Club car Tempo 2020 Manual

Tempo,TempoConnect,

andTempo2+2

Maintenanceand

ServiceManual

ElectricVehiclewithERICChargingSystem

GasolineVehiclewithKohlerECH440Engine

GasolineVehiclewithSubaruEX-40Engine

ManualNumber86753090024

EditionCodeC

INTRODUCTION

ClubCarvehiclesaredesignedandbuilttoprovidetheultimateinperformanceefciency;however,proper

maintenanceandrepairareessentialforachievingmaximumservicelifeandcontinuedsafeandreliableoperation.

Thismanualprovidesdetailedinformationforthemaintenanceandrepairoftheelectricandgasoline-powered

vehicles,andshouldbethoroughlyreviewedpriortoservicingthevehicle.Theproceduresprovidedhereinmustbe

properlyimplemented,andtheDANGER,WARNING,andCAUTIONstatementsmustbeheeded.

Thismanualwaswrittenforthetrainedtechnicianwhoalreadypossessesknowledgeandskillsinelectricaland

mechanicalrepair.Ifthetechniciandoesnothavesuchknowledgeandskills,attemptedserviceorrepairstothe

vehiclemayrenderthevehicleunsafe.Forthisreason,ClubCaradvisesthatallrepairsand/orservicebeperformed

byanauthorizedClubCardistributor/dealerrepresentativeorbyaClubCarfactory-trainedtechnician.

ItisthepolicyofClubCartoassistitsdistributorsanddealersincontinuallyupdatingtheirserviceknowledgeand

facilitiessotheycanprovidepromptandefcientserviceforvehicleowners.Regionaltechnicalrepresentatives,

vehicleserviceseminars,periodicservicebulletins,maintenanceandservicemanuals,andotherservicepublications

alsorepresentClubCar’scontinuingcommitmenttocustomersupport.

ClubCaroffersafulllineoftrainingandcontinuingeducationclassesfortechnicianswhowanttolearnmoreabout

ourproducts.Formoreinformation,contactyourlocaldealerorClubCar'sTechnicalServicesdepartmentfora

listofupcomingclasses.

Thismanualcoversallaspectsoftypicalvehicleservice;however,uniquesituationssometimesoccurwhenservicinga

vehicle.Ifitappearsthataservicequestionisnotansweredinthismanual,pleasecontactyournearestauthorized

ClubCardealerordistributorforassistance.

TondyourlocalauthorizedClubCardealer,visitwww.clubcardealer.com,call1-800-ClubCar(1-800-258-2227),or

scanthisQuickResponse(QR)codetobetakentotheClubCardealerlocator.RefertoFigure1.DownloadaQR

codereadersuchasRedLaserorBarcodeScannertoyourcellphoneortablet.

Ifyouwouldprefertowritetous,directyourletterto:ClubCarLLC,Attention:MarketingServices,P .O.Box204658,

Augusta,Georgia30917-4658USA.

DealerLocatorQRCode

ClubCarisaregisteredtrademarkofClubCar,LLC

ThismanualeffectiveJanuary,2020

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagei

INTRODUCTION

TECHNICALPUBLICATIONCUSTOMERSATISFACTIONONLINESURVEY

Letyourvoicebeheard!

PleaseparticipateintheTechnicalPublicationcustomersatisfactiononlinesurvey.

Thissurveytakeslessthanveminutestocompleteandyourresponseswillhelpexaminecurrentperformance

andidentifyareasforfutureimprovement.

Ourtoppriorityistoprovidetimely,accurate,anduserfriendlymanuals.

Theonlinesurveycanbefoundathttp://bit.ly/1w9uFMhorusingtheQRCodebelow.

OnlineSurveyQRCode

WARNING

•ReadSafetyonpage1-1beforeattemptinganyserviceonthevehicle.

•Beforeservicingthevehicle,readcompletesection(s)andanyreferencedinformationthatmaybe

relevanttotheserviceorrepairtobeperformed.

NOTE:Thismanualrepresentsthemostcurrentinformationatthetimeofpublication.ClubCariscontinuallyworking

tofurtherimproveitsvehiclesandotherproducts.Theseimprovementsmayaffectservicingprocedures.

Anymodicationand/orsignicantchangeinspecicationsorprocedureswillbeforwardedtoallClubCar

dealersandwill,whenapplicable,appearinfutureeditionsofthismanual.

ClubCarreservestherighttochangespecicationsanddesignsatanytimewithoutnoticeandwithoutthe

obligationofmakingchangestounitspreviouslysold.

Therearenowarrantiesexpressedorimpliedinthismanual.Seethelimitedwarrantyfoundinthevehicle

Owner’sManual.

NOTICES

Importantfeaturesuniquetothedifferentmodelscoveredinthismanualarehighlighted.ClubCar,LLCrecommends

theowner/operatorreadandunderstandthismanualandpayspecialattentiontofeaturesspecictotheirvehicle(s).

Refertotheowner’smanualprovidedwiththevehicleforinformationonthefollowingtopics:

•Pre-OperationandDailySafetyChecklist

•ControlsandIndicators

•DrivingInstructions

SERIALNUMBERDECAL

•Towing

•TransportingonaTrailer

•SubsequentOwnerRegistration

•Warranties

MODELIDENTIFICATION

Theserialnumberofeachvehicleisprintedonabarcodedecalmountedeitherbelowthepassengersidecupholder

orabovetheacceleratororbrakepedal(Example:CC5819–123456).

Thetwoletters(1)atthebeginningoftheserialnumberindicatethevehiclemodel.Thefollowingfourdigits(2)

indicatethemodelyearandproductionweekduringwhichthevehiclewasbuilt.Thesixdigits(3)followingthehyphen

representtheuniquesequentialnumberassignedtoeachvehiclebuiltwithinagivenmodelyear.SeefollowingNOTE.

NOTE:Havethevehicleserialnumberavailablewhenorderingpartsormakinginquiries.

SerialNumberDecal

2843B

Figure-1SerialNumberDecal

ClubCarisaregisteredtrademarkofClubCar,LLC

ThismanualeffectiveJanuary,2020

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPageiii

CONTENTS

SECTION1—Safety.........................................................................................................................................1-1

SafetyDetails................................................................................................................................................1-1

GeneralWarnings..........................................................................................................................................1-2

DisablingtheVehicle..................................................................................................................................1-3

DisconnecttheBattery-GasolineVehicles..................................................................................................1-3

ConnecttheBattery-GasolineVehicles......................................................................................................1-4

DisconnecttheBatteries–ElectricVehicles................................................................................................1-4

ConnecttheBatteries–ElectricVehicles....................................................................................................1-5

RecyclingLead-AcidBatteries....................................................................................................................1-6

Internationalsafetysymbolsonbatteries.....................................................................................................1-6

SECTION2—VehicleSpecications..................................................................................................................2-1

Electric-VehicleSpecications......................................................................................................................2-1

Dimensions...............................................................................................................................................2-1

Performance.............................................................................................................................................2-1

