Electric Powered Vehicle Service Parts Manual

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1 Electric Powered Vehicle ISSUED JANUARY 2013 REVISED MAY 2014

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3 SERVICE PARTS MANUAL ELECTRIC POWERED UTILITY VEHICLE SHUTTLE 8 STARTING MODEL YEAR 2012 DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) 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 E-Z-GO, and therefore is subject to change without notice. E-Z-GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE- QUENTIAL DAMAGES RESULTING FROM THE USE OF THE INFORMATION AND MATERIALS IN THIS MANUAL. TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: , FAX: SERVICE PARTS PHONE: GET-EZGO ( ), FAX: INTERNATIONAL: PHONE: , FAX: E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA Page i

4 GENERAL INFORMATION 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. Overfilling of batteries may void the warranty. 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. BATTERY DISPOSAL Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acidresistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ACCELERATOR A - 1 BATTERY CHARGER B - 1 BODY C - 1 BRAKES D - 1 PARKING BRAKE E - 1 ELECTRICAL SYSTEM F - 1 ELECTRONIC SPEED CONTROL G - 1 FRONT SUSPENSION AND STEERING H - 1 MOTOR J - 1 REAR AXLE K - 1 REAR SUSPENSION L - 1 SEATING M - 1 WEATHER PROTECTION N - 1 WHEELS AND TIRES P - 1 Page iii

6 NOTES Page iv

7 ,87 67 Front of Vehicle 83,88 81,86 84, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION ILLUSTRATED PARTS BREAKDOWN APPENDIX The first section, GENERAL INFORMATION, contains the following information: WARRANTY INFORMATION GENERAL INDEX HOW TO USE THE SERVICE PARTS MANUAL The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your vehicle. The third section, APPENDIX, contains a listing of specialty products and accessories. USE OF THE MANUAL To use this manual, consult the GENERAL INDEX 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 and then contact the Service Parts Department. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. 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. 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) Page v

8 HOW TO USE THE SERVICE PARTS MANUAL 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the General Index and select the most appropriate title. Turn to the page number indicated and locate the desired part on the illustration. From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying description for specific information regarding the part. 2. IF YOU KNOW THE PART NUMBER Locate the part number or description in the appropriate column on the parts list page. NOTE: It is suggested that you 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 and 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 HOW TO USE THE SERVICE PARTS MANUAL 3. COLOR CODE FOR BODY COMPONENTS The last two digits of the part number for the body part will denote the color code. Locate the part number for the cowl, rear body, seat pod, side panel or seat wrap then locate your color in the list below. Replace the last ** or XX with the two digit color code. CODE # DESCRIPTION CODE # DESCRIPTION 01 NO PAINT 53 MOSSY OAK NEW BREAK UP - DIPPED 02 SPECIAL COLOR 54 MOSSY OAK OBSESSION - DIPPED 05 JACOBSEN ORANGE 55 REALTREE ADVANTAGE MAX 4 - DIPPED 06 LIGHT GOLD PEARL 56 REALTREE HARDWOOD BROWN - DIPPED 07 SILVER PEARL METALLIC 57 REALTREE AP HOT PINK - DIPPED 11 BLACK 58 BLACK / SILVER MARBLE - DIPPED 12 EMERALD GREEN PEARL 59 RED / SILVER MARBLE - DIPPED 13 CLOUD GRAY 60 HOT PINK / SILVER MARBLE - DIPPED 14 VIPER BLUE METALLIC 61 REALTREE AP 19 PATRIOT BLUE PEARL 62 REALTREE MAX 4 20 INFERNO RED METALLIC 63 MOSSY OAK BREAKUP 23 ADVANTAGE CLASSIC CAMO 64 MOSSY OAK TREESTAND 24 NATURAL 65 REALTREE APG 25 VIVID NEW HOLLAND BLUE 66 REALTREE MAX 1 26 STEEL BLUE PEARL 67 REALTREE AP PINK 27 BRIGHT SILVER METALLIC 68 REALTREE AP - DIPPED 29 PRIMER ONLY 69 MONSTER GREEN 30 HD ADVANTAGE CAMO 74 BARLEY GOLD 31 METALLIC CHARCOAL 75 OASIS GREEN 32 LIGHT ALMOND PEARL 76 JAVA BROWN 33 TIMBERLINE GREEN 34 DEEP MOLTEN RED 35 SAFETY YELLOW 36 IVORY 37 FOREST GREEN 38 BRIGHT WHITE 39 FLAME RED 40 BLACK 41 ELECTRIC BLUE 42 PLATINUM 43 BURGUNDY 44 ALMOND 45 BLACK 46 FLAME RED 47 BURLINGTON GREEN 48 BLACK 49 FLAME RED 50 RECON GREEN 51 SUNBURST ORANGE 52 BRITISH RACING GREEN Page vii

10 ACCELERATOR ACCELERATOR PEDAL ASSEMBLY includes items PEDAL BOX ASSEMBLY includes items To Direction Selector Harness 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. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2-37) G01 PEDAL BOX AND COVER (SEAL AND BEARING) G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" G01 PLUNGER SLEEVE G01 PLUNGER G01 PLUNGER CAM G01 ACCELERATOR ROD G4 LOCK NUT, 5/16" G4 YOKE (ADJUSTABLE) G2 SPRING RETAINER, 3/8" G01 COMPRESSION SPRING G1 ACCELERATOR ROD BUSHING G1 SPRING RETAINER, 1/2" G02 MICRO SWITCH G01 PAN HEAD SCREW, #4-20 X 5/8" LG WIRING HARNESS (PEDAL BOX ASSEMBLY) G6 PHILLIPS SCREW, #8-32 X 3/4" LG G02 ACCELERATOR PEDAL BRACKET G01 PAN HEAD PHILLIPS SCREW, #8-16 X 1/2" LG G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 27-30) G04 ACCELERATOR PEDAL G01 ACCELERATOR PEDAL PAD G1 OVAL RIVET 3/16" X 7/16" 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. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 BUSHING G01 PEDAL PIVOT PIN G6 PUSHNUT, 9/32" I.D G3 CLEVIS PIN, 5/16" X 13/16" G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G01 PEDAL PIVOT COVER... 1 Page A-3

