1 - INCLUDES ITEMS SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLE ISSUED DATE JANUARY 2009 REVISED DATE SEPTEMBER 2009

Transcription

1 INCLUDES ITEMS SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLE ISSUED DATE JANUARY 2009 REVISED DATE SEPTEMBER 2009

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3 SERVICE PARTS MANUAL ELECTRIC UTILITY VEHICLES ST SPORT II STARTING MODEL YEAR 2009 DISCLAIMER: The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice. The E-Z-GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON- SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: FAX: OUTSIDE USA PHONE: , FAX: E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA Page i

4 NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty. When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture. BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75 F (-60 C). As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ILLUSTRATED PARTS BREAKDOWN vii ACCELERATOR A-1 BATTERY CHARGER, PORTABLE B-1 BODY C-1 BRAKES D-1 ELECTRICAL SYSTEM E-1 ELECTRONIC SPEED CONTROL F-1 ELECTRIC MOTOR G-1 FRONT SUSPENSION/STEERING H-1 REAR AXLE J-1 REAR SUSPENSION K-1 SEATING L-1 TRUCK BED, MANUAL LIFT M-1 WEATHER PROTECTION N-1 WHEELS AND TIRES P-1 SPECIALTY PRODUCTS APPENDIX A-1 OPTIONS/ACCESSORIES APPENDIX B-1 Page iii

6 TABLE OF CONTENTS Notes: Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle APPENDIX Contains a listing of specialty products and options/accessories USE OF THE MANUAL To use this manual, consult the TABLE OF CONTENTS (page iii) to locate the information or illustration required. Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your situation. Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its location) and note the complete number shown on the plate. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. Page v

8 Front of Vehicle ,88 81,86 84,89 82, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the INDEX OF MAJOR COMPONENTS and select the most appropriate component description. Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying description for specific information regarding the part that was not shown in the index. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. 2. IF YOU KNOW THE PART NUMBER Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on. Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying description for specific information regarding the part. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts. The asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. Page vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR 1 - Includes Items Includes Items RED GRN BLK WHT To Harness from Direction Selector Part of Frame Page A-1

11 ACCELERATOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G10 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2-36) G02 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-16 X 1/2" LG G01 PEDAL BOX AND COVER G6 SCREW, #8-32 X 3/4" LG G02 MICRO SWITCH G01 SCREW, #4-20 X 5/8" LG G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" PLUNGER G01 ACCELERATOR CAM ROD G1 SPRING RETAINER, 1/2" G1 BUSHING G01 COMPRESSION SPRING G2 SPRING RETAINER, 3/8" G01 ACCELERATOR ROD G4 LOCK NUT, 5/ G4 CLEVIS YOKE (ADJUSTABLE) G3 CLEVIS PIN, 5/16" X 1" LG G1 NYLON BUSHING G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 PEDAL PIVOT PIN G6 PUSH NUT, 9/32" G05 WIRING HARNESS (PEDAL BOX ASSEMBLY) Page A-2

12 ACCELERATOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 34-36) G1 OVAL RIVET, 3/16" X 3/8" LG G01 ACCELERATOR PEDAL PAD G04 ACCELERATOR PEDAL PLATE, BRACKET G6 SCREW, HEX HEAD G2 NUT (STAINLESS) G01 WASHER... 4 Page A-3

13 ACCELERATOR Notes: Page A-4

14 BATTERY CHARGER-PORTABLE 36 VOLT 1 Page B - 1

15 BATTERY CHARGER-PORTABLE 36 VOLT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY POWERWISE QE(DELTA), 36VOLT 10 CORD CHARGER KIT, AC CORD, 9, POWERWISE QE KIT, 10 DC CORD, 36V POWERWISE QE KIT, PCB/ EMI BRD, 36-48V PWISE QE KIT, CHARGER CVER/ HNDLE, 36V PW QE CHARGER HANDLE-POWERWISE QE... 1 Page B - 2