Tires.........................................................................................................................................................2-1

ElectricMotor............................................................................................................................................2-1

Batteries...................................................................................................................................................2-1

NoiseAndVibration...................................................................................................................................2-2

Transaxle..................................................................................................................................................2-2

VehicleWeightsAndLoadCapacities.........................................................................................................2-2

KohlerECH440-VehicleSpecications..........................................................................................................2-3

Dimensions...............................................................................................................................................2-3

Performance.............................................................................................................................................2-3

Tires.........................................................................................................................................................2-3

GasolineEngine........................................................................................................................................2-4

Battery......................................................................................................................................................2-4

NoiseAndVibration...................................................................................................................................2-4

Transaxle..................................................................................................................................................2-4

VehicleWeightsAndLoadCapacities.........................................................................................................2-4

SubaruEX-40-VehicleSpecications............................................................................................................2-5

Dimensions...............................................................................................................................................2-5

Performance.............................................................................................................................................2-6

Tires.........................................................................................................................................................2-6

GasolineEngine........................................................................................................................................2-6

Battery......................................................................................................................................................2-6

NoiseAndVibration...................................................................................................................................2-6

Transaxle..................................................................................................................................................2-6

VehicleWeightsAndLoadCapacities.........................................................................................................2-6

SECTION3—ExtendedStorage.......................................................................................................................3-1

ElectricVehicleExtendedStorage..................................................................................................................3-1

ExtendedStoragePreparation-Electric......................................................................................................3-1

ReturnToServiceFromExtendedStorage-Electric....................................................................................3-2

GasolineVehicleExtendedStorage................................................................................................................3-4

ExtendedStoragePreparation-Gasoline....................................................................................................3-4

ReturnToServiceFromExtendedStorage-Gasoline..................................................................................3-5

SECTION4—BodyandTrim............................................................................................................................4-1

CleaningTheWindshield...............................................................................................................................4-1

CleaningtheVehicleExterior..........................................................................................................................4-1

CleaningtheVehicleInterior...........................................................................................................................4-2

BodyRepair..................................................................................................................................................4-2

StressLinesorStreaks..............................................................................................................................4-2

MinorImpactDamage/Deformations...........................................................................................................4-2

MinorScratchesandSurfaceBlemishes.....................................................................................................4-3

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagev

Gouges,Punctures,Tears,LargeScratches,andAbrasions.........................................................................4-3

SeatHinge....................................................................................................................................................4-4

SeatHingeRemoval..................................................................................................................................4-4

SeatHingeInstallation...............................................................................................................................4-4

HipRestraint.................................................................................................................................................4-5

HipRestraintRemoval...............................................................................................................................4-5

HipRestraintInstallation............................................................................................................................4-5

FrontBody....................................................................................................................................................4-6

FrontBodyRemoval..................................................................................................................................4-7

FrontBodyInstallation...............................................................................................................................4-7

FrontBumper................................................................................................................................................4-8

FrontBumperRemoval..............................................................................................................................4-8

FrontBumperInstallation...........................................................................................................................4-8

UnderbodyBracket........................................................................................................................................4-9

UnderbodyBracketRemoval......................................................................................................................4-9

UnderbodyBracketInstallation...................................................................................................................4-9

Headlights...................................................................................................................................................4-10

HeadlightRemoval..................................................................................................................................4-10

HeadlightInstallation................................................................................................................................4-10

InstrumentPanel..........................................................................................................................................4-11

InstrumentPanelRemoval........................................................................................................................4-11

InstrumentPanelInstallation.....................................................................................................................4-11

DashAssembly...........................................................................................................................................4-12

DashassemblyRemoval..........................................................................................................................4-12

DashAssemblyInstallation......................................................................................................................4-12

FloorMatandRetainers...............................................................................................................................4-13

FloorMatRemoval..................................................................................................................................4-13

FloorMatInstallation................................................................................................................................4-13

FloorMatRetainerRemoval.....................................................................................................................4-13

FloorMatRetainerInstallation..................................................................................................................4-13

KickPlateandChargerReceptacleBezel–ElectricVehicles.........................................................................4-14

KickPlateandChargerReceptacleBezelRemoval...................................................................................4-14

KickPlateandChargerReceptacleBezelInstallation.................................................................................4-15

KickPlate–GasolineVehicles.....................................................................................................................4-17

KickPlateRemoval..................................................................................................................................4-17

KickPlateInstallation...............................................................................................................................4-17

AccessPanel..............................................................................................................................................4-18

AccessPanelRemoval............................................................................................................................4-18

AccessPanelInstallation.........................................................................................................................4-18

VisageDisplayUnitOverheadBaskets.........................................................................................................4-19

OverheadBasketRemoval.......................................................................................................................4-19

OverheadBasketInstallation....................................................................................................................4-19

OverheadSpeakerBasketRemoval.........................................................................................................4-20

OverheadSpeakerBasketInstallation.......................................................................................................4-20

Two-Passenger-Canopy.............................................................................................................................4-21

Two-PassengerCanopyRemoval.............................................................................................................4-21

Two-PassengerCanopyInstallation..........................................................................................................4-22

Two-PassengerCanopyWithVisageDisplayUnitRemoval.......................................................................4-22

Two-PassengerCanopyWithVisageDisplayUnitInstallation.....................................................................4-24

Two-PassengerFrontCanopyStrutRemoval............................................................................................4-26

Two-PassengerFrontCanopyStrutInstallation.........................................................................................4-27

Two-PassengerRearCanopySupportRemoval........................................................................................4-28

Two-PassengerRearCanopySupportInstallation.....................................................................................4-29

Two-Passenger-RearBody.........................................................................................................................4-29

UniversalAccessoryMounting..................................................................................................................4-29

StructuralAccessoryModule(SAM)..........................................................................................................4-30

SeatBack...............................................................................................................................................4-31

BagRackAssembly.................................................................................................................................4-32

BagStrap................................................................................................................................................4-33

SweaterBasket.......................................................................................................................................4-34

RearBeautyPanel...................................................................................................................................4-35

RearUnderbody......................................................................................................................................4-36

RearCrossmember.................................................................................................................................4-37

2+2-MonsoonCanopy................................................................................................................................4-38

PageviTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual

MonsoonCanopyRemoval......................................................................................................................4-38

MonsoonCanopyInstallation....................................................................................................................4-39

2+2FrontCanopyStrutRemoval..............................................................................................................4-40

2+2FrontCanopyStrutInstallation...........................................................................................................4-41

2+2RearCanopySupportRemoval..........................................................................................................4-42

2+2RearCanopySupportInstallation.......................................................................................................4-43

2+2-RearBody..........................................................................................................................................4-44

SeatBacks..............................................................................................................................................4-44

FixedRearSeat......................................................................................................................................4-46

Fold-DownRearSeat..............................................................................................................................4-49

SeatSupport...........................................................................................................................................4-53

FootDeck-2+2.......................................................................................................................................4-54

RearBeautyPanel(2+2Vehicles)............................................................................................................4-58

