:
MPT 800
COMMANDER 280
HAULER 800
INDUSTRIAL 800
WORKHORSE 800
TXT 2+2
TXT Gas
TXT Freedom
TXT Freedom HP
Serial No. Range: 1451059 - 2154517
cards)
Issue #1:
(Manufacture date 01/16/ 2002 - 11/02/03 see control
Fuel migration from carburetor
MANUFACTURER CHANGES
Resolution#1: New vehicles produced will have recommended parts installed at time of manufacturing.
FIELD MODIFICATIONS:See attached procedures. If any questions should arise please call 1-800241-5855 EXT. 4558.
* Kits will be provided at no charge based on information from the control cards.
Corrections should be submitted to ensure proper kit distribution. (Corrections
should be submitted to: gascar@textron.com or faxed to: 1-800-448-8124)
Read and understand the following text and warnings before attempting installation.
To prevent an ignition spark which could ignite gasoline from the fuel system and
result in personal injury, the negative battery cable must be removed from battery.
Wrap wrenches with vinyl tape to prevent the possibility of a
dropped wrench from ‘shorting out’ a battery, which could
result in an explosion and severe personal injury.
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 1
Bulletin No.
3A-05
AIR FILTER/ENGINE INSPECTION CHECKLIST
Turn key to off and remove the negative (-) battery cable at the battery to prevent the vehicle moving and the possible personal injury that may result.
1. Inspect governor / throttle system, repair or replace as required:
a. Inspect governor / throttle system to assure it has not been tampered with.
If tampering has occurred, reset or replace as required to factory
specifications.
b. Inspect governor cable to assure free travel without sticking
c. Inspect pedal box micro-switch to assure proper timing
Proper Micro Switch Adjustment
When the system is in correct adjustment, the micro switch in the accelerator pedal box will click when the top of
the accelerator pedal moves approximately 1/2" - 5/8" (13 - 16 mm). The accelerator cable (as seen at the rear
axle) should have some slack present and not show any movement until after the micro switch clicks.
d. Inspect throttle stop for proper closing
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 2
Bulletin No.
3A-05
2. Remove and inspect airbox cover. Replace with OEM parts if any of the
following conditions exist:
a. Excessive warpage along sealing edge
Airbox Cover Inspection
Check the contact pattern on the filter element for any signs of warpage or improper sealing between the airbox
cover and the filter element. A leak path of dirt and/or grime indicates a poor seal and the need to replace the
airbox cover and filter element. Non-E-Z-GO aftermarket filters are often made of inferior sealing and surface
materials.
b. Cracks
c. Broken or missing latches
3. Remove and inspect Air Filter, replace as required:
a. Look for presence of excessive dirt
b. Use only original E-Z-GO filter
4. Inspect airbox cavity directly in front of carburetor for evidence of melting or
warping. If these conditions exist, replace with OEM
parts and proceed with carburetor replacement as stated in this bulletin.
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 3
Bulletin No.
3A-05
Subject: Pre-MCI Engine modification
NOTE: REFERENCE PART NO. 603913
Read and understand the following text and warnings before attempting installation.
To prevent an ignition spark which could ignite gasoline from the fuel system and
result in personal injury, the negative battery cable must be removed from battery.
Wrap wrenches with vinyl tape to prevent the possibility of a
dropped wrench from ‘shorting out’ a battery, which could
result in an explosion and severe personal injury.
A.
Carburetor Removal (See Fig. 1)
1.
To prevent an ignition spark which could result in personal injury, the negative battery cable must
be removed from battery. Wrap wrenches with vinyl tape to prevent the possibility of a dropped
wrench from ’shorting out’ a battery. Cover the battery with a cloth or piece of old floormat to prevent the possibility of ‘shorting out’ from contact with other metal objects.
2.
Disconnect the solid linkage (8) from the carburetor throttle lever. Remove the choke cable (9) from
the choke lever swivel (10) on carburetor.
3.
Unsnap the three retaining clips (1) securing the cover (2) to the air box (3). Remove the cover and
remove the air filter element (4). Remove the hardware (11) connecting the airbox to the coil
bracket mount. Retain hardware for later use in reassembly.
4.
Remove the PCV valve hose (5) from the rear of the air box.
5.
Remove the two flanged nuts (12) securing the carburetor baffle and remove them both from the
airbox.
6.
Remove the two nuts (12), lock washers (13) and flanged bolts (14) securing the airbox to the carburetor. Retain the hardware for reassembly. Remove the air filter housing. Disconnect the fuel line
(6) from the carburetor (7) and plug the fuel line.
7.
Remove the choke bracket (15) and gaskets and slide the carburetor from the engine studs.
8.
