RXV GASOLINE SERVICE PARTS MANUAL

Transcription

1 RXV GASOLINE SERVICE PARTS MANUAL ISSUED JANUARY 2008

2

3 SERVICE PARTS MANUAL GASOLINE POWERED GOLF CARS & PERSONAL VEHICLES RXV GOLF CAR RXV FREEDOM RXV SHUTTLE Starting Model Year 2008 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 LIABILITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL 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 ROAD, AUGUSTA, GEORGIA USA Page i

4 GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a World Vehicle. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved 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). Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL Vii ACCELERATOR PEDAL ASSEMBLY A-1 Pedal Cover Accelerator Pedal Accelerator Pedal Switch AIR FILTER B-1 Air Cleaner Element Air Filter Housing Air Cleaner Hose BODY - FRONT C-1 Front Bumper Front Splash Shield Cowl Nameplate Instrument Panel Instrument Panel Trim Cup Holder BODY - MID SECTION C-5 Pedal Cover Floorboard Floormat Rocker Panels BODY - REAR C-7 Rear Body Rear Splash Shields Seat Support Bagwell Liner Access Panel BODY - ACCESSORIES C-11 Sand Bottle Cooler Jug Scuff Guard Soft Swipe BODY - ACCESSORIES C-13 Divot Repair Kit Club & Ball Washer BRAKES D-1 Brake Pedal Pad Brake Pedal Brake Cable Brake Drum Assembly CARBURETOR AND CHOKE E-1 Carburetor Main Jet Choke Cable CLUTCH F-1 Drive Clutch Driven Clutch Page iii

6 TABLE OF CONTENTS SECTION Page No. DIRECTION SELECTOR G-1 Push/Pull Shifter Cable Compression Spring Neutral Lock Bracket ELECTRICAL SYSTEM H-1 Main Harness Battery Hour Meter Ground Cable Turn Signal Headlight Key Switch Tail Lights ENGINE AND MUFFLER J-1 Engine Muffler Oil Dip Stick Oil Filter ENGINE MOUNTING K-5 Engine Pan Mount Front Engine Mount FRONT SUSPENSION AND STEERING L-1 Strut Spindle A-Arm Steering Box Steering Column Steering Wheel FUEL SYSTEM M-1 Fuel Tank Pulse Line REAR AXLE N-1 Axle Shaft Axle Tube Oil Check Plug REAR SUSPENSION P-1 Shocks Leaf Spring Shackles SEATING - GOLF CAR Q-1 Seat Bottom Seat Back Hip Restraints Seat Back Support SEATING - SHUTTLE Q-5 Seat Bottom, Rear Facing Seat Seat Back, Rear Facing Seat Floorboard, Rear Facing Seat Arm Rest, Rear Facing Seat Page iv

7 TABLE OF CONTENTS SECTION Page No. STARTER / GENERATOR R-5 Starter Starter Belt Starter Tensioner TOW BAR S-1 WEATHER PROTECTION - GOLF CAR T-1 Sun Top WEATHER PROTECTION - SHUTTLE T-3 Sun Top WEATHER PROTECTION - WINDHIELD T-5 WHEELS AND TIRES U-1 Tire & Wheel Assembly Lug Nuts Dust Cap Page v

8 TABLE OF CONTENTS SECTION Page No. Page vi

9 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. 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. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. SERIAL NUMBER LOCATION Three serial number and manufacture date code labels are on the vehicle. One is placed on the steering column, the second is located on the frame member under the front splash shield on the driver side and the third is located on the passenger side frame rail at the rear of the vehicle. In order to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must be provided when ordering service parts. Serial Number Serial Number Serial Number Page vii

10 HOW TO USE THE SERVICE PARTS MANUAL Title Title Front of Vehicle 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 TABLE OF CONTENTS 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. 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 viii

11 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page ix

12 ACCELERATOR Page A-1

13 ACCELERATOR Differential Page A-2

14 ACCELERATOR 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 ACCELERATOR PEDAL ASSEMBLY ACCELERATOR PEDAL COVER BOLT, M X BOLT, M BOLT, ACCELERATOR CABLE ACCELERATOR PEDAL SWITCH SOCKET HEAD SCREW, M5 X UPPER GOVERNOR BRACKET LOWER GOVERNOR BRACKET BOLT, M6-1 X BOLT, M6-1 X NUT, M GOVERNOR LEVER BUSHING GOVERNOR ROD GOVERNOR ROD GUARD BOLT, M6-1 X BOLT, M X GOVERNOR CABLE/DIRECTION SELECTOR BRACKET BOLT, M X Page A-3