RearUnderBody......................................................................................................................................4-59

SECTION5—AcceleratorandBrakePedalGroup.............................................................................................5-1

PedalGroup–ElectricVehicle.......................................................................................................................5-1

PedalGroupRemoval................................................................................................................................5-1

PedalGroupInstallation.............................................................................................................................5-3

PedalGroup–GasolineVehicle.....................................................................................................................5-5

PedalGroupRemoval................................................................................................................................5-5

ThrottlePositionSensor.............................................................................................................................5-6

PedalGroupInstallation.............................................................................................................................5-7

DebrisShields...............................................................................................................................................5-9

DebrisShieldsRemoval.............................................................................................................................5-9

DebrisShieldsInstallation..........................................................................................................................5-9

AcceleratorPedal........................................................................................................................................5-10

AcceleratorpedalRemoval......................................................................................................................5-10

AcceleratorPedalInstallation...................................................................................................................5-10

BrakePedal.................................................................................................................................................5-11

BrakePedalRemoval...............................................................................................................................5-11

BrakePedalInstallation............................................................................................................................5-11

SECTION6—WheelBrakeAssemblies.............................................................................................................6-1

GeneralInformation.......................................................................................................................................6-1

BrakeShoeRemoval.....................................................................................................................................6-1

BrakeAssemblyCleaning..............................................................................................................................6-4

BrakeShoeInstallation..................................................................................................................................6-7

BrakeCableEqualizerAdjustment................................................................................................................6-10

BrakeCluster..............................................................................................................................................6-12

BrakeClusterRemoval............................................................................................................................6-12

BrakeClusterInstallation.........................................................................................................................6-14

BrakeCable................................................................................................................................................6-16

BrakeCableRemoval..............................................................................................................................6-16

BrakeCableInstallation...........................................................................................................................6-19

SECTION7—SteeringandFrontSuspension....................................................................................................7-1

GeneralInformation.......................................................................................................................................7-1

SteeringWheel..............................................................................................................................................7-1

SteeringWheelRemoval............................................................................................................................7-1

SteeringWheelInstallation.........................................................................................................................7-2

SteeringColumn............................................................................................................................................7-3

SteeringColumnRemoval..........................................................................................................................7-3

SteeringColumnInstallation.......................................................................................................................7-4

RackandPinion............................................................................................................................................7-4

RackandPinionInspection........................................................................................................................7-5

RackandPinionRemoval..........................................................................................................................7-5

RackandPinionInstallation.......................................................................................................................7-6

FrontSuspension..........................................................................................................................................7-7

Lubrication................................................................................................................................................7-7

WheelAlignment.......................................................................................................................................7-7

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagevii

FrontSuspensionComponents.....................................................................................................................7-10

TieRodEndRemoval..............................................................................................................................7-10

TieRodInstallation..................................................................................................................................7-12

LeafSpringRemoval...............................................................................................................................7-12

LeafSpringInstallation.............................................................................................................................7-13

KingpinandSteeringSpindleRemoval.....................................................................................................7-14

KingpinandSteeringSpindleInstallation...................................................................................................7-15

ControlArmRemoval...............................................................................................................................7-17

ControlArmInstallation............................................................................................................................7-17

FrontShockAbsorberInspection..............................................................................................................7-18

FrontShockAbsorberRemoval................................................................................................................7-19

FrontShockAbsorberInstallation.............................................................................................................7-20

FrontWheelHubs........................................................................................................................................7-21

FrontWheelFreePlayInspection.............................................................................................................7-21

FrontWheelHubRemoval.......................................................................................................................7-21

FrontWheelHubInstallation....................................................................................................................7-22

SECTION8—WheelsandTires........................................................................................................................8-1

GeneralInformation.......................................................................................................................................8-1

LiftTheVehicle..............................................................................................................................................8-1

LiftTheFrontOfTheVehicle......................................................................................................................8-2

LowerTheFrontOfTheVehicle.................................................................................................................8-2

LiftTheRearOfTheVehicle......................................................................................................................8-2

LowerTheRearOfTheVehicle..................................................................................................................8-4

Tires.............................................................................................................................................................8-4

TirePressureMeasurement.......................................................................................................................8-4

TireRemoval.............................................................................................................................................8-4

TireRepair................................................................................................................................................8-5

TireInstallation..........................................................................................................................................8-6

WheelAssembly............................................................................................................................................8-7

WheelAssemblyRemoval..........................................................................................................................8-7

WheelAssemblyInstallation.......................................................................................................................8-7

SECTION9—RearSuspension........................................................................................................................9-1

GeneralInformation.......................................................................................................................................9-1

ShockAbsorbers...........................................................................................................................................9-1

RearShockAbsorberInspection.................................................................................................................9-1

RearShockAbsorberRemoval...................................................................................................................9-2

RearShockAbsorberInstallation................................................................................................................9-3

PanhardandBracket.....................................................................................................................................9-4

PanhardandBracketRemoval...................................................................................................................9-4

PanhardandBracketInstallation................................................................................................................9-4

LeafSprings(Two-Passenger).......................................................................................................................9-5

LeafSpringRemoval(Two-Passenger).......................................................................................................9-5

LeafSpringInstallation(Two-Passenger)....................................................................................................9-7

LeafSprings(Four-Passenger).......................................................................................................................9-8

LeafSpringRemoval(Four-Passenger)......................................................................................................9-8

LeafSpringInstallation(Four-Passenger)..................................................................................................9-10

LeafSprings(Four-Passenger-HeavyDutyWithPanhard)............................................................................9-11

LeafSpringRemoval(Four-Passenger-HeavyDutyWithPanhard)............................................................9-11

LeafSpringInstallation(Four-Passenger-HeavyDutyWithPanhard)........................................................9-13

SECTION10—VehicleMaintenance...............................................................................................................10-1

GeneralInformation.....................................................................................................................................10-1

Pre-OperationandDailySafetyChecklist......................................................................................................10-1

..............................................................................................................................................................10-1

PerformanceInspection...........................................................................................................................10-2

Maintenance...............................................................................................................................................10-3

PeriodicServiceSchedules..........................................................................................................................10-4

ElectricVehicle-PeriodServiceSchedule................................................................................................10-4

GasolineVehicle-PeriodicServiceSchedule............................................................................................10-6

PageviiiTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual

PeriodicLubricationSchedules.....................................................................................................................10-8

ElectricVehicle-PeriodicLubricationSchedule.........................................................................................10-8

GasolineVehicle-PeriodicLubricationSchedule.......................................................................................10-9

AirFilter.....................................................................................................................................................10-10

AirFilterRemoval...................................................................................................................................10-10

AirFilterInstallation................................................................................................................................10-10

KohlerECH440-EngineOil........................................................................................................................10-10

KohlerECH440-EngineOilViscosity......................................................................................................10-10

KohlerECH440-EngineOilLevelInspection...........................................................................................10-11

KohlerECH440-EngineOilReplacement...............................................................................................10-12