Remove the remaining carburetor insulators and gaskets from the engine.
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 4
Bulletin No.
1
2
4
11
12
12
3
13
14
Coil Bracket Mounted
to Engine
5
6
15
7
9
10
8
3A-05
Fig. 1 Carburetor Removal
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 5
Bulletin No.
B. Carburetor Installation (See Figure 2 and Figure 3)
Do not let the carburetor vent hose become clogged or kinked.
Engine heat will cause the fuel in the carburetor bowl to expand
and may result in fuel being expelled from the carburetor if
unable to vent through the vent tube.
1.
Remove existing carburetor studs and replace with the new studs (1-NEW). Tighten new studs to
35 - 43 in. lbs. (4 - 5 Nm) torque.
2.
Install new insulators (3-NEW & 4-NEW) and new gaskets (2-NEW) to ensure sealing of carburetor
system in all locations. See Figure 2 for proper sequence and placement.
3.
Install new carburetor shield (5-NEW), new carburetor (6-NEW) and new gaskets (2-NEW & 7NEW).
4.
Reinstall existing choke bracket and use new gasket (7-NEW).
5.
Reconnect the fuel line and tighten clamp securely. Make sure the fuel line clamp does not interfere or crimp the two vent hoses on each side of the fuel line. See Figure 3.
6.
If gray vent hose is loose, replace with new carburetor kit.
7.
Replace air filter assembly in reverse order of disassembly.
8.
Tighten hardware in airbox to 50 - 70 in. lbs. (6 - 8 Nm) torque.
9.
Reconnect the throttle cable linkage and choke cable, throttle cable linkage must be adjusted to fit
to the repositioned throttle lever location.
10.
Reconnect the PCV valve hose to the rear of the airbox. See Figure 3 for correct location.
11.
Using the coil bracket adapter (8-new), remount the coil bracket mount to the airbox. Use new bolts
(9-NEW) to attach the adapter to the coil bracket. Use the existing hardware to attach mount to the
airbox.
12.
Reconnect the negative battery cable to the battery.
13.
Test drive the vehicle and confirm that the factory recommended governed speed is achieved. If the
speed is not within the specified speed range, stop the vehicle and adjust as described in the repair
and service manual.
14.
Return unit to service.
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 6
3A-05
Bulletin No.
Existing Hardware
9-NEW
8-NEW
Coil Bracket Mounted
to Engine
7-NEW
6-NEW
4-NEW
5-NEW
2-NEW
3-NEW
1-NEW
3A-05
Fig. 2 Carburetor Installation Update
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 7
Bulletin No.
3A-05
PCV Valve Hose
Ensure this hose is
routed as shown.
Black Hose
Position hose to angle
away from carburetor,
DO NOT position hose
downward or allow any
kink in the vent hose.
Gray Hose
Ensure this hose is
positioned as shown,
DO NOT allow any kink
in the vent hose.
Fig. 3 Carburetor Vent Hose Installation
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 8
Bulletin No.
Tools:
Tool
Qty. Required
Socket, 10 mm deep well, 3/8" drive. . . . . . . . . . . . . . . . . . . . . . . . . . .1
Ratchet, 3/8" drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Nut driver, 1/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Parallel jaw pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Straight blade screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Phillips screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Open end wrench, 9/16". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Open end wrench, 3/8". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Torque wrench, 3/8" drive, in. lbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Open end wrench, 1/2". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Riverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PARTS INCLUDED IN KIT:
Item #
Parts Required
Description
Qty
1-NEW
603911
Carburetor Stud
2
2-NEW
26726G01
Gasket
4
3-NEW
72883G01
Carburetor Insulator
1
4-NEW
72854G01
Carburetor Insulator (thick)
1
5-NEW
603871
Carburetor Shield
1
6-NEW
603901
Carburetor
1
7-NEW
26727G01
Choke Plate Gasket
2
8-NEW
603910
Bracket Adapter
1
9-NEW
72870G01
Flanged Bolt
2
SEE UNITS AFFECTED
REPAIR AS REQUIRED ONLY
INSPECT, REPORT & REPAIR AS REQUIRED
x REPAIR & REPORT BY CONTROL CARD
LIMITATIONS:
Control Cards Attached:
x
Yes
No
Standard Warranty Applies:
x
Yes
No (* see below)
Information Only
Yes
Parts Ordering Process:
See NOTES below.
Labor: 18 MIN.
Mileage: .50 /Mile (Round trip mileage to be documented on claim)
Claims paid on receipt of control cards
x Yes
E-Z-GO Division of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia
USA 30906-3852 Phone: 1-800-774-3946, FAX: 1-800-448-8124
Page 9
N/A
3A-05