15 ACCELERATOR Notes: Page A-4

16 AIR FILTER 1 - Includes items Page B-1

17 AIR FILTER 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 AIR CLEANER ASSEMBLY G01 AIR CLEANER ELEMENT AIR CLEANER BASE GROMMET AIR FILTER LATCH INTAKE TUBE GASKET AIR FILTER HOUSING AIR FILTER INTAKE TUBE AIR FILTER COVER G7 HOSE CLAMP AIR CLEANER HOSE... 1 Page B-2

18 BODY Page C-1

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. 1 6XXXXX*** FRONT COWL, WITHOUT HEADLIGTH OPENING (see colors below) IVORY FORREST GREEN PATRIOT BLUE BLACK MOLTEN RED BRIGHT WHITE FLAME RED STEEL BLUE PLATINUM ALMOND ELECTRIC BLUE INFERNO RED 2 6XXXXX*** FRONT COWL, WITH HEADLIGHT OPENING (see colors below) IVORY FORREST GREEN PATRIOT BLUE BLACK MOLTEN RED BRIGHT WHITE FLAME RED STEEL BLUE PLATINUM ALMOND ELECTRIC BLUE INFERNO RED INSTRUMENT PANEL TRIM, FLEET INSTRUMENT PANEL TRIM, FREEDOM BALL HOLDER INSERT, DRIVER SIDE BALL HOLDER INSERT, PASSENGER SIDE ACCESS COVER ASSEMBLY U-CLIP Page C-2

20 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 INSTRUMENT PANEL SPRING CLIP FRONT BUMPER FLAT WASHER, M10 (O.D. 30, I.D. 10.5, THK. 1.75) FLANGED HEX NUT WITH PLASTIC INSERT, M PAN HEAD PHILLIPS SCREW, #10-16 SELF TAPING G7 NOISE SUPPRESION STRIP COWL SUPPORT FRONT SPLASH GUARD G2 CHRISTMAS TREE RIVET CUPHOLDER ASSEMBLY (includes item 27) WARNING AND INSTRUCTION DECAL G01 SELF THREADING NUT E - Z - GO NAMEPLATE AMBER REFLEX REFLECTOR, FRON Page C-3

21 BODY Notes: Page C-4

22 BODY Page C-5

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 UPPER ROCKER PANEL, DRIVER SIDE UPPER ROCKER PANEL, PASSENGER SIDE BUTTON HEAD TORX SCREW, THREAD FORMING, M LOWER ROCKER PANEL, DRIVER SIDE LOWER ROCKER PANEL, PASSENGER SIDE BUTTON HEAD TORX SCREW, THREAD FORMING, M FLOORMAT WITHOUT HOLE FOR HORN FLOORMAT WITH HOLE FOR HORN G2 CHRISTMAS TREE RIVET (.25 X.88) PEDAL COVER PLATE G2 CHRISTMAS TREE RIVET (.25 X.88) FLOOR BOARD FLAT WASHER, M10 (O.D. 30, I.D. 10.5, THK. 1.75) TORX SOCKET HEAD CAP SCREW, M X Page C-6

24 BODY Page C-7

25 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. 1 6XXXXX REAR BODY ASSEMBLY WITHOUT LIGHT OPENINGS (includes items 5-9) (see colors below) IVORY FORREST GREEN PATRIOT BLUE BLACK MOLTEN RED BRIGHT WHITE FLAME RED STEEL BLUE PLATINUM ALMOND ELECTRIC BLUE INFERNO RED 2 6XXXXX REAR BODY ASSEMBLY WITH LIGHT OPENINGS (includes items 5-9) (see colors below) IVORY FORREST GREEN PATRIOT BLUE BLACK MOLTEN RED BRIGHT WHITE FLAME RED STEEL BLUE PLATINUM ALMOND ELECTRIC BLUE INFERNO RED BAGWELL LINER INSERT G2 CHRISTMAS TREE RIVET REAR BODY ACCESS PANEL BARREL CLIP, M BUTTON HEAD TORX BOLT, M6-1 X Page C-8