16 BODY Includes Items Page C-1

17 BODY Page C-2

18 BODY Page C-3

19 BODY Page C-4

20 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 UPPER FLOORPAN G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 LOWER FLOORPAN G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ACCESS COVER G01 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 9-12) G01 DEFLECTOR (PASSENGER SIDE) G01 DEFLECTOR (DRIVER SIDE) G5 SCREW, #8-18 X 5/8" LG G01 INSTRUMENT PANEL INSERT (FOUR CUP) G01 LABEL (SAFETY) (TEXT) G01 LABEL (SAFETY) (PICTOGRAPH) G01 LABEL (ANTI-ROLLBACK) G01 SPLASH PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG (ALUMINUM) G** COWL G01 NAMEPLATE (E-Z-GO) (OVAL) G01 RIVET, 3/16" X 1" LG G01 RIVET, 3/16" X 1" LG G01 FENDER FLARE (DRIVER SIDE)... 1 Page C-5

21 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 FENDER FLARE (PASSENGER SIDE) G04 FRONT SHIELD G02 FRONT SHIELD BRACE G01 SCREW, 1/4-20 X 1/2" LG G1 WASHER, 1/4" G01 RIVET, KTR, 1/4" X 1" LG BUMPER G2 WASHER, 5/16" G04 SPACER, 1" G01 SPACER, 1/2" G8 LOCK WASHER, 5/16" G02 BOLT, 5/16-18 X 2 1/2" LG G02 COWL SUPPORT BRACKET G02 SELF TAPPING SCREW, 1/4-20 X 1/2" LG G01 RIVET, 3/16" X 1.0" LG DECAL (ST-SPORT II E) G01 LABEL, TILT WARNING PICTOGRAPH Page C-6

22 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY * SERIAL NUMBER PLATE G6 RIVET, BLACK (ALUMINUM) G01 ROCKER PANEL (DRIVER SIDE) G01 ROCKER PANEL (PASSENGER SIDE) G6 LOCK NUT, 5/ G01 SEAT FRAME G8 WASHER, 5/16" G6 BOLT, 5/16-18 X 3/4" LG G01 SCREW, 3/8-16 X 1/4" LG G2 BOLT, 5/16-18 X 13/16" LG G02 BATTERY RACK G1 SCREW, 1/4-20 X 1" LG G4 SPACER G4 LOCK NUT, 1/ G01 SILL PLATE TREAD (PASSENGER SIDE) G02 SILL PLATE TREAD (DRIVER SIDE) Page C-7

23 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 FLOORMAT (AXLE MOUNTED STEERING) G21 SEAT WRAP PANEL G01 PEDAL PIVOT COVER G10 RIVET, 5/32" X 9/16" LG G01 SEAT HINGE PLATE G11 RIVET, 3/16" X 3/4" LG G01 SIDE PANEL (DRIVER SIDE) G02 SIDE PANEL (PASSENGER SIDE) G10 RIVET, 5/32" X 9/16" LG G12 RIVET, 1/4" X 1/2" LG G03 SPLASH PANEL G2 BOLT, 5/16-18 X 13/16" LG G01 FENDER (DRIVER SIDE) G02 FENDER (PASSENGER SIDE) G4 LOCK NUT, 1/ G7 WASHER, 1/4" G6 BOLT, 1/4-20 X 3/4" LG G01 REAR PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 SEAT FILLER PANEL (DRIVER SIDE)... 1 Page C-8

24 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 SEAT FILLER PANEL (PASSENGER SIDE) G10 RIVET, 5/32" X 9/16" LG G02 HITCH RECEIVER G8 SCREW, 5/16-18 X 1" LG G2 WASHER, 5/16" G6 LOCK NUT, 5/ G04 ASH TRAY KIT (INCLUDES ITEMS ) G01 ASH TRAY G01 GASKET G02 BRACKET G4 SCREW, #10-16 X 1/2" LG... 4 Page C-9