13 ACCELERATOR Notes: Page A-4

14 BATTERY CHARGER 1 5 DELTA - Q BATTERY CHARGER includes items 2-3 DELTA - Q BATTERY CHARGER includes items Page B-1

15 BATTERY CHARGER When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY V DELTA - Q BATTERY CHARGER WITH 10 DC CORD (INCLUDES ITEMS 2-3) G01 DC CABLE ASSEMBLY, G01 AC POWER CORD V DELTA - Q BATTERY CHARGER WITH 18 DC CORD (INCLUDES ITEMS 6-7) G03 DC CABLE ASSEMBLY, G01 AC POWER CORD... 1 Page B-2

16 ! F R P N F BODY To Prevent Roll-Back 2. Apply Service On a Hill From a Brake With Stopped Position Left Foot 3. Fully 4. Depress Accelerator While Release Releasing Service Brake As Park Brake Vehicle Starts 74443G01 2 < 14 25% < 14 25% P P ASH TRAY KIT includes items Page C-1

17 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 INSTRUMENT PANEL ASSEMBLY G01 ANTI-ROLLBACK DECAL G2 RATCHET FASTENER, 1/4" X 3/4" LG OPERATOR INSTRUCTION DECAL G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG (3/8" GRIP) G** COWL (SEE COLOR CODES IN HOW TO USE SECTION) G01 RIVET, 3/16" X 1" LG (3/8" GRIP) GRILL COVER G01 SELF THREADING NUT, 3/16" G01 RIVET, 3/16" X 1" LG (3/8" GRIP) FENDER FLARE (DRIVER SIDE) FENDER FLARE (PASSENGER SIDE) FRONT FASCIA FASCIA BRACKET G1 RIVET (ALUMINUM) (BLACK), 3/16" X 0.45" (1/4" GRIP) G02 FRONT SHIELD BRACE HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G4 LOCK NUT, 1/4" G01 FLANGED HEX HEAD THREAD FORMING BOLT, 1/4" - 20 X 3/4" LG G1 FENDER WASHER, 1 1/4" O.D. X 9/32" I.D Page C-2

18 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY CUSHMAN COWL DECAL BRUSHGUARD G2 HEX HEAD BOLT, 5/16" - 18 X 2 1/4" LG G6 HEX HEAD BOLT, 5/16" - 18 X 2 3/4" LG G2 FLAT WASHER, 5/16" G04 SPACER, 1" LG G02 SPACER, 1 5/16" LG G8 NARROW FLAT WASHER, 5/16" G8 LOCK WASHER, 5/16" Page C-3

19 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY UPPER FLOORPAN G11 RIVET (ALUMINUM), 3/16" X 9/16" LG LOWER FLOORPAN G01 ACCESS COVER G04 ASH TRAY KIT (INCLUDES ITEMS 78-81) G01 ASH TRAY G01 GASKET G02 BRACKET G4 SELF - TAPPING SCREW, #10-16 X 1/2" LG Page C-4

20 BODY Front of Vehicle Page C-5

21 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SEAT FRAME BATTERY RACK G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 TRUSS HEAD TORX BOLT, 3/8" - 16 X 3/4" LG G10 RIVET (SS), 5/32" X 9/16" LG MID FLOOR PANEL G01 REAR FLOOR PANEL FLOORMAT ROCKER PANEL (DRIVER SIDE) ROCKER PANEL (PASSENGER SIDE) G2 TRUSS HEAD PHILLIPS SCREW (SS), #10-24 X 1" LG G5 FLAT WASHER, # G10 LOCK NUT, # G1 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1" LG G4 LOCK NUT, 1/4" G4 SPACER, 5/16" G6 RIVET (ALUMINUM), 3/16" X 15/16" LG G4 SPACER, 5/16" Page C-6

22 BODY Front of Vehicle Page C-7

23 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 BATTERY TRAY (PASSENGER SIDE) G01 BATTERY TRAY (DRIVER SIDE) G2 HEX HEAD BOLT, 5/16" - 18 X 0.80" LG G02 COVER PLATE (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 RIVET (ALUMINUM), 3/16" X 1" (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G02 FENDER LINER (PASSENGER SIDE) G01 FENDER LINER (DRIVER SIDE) G2 RATCHET FASTENER G1XX REAR BODY W/LIGHTS (SEE COLOR CODES IN HOW TO USE SECTION) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G1** REAR BODY (SEE COLOR CODES IN HOW TO USE SECTION) G12 RIVET (ALUMINUM), 1/4" X 9/16" LG G01 PLUG G01 ACCESS PANEL G01 PAN HEAD TORX SCREW, #8 X 5/8" LG G02 J CLIP G2 RATCHET RIVET,.25" X.887" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) PLASTIC DRIVE RIVET,.625" X 1" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 HINGE PLATE G11 RIVET (SS), 3/16" X 3/4" LG G02 REAR BUMPER G2 FLAT WASHER, 5/16" G01 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G01 BUMPER PLUG G03 HEX HEAD BOLT, 1/4" - 20 X 1.15" LG G01 J - TYPE NUT RETAINER, 1/4" Page C-8

24 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 PLASTIC DRIVE RIVET, 1/4" X 9/16" LG * CUSHMAN LOGO DECAL... 1 Page C-9

25 BODY Notes: Page C-10

26 BODY FOR SEAT BOTTOM AND BACK - SEE SEATING SECTION Front of Vehicle Page C-11

27 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY GXX SEAT POD (SEE COLOR CODES IN HOW TO USE SECTION) G8 HEX HEAD BOLT, 5/16" - 18 X 2" LG G1 FLAT WASHER (SS), 1 1/4" O.D. X 3/8" I.D G01 RUBBER WASHER, 1 1/2" O.D. X 5/8" I.D G9 SPACER, 3/4" G6 LOCK NUT (SS), 5/16" G01 RIVET, 3/16" X 1" LG G6 TRIM, 118" LG SEAT BACK BRACKET G8 HEX HEAD BOLT, 3/8" - 16 X 2" LG G1 FLAT WASHER (SS), 1 1/4" O.D. X 3/8" I.D G4 SPACER, 5/16" G5 CROWN NUT, 3/8" G06 TRUSS HEAD PHILLIPS SCREW (SS), 5/16" - 18 X 3/4" LG G6 LOCK NUT (SS), 1/4" G01 VENT PLUG G01 FLUSH MOUNT ASH TRAY Page C-12