26 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 PAN HEAD TORX BOLT, M X FLAT WASHER, M10 (O.D. 30, I.D. 10.5, THK. 1.75) SEAT HINGE PLATE PAN HEAD TORX BOLT, M X FRONT SEAT SUPPORT ASSEMBLY PAN HEAD TORX BOLT, M X REAR SPLASH GUARD, DRIVER SIDE G2 CHRISTMAS TREE RIVET (.25 X.88) REAR SPLASH GUARD, PASSENGER SIDE G2 CHRISTMAS TREE RIVET (.25 X.88) RUBBER PAD SCUFF GUARD, DRIVER SIDE SCUFF GUARD, PASSENGER SIDE G2 CHRISTMAS TREE RIVET (.25 X.88) FLAT WASHER, (O.D. 30, I.D. 10.5, THK. 1.75) BUTTON HEAD TORX SCREW, THREAD FORMING, M REAR BUMPER FLAT WASHER, M10 (O.D. 30, I.D. 10.5, THK. 1.75) HEX HEAD FLANGED BOLT, M X BUTTON HEAD TORX BOLT, M X Page C-9

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 RXV DECAL E - Z - GO FREEDOM DECAL E - Z - GO SHUTTLE DECAL RED REFLEX REFLECTOR, REAR... 4 Page C-10

28 BODY Beverage Cooler Kit, Driver Side includes items Beverage Cooler Kit, Driver Side includes items Sand Bottle Kit includes items Sand Bottle Assembly includes items 22 & Page C-11

29 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 SIDE BASKET, DRIVER SIDE (use existing hardware) SIDE BASKET, PASSENGER SIDE (use existing hardware) BEVERAGE COOLER KIT, DRIVER SIDE (includes items BEVERAGE COOLER KIT, PASSENGER SIDE (includes items 8 - ) MOUNTING BRACKET, DRIVER SIDE BUTTON HEAD TORX BOLT, M X POLYPROPYLENE WASHER LOCKING NUT, M BEVERAGE COOLER MOUNTING BRACKET, PASSENGER SIDE SOFTSWIPE BUTTON HEAD TORX SCREW, THREAD FORMING, M PAN HEAD PHILLIPS SCREW, #10 X 2" SAND BOTTLE KIT (includes items 21-25) SAND BOTTLE ASSEMBLY (includes items 22 & 23) SAND BOTTLE SAND BOTTLE CAP PAN HEAD TORX SCREW, TAPTITE M X SAND BOTTLE MOUNTING BRACKET... 1 Page C-12

30 BODY 1 Divot Repair Kit, Driver Side includes items Divot Repair Kit, Driver Side includes items Club & Ball Washer Kit, Driver Side includes items Club & Ball Washer Kit, Driver Side includes items Page C-13

31 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 DIVOT REPAIR KIT, DRIVER SIDE (includes items 3-8) DIVOT REPAIR KIT, PASSENGER SIDE (includes items 4-9) MOUNTING BRACKET, DRIVER SIDE BUTTON HEAD TORX BOLT, M X POLYPROPYLENE WASHER LOCKING NUT, M DIVOT REPAIR BUCKET SCOOP MOUNTING BRACKET, PASSENGER SIDE CLUB & BALL WASHER KIT, DRIVER SIDE (includes items 16-20) CLUB & BALL WASHER KIT, PASSENGER SIDE (includes items 17-21) MOUNTING BRACKET, DRIVER SIDE BUTTON HEAD TORX BOLT, M X POLYPROPYLENE WASHER LOCKING NUT, M CLUB & BALL WASHER MOUNTING BRACKET, PASSENGER SIDE... 1 Page C-14

32 BRAKES Page D-1

33 BRAKES Page D-2

34 BRAKES Page D-3

35 BRAKES 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 BRAKE PEDAL ASSEMBLY SOCKET HEAD SCREW, M X BRAKE PEDAL COVER BRAKE PEDAL RUBBER COVER PARK BRAKE PEDAL RUBBER COVER BOLT, M4 -.7 X PARK BRAKE KICK-OFF LINKAGE BRAKE LIGHT SWITCH S-CLIP G1 NYLON CLAMP EQUALIZER BRAKE CABLE CLIP CLEVIS PIN, 8MM X 21.5MM E CLIP RING, 8 MM CLEVIS PIN, 8MM X 27.0MM BRAKE CABLE, PASSENGER SIDE BRAKE CABLE, DRIVER SIDE G3 CLEVIS PIN G3 COTTER PIN.94 X G01 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 30-38) G02 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 30-37, 39) G01 BRAKE SHOE... 4 Page D-4