KohlerECH440-AddEngineOil.............................................................................................................10-14

Refuel........................................................................................................................................................10-16

SECTION11—ControllerDiagnosticT ool(CDT)...............................................................................................11-1

GeneralInformation......................................................................................................................................11-2

Features..................................................................................................................................................11-2

PluggingtheCDTintotheVehicle..................................................................................................................11-3

IntroductoryDisplay..................................................................................................................................11-3

QuickReferenceGuide–ERICChargingSystem...........................................................................................11-4

SystemInfo..................................................................................................................................................11-5

ModelNumber..........................................................................................................................................11-5

SerialNumber..........................................................................................................................................11-5

HardwareVersion.....................................................................................................................................11-5

ProtocolVersion.......................................................................................................................................11-5

ParamBlockVersion.................................................................................................................................11-5

MFGDateCode.......................................................................................................................................11-5

OSVersion...............................................................................................................................................11-5

SMVersion..............................................................................................................................................11-5

VCLAppVersion......................................................................................................................................11-5

Parameters..................................................................................................................................................11-6

Settings...................................................................................................................................................11-6

AmpHours...............................................................................................................................................11-8

AccessCodes..........................................................................................................................................11-8

VehicleID................................................................................................................................................11-9

MonitorMenu...............................................................................................................................................11-9

BattVoltage............................................................................................................................................11-10

VminI...................................................................................................................................................11-10

SignedBatteryCurrent............................................................................................................................11-10

BDIPercent............................................................................................................................................11-10

Speed....................................................................................................................................................11-10

Throttle..................................................................................................................................................11-10

Temperature...........................................................................................................................................11-10

ArmCurrent...........................................................................................................................................11-10

FieldCurrent..........................................................................................................................................11-11

ArmaturePWM.......................................................................................................................................11-11

FieldPWM.............................................................................................................................................11-11

SpeedPulses.........................................................................................................................................11-11

FootInput..............................................................................................................................................11-11

KeyInput...............................................................................................................................................11-11

ForwardInput.........................................................................................................................................11-11

ReverseInput.........................................................................................................................................11-11

ModeSwitchInput..................................................................................................................................11-11

ChargerInhibit........................................................................................................................................11-11

MainContDriver....................................................................................................................................11-11

LEDDriver.............................................................................................................................................11-12

PasswordTries(OEMAccessLevelOnly)................................................................................................11-12

Odometer...............................................................................................................................................11-12

BDIInfo.................................................................................................................................................11-12

BatteryMonitor.......................................................................................................................................11-12

ChargingTotals......................................................................................................................................11-12

AmpHoursDisplay.................................................................................................................................11-13

LIN........................................................................................................................................................11-13

VehicleSpeeds.......................................................................................................................................11-13

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPageix

PedalCounters.......................................................................................................................................11-13

FaultCounters........................................................................................................................................11-13

FaultCountOdometers...........................................................................................................................11-14

DiagnosticsMenu.......................................................................................................................................11-15

PresentErrorsFolder..............................................................................................................................11-15

FaultHistoryFolder................................................................................................................................11-15

CausesofFaults....................................................................................................................................11-16

FaultRecovery.......................................................................................................................................11-18

FaultDescriptions.......................................................................................................................................11-19

IncorrectPassword(OEMAccessLevelOnly)..........................................................................................11-19

MaxPasswordTries(OEMAccessLevelOnly)........................................................................................11-19

ThrottleFault..........................................................................................................................................11-19

LowBatteryVoltage(Undervoltage).........................................................................................................11-19

Overvoltage............................................................................................................................................11-19

ThermalCutback....................................................................................................................................11-20

Anti-TamperFault...................................................................................................................................11-20

HPD......................................................................................................................................................11-20

MainDrvrOverCurrent............................................................................................................................11-20

LockoutFault.........................................................................................................................................11-20

LowSOC...............................................................................................................................................11-20

MainWelded..........................................................................................................................................11-21

HighSpeedWalkAway............................................................................................................................11-21

Speedsensor.........................................................................................................................................11-21

MainDriverOn.......................................................................................................................................11-21

MainCoilOpen.......................................................................................................................................11-21

MainDropout(1or2)..............................................................................................................................11-22

MotorStall..............................................................................................................................................11-22

MainDriverOff.......................................................................................................................................11-22

CurrentSenseFault................................................................................................................................11-22

M–Shorted............................................................................................................................................11-22

FLD(Field)Missing.................................................................................................................................11-23

HWFailsafe...........................................................................................................................................11-23

FaultHistory...........................................................................................................................................11-23

ClearFaultHistory..................................................................................................................................11-23

Programming.............................................................................................................................................11-23

Cloning..................................................................................................................................................11-24

Favorites....................................................................................................................................................11-24

HHPSettings.............................................................................................................................................11-24

Plot&Log..................................................................................................................................................11-26

Plot........................................................................................................................................................11-26

Log........................................................................................................................................................11-26

CDTTroubleshooting..................................................................................................................................11-27

ConnectionTests........................................................................................................................................11-28

SECTION12—ElectricVehicle-TroubleshootingandElectricalSystem............................................................12-1

GeneralInformation.....................................................................................................................................12-1

Accessories.............................................................................................................................................12-1

ChargeIndicatorLight..............................................................................................................................12-1

Features.................................................................................................................................................12-2

BatteryWiringDiagram................................................................................................................................12-3

SonicWeld,Fuse,and10kOhmLocations...................................................................................................12-4

Troubleshooting...........................................................................................................................................12-5

TroubleshootingtheVehiclewiththeCDT.................................................................................................12-5

TroubleshootingGuide1..........................................................................................................................12-5

TroubleshootingGuide2..........................................................................................................................12-8

TestProcedures.........................................................................................................................................12-11

TestingBasics........................................................................................................................................12-11

SECTION13—ElectricVehicle-ElectricalComponents...................................................................................13-1

KeySwitch..................................................................................................................................................13-1

TestingtheKeySwitch.............................................................................................................................13-1

KeySwitchRemoval................................................................................................................................13-1

PagexTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual

KeySwitchInstallation.............................................................................................................................13-1

ChargeIndicatorLight..................................................................................................................................13-2

TestingtheChargeIndicatorLight.............................................................................................................13-2

ChargeIndicatorLightRemoval................................................................................................................13-2

ChargeIndicatorLightInstallation.............................................................................................................13-2

USBPort.....................................................................................................................................................13-3

USBPortRemoval...................................................................................................................................13-3

USBPortInstallation...............................................................................................................................13-4

Forward/Neutral/ReverseRockerSwitch.......................................................................................................13-4

TestingtheForward/Neutral/ReverseRockerSwitch..................................................................................13-4

Forward/Neutral/ReverseRockerSwitchRemoval.....................................................................................13-4

Forward/Neutral/ReverseRockerSwitchInstallation..................................................................................13-5

ElectronicsModuleCover.............................................................................................................................13-6

ElectronicsModuleCoverRemoval..........................................................................................................13-6

ElectronicsModuleCoverInstallation........................................................................................................13-6