25 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. Page C-10

26 BRAKES Part of Frame Accelerator Pedal Includes Items Includes Items Includes Items 19, Includes Items Page D-1

27 BRAKES Front of Vehicle Includes Items 54, Includes Itmes 54, Includes Items Includes Items Includes Items 64, Includes Items 64, Includes Items 71, Page D-2

28 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-10) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" G02 BRAKE PEDAL G01 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 8-10) G01 SERVICE BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 7/16" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) G01 FLANGED BUSHING G01 TORSION SPRING G1 WASHER, 3/8" G5 LOCK NUT, 3/ G04 COMPENSATOR ASSEMBLY (INCLUDES ITEMS 19, 20) G01 SPHERICAL NUT, 5/ G9 LOCK NUT, 5/ G03 EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23-26) G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER G04 BRAKE CABLE (DRIVER SIDE) G03 BRAKE CABLE (PASSENGER SIDE) G01 RETAINING RING, 13/32" (STAINLESS STEEL) Page D-3

29 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G3 CLEVIS PIN, 5/16" X 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 5/8" LG G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW, 1/4-20 X 1/2" LG G4 SPACER G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G02 CATCH BRACKET G6 BOLT, 1/4-20 X 3/4" LG G4 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 54, 55) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 54, 55) G01 BRAKE SHOE KIT (INCLUDES ITEM 55) G01 BRAKE SHOE G01 BRAKE SPRING KIT (INCLUDES ITEMS 57-61) * UPPER SPRING * LOWER SPRING * PIN... 2 Page D-4

30 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 60 * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 64, 65) G02 BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCL. ITEMS 64, 65) * ADJUSTER * TEFLON WASHER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 WASHER, 13/16" G2 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS 71, 72) * BRAKE DRUM G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 WASHER, 1 3/8" O.D. X 21/32" CASTELLATED NUT, 5/ G1 COTTER PIN, 1/8" X 1 1/2" LG G03 BRAKE CABLE BRACKET (PASSENGER SIDE) G04 BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-5

31 BRAKES Notes: Page D-6

32 ELECTRICAL SYSTEM CHARGER RECEPTACLE Includes Items A A 5 6 Control Harness (See Electronic Speed Control Section) Controller (See Electronic Speed Control Section) Power Harness (See Electronic Speed Control Section) Clamp (See REAR AXLE Section) Page E-1

33 ELECTRICAL SYSTEM GRN OFF ON KEY SWITCH AND KEY SET Includes Items Page E-2

34 ELECTRICAL SYSTEM Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 6 VOLT BATTERY G01 HOLD DOWN BOLT (STAINLESS STEEL) G01 BATTERY RETAINER G1 LOCK NUT, 5/ G13 6 GA WIRE (BATTERY INTERCONNECT, BLACK, 10 1/2") G18 6 GA WIRE (BATTERY INTERCONNECT, 6") G2 NUT, 5/ G01 CHARGER RECEPTACLE ASSEMBLY (INCLUDES ITEMS 14-23) G03 RECEPTACLE COVER G29 RECEPTACLE BOTTOM G05 FEMALE CONNECTOR G06 INSULATOR SLEEVE G08 SCREW, #10-32 X 1/2" LG (BRASS) G09 SCREW, #6-32 X 1 3/4" LG (STAINLESS STEEL) G10 LOCK NUT, # WIRE HARNESS (CHARGER) G1 WIRE TIE G01 RIVET, 3/16" X 1" LG (ALUMINUM) G1 WIRE TIE Page E-3

35 ELECTRICAL SYSTEM Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 CABLE CLAMP G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G1 WIRE TIE G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 NUT, 5/16-18 (BRASS) G02 BRASS NUT, 1/ G02 LOCK WASHER (SILICON BRONZE) G1 FUSE BLOCK G01 RIVET, 1/8" X 13/16" LG G1 15 AMP FUSE... AR G** KEY SWITCH (WITH LIGHTS) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/ G1 KEY (SET) G1 HEADLIGHTx G6 SCREW, #10-16 X 1" LG G01 JUMPER WIRE (HEADLIGHT) G5 LENS, AMBER... 1 Page E-4

