EZ-GO GX-440 GX-444 (EZ GO) Service & Repair Manual

This Operation and Service manual has been prepared to serve two purposes. First,it will acquaint the reader with the operation of the E-Z-GO product and assist him in performing minor service and repairs. Secondly, it will introduce to the mechanic the most efficient service specifications and procedures.

It is our hope that these procedures together with the trouble-shooting tips outlined herein will enable the customer to receive the best possible service from our product.

TABLE OF CONTENTS
GENERAL

Specifications
Model Identification
General Operation
Operating Instructions
Towing
Safe Driving Tips

SERVICE
Servicing A New Gasoline Car :
Engine Fuel and Lubrication
Air Cleaner Service
Tires
Battery
Periodic Service Schedule
Lubrication Chart
Seats

BRAKES
Adjusting Brakes
Dis-assembly of Brakes
Hill Brake Adjustment
Dis-assembly of Brake Pedal
Seat Brake (Optional Equipment)
CONTROL LINKAGES
Accelerator Control Cable
Accelerator Adjustment
Actuator Rod
Adjustment - Cutout Switch
Choke Control
Governor Control

STEERING
Steering Assembly Removal
Dis-assembly
Fork (3 Wheel Cars)
Front Wheel Bearing (3 Wheel Cars)
Front Wheel Alignment
3 Wheel Car
4 Wheel Car
Front Wheel Bearings (4 Wheel Cars)

SUSPENSION
Front - 4 Wheel Cars
Front Shocks - 3 Wheel Cars
Rear Suspension
Wheels and Tires

ENGINE
Specifications
Storage
Engine Repair
Removing and Installing Engine
Engine Dis-assembly
Cylinder Dis-assembly
Cylinder Inspection
Starter-Dynamo Dis-assembly
Crankcase Repairs
Engine Assembly Bolt Torque Requirements
Engine Mounts

ELECTRICAL
Circuits and Controls
Wiring
Circuit Testing
Control Wiring Schematic
Points and Condenser
Brushes
Spark Plug
Starter Dynamo
Accelerator Controlled Cutout Switch
Timing Procedure
Battery Service

CARBURETOR & FUEL SYSTEM
Carburetor Operation
Removal from Engine
Dis-assembly
Reassembly
Fuel Pump
Fuel Tank and Filter
Trouble Data
High Altitude/High Temp Jetting

CLUTCH ASSEMBLIES
General
Belt Service
Drive Clutch Removal
Driven Clutch Removal
Dis-assembly
Replacing Bushing
Replacing Broker Ramp Buttons

REAR AXLE
Differential Lubrication
Shaft Removal
Wheel Bearing Replacement
Installing Axle Shaft
Drive Pinion Oil Seal Replacement
Removing Rear Axle Assembly from Car
Wrench Torque Requirements

BODY PANELS AND TRIM
Trim Removal and Installation
Removal and Installation of Rear Fender
Removal and Installation of Front Cowl
Seat Wrap Removal

Covered Models:
* 1970 - 1990 with Two Stroke Engines
* GX 440
* GX 444


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