Tow/RunSwitch...........................................................................................................................................13-7

TestingtheTow/RunSwitch......................................................................................................................13-7

Tow/RunSwitchRemoval.........................................................................................................................13-7

Tow/RunSwitchInstallation......................................................................................................................13-7

MotorControllerOutputRegulator(MCOR)...................................................................................................13-8

TestingtheMCOR...................................................................................................................................13-8

MCORRemoval......................................................................................................................................13-8

MCORInstallation...................................................................................................................................13-8

ReverseBuzzer...........................................................................................................................................13-9

TestingtheReverseBuzzer......................................................................................................................13-9

ReverseBuzzerRemoval.........................................................................................................................13-9

ReverseBuzzerInstallation......................................................................................................................13-9

ElectronicsModule.....................................................................................................................................13-10

ElectronicsModuleRemoval...................................................................................................................13-10

ElectronicsModuleInstallation................................................................................................................13-11

SpeedController........................................................................................................................................13-12

TestingtheSolidStateSpeedController..................................................................................................13-12

SpeedControllerRemoval......................................................................................................................13-12

SpeedControllerInstallation....................................................................................................................13-12

Solenoid.....................................................................................................................................................13-13

TestingtheSolenoid...............................................................................................................................13-13

SolenoidRemoval..................................................................................................................................13-13

SolenoidInstallation................................................................................................................................13-14

ChargerReceptacle....................................................................................................................................13-14

TestingtheChargerReceptacle...............................................................................................................13-14

ChargerReceptacleInspection................................................................................................................13-14

ChargerReceptacleRemoval..................................................................................................................13-14

ChargerReceptacleInstallation...............................................................................................................13-15

SECTION14—ElectricVehicle-Batteries.......................................................................................................14-1

GeneralInformation.....................................................................................................................................14-1

BatteryTestingBasics–8Volt......................................................................................................................14-2

Observation.............................................................................................................................................14-2

MeasuringVoltageofBatterySet..............................................................................................................14-2

BatteryCellNumbering............................................................................................................................14-2

BatteryTesting–8Volt................................................................................................................................14-3

BatteryRegrouping......................................................................................................................................14-3

BatteryReplacement...................................................................................................................................14-5

BatteryCare................................................................................................................................................14-6

WaterQuality..........................................................................................................................................14-6

Deionizer................................................................................................................................................14-7

BatteryCare–VehiclesEquippedwiththeSingle-PointWateringSystem...................................................14-8

BatteryCare–VehiclesWithouttheSingle-PointWateringSystem.............................................................14-9

Self-Discharge.........................................................................................................................................14-9

ElectrolyteLevel.....................................................................................................................................14-10

VibrationDamage...................................................................................................................................14-10

SinglePointWateringSystem(SPWS).........................................................................................................14-11

InitialMaintenanceoftheSPWS..............................................................................................................14-11

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagexi

WateringBatterieswiththeSPWS...........................................................................................................14-11

BatteryStorage..........................................................................................................................................14-13

FleetRotation.............................................................................................................................................14-13

Deep-Discharge.........................................................................................................................................14-13

EarlyExcessiveDischarging.......................................................................................................................14-13

SECTION15—ElectricVehicle-BatteryCharger.............................................................................................15-1

GeneralInformation.....................................................................................................................................15-2

IC650BatteryChargerSpecications...........................................................................................................15-3

GovernmentalAndIndustryCertications......................................................................................................15-3

EuropeanConformity...............................................................................................................................15-3

FederalCommunicationsCommission......................................................................................................15-4

InternationalProtectionMarking...............................................................................................................15-4

UnderwritersLaboratoriesAndCanadianStandardsAssociation................................................................15-4

Features.....................................................................................................................................................15-5

ACElectricalCordAndPlug.....................................................................................................................15-5

OnboardBatteryChargerInterface...........................................................................................................15-5

StatusIndicatorLights..............................................................................................................................15-6

BatteryChargingInterlock........................................................................................................................15-7

ExternalBatteryChargerMounting...........................................................................................................15-7

HowToMakeAStrainReliefAndDripLoop..............................................................................................15-8

TheChargeCircuit.......................................................................................................................................15-9

ExternalChargeCircuit............................................................................................................................15-9

OnboardChargeCircuit..........................................................................................................................15-10

BatteryChargerOperation..........................................................................................................................15-11

ChargingWithExternalCharger..............................................................................................................15-11

ChargingWithOnboardCharger..............................................................................................................15-12

Algorithm...................................................................................................................................................15-13

HowToViewAlgorithmOnExternalCharger............................................................................................15-13

HowToInstallTrojanAlgorithm-ExternalCharger...................................................................................15-15

HowToChangeOnboardChargerAlgorithm............................................................................................15-18

UpdateBatteryChargerWithUSB...........................................................................................................15-19

InspectionAndMaintenance.......................................................................................................................15-20

ElectricalCords......................................................................................................................................15-20

ElectricalPlugsandReceptacles.............................................................................................................15-21

CleanTheElectricalPlugsandReceptacles.............................................................................................15-21

BatteryChargerUSBReceptacle.............................................................................................................15-21

CleantheUSBReceptacle......................................................................................................................15-21

BatteryChargerTroubleshooting.................................................................................................................15-22

NumberingVehiclesandChargers...........................................................................................................15-22

ACPowerSource...................................................................................................................................15-22

TerminalBlockCover..............................................................................................................................15-22

ResetPower–ExternalCharger..............................................................................................................15-23

ResetPower–OnboardCharger.............................................................................................................15-23

ExternalChargerTroubleshootingIndicators............................................................................................15-24

OnboardBatteryChargerErrorCodes.....................................................................................................15-26

OnboardBatteryChargerFaultCodes.....................................................................................................15-27

TestProcedures.........................................................................................................................................15-28

ExternalChargerRepairs............................................................................................................................15-31

TerminalBlockCoverRemoval................................................................................................................15-31

TerminalBlockCoverInstallation.............................................................................................................15-31

DCCordRemoval..................................................................................................................................15-32

DCCordInstallation................................................................................................................................15-33

HandleRemoval.....................................................................................................................................15-34

HandleInstallation..................................................................................................................................15-34

FootRemoval.........................................................................................................................................15-35

FootInstallation......................................................................................................................................15-35

OnboardChargerRepairs...........................................................................................................................15-36

Two-PassengerOnboardCharger...........................................................................................................15-36

FixedRearSeatOnboardCharger...........................................................................................................15-41

Fold-DownRearSeatOnboardCharger...................................................................................................15-47

TerminalBlockCoverRemoval................................................................................................................15-51

TerminalBlockCoverInstallation.............................................................................................................15-51

PagexiiTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual

DCCordRemoval..................................................................................................................................15-52

DCCordInstallation................................................................................................................................15-52

SECTION16—ElectricVehicle-Motor............................................................................................................16-1

GeneralInformation.....................................................................................................................................16-1

ExternalMotorTesting.................................................................................................................................16-1