36 BRAKES 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. 31 * BRAKE SHOES G01 BRAKE SPRING KIT (INCLUDES ITEMS 33-37) * UPPER SPRING * LOWER SPRING * PIN * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCLUDES ITEMS 40, 41) G02 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 40, 41) * ADJUSTER * TEFLON WASHER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 INNER BRAKE DRUM WASHER, 1 5/16" O.D. X 1" I.D. X 1/32" G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS 47-48) * BRAKE DRUM G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 OUTER BRAKE DRUM WASHER G8 CASTELLATED NUT, 3/ G1 COTTER PIN, 1/8" X 1 1/2" LG G01 SPINDLE CAP BRAKE CABLE BRACKET (PASSENGER SIDE) BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-5

37 BRAKES Notes: Page D-6

38 CARBURETOR AND CHOKE Page E-1

39 CARBURETOR AND CHOKE Page E-2

40 CARBURETOR AND CHOKE 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 CARBURETOR (INCLUDES ITEMS 3-21) MAIN JET (#104) PILOT JET (#44) PLUG NEEDLE VALVE FLOAT FLOAT PIN FLOAT BOWL GASKET FLOAT CHAMBER BOWL SCREW BOWL GASKET BREATHER TUBE CLAMP, INTAKE TUBE CLAMP CYLINDER HEAD TUBE INTAKE TUBE CHOKE GASKET NUT, M6 X THROTTLE ROD ATTACHMENT BUSHING MAIN JET (#102) (FOR ELEVATIONS OF 3000 FT FT) MAIN JET (#100) (FOR ELEVATIONS OF 6000 FT FT) CARBURETOR MOUNT GASKET CARBURETOR INSULATOR CHOKE/AIR INTAKE ADAPTER CHOKE CABLE (22 1/4" LG WITH NUTS)... 1 Page E-3

41 CARBURETOR AND CHOKE Notes: Page E-4

42 CLUTCH 7 - Includes items Page F-1

43 CLUTCH 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 DRIVE CLUTCH BOLT, M X 160MM LG WASHER, M WASHER DRIVEN CLUTCH ASSEMBLY (INCLUDES ITEMS 8-15) * MOVABLE SHEAVE SCREW, M4 X RAMP BUTTON * CAM COMPRESSION SPRING * SHEAVE AND POST HEAVY DUTY RETAINING RING BOLT, M X 120MM LG WASHER, M DRIVE BELT... 1 Page F-2

44 DIRECTION SELECTOR Page G-1

45 DIRECTION SELECTOR 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 DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 2-28) DIRECTION SELECTOR BRACKET WITH BUSHING DIRECTION SELECTOR SHAFT DIRECTION SELECTOR CAM G1 LOCK NUT, 3/ G2 BUSHING G01 NEUTRAL LOCK PIN G01 COMPRESSION SPRING, 3/8" X 5/8" LG G01 NEUTRAL LOCK BRACKET G2 LOCK NUT, 1/ G01 EXTENSION SPRING G01 BALL STUD, 1/4" G5 LOCK NUT, # G01 MICRO SWITCH G01 SCREW, #4-40 X 1" LG G1 WASHER, # G1 LOCK WASHER, # G2 NUT, # PUSH / PULL SHIFTER CABLE G01 CUP WASHER, 1/4" G01 COMPRESSION SPRING, 19/32" X 1" LG SHIFTER BRACKET WITH BUSHING G5 LOCK NUT, # Page G-2

46 DIRECTION SELECTOR 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 BOLT, M X NUT, M G01 LOCK NUT, M8 X 1.25 MM G01 DIRECTION SELECTOR HANDLE G4 SCREW, #10-32 X 1/2" LG (STAINLESS STEEL) BOLT, M X NUT, M G01 CABLE CLIP... 2 Page G-3

47 DIRECTION SELECTOR Notes: Page G-4

48 ELECTRICAL SYSTEM Page H-1

49 ELECTRICAL SYSTEM Page H-2

50 ELECTRICAL SYSTEM Page H-3

51 ELECTRICAL SYSTEM Includes items Includes items Page H-4

52 ELECTRICAL SYSTEM Includes items Includes items Page H-5

53 ELECTRICAL SYSTEM 71 Page H-6

54 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 MAIN HARNESS, FLEET G1 BATTERY, 12V BATTERY TIE DOWN BOSS SCREW, M POSITIVE BATTERY CABLE (SOL - BATT+) GA. WIRE, (SOL - F2) RELAY, 12V G01 VOLTAGE REGULATOR G1 RACHET FASTENER SCREW, M6-1.0 X NUT, M NUT, M SCREW, M4-0.7 X SCREW, M6-1.0 X COVER BRACKET GROUND CABLE CLAMP BOLT, M6-1.0 X BOLT, M HOUR METER HOUR METER BRACKET Page H-7