36 ELECTRICAL SYSTEM Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G3 TURN SIGNAL LIGHT ASSEMBLY (INCLUDES ITEMS 62-69) G3 TURN SIGNAL LIGHT G7 WASHER, 1/4" (STAINLESS STEEL) G1 WIRE ASSEMBLY G7 LOCK WASHER, 1/4" G1 NUT, 1/ G01 TURN SIGNAL JUMPER, RED/BLACK (PASSENGER SIDE) G02 TURN SIGNAL JUMPER, GREEN/BLACK (DRIVER SIDE) G1 PUSH-ON TERMINAL (MALE)... 1 Page E-5

37 ELECTRICAL SYSTEM Notes: Page E-6

38 ELECTRONIC SPEED CONTROL - PDS A BLK WHT 1 - Includes Items Includes Items Includes Items F2 F1 B+ B- A Pin Performance Option Inline Connector Pin Tow/Maintenance Box Connector Pin Accelerator Inline Connector See ACCELERATOR 3 Pin Speed Sensor Inline Connector See ELECTRIC MOTOR A C From Power Harness YEL BLU From Control Harness RED From Control Harness Ref Esp 1-1 Page F-1

39 ELECTRONIC SPEED CONTROL - PDS Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-35) G5 LOCK WASHER, # G4 NUT, G1 RESISTOR G4 NUT, 5/ G8 LOCK WASHER, 5/16" G18 4 GA WIRE ASSY BLACK 6" LOCK NUT, 1/ G02 SOLENOID, 36 VOLT G01 HEATSINK ELECTRONIC SPEED CONTROLLER G01 THERMAL MOUNTING PAD G01 BOLT, 1/4-20 X 3/4" LG G1 WIRE TIE G01 DOUBLE TUBE CLAMP G01 BOLT, 1/4-20 X 3/4" LG G01 WIRE HARNESS (POWER) G02 WIRE HARNESS (CONTROL) G5 BOLT, 5/16-18 X 5/8" LG G1 LOCK NUT, 5/ G01 SOLENOID BRACKET G01 COVER ASSEMBLY (INCLUDES ITEMS 25-33) G02 COVER (WITH GASKET) G01 LABEL (TOW SWITCH) G01 TOGGLE SWITCH WITH SEAL (INCLUDES ITEMS 28-31) * SCREW, # * NUT, 15/ Page F-2

40 ELECTRONIC SPEED CONTROL - PDS Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SEALED NUT, 15/ G02 WIRE HARNESS (TOW SWITCH) G1 WIRE TIE GA WIRE (BLACK 27", BL+ TO SOL) GA WIRE (BLACK 36", BL- TO B-) G01 BOLT, 1/4-20 X 3/4" LG G01 PERFORMANCE OPTION...1 Page F-3

41 ELECTRONIC SPEED CONTROL - PDS Notes: Page F-4

42 ELECTRIC MOTOR 1 - Includes Items S1 S2 A2 8 7 A Ref Mtr 3-1 Page G-1

43 ELECTRIC MOTOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 MOTOR (SERIES, FLEET SPEED) (INCLUDES ITEMS 3-12) G18 ARMATURE G03 BRUSH SPRING G15 BRUSH PLATE AND BOX G25 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G09 COVER PLATE AND SCREW G19 COVER COMMUTATOR END G29 FRAME AND FIELD COIL (INCLUDES HARDWARE) G01 SPEED SENSOR, MAGNET G02 SCREW, TORX T Page G-2

44 FRONT SUSPENSION/STEERING Front of Vehicle 25 Part of Frame , 15 19, Part of Frame LUG , Includes Items Includes Item Includes Items 5-10, 15 *NOTE: Tie Rod not shown for clarity Page H-1

45 FRONT SUSPENSION/STEERING Front of Vehicle Includes Items 42-47, Includes Items Includes Items Includes Items 80, Includes Items Page H-2