Motor..........................................................................................................................................................16-4

MotorRemoval........................................................................................................................................16-4

MotorDisassembly..................................................................................................................................16-5

MotorComponentTestingandInspection......................................................................................................16-8

ArmatureInspectionandTesting...............................................................................................................16-8

MotorFrameandFieldWindingsInspection.............................................................................................16-10

MotorBrush,Spring,andTerminalInsulatorInspection.............................................................................16-10

ReconditioningtheMotor............................................................................................................................16-13

MotorSpecications...............................................................................................................................16-13

MotorAssembly..........................................................................................................................................16-13

MotorInstallation........................................................................................................................................16-15

SECTION17—ElectricVehicle-Transaxle......................................................................................................17-1

Lubrication..................................................................................................................................................17-1

AxleBearingandShaft................................................................................................................................17-1

AxleShaft...............................................................................................................................................17-1

AxleBearing............................................................................................................................................17-4

TransaxleRemoval......................................................................................................................................17-5

TransaxleDisassembly,Inspection,andAssembly.........................................................................................17-7

TransaxleDisassemblyandInspection......................................................................................................17-7

TransaxleAssembly.................................................................................................................................17-9

TransaxleInstallation..................................................................................................................................17-10

SECTION18—GasolineVehicle-Transaxle....................................................................................................18-1

GeneralInformation.....................................................................................................................................18-1

ShifterLever............................................................................................................................................18-1

Maintenance/OperateSwitch....................................................................................................................18-1

GovernorSystem.....................................................................................................................................18-2

TransaxleService....................................................................................................................................18-2

Lubrication..............................................................................................................................................18-2

ToolsRequiredForThisSection...............................................................................................................18-3

RearHubs...................................................................................................................................................18-4

RearHubRemoval..................................................................................................................................18-4

RearHubInstallation...............................................................................................................................18-4

AxleTubes,AxleShaftsandWheelBearings................................................................................................18-6

AxleTubeandAxleShaftRemoval...........................................................................................................18-6

AxleTubeandAxleShaftInstallation........................................................................................................18-7

RearWheelBearingRemoval..................................................................................................................18-7

RearWheelBearingInstallation................................................................................................................18-7

AxleShaftOilSealRemoval.....................................................................................................................18-7

AxleShaftOilSealInstallation..................................................................................................................18-8

TransaxleRemoval......................................................................................................................................18-9

TransaxleInstallation..................................................................................................................................18-12

Forward/Neutral/ReverseHandle.................................................................................................................18-13

Forward/Neutral/ReverseHandleRemoval...............................................................................................18-13

Forward/Neutral/ReverseHandleInstallation............................................................................................18-13

ShifterCable..............................................................................................................................................18-13

ShifterCableRemoval............................................................................................................................18-13

ShifterCableInstallation.........................................................................................................................18-14

ShifterCableAdjustment.........................................................................................................................18-14

SECTION19—KohlerECH400-TroubleshootingandElectricalSystem...........................................................19-1

GeneralInformation.....................................................................................................................................19-1

Accessories.............................................................................................................................................19-1

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagexiii

FeaturesoftheElectronicFuelInjection(EFI)System...............................................................................19-1

GroundLocations....................................................................................................................................19-1

LowOilWarningLight..............................................................................................................................19-2

MalfunctionIndicatorLight........................................................................................................................19-2

TroubleshootingGuide.................................................................................................................................19-2

GasolinePowertrain................................................................................................................................19-3

FuseAndRelayLocations............................................................................................................................19-5

ElectricalSystem.........................................................................................................................................19-6

TestProcedures..........................................................................................................................................19-7

TestingBasics.........................................................................................................................................19-7

SECTION20—KohlerECH400-ElectricalComponents...................................................................................20-1

Battery........................................................................................................................................................20-1

GeneralInformation.................................................................................................................................20-1

PreventiveMaintenance...........................................................................................................................20-2

Self-Discharge.........................................................................................................................................20-2

VibrationDamage....................................................................................................................................20-2

BatteryRemoval......................................................................................................................................20-3

ChargingtheBattery................................................................................................................................20-3

BatteryInstallation...................................................................................................................................20-3

BatteryStorage.......................................................................................................................................20-4

ChargingaDeadBattery..........................................................................................................................20-4

GroundCables............................................................................................................................................20-4

Starter/Generator.........................................................................................................................................20-4

Starter/GeneratorRemoval......................................................................................................................20-4

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................20-5

BrushInspectionandReplacement...........................................................................................................20-5

BrushSpringInspectionandReplacement................................................................................................20-6

Starter/GeneratorAssembly.....................................................................................................................20-6

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................20-7

BearingCleaningandInspection..............................................................................................................20-8

BearingRemoval.....................................................................................................................................20-9

FieldCoilAssembly.................................................................................................................................20-9

VisualInspectionofArmature...................................................................................................................20-9

CommutatorCleaningandInspection......................................................................................................20-10

ArmatureGroundTest.............................................................................................................................20-11

VisualInspectionofFieldCoils................................................................................................................20-12

Starter/GeneratorRework.......................................................................................................................20-12

Starter/GeneratorAssembly....................................................................................................................20-12

Starter/GeneratorInstallation...................................................................................................................20-15

BeltTensionAdjustmentforEFIEngines..................................................................................................20-16

Solenoid.....................................................................................................................................................20-18

SolenoidRemoval..................................................................................................................................20-18

SolenoidInstallation................................................................................................................................20-19

VoltageRegulator.......................................................................................................................................20-20

VoltageRegulatorRemoval.....................................................................................................................20-20

VoltageRegulatorInstallation..................................................................................................................20-21

EngineControlUnit(ECU)..........................................................................................................................20-21

EngineControlUnitRemoval...................................................................................................................20-21

EngineControlUnitInstallation................................................................................................................20-22

FuelLevelSendingUnit..............................................................................................................................20-22

Maintenance/OperateSwitch.......................................................................................................................20-22

Maintenance/OperateSwitchRemoval.....................................................................................................20-22

Maintenance/OperateSwitchInstallation..................................................................................................20-23

AcceleratorPedalLimitSwitch....................................................................................................................20-23

KillLimitSwitch..........................................................................................................................................20-24

Multi-PurposeBuzzerLimitSwitch...............................................................................................................20-24

Multi-PurposeBuzzerLimitSwitchRemoval.............................................................................................20-24

Multi-PurposeBuzzerLimitSwitchInstallation..........................................................................................20-25

NeutralLockoutLimitSwitch.......................................................................................................................20-25

NeutralLockoutLimitSwitchRemoval.....................................................................................................20-25

NeutralLockoutLimitSwitchInstallation...................................................................................................20-26

TransaxleLimitSwitch................................................................................................................................20-27

PagexivTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual

TransaxleLimitSwitchRemoval..............................................................................................................20-27

TransaxleLimitSwitchInstallation...........................................................................................................20-27

BrakeLightRelay.......................................................................................................................................20-28

BrakeLightRelayRemoval.....................................................................................................................20-28