28 BODY Notes: Page C-13

29 BODY Notes: Page C-14

30 HYDRAULIC BRAKES PEDAL ASSEMBLY includes items Page D-1

31 HYDRAULIC BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY BRAKE PEDAL ASSEMBLY (INCLUDES ITEMS 2-4) G01 BRAKE PEDAL G01 BRAKE PEDAL PAD G1 OVAL HEAD RIVET, 3/8" X 15/32" G01 ACETAL BUSHING G01 TORSION SPRING G01 SHOULDER BOLT, 3/8" G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/16" G1 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED) G3 CLEVIS PIN, 5/16" DIA X 13/16" G3 COTTER PIN, 15/16" X 3/4" G8 LINKAGE ROD PRESSURE SEALING WASHER G01 BELLCRANK G01 ACETAL BUSHING G01 PIVOT SHAFT G01 RETAINING RING (SS) G01 ADAPTER G3 CLEVIS PIN, 5/16" DIA X 1" G3 COTTER PIN, 15/16" X 3/4" G01 TANDEM MASTER CYLINDER STOP LIGHT SWITCH G1 HEX HEAD BOLT, 5/16" - 18 X 1 1/8" LG FLANGED LOCK NUT, 5/16" PUSH ROD ASSEMBLY REAR BRAKE LINE... 1 Page D-2

32 HYDRAULIC BRAKES Disc Hub Front Brake Line Caliper Page D-3

33 HYDRAULIC BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRONT BRAKE LINE G01 SWAGEFORM SCREW, 1/4" - 20 X.7" LG G01 WIRE RETAINER CRUSH WASHER, M BANJO BOLT, M10-1" X 20" LG G6 HEX HEAD BOLT, 3/8" - 16 X 3/4" LG (GRADE 5) G1 LOCK WASHER, 3/8" G01 CALIPER ASSEMBLY (PASSENGER SIDE) G02 CALIPER ASSEMBLY (DRIVER SIDE) G01 BRAKE PADS AND PINS SERVICE KIT (NOT ILLUSTRATED) DISC BRAKE ROTOR AND HUB G01 DRIVE FLANGE STUD G1 GREASE SEAL G2 ROLLER BEARING G1 BEARING RACE G1 THIN SLOTTED NUT, 17/32" G8 COTTER PIN, 5/32" X 1 3/4" Page D-4

34 HYDRAULIC BRAKES BRAKE LINE ASSEMBLY includes items BRAKE ASSEMBLY includes items 82, 84, BRAKE ASSEMBLY includes items 82, 84, BRAKE SHOE KIT includes item BRAKE SPRING KIT includes items BRAKE ADJUSTER KIT, DRIVER SIDE includes items 92, 93 BRAKE ADJUSTER KIT, PASSENGER SIDE includes items 92, BRAKE DRUM ASSEMBLY includes items 97, Page D-5

35 HYDRAULIC BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY BRAKE LINE ASSEMBLY (INCLUDES ITEMS 64-66) LONG BRAKE LINE SHORT BRAKE LINE UNION TEE G01 FLEXIBLE BRAKE LINE (SS) G1 FLEX HOSE CLIP G01 HEX HEAD BANJO BOLT, 3/8" - 16 X.88" LG G01 COPPER GASKET G01 BRAKE LINE CLAMP G1 NYLON CLAMP (NOT ILLUSTRATED) BRAKE CABLE BRACKET (DIRVER SIDE) BRAKE CABLE BRACKET (PASSENGER SIDE) G2 HEX HEAD BOLT, 5/16" - 24 X 1" LG G1 LOCK NUT, 5/16" G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 82, 84, 90) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 82, 84, 91) G01 BRAKE SHOE KIT (INCLUDES ITEM 83) * BRAKE SHOE G01 BRAKE SPRING KIT (INCLUDES ITEMS 85-89) * UPPER SPRING * LOWER SPRING * PIN * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 92, 93) G02 BRAKE ADJUSTER KIT(PASSENGER SIDE) (INCLUDES ITEMS 92, 93) 1 92 * ADJUSTER * TEFLON WASHER... 2 Page D-6

36 HYDRAULIC BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 INNER BRAKE DRUM WASHER, 1.31" O.D. X 1" I.D. X.031" G2 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS 97, 98) * BRAKE DRUM G2 LUG BOLT, 1/2" - 20 X 1.18" LG G1 OUTER BRAKE DRUM WASHER, 1.50" O.D. X.76" I.D. X.119" CASTLE NUT, 3/4" G1 COTTER PIN, 1/8" X 1.50" G01 MOLDED DUST CAP... 2 Page D-7

37 HYDRAULIC BRAKES Notes: Page D-8

38 PARKING BRAKE PARK BRAKE LEVER ASSEMBLY includes items 2 & 21 2 PARK BRAKE ASSEMBLY includes items Page E-1

39 PARKING BRAKE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY PARK BRAKE LEVER ASSEMBLY (INCLUDES ITEMS 2 & 21) PARK BRAKE ASSEMBLY (INCLUDES ITEMS 3-20) * BRAKE LEVER ASSEMBLY * PIVOT FASTENER * PIVOT NUT * CONNECTING LINK * CLEVIS PIN * HAIR PIN OR COTTER PIN * CLEVIS PIN * FLAT WASHER * SPACER * CLAMP * SPACER * MAGNETIC SWITCH ASSEMBLY * MAGNET ASSEMBLY * PHILLIPS HEAD SCREW * SIDE PLATE G1 PUSH ON TERMINAL (FEMALE) MOUNTING BRACKET G7 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G7 FLAT WASHER, 1/4" G4 LOCK NUT, 1/4" G3 CLEVIS PIN, 1.0" X 2.406" G3 COTTER PIN,.094" X.75" PARKING BRAKE BOOT G1 NYLON CLAMP (NOT ILLUSTRATED)... 8 Page E-2