46 FRONT SUSPENSION/STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRONT AXLE G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 4-10) G02 SPINDLE ASSEMBLY (PASSENGER SIDE) G1 GREASE SEAL G2 ROLLER BEARING AND RACE ASSEMBLY G01 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 8) G1 LUG BOLT, 1/2-20 X 1 7/32" LG G1 SLOTTED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 5-10, 15) G02 SPINDLE ASSEMBLY (DRIVER SIDE) G6 BOLT, 1/2-13 X 6" LG G3 WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER (STAINLESS STEEL) G6 LOCK NUT, 1/ G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING... 8 Page H-3

47 FRONT SUSPENSION/STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G6 NUT, 3/ G01 VINYL CAP G03 LEAF SPRING (HEAVY DUTY) G03 SPRING PLATE G1 LOCK NUT, 7/ G11 BOLT, 7/16-14 X 1 3/4" LG G01 STEERING RACK COVERING & BEARING (INCLUDES ITEMS 42-47, 48-53) G01 RACK EXTENSION * JAM NUT, 1/ G01 RACK BOOT G2 NYLON CLAMP G8 HOSE CLAMP G01 PINION SEAL G01 RACK BALL JOINT (INCLUDES ITEMS 50-53) G1 RUBBER BOOT G2 SLOTTED NUT, 7/ G2 COTTER PIN, 3/32" X 1" LG G3 GREASE FITTING, STRAIGHT G6 BOLT, 7/16-14 X 2 3/4" LG G01 BOLT, 7/16-14 X 3 1/2" LG G02 SPACER G03 SPACER (SHORT)... 1 Page H-4

48 FRONT SUSPENSION/STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 LOCK NUT, 7/ G01 STEERING SHAFT G05 STEERING COLUMN KIT (INCLUDES ITEMS 67-69) G03 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG G01 BOLT, 3/8-16 X 1 1/4" LG WITH PATCHLOCK G1 LOCK WASHER, 3/8" G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 80, 81) G01 BOLT, M8 X 1 1/4" LG G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER STEERING WHEEL G01 STEERING WHEEL COVER... 1 Page H-5

49 FRONT SUSPENSION/STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 LOCK NUT, 5/ G01 TIE ROD ASSEMBLY (INCLUDES ITEMS ) G01 THREADED ROD (24" LG) G01 TIE ROD END (LEFT HAND THREADS) G01 JAM NUT, M12 X (LEFT HAND THREADS) G02 TIE ROD END (RIGHT HAND THREADS) G02 JAM NUT, M12 X (RIGHT HAND THREADS) G1 LOCK NUT, 7/ Page H-6

50 FRONT SUSPENSION/STEERING Notes: Page H-7

51 FRONT SUSPENSION/STEERING Notes: Page H-8

52 REAR AXLE 1 - Includes Items 2-7 NOTE: Apply a light coat of moly grease to male spline before assembly. Reference part number Page J-1

53 REAR AXLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 REAR AXLE ASSEMBLY, 12.44:1 (INCLUDES ITEMS 3-7) G12 AXLE SHAFT (PASSENGER SIDE) G11 AXLE SHAFT (DRIVER SIDE) G1 DIFFERENTIAL COVER G01 FILL/CHECK PLUG G1 SCREW, 5/16-18 X 3/4" LG G01 VENT G1 BUMPER SPLINE G2 BOLT, 1/4-20 X 1 1/4" LG G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G7 WASHER, 1/4" (STAINLESS STEEL) G01 MOLY LUBE, 2 OZ... AR Page J-2

54 REAR SUSPENSION Ref Rsp Page K-1

55 REAR SUSPENSION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING G6 NUT, 3/ G03 LEAF SPRING (HEAVY DUTY) G01 U BOLT, 3/8-16 X 2" X 2 1/2" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G02 SPACER G01 RUBBER BUSHING SHACKLE PLATE G9 BOLT, 3/8-16 X 3 1/2" LG (STAINLESS STEEL) G5 LOCK NUT, 3/ G1 SHOULDER BOLT, 3/8-16 X 3 1/4" LG G1 LOCK NUT, 3/ G01 VINYL CAP... 2 Page K-2