BrakeLightRelayInstallation..................................................................................................................20-29

FuelGauge/HourMeter..............................................................................................................................20-29

GeneralInformation................................................................................................................................20-29

FuelGauge/HourMeterRemoval............................................................................................................20-30

FuelGauge/HourMeterInstallation..........................................................................................................20-30

HeadlightSwitch.........................................................................................................................................20-31

HeadlightSwitchRemoval.......................................................................................................................20-31

HeadlightSwitchInstallation....................................................................................................................20-31

KeySwitch.................................................................................................................................................20-32

KeySwitchRemoval...............................................................................................................................20-32

KeySwitchInstallation............................................................................................................................20-32

LowOilWarningLight.................................................................................................................................20-33

LowOilWarningLightRemoval...............................................................................................................20-33

LowOilWarningLightInstallation............................................................................................................20-33

MalfunctionIndicatorLight(MIL)..................................................................................................................20-34

MalfunctionIndicatorLightRemoval.........................................................................................................20-34

MalfunctionIndicatorLightInstallation......................................................................................................20-34

Multi–PurposeBuzzer.................................................................................................................................20-35

Multi–PurposeBuzzerRemoval...............................................................................................................20-35

Multi-PurposeBuzzerInstallation.............................................................................................................20-35

USBReceptacle.........................................................................................................................................20-36

USBReceptacleRemoval.......................................................................................................................20-36

USBReceptacleInstallation...................................................................................................................20-36

OxygenSensor...........................................................................................................................................20-37

OxygenSensorRemoval........................................................................................................................20-37

OxygenSensorInstallation......................................................................................................................20-37

SECTION21—KohlerECH400-Engine..........................................................................................................21-1

GeneralInformation.....................................................................................................................................21-1

BeforeServicing......................................................................................................................................21-1

EngineRemoval..........................................................................................................................................21-2

EngineInstallation.......................................................................................................................................21-5

Snubber......................................................................................................................................................21-8

SnubberRemoval....................................................................................................................................21-8

SnubberInstallation.................................................................................................................................21-8

SECTION22—KohlerECH400-FuelSystem..................................................................................................22-1

GeneralInformation.....................................................................................................................................22-1

EFISystemFeatures/Specications..........................................................................................................22-1

EngineControlLinkages..............................................................................................................................22-2

GeneralInformation.................................................................................................................................22-2

GroundSpeed.........................................................................................................................................22-2

GovernorCable.......................................................................................................................................22-2

AcceleratorCable....................................................................................................................................22-5

IdleAdjustment........................................................................................................................................22-8

HowtoMeasureGroundSpeed................................................................................................................22-8

EngineRPMAdjustment..........................................................................................................................22-9

AirIntakeSystem.......................................................................................................................................22-10

AirCleanerRemoval...............................................................................................................................22-10

AirCleanerInstallation............................................................................................................................22-10

RelievingFuelPressure..............................................................................................................................22-11

ToRelieveFuelPressure........................................................................................................................22-11

CarbonCanister.........................................................................................................................................22-12

CarbonCanisterRemoval.......................................................................................................................22-12

CarbonCanisterInstallation....................................................................................................................22-12

FuelLine....................................................................................................................................................22-13

FuelLineRemoval..................................................................................................................................22-13

FuelLineInstallation...............................................................................................................................22-15

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagexv

FuelPumpModule......................................................................................................................................22-17

GeneralInformation................................................................................................................................22-17

FuelPumpModuleRemoval...................................................................................................................22-17

FuelPumpModuleInstallation.................................................................................................................22-19

FuelTank...................................................................................................................................................22-20

GeneralInformation................................................................................................................................22-20

FuelTankRemoval.................................................................................................................................22-20

FuelTankDisposal.................................................................................................................................22-22

FuelTankStorage..................................................................................................................................22-22

FuelTankInstallation..............................................................................................................................22-22

FuelFilter...................................................................................................................................................22-24

GeneralInformation................................................................................................................................22-24

FuelFilterRemoval.................................................................................................................................22-24

FuelFilterInstallation..............................................................................................................................22-25

SECTION23—KohlerECH400-ExhaustSystem............................................................................................23-1

Mufer........................................................................................................................................................23-1

MuferRemoval......................................................................................................................................23-1

MuferInstallation....................................................................................................................................23-2

SECTION24—KohlerECH400-Clutches.......................................................................................................24-1

GeneralInformation.....................................................................................................................................24-1

Troubleshooting...........................................................................................................................................24-1

DriveBelt....................................................................................................................................................24-3

DriveBeltRemoval..................................................................................................................................24-3

DriveBeltInstallation...............................................................................................................................24-3

DriveClutch................................................................................................................................................24-4

DriveClutchRemoval..............................................................................................................................24-5

DriveClutchCleaningandInspection........................................................................................................24-6

DriveClutchDisassembly.........................................................................................................................24-6

InspectionofDriveClutchParts................................................................................................................24-9

DriveClutchAssembly............................................................................................................................24-10

DriveClutchInstallation..........................................................................................................................24-11

DrivenClutch.............................................................................................................................................24-12

DrivenClutchRemoval...........................................................................................................................24-13

DrivenClutchDisassembly......................................................................................................................24-13

DrivenClutchInspection.........................................................................................................................24-15

DrivenClutchAssembly..........................................................................................................................24-16

DrivenClutchInstallation.........................................................................................................................24-18

SECTION25—KohlerEngineServiceManual.................................................................................................25-1

SECTION26—SubaruEX-40-TroubleshootingandElectricalSystem..............................................................26-1

GeneralInformation.....................................................................................................................................26-1

Accessories.............................................................................................................................................26-1

LowOilWarningLight..............................................................................................................................26-1

GroundLocations....................................................................................................................................26-1

FeaturesoftheElectronicFuelInjection(EFI)System...............................................................................26-2

TroubleshootingGuide.................................................................................................................................26-2

ECUErrorCodes(DisplayedbytheLowOilWarningLight).......................................................................26-2

GasolinePowertrain................................................................................................................................26-4

SonicWeld,Fuse,andDiodeLocations........................................................................................................26-8

ElectricalSystem.........................................................................................................................................26-9

TestProcedures.........................................................................................................................................26-10

TestingBasics........................................................................................................................................26-10

SECTION27—SubaruEX-40-ElectricalComponents.....................................................................................27-1

Starter/Generator.........................................................................................................................................27-1

Starter/GeneratorRemoval......................................................................................................................27-1

PagexviTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual

DisassemblyoftheStarter/GeneratortoServicetheBrushes.....................................................................27-1

BrushInspectionandReplacement...........................................................................................................27-2

BrushSpringInspectionandReplacement................................................................................................27-2

Starter/GeneratorAssembly.....................................................................................................................27-3

DisassemblyoftheStarter/GeneratortoServicetheArmature/Commutator................................................27-4

BearingCleaningandInspection..............................................................................................................27-5

BearingRemoval.....................................................................................................................................27-6

FieldCoilAssembly.................................................................................................................................27-6