55 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 FUEL GAUGE HEADLIGHT SWITCH KEY SWITCH TURN SIGNAL SWITCH KIT (includes items 36-38) TURN SIGNAL ASSEMBLY G3 COVER RUBBER TAPE/INSULATION HORN ASSEMBLY KIT (includes items 41-46) G01 CLIP LOCK NUT, M BUTTON HEAD TORX BOLT, M6-1 X HORN ASSEMBLY HORN BUTTON SWITCH ASSEMBLY HORN PLATE HEADLIGHT KIT (includes items 50-59) HEADLIGHT ASSEMBLY, DRIVER SIDE (includes items 52-58) HEADLIGHT ASSEMBLY, PASSENGER SIDE (includes items 53-59) GASKET, DRIVER SIDE G01 HEADLIGHT BULB TURN SIGNAL BULB BULB RETAINER BUTTON HEAD TORX SCREW, PLASTITE TURN SIGNAL WIRE HARNESS HEADLIGHT RETAINING CLIP GASKET, PASSENGER SIDE Page H-8

56 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 TAIL LIGHT KIT (includes items 63-69) TAIL LIGHT HARDWARE KIT (INCLUDES ITEMS 64 & 65 ) BUTTON HEAD TORX BOLT, M6-1 X BARRELL CLIP, M TAIL LIGHT ASSEMBLY, DRIVER SIDE (includes items 68 & TAIL LIGHT ASSEMBLY, PASSENGER SIDE (includes items 68 & 69) TAIL LIGHT BULB TAIL LIGHT LENS ACCESSORY HARNESS BRAKE LIGHT SWITCH ASSEMBLY S-CLIP... 1 Page H-9

57 ELECTRICAL SYSTEM Notes: Page H-10

58 ENGINE AND MUFFLER Page J-1

59 ENGINE AND MUFFLER Page J-2

60 ENGINE AND MUFFLER 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 ENGINE DIP STICK OIL FILTER SPARK PLUG (BPR2ES) OIL DRAIN PLUG O RING, 16MM MUFFLER EXHAUST PIPE WASHER, 8MM NUT, M8 X NUT, M BOLT, M X BOLT, M X EXHAUST GASKET... 2 Page J-3

61 ENGINE AND MUFFLER Notes: Page J-4

62 ENGINE MOUNTING ? 3 24? 25? FRONT 21 FRONT 5 Page K-1

63 ENGINE MOUNTING 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 FRONT ENGINE MOUNT ENGINE PAN MOUNT BOLT, M X NUT, M NUT PLATE BOLT, FLAT WASHER, M10 X NUT, M BOLT, M X FLAT HEAD SCREW, T DIFFERENTIAL PLATE BOLT, M X BOLT, M X ISO MOUNT BOLT, M X BOLT, M RUBBER WASHER DELRIN WASHER G2 CAP ADAPTER COMPRESSION SPRING WASHER, M X Page K-2

64 FRONT SUSPENSION Front Suspension Assembly Passenger Side includes items 18, Front Suspension Assembly Diver Side includes items 2, 5-13 Page L-1

65 FRONT 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 FRONT SUSPENSION ASSEMBLY, DRIVER SIDE (includes items 2-13) SPINDLE ASSEMBLY, DRIVER SIDE STRUT ASSEMBLY, DRIVER SIDE KINGPIN TUBE THRUST WASHER KINGPIN, HEX HEAD FLANGED BOLT, M X HEX NUT, FLANGED, M HUB ASSEMBLY (includes item 11) WHEEL STUD LOCKING HEX NUT, M G3 SPINDLE CAP FRONT SUSPENSION ASSEMBLY, PASSENGER SIDE (inc items 18-29) SPINDLE ASSEMBLY, PASSENGER SIDE STRUT ASSEMBLY, PASSENGER SIDE KINGPIN TUBE THRUST WASHER KINGPIN, HEX HEAD FLANGED BOLT, M X HEX NUT, FLANGED, M HUB ASSEMBLY (includes item 27) WHEEL STUD LOCKING HEX NUT, M G3 SPINDLE CAP Page L-2