56 SEATING 15 - Includes Items 16, Includes Items Front of Vehicle Ref Sea Page L-1

57 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 SEAT BACK SUPPORT G2 BOLT, 5/16-18 X 13/16" LG G8 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G02 SEAT BACK SUPPORT BRACKET G01 BOLT, 3/8-16 X 1 1/4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G** SEAT BACK ASSEMBLY (INCLUDES ITEMS 16, 17) G01...WHITE SEAT BACK ASSEMBLY 71274G04...GRAY SEAT BACK ASSEMBLY 71274G07...BROWN SEAT BACK ASSEMBLY G** VINYL SEAT BACK COVER G1...WHITE SEAT BACK COVER 18144G4...GRAY SEAT BACK COVER 18144G8...BROWN SEAT BACK COVER G01 PLASTIC SEAT BACK COVER (BLACK) SCREW, 1/4-20 X 1" LG G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 24-32) G01...WHITE SEAT BOTTOM ASSEMBLY 71611G03...GRAY SEAT BOTTOM ASSEMBLY 71611G16...BROWN SEAT BOTTOM ASSEMBLY Page L-2

58 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G** VINYL SEAT BOTTOM COVER G01...WHITE - VINYL SEAT BOTTOM COVER 71602G02...GRAY - VINYL SEAT BOTTOM COVER 71602G07...BROWN - VINYL SEAT BOTTOM COVER G01 VINYL TRIM (SEAT BOTTOM) G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 BOLT, 1/4-20 X 7/8" LG G1 DROP SOLING SLAB... 2 Page L-3

59 SEATING Notes: Page L-4

60 TRUCK BED, MANUAL LIFT 1 - Includes Items A B 10 4 A 5 B Page M-1

61 TRUCK BED, MANUAL LIFT Page M-2

62 TRUCK BED, MANUAL LIFT Page M-3

63 TRUCK BED, MANUAL LIFT , Includes Items SEEING FROM THE BOTTOM Page M-4

64 TRUCK BED, MANUAL LIFT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 ASSEMBLY PLASTIC BED ( INCLUDES ITEMS 2-11 ) G01 PLASTIC BED 36" G01 TAILGATE 36", PLASTIC G01 ANGLE, BOWED G01 SHAFT, PIVOT G02 CABLE ASSEMBLY, TAILGATE G2 SCREW, 1/4-20 X 1 1/4" LG G01 BOLT, SHOULDER G01 CHANNEL, EXTRUSION G2 SCREW, 1/4-2 X 5/8" LG G5 RACHET FASTNER G01 CLEVIS PIN G5 WASHER, 1/2" G1 COTTER PIN G01 SCREW, 1/4-20 X 5/8" LG G7 WASHER, 1/4" G01 FLANGED BUSHING G01 BED FRAME G2 SCREW, 5/16-18 X 1 1/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G6 SCREW, 4/4-20 X 1 3/4" LG G2 LOCK NUT, 1/ Page M-5

65 TRUCK BED, MANUAL LIFT THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information G7 SCREW, 7/16-14 X.875" LG G1 NUT, 7/ G02 INSTALLATION LATCH ( INCLUDES ITEMS ) G01 WELDMENT LATCH BED G02 BRACKET G02 LATCH PLATE G01 TORSION SPRING G01 SCREW, 1/4-2 X 5/8" LG G01 HANDLE GRIP G01 BUMPER G1 LOCK NUT, 5/ G01 BRACKET BUMPER LATCH PLATE (LEFT SIDE) LATCH PLATE (RIGHT SIDE) G03 BOLT, 1/ G7 WASHER, 1/4" G4 LOCK NUT, 1/ LABEL EZGO G06 BED CAPACITY LABEL (500 LB) G01 RIVET, 3/16"... 5 Page M-6