40 PARKING BRAKE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY BRAKE CABLE ASSEMBLY (DRIVER SIDE) BRAKE CABLE ASSEMBLY (PASSENGER SIDE) HEX HEAD BOLT, M X 60MM LG LOCK NUT, M8 X Page E-3

41 PARKING BRAKE Notes: Page E-4

42 ELECTRICAL SYSTEM 1 3 CHARGER HARNESS includes items 2-3 CHARGER HARNESS RECEPTACLE includes items A2 F2 25 A1 F Page F-1

43 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 CHARGER HARNESS / RECEPTACLE (INCLUDES ITEMS 2-3) CHARGER HARNESS WITH FUSE G30 CHARGER HARNESS RECEPTACLE (INCLUDES ITEMS 4-11) G22 RECEPTACLE BOTTOM G21 RECEPTACLE COVER G08 BINDING HEAD SCREW, #10-32 X 1/2" LG G09 PAN HEAD PHILLIPS SCREW, #6-32 X 1 3/4" LG G10 LOCK NUT, # G25 18 GA JUMPER WIRE (RED) G23 FEMALE RADSOCK (48V) G24 INSULATED FEMALE RADSOK (48V) G01 RIVET, 3/16" X 1" LG G01 POWER HARNESS G01 LOCK WASHER (SILICON BRONZE), 5/16" G01 BRASS NUT, 5/16" G02 LOCK WASHER (SILICON BRONZE), 1/4" G02 BRASS NUT, 1/4" G02 TWISTED CLAMP G11 RIVET (SS), 3/16" X 3/4" G2 HEAVY HEX NUT, 5/16" G01 6 VOLT BATTERY BATTERY RETAINER G01 HOLD DOWN BOLT G1 LOCK NUT, 5/16" G01 HOLD DOWN BOLT G01 BATTERY RETAINER G13 4 GA WIRE (BLACK 10 1/2") G18 4 GA WIRE (BLACK 6") G16 4 GA WIRE (BLACK 19")... 1 Page F-2

44 ELECTRICAL SYSTEM RED GRN/BLK OFF ON DC TO DC CONVERTER KIT For Models before 02 OCT DC TO DC CONVERTOR KIT includes items For Models from 02 OCT 2013 Page F-3

45 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 IGNITION SWITCH (WITH LIGHTS, STANDARD KEY) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/4" G1 NYLON CLAMP (NOT ILLUSTRATED) G02 IGNITION SWITCH (WITH LIGHTS, GROUP KEY) G06 CONSOLE PLATE WITH DIRECTION SELECTOR AND SOC G01 CONSOLE PLATE DECAL WITH DIRECTION SELECTOR AND SOC G02 BLACK PLASTIC DRIVE RIVET G03 IGNITION SWITCH (WITH LIGHTS, INDIVIDUAL KEY) G01 DIRECTION SELECTOR SWITCH (FNR) G05 STATE OF CHARGE METER (SOC) STATE OF CHARGE FUSE HARNESS CONTROL HARNESS G74 18 GA JUMPER WIRE (RED 6") DC - DC CONVERTER KIT (INCLUDES ITEMS 50-60) DC - DC CONVERTER (FOR MODELS BEFORE 02 OCT 2013) BRACKET DC - DC WIRING HARNESS G4 PAN HEAD PHILLIPS SCREW, #10-24 X 1/2" LG G5 CHRISTMAS TREE RIVET, 3/16" X 1/2" G2 THREADED SCREW, 5/16" - 18 X.80" LG G5 SPRING LOCK WASHER, #4-5/16" G5 FLAT WASHER, # G3 HEX NUT, # DC - DC CONVERTER (FOR MODELS FROM 02 OCT 2013) PAN HEAD PHILLIPS SCREW, #10-24 X 1/2" LG G02 CONTINUOUS TONE BUZZER G01 RIVET, 5/32" DIA... 2 Page F-4

46 ELECTRICAL SYSTEM FUSE BLOCK BLU/WHT ORN/WHT RED GRN FLOOR MOUNTED HORN BUTTON 82 Floorboard HOUR METER KIT includes items HORN Passenger Side Seat Support Front of Vehicle Electrical Components Cover YEL BLK Page F-5

47 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 FUSE BLOCK G01 RIVET, 5/32" X 3/8" LG G1 FUSE, 15 AMP ACCESSORY WIRE HARNESS (NOT ILLUSTRATED) G4 FLAT WASHER, #8 (NOT ILLUSTRATED) G1 HORN G1 HORN SWITCH G01 HORN SWITCH BOOT G2 HORN SWITCH CAP AND NUT HORN SWITCH LABEL G01 RIVET, 5/32" X 3/4" LG G06 HOUR METER KIT (INCLUDES ITEMS 79-83) G01 HOUR BRACKET G11 RIVET (SS), 3/16" DIA G02 HOUR METER G01 RETAINER CLIP G04 HOUR METER WIRE HARNESS G01 INTERMITTENT BUZZER Page F-6

48 ELECTRICAL SYSTEM 110 TURN SIGNAL KIT includes items TURN SIGNAL SWITCH ASSEMBLY includes item WHT to BLK from Harness - Both Sides BLK to BLU/WHT from Harness - Both Sides RED to WHT from Harness - Driver Side RED to YEL from Harness - Passenger Side RED TO BRN from Harness - (W/O Turn Signals) Page F-7