66 FRONT 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 HEX HEAD FLANGED BOLT, M X HEX NUT, FLANGED LOCK, M A-ARM ASSEMBLY A-ARM BUSHING A-ARM CARRIER TUBE HEX HEAD FLANGED BOLT, M X HEX NUT, FLANGED LOCK, M HEX HEAD FLANGED BOLT, M X Page L-3

67 FRONT SUSPENSION Notes: Page L-4

68 FRONT SUSPENSION Steering Column Assembly inculdes items Rack Cover Bellows Kit includes items Steering Rack Assembly includes items Page L-5

69 FRONT 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 STEERING RACK ASSEMBLY (includes items 2-4) STEERING ROD ROD END RACK COVER BELLOWS KIT (includes items 5-7) BELLOWS BELLOWS CLAMP (small end) BELLOWS CLIP (large end) TORX SOCKET HEAD CAP SCREW, M X CASTLE HEX NUT, M G2 COTTER PIN STEERING COLUMN ASSEMBLY (includes items 15-18) STEERING COLUMN SUB ASSEMBLY YOKE SUB ASSEMBLY KIT (includes items 17 & 18) STEERING YOKE HEX HEAD BOLT WITH LOCK WASHER, M X PAN HEAD TORX SCREW, TAPTITE M X STEERING WHEEL LOCK NUT, M SCORECARD HOLDER ASSEMBLY... 1 Page L-6

70 FUEL SYSTEM 1 - Includes Items Includes Items 3-13 & Page M-1

71 FUEL SYSTEM 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 FUEL TANK ASSEMBLY FUEL TANK FUEL TANK CAP G03 SIPHON TUBE G01 GROMMET G1 FUEL HOSE, (BULK)... 8" G01 FUEL FILTER G1 CLAMP, 1/2" G1 FUEL HOSE, (BULK) (TO CARBURETOR) " ROLLOVER VALVE ROLLOVER VALVE GROMMET FUEL PUMP G4 CLAMP, 1/2" FUEL TANK ASSEMBLY WITH LEVEL SWITCH (INCLUDES ITEMS 3-12 & 16-21) FUEL TANK (FOR VEHICLES WITH FUEL GUAGE) G01 FUEL LEVEL SENDER ADAPTER G01 SCREW, #6-32 X 1/2" LG FUEL LEVEL SENDER (INCLUDES ITEM 13) * GASKET G01 SCREW, #10 x 3/4" LG BOSS SCREW TORX, M X WASHER, WASHER M10, 10.5 X HEX BOLT, M X BARREL CLIP NUT, M G1 WIRE TIE G01 PULSE LINE (BULK), (BLACK WITH WHITE LINE MARKING)... 28" Page M-2

72 FUEL SYSTEM 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 CLAMP, 1/2"... 2 Page M-3

73 FUEL SYSTEM Notes: Page M-4

74 REAR AXLE ? Page N-1

75 REAR AXLE 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 REAR AXLE, (INCLUDES ITEMS 3-23) G01 OIL CHECK PLUG G01 GASKET, 14 MM G01 OIL DRAIN PLUG G01 GASKET, 14 MM G01 INPUT SHAFT OIL SEAL G01 AXLE SHAFT OIL SEAL AXLE TUBE (DRIVER SIDE) AXLE TUBE (PASSENGER SIDE) AXLE SHAFT (DRIVER SIDE) AXLE SHAFT (PASSENGER SIDE) G01 RETAINING RING G01 BALL BEARING G01 FLANGED BOLT, M10 X 1.5 X 23 MM LG SLOTTED NUT, M22 X Page N-2

76 REAR SUSPENSION Page P-1

77 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 TAPERED LEAF SPRING HEAVY DUT TAPERED LEAF SPRING U-BOLT LEAF SPRING PLATE LOCK NUT, M FRONT SPRING BUSHING FLANGED HEX HEAD BOLT, M LOCK NUT, M G01 FLANGED URETHANE BUSHING (small) SPLIT STEEL SPACER SHACKLE PLATE FLANGED HEX HEAD BOLT, M X LOCK NUT, M SHOCK ABSORBER FLANGED HEX HEAD BOLT, M X FLAT WASHER, 10.5 X 30 X Page P-2

78 SEATING & BASKET 1 Seat Bottom Assembly includes items Seat Back Assembly includes items Sweater Basket Assembly includes items Page Q-1