66 WEATHER PROTECTION 3 Front of Vehicle 6 7 8, DETAIL A 92 DETAIL B Front of Vehicle Front of Vehicle DETAIL C (FRONT) , 9 DETAIL D (REAR) Ref Wea 20-1 Page N-1

67 WEATHER PROTECTION 23 Front Top Strut 24 REAR VIEW MIRROR 21 - Includes Items Setscrew SIDED SOFT ENCLOSURE 26 - Includes Items Ref Wea 20-2 Page N-2

68 WEATHER PROTECTION Includes Items 45, 46, Strut Front of Vehicle 47 - Includes Items 48, 49, Windshield Retainer 48 Rubber Latch Strut Front of Vehicle Page N-3

69 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G** SUN TOP KIT (INCLUDES ITEMS 2-19) G** SUN TOP G05 FRONT STRUT G2 BOLT, 5/16-18 X 2 1/4" LG G8 LOCK WASHER, 5/16" G01 SPACER, 1/2" G2 WASHER, 5/16" G04 REAR STRUT (PASSENGER SIDE) G03 REAR STRUT (DRIVER SIDE) G7 BOLT, 5/16-18 X 1 3/4" LG G03 WASHER, 5/16" G6 LOCK NUT, 5/ G5 SCREW, 1/4-20 X 2" LG (STAINLESS STEEL) G6 SCREW, 1/4-20 X 2 1/4" LG (STAINLESS STEEL) G01 WASHER, 1/4" (STAINLESS STEEL) G01 SPACER G2 LOCK NUT, 1/ G1 END CAP, 1" G2 REAR VIEW MIRROR KIT (REQUIRES SUN TOP) (INCLUDES ITEMS 22-24) G1 REAR VIEW MIRROR G2 SUPPORT BRACKET G1 SCREW, #8-32 X 5/8" LG (STAINLESS STEEL) G** 3-SIDED SOFT ENCLOSURE (REQUIRES SUN TOP) (INCLUDES ITEMS 27-28) * ENCLOSURE * VELCRO... AR 29 Page N-4

70 WEATHER PROTECTION Replacement parts for the windshield may be obtained from Eagle Parts, Inc Marvin Griffin Rd. Augusta, GA Telephone (706) * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 BOLT, 1/4-20 X 1 3/4" LG. (STAINLESS STEEL) G04 WASHER, 1/4" (STAINLESS STEEL) G06 RUBBER GROMMET G05 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 SAFETY LABEL G03 WINDSHIELD KIT (FULL) (INCLUDES ITEMS 45, 46, 34-37) G01 WINDSHIELD (FULL) G01 SASH, 26" LG G04 WINDSHIELD KIT (SPLIT) (INCLUDES ITEMS 48, 49, 34-37) G01 WINDSHIELD (SPLIT) G02 SASH, 12" LG Page N-5

71 WEATHER PROTECTION Notes: Page N-6

72 WHEELS AND TIRES 1 - Includes Items 3, 4, Includes Items 3, 4, Includes Items Includes Items Includes Items , 11, , 10, 14 3, 9, 13, 19 (Style of tire may differ from tire shown) Page P-1