49 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HEADLIGHT W/BULB W/O TURN SIGNAL BULB (PASSENGER SIDE) HEADLIGHT W/BULB W/O TURN SIGNAL BULB (DRIVER SIDE) HEADLIGHT BULB G02 VINYL TAPE G01 SELF THREADING NUT, 5 X 10 X 15MM G1 TAILLIGHT ASSEMBLY G01 BEZEL (DRIVER SIDE) G02 BEZEL (PASSENGER SIDE) G01 PHILLIPS HEAD TAPPING SCREW, # 8-18 X 3/4" LG G02 J - CLIP G11 RIVET (ALUMINUM), 3/16" X 9/16" G1 DUAL FILAMENT BULB, 12V G4 PAN HEAD PHILLIPS SCREW, # 8-18 X 1 1/2" LG BEZEL (DRIVER SIDE) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) BEZEL (PASSENGER SIDE) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) TURN SIGNALS KIT (INCLUDES ITEMS ) TURN SIGNAL BULB G3 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE (NOT ILLUSTRATED) G3 STEERING COLUMN COVER TURN SIGNAL SWITCH ASSEMBLY(INCLUDES ITEM 116) G01 FLASHER UNIT PARK BRAKE/BUZZER HARNESS... 1 Page F-8

50 RUN l P/N G01 ELECTRONIC SPEED CONTROL ELECTRONIC SPEED CONTROL ASSEMBLY includes items 2-11, V SOLENOID ASSEMBLY includes items 5-8 ELECTRONIC SPEED CONTROLLER SERVICE KIT includes items 3, Purple From Walkaway Fuse to Solenoid+ Walkaway Fuse Walkaway Relay #10 Black From Motor F2 (Power Harness) #4 Black From Motor A1 (Power Harness) #4 Black From Motor A2 (Power Harness) #18 Yellow From J1 Pin 5 (Control Harness) 30 #18 Blue From J1 Pin 17 (Control Harness) Red From Walkaway Relay to Solenoid (-) 3 J3 F2 J2 B+ M J1 B- #18 Red From Tow Switch and Reverse Buzzer (Control Harness) Control Harness Charger Receptacle Harness Speed Sensor Harness F1 #18 Red/White From Tow Switch (Control Harness) To Ignition Interlock (Charger Receptacle) #4 Black From Charger (Charger Harness) 4 #10 White From Charger Receptacle #4 Black From Battery (+) To Solenoid (-) #4 Black From Battery (-) (Power Harness) Power Harness #4 Black From Motor A1 (Power Harness) Code Fault Code Symptoms Corrective Action 1-1 HW FAILSAFE Vehicle will not run Check motor wiring, replace controller 1-2 THROTTLE FAULT 1 Vehicle will not run Check pedal box adjustment, connections, replace ITS 1-3 SPEED SENSOR FAULT Vehicle runs slowly Check speed sensor connection, and wiring, replace sensor if required 1-4 HPD Vehicle will not run Release and reapply pedal. Check pedal box, linkage, switch and key switch 1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage 2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries 2-2 OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC WARNING Always select 'TOW / MAINTENANCE' position before towing. TOWING MAINTENANCE TOW MAINTENANCE Possibility of electrical arc and battery explosion. Before removing/connecting batteries or electrical components turn switch to 'TOW/MAINTENANCE' position. To disable electrical system place switch in 'TOW/MAINTENANCE' position and remove battery wire. After reconnecting batteries, allow a minimum of 30 seconds before selecting 'RUN' position 73340G THERMAL CUTBACK Vehicle performance reduced Allow controller to cool 2-4 MAIN DRIVER ON Vehicle runs slowly Solenoid driver defective, replace controller 2-5 VDD FAULT Vehicle will not run Replace controller 3-1 MAIN DRIVER OFF Solenoid does not close Replace controller 3-2 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid 3-3 PRECHARGE FAULT Vehicle will not run Check for additional electronics attached to B+, replace controller 3-4 FIELD MISSING Solenoid closes, vehicle will Check wiring. not run Replace power harness and motor if required. 3-5 FIELD OVERCURRENT Vehicle will not run Field windings or power harness shorted. Verify, replace motor if necessary. 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller 4-4 AUX CONT DNC Vehicle will not run Replace controller 4-5 WELDED AUX CONT Vehicle runs slowly Replace controller 5-1 EEPROM FAILSAFE Vehicle will not run Replace controller 5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring. Replace solenoid if necessary 5-3 MAIN CONT DNC Vehicle will not run Check all solenoid wiring. Replace solenoid if necessary 5-5 MISSING CONTACTOR Vehicle stops Check all solenoid wiring. Replace solenoid if necessary Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close), HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor), M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault) DIAGNOSTIC FAULT CODES The LED will flash a diagnostic fault code when a fault is detected Some faults may only be detected by operating the vehicle with the rear of the vehicle raised and supported on safety stands Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery compartment) to the 'TOW/MAINTENANCE' position before performing any repairs or maintenance to the vehicle Select 'RUN' before returning the vehicle to service Page G-1

51 ELECTRONIC SPEED CONTROL When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G04 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-11, 24-30) G01 CONTROLLER BRACKET ELECTRONIC SPEED CONTROLLER G01 48 VOLT SOLENOID (INCLUDES ITEMS 5-8) G5 LOCK WASHER, # G4 HEX NUT, # G8 LOCK WASHER, 5/16" G4 JAM NUT, 5/16" G01 90 FASTON TAB G2 LOCK NUT, 1/4" G17 4 GA BLACK WIRE, 9" G01 DOUBLE TUBE CLAMP G2 LOCK NUT, 1/4" G01 CONTROLLER COVER G01 HEX HEAD BOLT, 8MM X 16MM G01 LOCK WASHER, 5/16" G01 HEX HEAD BOLT, 6MM X 1 X 12MM G02 LOCK WASHER, 1/4" G1 PLASTIC RATCHET FASTENER, 1/4" X 11/16" G03 TOW - MAINTENANCE SWITCH ASSEMBLY G01 RIVET, 5/32" X 3/4" LG G01 FAULT CODE DIAGNOSTIC LABEL ELECTRONIC SPEED CONTROLLER SERVICE KIT (INCLUDES ITEMS 3, 25-30) G1 NYLON WIRE TIE (NOT ILLUSTRATED) WALKAWAY RELAY HARNESS ASSEMBLY (INCLUDES ITEM 27) RELAY G5 PLASTIC RATCHET FASTENER, 3/16" X.55" G2 PLASTIC RATCHET FASTENER, 1/4" X.88" G01 FUSE COVER... 1 Page G-2