79 SEATING & BASKET 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 6XXXXX SEAT BOTTOM ASSEMBLY (select color below), (includes items 2-7) STONE BEIGE SEAT BOTTOM OYSTER SEAT BOTTOM 2 6XXXXX SEAT BOTTOM VINYL COVER (select color below) STONE BEIGE SEAT BOTTOM VINYL COVER OYSTER SEAT BOTTOM VINYL COVER SEAT BOTTOM FOAM SEAT BOTTOM WOODEN BASE ASSEMBLY SEAT BOTTOM COVER PLATE G2 CHRISTMAS TREE RIVET G01 SEAT HINGE G08 FLAT HEAD PHILLIPS TAPPING SCREW, #12-14 X HIP RESTRAINT, DRIVER SIDE HIP RESTRAINT, PASSENGER SIDE BUTTON HEAD TORX BOLT, M X SEAT BACK SUPPORT STRUT FLANGED HEX HEAD BOLT, M X LOCK NUT, M SEAT BACK SUPPORT STRUT COVER XXXXX SEAT BACK ASSEMBLY (select color below), (includes items 22 - ) STONE BEIGE SEAT BACK ASSEMBLY OYSTER SEAT BACK ASSEMBLY 22 6XXXXX SEAT BACK VINYL COVER (select color below) STONE BEIGE SEAT BACK VINYL COVER OYSTER SEAT BACK VINYL COVER G01 SEAT BACK FOAM SEAT BACK WOODEN BASE ASSEMBLY... 1 Page Q-2

80 SEATING & BASKET 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 SEAT BACK BLACK PLASTIC COVER BUTTON HEAD TORX SCREW, PLASTITE THREAD FORMING, M BUTTON HEAD TORX BOLT, M X SWEATER BASKET ASSEMBLY (includes items 33-36) SWEATER BASKET BAG STRAP CLAMP G1 CHRISTMAS TREE RIVET BAG STRAP BUTTON HEAD TORX BOLT, M X BUTTON HEAD TORX BOLT, M X LOCK NUT, M Page Q-3

81 SEATING & BASKET Notes: Page Q-4

82 SEATING & BASKET 1 23 Seat Bottom Assembly includes items Seat Back Assembly includes items Floor Board Assembly includes items Page Q-5

83 SEATING & BASKET 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 SEAT BACK SUPPORT, SEAT HEX HEAD FLANGED BOLT, M X LOCK NUT, M REAR SEAT BACK MOUNTING BRACKET ARM REST, DRIVER SIDE ARM REST, PASSENGER SIDE BUTTON HEAD TORX BOLT, M X LOCK NUT, M REAR FACING SEAT FLOORBOARD ASSEMBLY (includes items 7-10) FOOTREST WELDMENT G01 WARNING DECAL G1 END CAP RUBBER FLOORMAT HEX HEAD FLANGED BOLT, M X HEX HEAD FLANGED BOLT, M X LOCK NUT, M XXXX SEAT BOTTOM ASSEMBLY (select color below) (includes items 24-26) STONE BEIGE SEAT BOTTOM ASSEMBLY OYSTER SEAT BOTTOM ASSEMBLY 24 6XXXXX SEAT BOTTOM VINYL COVER (select color below) STONE BEIGE SEAT BOTTOM VINYL COVER OYSTER SEAT BOTTOM VINYL COVER SEAT BOTTOM FOAM SEAT BOTTOM WOODEN BASE ASSEMBLY HEX HEAD FLANGED BOLT, M X Page Q-6

84 SEATING & BASKET 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 XXXX SEAT BACK ASSEMBLY (select color below) STONE BEIGE SEAT BACK ASSEMBLY OYSTER SEAT BACK ASSEMBLY 31 6XXXXX SEAT BACK VINYL COVER (select color below) STONE BEIGE SEAT BACK VINYL COVER OYSTER SEAT BACK VINYL COVER G01 SEAT BACK FOAM SEAT BACK WOODEN BASE ASSEMBLY SEAT BACK BLACK PLASTIC COVER BUTTON HEAD TORX SCREW, PLASTITE THREAD FORMING, M BUTTON HEAD TORX BOLT, M X BUTTON HEAD TORX BOLT, M X LOCK NUT, M Page Q-7