73 WHEELS AND TIRES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 WHEEL & TRAIL WOLF TIRE ASSEMBLY DRIVER SIDE (INCLUDES ITEM 3, 4, 5)... AR G04 WHEEL & TRAIL WOLF TIRE ASSEMBLY PASSENGER SIDE (INCLUDES ITEM 3, 4, 5) G05 TIRE, 20 X TRAIL WOLF VALVE STEM WHEEL G2 SPINDLE CAP... AR G1 LUG NUT, 1/ AR SPEEDRACER TIRE AND WHEEL, 10X7, DRIVER SIDE (INCLUDES 9-11) (MUST USE ITEM 16 LUG NUTS, ORDER SEPARATELY) SPEED RACER, 10X7 DRIVER SIDE WHEEL, 10" DIAMOND FINISHED WHEEL VALVE STEM, CHROME SPEEDRACER TIRE AND WHEEL, 10X7, PASSENGER SIDE (INCLUDES 13-15) (MUST USE ITEM 16 LUG NUTS, ORDER SEPARATELY) SPEED RACER, 10X7 DRIVER SIDE WHEEL, 10 " DIAMOND FINISHED WHEEL VALVE STEM, CHROME DIAMOND LUG NUTS DIAMOND WHEEL CAP G03 WHEEL AND TIRE ASSY, TURF SAVER (INCLUDES ITEMS 2-4) G02 TIRE, 20 X TURF SAVER G02 WHEEL RIM (BLACK, 4 LUG) G1 VALVE STEM... 1 AR Page P-2

74 WHEELS AND TIRES Notes: Page P-3

75 SPECIALTY PRODUCTS SPECIALTY PRODUCTS Appendix A-1

76 SPECIALTY PRODUCTS SPECIAL TOOLS PART NO. BATTERY MAINTENANCE KIT G01 SEAL INSTALLATION TOOL (REAR AXLE SHAFT SEAL) G1 BATTERY SET DISCHARGER, 36 VOLT, 75 AMP G01 CURRENT INDICATOR G2 DIGITAL MULTI-METER G01 CRIMPING TOOL G01 SLIDE HAMMER (AXLE/HUB REMOVAL) G1 SLIDE HAMMER (AXLE REMOVAL ONLY) G1 TOUCH UP PAINT PART NO. PEN 3 OUNCE (89 ML) - HUNTER GREEN G02 PEN 3 OUNCE (89 ML) - CHAMPAGNE BEIGE G01 PEN 3 OUNCE (89 ML) - WHITE G05 PEN 3 OUNCE (89 ML) - INDUSTRIAL YELLOW G03 PEN 3 OUNCE (89 ML) - ORANGE G04 PEN 3 OUNCE (89 ML) - STEEL BLUE PEARL G** PEN 3 OUNCE (89 ML) - CAMOUFLAGE PAINT (THREE PENS) G01 AEROSOL 12 OUNCE (360 ML) - HUNTER GREEN G09 AEROSOL 12 OUNCE (360 ML) - CHAMPAGNE BEIGE G15 AEROSOL 12 OUNCE (360 ML) - WHITE G03 AEROSOL 12 OUNCE (360 ML) - INDUSTRIAL YELLOW G14 AEROSOL 12 OUNCE (360 ML) - ORANGE G13 AEROSOL 12 OUNCE (360 ML) - STEEL BLUE PEARL G** MAINTENANCE PRODUCTS PART NO. PLEXUS CLEANER, 7 OUNCE (210 ML) (FOR WINDSHIELDS) G01 BATTERY PROTECTOR, 14 OUNCE (410 ML) SPRAY G01 E-Z-GO ALLSURFACE CLEANER E-Z-GO FIBERGLASS/PLASTIC RESTORER WIND SHIELD AND PLASTIC PROTECTOR OZ HAND CLEANER OZ HAND CLEANER Appendix A-2

77 OPTIONS / ACCESSORIES OPTIONS/ACCESSORIES Appendix B-1

78 OPTIONS/ACCESSORIES ITEM KIT NO. COMMENTS ASHTRAY KIT G See BODY BUMPER KIT G See BODY ELECTRIC DUMP KIT G See TRUCKBED REAR VIEW MIRROR KIT G See WEATHER PROTECTION SOFT ENCLOSURE G See WEATHER PROTECTION SUN TOP KIT G0* See WEATHER PROTECTION TURN SIGNAL KIT G See ELECTRICAL SYSTEM WINDSHIELDS G0* See WEATHER PROTECTION Appendix B-2

79

80 E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA TO CONTACT US North America: Technical Assistance & Warranty Phone: , FAX: Service Parts Phone: GET-EZGO ( ), FAX: International: Phone: , FAX: Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department