52 FRONT SUSPENSION AND STEERING *Truck Models Only Front of Vehicle 28 Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity SPINDLE AND HUB ASSEMBLY (PASSENGER SIDE) includes items 4, SPINDLE AND HUB ASSEMBLY (DRIVER SIDE) includes items 5, 6-14 Page H-1

53 FRONT SUSPENSION AND STEERING Front of Vehicle FOUR LINK ROD ASSEMBLY includes items RACK AND PINION UNIT ASSEMBLY includes items TIE ROD ASSEMBLY includes items STEERING COLUMN ASSEMBLY includes items Page H-2

54 FRONT SUSPENSION AND STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRONT AXLE SPINDLE AND HUB ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 4, 6-14) SPINDLE AND HUB ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 5, 6-14) SPINDLE (PASSENGER SIDE) SPINDLE (DRIVER SIDE) G01 FLANGED BEARING G01 BEARING G1 GREASE SEAL G2 ROLLER BEARING G1 BEARING RACE HUB - DISC BRAKE G1 SLOTTED NUT, 17/32" G01 DRIVE FLANGE STUD, 1 1/2" G8 COTTER PIN, 5/32" X 1 3/4" G01 LOCK NUT, M10-1 1/4" (NOT ILLUSTRATED) G01 LINK ROD ASSEMBLY (INCLUDES ITEMS 18-22) G02 TIE ROD END - RH THREAD G01 JAM NUT, M10-1 1/4" - RH THREAD LINK ROD G02 JAM NUT, M10-1 1/4" - LH THREAD G01 TIE ROD END - LH THREAD G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG G3 FLAT WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER (SS), 1" G6 LOCK NUT, 1/2" G01 SHOCK ABSORBER Page H-3

55 FRONT SUSPENSION AND STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 SHOCK ABSORBER WASHER,.406" I.D. X 1.25" O.D G1 RUBBER BUSHING G6 HEX NUT, 1/4" G03 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) G03 SPRING PLATE G1 LOCK NUT, 7/16" G11 HEX HEAD BOLT, 7/16" - 14 X 1 1/2" LG G01 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 39-61) G01 STEERING RACK COVER AND BEARING * JAM NUT, 1/2" G01 RETAINING RING - EXTERNAL G1 BALL BEARING G01 PINION G01 RETAINING RING - INTERNAL G01 PINION SEAL G01 STEERING RACK * SOCKET HEAD SCREW, # G01 RACK LOADER G01 COMPRESSION SPRING G01 RACK LOADER COVER GASKET G01 RACK LOADER COVER G01 HEX HEAD BOLT, 1/4" G3 GREASE FITTING, STRAIGHT G01 TIE ROD END - OUTER * GROMMET (NOT ILLUSTRATED) * SLOTTED NUT, 7/16" - 20 (NOT ILLUSTRATED) G01 ROD END - INNER G01 BELLOWS RACK COVER G2 NYLON CLAMP, 10" G8 HOSE CLAMP, Page H-4

56 FRONT SUSPENSION AND STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 HEX HEAD BOLT, 7/16" - 14 X 3 1/2" LG G02 SPACER, 1.21" G04 STEERING HOUSING SPACER G7 HEX NUT, 1/4" G2 FLAT WASHER, 3/8" G1 LOCK NUT, 7/16" G01 SPRING PLATE (DRIVER SIDE) G02 SPRING PLATE (PASSENGER SIDE) G8 HEX HEAD BOLT, 7/16" - 14 X 2 3/4" LG G02 TIE ROD ASSEMBLY (INCLUDES ITEMS 78-82) G02 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, 7/16" G01 VINYL CAP G05 STEERING COLUMN ASSEMBLY (INCLUDES ITEMS 87-97) G01 STEERING SHAFT G01 INTERMEDIATE SHAFT G01 RETAINING RING, EXTERNAL G01 RETAINING RING, INTERNAL G1 BALL BEARING G01 BUSHING... 1 Page H-5

57 FRONT SUSPENSION AND STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 HEX HEAD BOLT, M8-1.25" X 30MM LG G8 SPRING LOCK WASHER G01 HEX HEAD BOLT, #6-20 X 5/16" LG G01 WAVE WASHER (SS) G03 STEERING COLUMN ASSEMBLY STEERING WHEEL (PREMIUM) G01 STEERING WHEEL COVER G1 FLAT WASHER, 3/8" G2 LOCK NUT, 5/8" G01 HEX HEAD BOLT, M8-1 1/4" X 30MM LG G8 LOCK WASHER, 5/16" G01 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG G2 COTTER PIN,.094" X 1"... 1 Page H-6

58 MOTOR Page J-1

59 MOTOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY ELECTRIC MOTOR, 48V G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G7 LOCK WASHER, 1/4" X 17/64" G01 FLAT WASHER, 1/4" G01 TWISTED CLAMP O - RING... 1 Page J-2

60 REAR AXLE REAR AXLE ASSEMBLY includes items INPUT GEAR KIT includes items 2, 5-8, 24 & INTERNAL GEAR KIT includes items 2, BALL BEARING KIT includes items 7, 8, 10 & 17 CARRIER COVER ASSY KIT includes items 22, Page K-1

61 REAR AXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 REAR AXLE (INCLUDES ITEMS 2-31) INPUT GEAR G1 BEARING CAP BOLT, 3/8" - 16 X 2 1/8" LG INPUT GEAR KIT (INCLUDES ITEMS 2, 5-8, 24 & 31) G1 RETAINING RING G1 O - RING G1 BALL BEARING G1 BALL BEARING END CAP PLUG BALL BEARING AXLE SHAFT - LH AXLE SHAFT - RH RETAINING RING BALL BEARING OIL SEAL O - RING G1 BALL BEARING DIFFERENTIAL ASSEMBLY LOCK NUT, 3/8" HEX HEAD BOLT, 3/8" - 24 X 1 1/4" LG G1 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG HEX HEAD PLUG COVER PLATE OIL SEAL INTERMEDIATE GEAR ASSEMBLY DRIVE GEAR GASKET INTERNAL GEAR KIT (INCLUDES ITEMS 2, 25-26) BALL BEARING KIT (INCLUDES ITEMS 7, 8, 10 & 17) CARRIER COVER ASSEMBLY KIT (INCLUDES ITEMS 22, 23) O - RING... 1 Page K-2