VisualInspectionofArmature...................................................................................................................27-6

CommutatorCleaningandInspection.......................................................................................................27-7

ArmatureGroundTest..............................................................................................................................27-8

VisualInspectionofFieldCoils.................................................................................................................27-9

Starter/GeneratorRework........................................................................................................................27-9

Starter/GeneratorAssembly.....................................................................................................................27-9

Starter/GeneratorInstallation...................................................................................................................27-12

BeltTensionAdjustmentforEFIEngines..................................................................................................27-13

VoltageRegulator.......................................................................................................................................27-15

VoltageRegulatorRemoval.....................................................................................................................27-15

VoltageRegulatorInstallation..................................................................................................................27-16

EngineControlUnit(ECU)..........................................................................................................................27-17

EngineControlUnitRemoval...................................................................................................................27-17

EngineControlUnitInstallation................................................................................................................27-17

KeySwitch.................................................................................................................................................27-18

KeySwitchRemoval...............................................................................................................................27-18

KeySwitchInstallation............................................................................................................................27-19

Maintenance/OperateSwitch.......................................................................................................................27-19

Maintenance/OperateSwitchRemoval.....................................................................................................27-19

Maintenance/OperateSwitchInstallation..................................................................................................27-19

NeutralLockoutLimitSwitch.......................................................................................................................27-20

NeutralLockoutLimitSwitchRemoval.....................................................................................................27-20

NeutralLockoutLimitSwitchInstallation...................................................................................................27-20

Solenoid.....................................................................................................................................................27-21

TestingtheSolenoid...............................................................................................................................27-21

SolenoidRemoval..................................................................................................................................27-21

SolenoidInstallation................................................................................................................................27-21

Fuse..........................................................................................................................................................27-22

FuseRemoval........................................................................................................................................27-22

FuseInstallation.....................................................................................................................................27-22

AcceleratorPedalLimitSwitch....................................................................................................................27-23

TestingtheAcceleratorPedalLimitSwitch...............................................................................................27-23

KillLimitSwitch..........................................................................................................................................27-23

TestingtheKillLimitSwitch.....................................................................................................................27-23

ReverseWarningBuzzer.............................................................................................................................27-23

ReverseWarningBuzzerRemoval..........................................................................................................27-23

ReverseWarningBuzzerInstallation........................................................................................................27-24

ReverseBuzzerLimitSwitch.......................................................................................................................27-25

ReverseBuzzerLimitSwitchRemoval.....................................................................................................27-25

ReverseBuzzerLimitSwitchInstallation..................................................................................................27-25

LowOilWarningLight.................................................................................................................................27-26

LowOilWarningLightRemoval...............................................................................................................27-26

LowOilWarningLightInstallation............................................................................................................27-26

FuelGauge................................................................................................................................................27-27

FuelGaugeRemoval..............................................................................................................................27-27

FuelGaugeInstallation...........................................................................................................................27-27

FuelLevelSendingUnit..............................................................................................................................27-28

HourMeter.................................................................................................................................................27-28

TestingtheHourMeter............................................................................................................................27-28

HourMeterRemoval...............................................................................................................................27-28

HourMeterInstallation............................................................................................................................27-28

OilLevelSensor.........................................................................................................................................27-29

OilLevelSensorRemoval.......................................................................................................................27-29

OilLevelSensorInstallation....................................................................................................................27-29

Battery.......................................................................................................................................................27-30

GeneralInformation................................................................................................................................27-30

Tempo,TempoConnect,andTempo2+2MaintenanceandServiceManualPagexvii

TestingtheBattery..................................................................................................................................27-30

PreventiveMaintenance..........................................................................................................................27-30

Self-Discharge........................................................................................................................................27-31

VibrationDamage...................................................................................................................................27-31

BatteryRemoval.....................................................................................................................................27-32

ChargingtheBattery...............................................................................................................................27-32

BatteryInstallation..................................................................................................................................27-32

BatteryStorage......................................................................................................................................27-33

ChargingaDeadBattery.........................................................................................................................27-33

GroundCables...........................................................................................................................................27-33

SECTION28—SubaruEX-40-Engine............................................................................................................28-1

GeneralInformation.....................................................................................................................................28-1

BeforeServicing......................................................................................................................................28-1

EngineRotation.......................................................................................................................................28-1

TorqueSpecications...............................................................................................................................28-2

AdjustmentsandSettings.........................................................................................................................28-2

EngineOil–GasolineVehicle...................................................................................................................28-2

SparkPlug..............................................................................................................................................28-5

Breather..................................................................................................................................................28-6

ValveClearanceCheckandAdjustment....................................................................................................28-7

EngineRemoval..........................................................................................................................................28-8

EngineRemoval......................................................................................................................................28-8

EngineInstallation.......................................................................................................................................28-9

EngineInstallation...................................................................................................................................28-9

Flywheel....................................................................................................................................................28-10

FlywheelRemoval..................................................................................................................................28-11

FlywheelInstallation...............................................................................................................................28-12

OilLevelSensor.........................................................................................................................................28-12

TestingtheOilLevelSensor....................................................................................................................28-12

OilLevelSensorRemoval.......................................................................................................................28-12

OilLevelSensorInstallation....................................................................................................................28-13

IgnitionCoil................................................................................................................................................28-14

TestingtheIgnitionCoil...........................................................................................................................28-14

IgnitionCoilRemoval..............................................................................................................................28-14

IgnitionCoilInstallation...........................................................................................................................28-14

Snubber.....................................................................................................................................................28-15

SnubberRemoval...................................................................................................................................28-15

SnubberInstallation................................................................................................................................28-15

SECTION29—SubaruEX-40-FuelSystem....................................................................................................29-1

GeneralInformation.....................................................................................................................................29-1

EFISystemFeatures/Specications..........................................................................................................29-1

RelievingFuelPressure...............................................................................................................................29-2

ToRelieveFuelPressure.........................................................................................................................29-2

ThrottleBody...............................................................................................................................................29-3

ThrottleBodyRemoval.............................................................................................................................29-3

ThrottleBodyInstallation..........................................................................................................................29-5

EngineControlLinkages..............................................................................................................................29-6

GeneralInformation.................................................................................................................................29-6

GroundSpeed.........................................................................................................................................29-7

GovernorCable.......................................................................................................................................29-7

AcceleratorCable....................................................................................................................................29-8

ClosedThrottleorIdleAdjustment–Pedal-StartVehicles.........................................................................29-10

HowtoMeasureGroundSpeed...............................................................................................................29-10

EngineRPMAdjustment.........................................................................................................................29-11

AirIntakeSystem.......................................................................................................................................29-12

GeneralInformation................................................................................................................................29-12

AirFilter.................................................................................................................................................29-12

AirIntakeSystemRemoval.....................................................................................................................29-13

AirIntakeSystemInstallation...................................................................................................................29-14

FuelLine....................................................................................................................................................29-15

PagexviiiTempo,TempoConnect,andTempo2+2MaintenanceandServiceManual