85 SEATING & BASKET Notes: Page Q-8

86 STARTER / GENERATOR Includes Items Includes Items Includes Items Page R-1

87 STARTER / GENERATOR Page R-2

88 STARTER / GENERATOR 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 STARTER / GENERATOR (INCLUDES ITEMS 2-27) G01 ARMATURE G01 REAR BALL BEARING G01 FRONT BALL BEARING G01 BEARING HOLDER G01 FIELD COIL G01 INSULATING BRUSH ASSEMBLY ( F ) G01 POLE CORE SETSCREW G01 FRONT COVER G01 REAR COVER G01 TERMINAL ASSEMBLY ( A ) G01 BRUSH HOLDER ASSEMBLY (INCLUDES ITEMS 17-19) G01 BRUSH G01 BRUSH SPRING G01 BRUSH CONNECTOR G01 KEY G01 PULLEY G01 BRUSH AND PULLEY HARDWARE KIT G01 BRUSH 1 COVER G01 BRUSH 2 COVER G01 HOUSING HARDWARE KIT Page R-3

89 STARTER / GENERATOR 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 G4 BOLT, 1/2-13 X 8" LG G3 WASHER, 1/2" G3 LOCK WASHER, 1/2" G1 NUT, 1/ BOLT, M X NUT, M BOLT, M X STARTER/GENERATOR BRACKET TENSIONER BRACKET BOLT, M X BOLT, M X NUT, M NUT, M STARTER/GENERATOR BELT G4 PUSH NUT, 5/16" TENSIONER BOLT... 1 Page R-4

90 TOW BAR 9 4 Permanent Rear Tow Bar includes items Page S-1

91 TOW BAR 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 PAN HEAD TORX BOLT, M X FLAT WASHER, M12, 13.5 X 32 X PERMANENT TOW BAR (towing vehicle), (includes items 5-17) TOW BAR LATCH G01 LATCH STOP HEX HEAD FLANGED BOLT, M X FLANGED LOCK NUT, M G2 COMPRESSION SPRING G02 CUP WASHER PIVOT PIN SPRING PIN G01 DELRIN WASHER TOW BAR SWIVEL G01 FLANGED BUSHING TOW BAR WARNING DECAL WAVE SPRING WASHER, 32mm TOW BAR PIVOT FLAT WASHER, M12, 13.5 X 32 X FLANGED HEX NUT, M REAR TOW BAR RETAINER FLANGED HEX NUT, M RETAINER BACKING PLATE... 1 Page S-2

92 TOW BAR 1 Permanent Front Tow Bar includes items Tow Bar Steering Link includes items Page S-3

93 TOW BAR 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 PERMANENT TOW BAR (towed vehicle) (includes items 2-12) TOW BAR STEERING LINK (includes items 3-8) TOW BAR TIE ROD LEFT HAND TIE ROD END RIGHT HAND TIE ROD END JAM NUT, M LH JAM NUT, M RH SPACER FRONT TOW BAR CASTING BEARING INTERNAL SNAP RING FLANGED HEX NUT, M HEX HEAD FLANGED BOLT, M16-2 X FRONT TOW BAR SPACER LOCKING HEX NUT, M Page S-4

94 WEATHER PROTECTION Stone Beige Sun Top Kit includes items Oyster Sun Top Kit includes items Strut Kit includes items Sun Top Hardware Kit includes items Page T-1

95 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, STONE BEIGE (includes items 3-13) SUN TOP KIT, OYSTER (includes items 4-14) SUN TOP, STONE BEIGE SUN TOP STRUT KIT (includes items FRONT STRUT REAR STRUT, PASSENGER SIDE REAR STRUT, DRIVER SIDE SUN TOP HARDWARE KIT (includes items 9-13) HEX HEAD FLANGED BOLT, M X FLANGED LOCK NUT, M HEX HEAD FLANGED BOLT, M X GROMMET, DRIVER SIDE GROMMET, PASSENGER SIDE SUN TOP, OYSTER... 1 Page T-2

96 WEATHER PROTECTION Stone Beige Sun Top Kit includes items Sun Top Hardware Kit includes items 8-15 Page T-3

97 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, STONE BEIGE (includes items 3-13) SUN TOP, STONE BEIGE FRONT STRUT REAR STRUT, DRIVER SIDE REAR STRUT, PASSENGER SIDE SUN TOP HARDWARE KIT (includes items 7 - ) HEX HEAD FLANGED BOLT, M X HEX HEAD FLANGED BOLT, M X FLANGED LOCK NUT, M HEX HEAD FLANGED BOLT, M X SPACER TUBE HEX HEAD FLANGED BOLT, M X STRUT GROMMET, DRIVER SIDE STRUT GROMMET, PASSENGER SIDE... 1 Page T-4

98 WEATHER PROTECTION 5 1 Split Windshield Kit includes items Split Windshield Assembly includes items Split Windshield Hardware Kit includes items 10 & Page T-5