62 REAR AXLE When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 HEX HEAD BOLT, 5/16" - 24 X 1" LG G1 LOCK NUT, 5/16" Page K-3

63 REAR AXLE Notes: Page K-4

64 REAR SUSPENSION Page L-1

65 REAR SUSPENSION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** 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 HEX NUT, 3/8" LEAF SPRING (HEAVY DUTY) G01 U BOLT, 3/8" - 16 X 2" X 2 1/2" LG G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G02 SPLIT STEEL SPACER FLANGED BUSHING G02 SHACKLE PLATE G9 HEX HEAD BOLT (SS), 3/8" - 16 X 3 1/2" LG G5 LOCK NUT, 3/8" G1 SHOULDER BOLT, 3/8" - 16 X 3 1/4" LG G1 LOCK NUT, 3/8" G01 VINYL CAP... 2 Page L-2

66 SEATING 17 1 SEAT BACK ASSEMBLY includes items 3-6 & SEAT BOTTOM ASSEMBLY includes items Front of Vehicle SEAT BOTTOM ASSEMBLY includes items Front of Vehicle Front of Vehicle FLIP FLOP SEAT BOTTOM ASSEMBLY includes items FLIP FLOP SEAT BOTTOM ASSEMBLY includes items 43-45, 92 Page M-1

67 SEATING HANDRAIL KIT, FLIP FLOP SEAT includes items HANDRAIL KIT, FLIP FLOP SEAT includes items 66-70, MAX 250 lbs. 110 kg MAX 4 in. 10 cm MAX 14 o / 25% Front of Vehicle Top of Vehicle Page M-2

68 SEATING 73 SEAT BOTTOM ASSEMBLY includes items Front of Vehicle Floormat 34 Page M-3

69 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 2-6 & 8-9) G01 WHITE 71751G02 GRAY 71751G03 OYSTER 71751G04 TAN 71751G06 BROWN 71751G07 BLACK RED/BLACK WHITE/BLUE WHITE/RED (FOR VEHICLES MANUFACTURED FROM MARCH 2014) WHITE/BLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) WHITE/YELLOW (FOR VEHICLES MANUFACTURED FROM MARCH 2014) GRAY/BLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) OYSTER/GARNET (FOR VEHICLES MANUFACTURED FROM MARCH 2014) SEAT BACK SUPPORT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) * FLAT STAPLE... AR G01 PLASTIC SEAT BACK COVER G01 SEAT BACK (WOOD) G01 PAN HEAD TORX SCREW (SS), #8 X 3/8" LG PAN HEAD SCREW, #8 X 0.88" LG G01 FOAM PADDING (SEAT BACK) *** VINYL SEAT BACK COVER G01 WHITE 71753G02 GRAY 71753G03 OYSTER 71753G04 TAN 71513G06 BROWN Page M-4

70 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G07 BLACK G0304 RED/BLACK G0102 WHITE/BLUE G0304 RED/BLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G0104 WHITE/BLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G0506 OYSTER/GARNET (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G8 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G7 LOCK WASHER (SS), 0.255" SEAT BACK SUPPORT G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG SEAT FRAME SUPPORT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G6 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) *** SEAT BACK ASSEMBLY G03 TAN 71274G04 GRAY 71274G05 OYSTER HEX HEAD BOLT, 1/4" - 20 X 1" LG SEAT FRAME WELDMENT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G2 HEX HEAD BOLT, 3/8" - 49 X 1.25" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) *** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 22-33) G01 WHITE 71611G03 GRAY 71611G05 OYSTER 71611G07 TAN G1 RUBBER PAD * FLAT STAPLE... AR Page M-5

71 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 24 * FLAT STAPLE... AR G01 VINYL TRIM (SEAT BOTTOM) *** VINYL SEAT BOTTOM COVER G01 WHITE 71602G02 GRAY 71602G03 OYSTER 71602G04 TAN G02 FOAM PADDING (SEAT BOTTOM) SEAT BOTTOM (WOOD) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 HIP RESTRAINT (DRIVER SIDE) G01 HIP RESTRAINT (PASSENGER SIDE) G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG G01 SEAT HINGE G08 FLAT HEAD PHILLIPS SCREW, #12-14 X 1" LG G01 HAND GRIP WELDMENT G02 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 2" LG G01 T-KNOB STUD, 1/4" - 20 X 1" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG *** FLIP FLOP SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 42-45) BLACK TAN WHITE / RED WHITE / BLUE WHITE / YELLOW WHITE / BLACK OYSTER / GARNET Page M-6

72 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY GRAY / BLACK OYSTER BLACK TAN WHITE / RED WHITE / BLUE WHITE / YELLOW WHITE / BLACK OYSTER / GARNET GRAY / BLACK WHITE/BLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) RED/BLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) WHITEBLACK (FOR VEHICLES MANUFACTURED FROM MARCH 2014) DECK BOARD ASSEMBLY G1 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1" LG SEAT STRAP G7 FLAT WASHER, 1/4" SEAT FRAME WELDMENT FOOTREST WELDMENT ARMREST, REAR SEAT SEAT FRAME SUPPORT FOOTREST BRACKET (PASSENGER SIDE) FOOTREST BRACKET (DRIVER SIDE) G01 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG G2 HEX HEAD BOLT, 3/8" - 16 X 1 1/2" LG Page M-7

73 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 HEX HEAD BOLT, 3/8" - 16 X 3 1/4" LG G9 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1 1/4" LG FLAT WASHER, 3/8" G7 FLAT WASHER, 1/4" G5 LOCK NUT, 3/8" G5 LOCK NUT, 3/8" G4 LOCK NUT, 1/4" G1 SQUARE TUBE CAP, 1" HANDRAIL KIT, FLIP FLOP SEAT (INCLUDES ITEMS 65-70) FOOTREST HANDLE WELDMENT G1 SQUARE TUBE CAP, 3/4" DECAL G8 HEX HEAD BOLT, 3/8" - 16 X 2" LG FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" GXX SEAT BACK ASSEMBLY G** SEAT BOTTOM (INCLUDES ITEMS 74-78) G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 FLAT WASHER (SS), 1/4" G7 LOCK WASHER (SS), 1/4" G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG HANDRAIL KIT, FLIP-FLOP SEAT (INCLUDES ITEMS 66-70, 80) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) FOOTREST HANDLE WELDMENT *** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 82-89) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G0401 OYSTER G0403 TAN G0404 GRAY G0406 BLACK Page M-8

74 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G0407 BROWN G0409 WHITE/BLUE G0410 RED/BLACK G0411 WHITE/RED G0412 WHITE/BLACK G0413 WHITE/YELLOW G0414 GRAY/BLACK G0415 OYSTER/GARNET 82 *** FRONT SEAT BOTTOM G02 GRAY 71624G03 OYSTER 71624G04 TAN 71624G05 SPECIAL 71624G06 BROWN 71624G07 BLACK 83 *** VINYL SEAT BOTTOM COVER G0103 WHITE/RED G0104 WHITE/BLACK G0108 WHITE/YELLOW G0704 GRAY/BLACK G0506 OYSTER/GARNET G01 FOAM PADDING (SEAT BOTTOM) SEAT BOTTOM (WOOD) TORX HEAD BOLT, M X 25MM LG G1 FLAT STAPLE, 3/8" HIP RESTRAINT (DRIVER SIDE) HIP RESTRAINT (PASSENGER SIDE) *** FLIP FLOP SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 43-45, 92) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 OYSTER G03 TAN G04 GRAY Page M-9

75 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G G G G G G G G G15 BLACK BROWN WHITE/BLUE RED/BLACK WHITE/RED WHITE/BLACK WHITE/YELLOW GRAY/BLACK OYSTER/GARNET DECK BOARD ASSEMBLY (FOR VEHICLES MANUFACTURED FROM MARCH 2014) REAR SEAT ARM REST (FOR VEHICLES MANUFACTURED FROM MARCH 2014) FOOTREST WELDMENT (FOR VEHICLES MANUFACTURED FROM MARCH 2014)... 1 Page M-10

76 SEATING Notes: Page M-11

77 SEATING Notes: Page M-12

78 WEATHER PROTECTION D Rear of Vehicle Front Of Vehicle (Driver Side Shown) D A C B A C Sun 15 Top Front of Vehicle B Front Strut SUN TOP KIT, BLACK includes items 4-6, 7 & 10 SUN TOP KIT, WHITE includes items 4-6, 8 & SUN TOP KIT, BEIGE includes items 4-6, 9 & 10 SUN TOP HARDWARE KIT includes items SUN TOP KIT, WHITE includes items 4, 8 & SUN TOP KIT, BLACK includes items 4, 7 & SUN TOP KIT, BEIGE includes items 4, 9 & Page N-1

79 WEATHER PROTECTION WINDSHIELD 37 REAR VIEW MIRROR KIT includes items Front Top Strut REAR VIEW MIRROR WINDSHIELD Page N-2

80 WEATHER PROTECTION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SUN TOP KIT, BLACK (INCLUDES ITEMS 4-6, 7 & 10) SUN TOP KIT, WHITE (INCLUDES ITEMS 4-6, 8 & 10) SUN TOP KIT, BEIGE (INCLUDES ITEMS 4-6, 9 & 10) FRONT SUPPORT REAR SUPPORT (DRIVER SIDE) REAR SUPPORT (PASSENGER SIDE) SUN TOP, BLACK SUN TOP, WHITE SUN TOP, BEIGE SUN TOP HARDWARE KIT (INCLUDES ITEMS 11-25) G2 HEX HEAD BOLT, 5/16" - 18 X 2 1/4" LG G8 LOCK WASHER, 5/16" G5 NYLON WASHER, 3/8" G01 SPACER, 1/2" G1 ALUMINUM SPACER, 3" LG G8 HEX HEAD BOLT (SS), 3/8" - 16 X 5" LG G5 HEX HEAD BOLT (SS), 3/8" - 16 X 1 3/4" LG G6 HEX HEAD BOLT (SS), 3/8" - 16 X 2" LG G5 LOCK NUT, 3/8" AR G8 FLAT WASHER (BLACK), 5/16" G1 FLAT WASHER (SS), 5/8" G1 SPACER (THICK), 1/4" G3 HEX HEAD BOLT (SS), 3/8" - 16 X 2 1/2" LG G1 LOCK WASHER, 3/8" G1 END CAP, 1" REAR SUPPORT REAR CROSS SUPPORT SUN TOP KIT, WHITE (INCLUDES ITEMS 4, 8 & 10) SUN TOP KIT, BLACK (INCLUDES ITEMS 4, 7 & 10) SUN TOP KIT, BEIGE (INCLUDES ITEMS 4, 9 & 10)... 1 Page N-3

81 WEATHER PROTECTION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY WINDSHIELD KIT SASH, 26" WINDSHIELD KIT SASH, 12" G2 REAR VIEW MIRROR KIT (INCLUDES ITEMS 38-40) G1 REAR VIEW MIRROR G2 SUPPORT BRACKET G1 PAN HEAD SCREW (SS), # 8-32 X 5/8" LG... 1 Page N-4

82 WHEELS AND TIRES 1 WHEEL AND TIRE ASSEMBLY includes items Page P-1

83 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. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY WHEEL AND TIRE ASSEMBLY - LOAD STAR (INCLUDES ITEMS 2-4) WHEEL - MONITOR, 8" X 7" TIRE G2 VALVE STEM G1 LUG NUT, 1/2" HUB CAP SILVER HUB CAP GOLD... 4 Page P-2

84 WHEELS AND TIRES Notes: Page P-3

85

86 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA s, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at 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