600115G01 SERVICE PARTS MANUAL GASOLINE POWERED UTILITY VEHICLE ISSUED SEPTEMBER 2005 REVISED MAY INCLUDES ITEMS 3-16

Transcription

1 INCLUDES ITEMS G01 SERVICE PARTS MANUAL GASOLINE POWERED UTILITY VEHICLE ISSUED SEPTEMBER 2005 REVISED MAY 2008

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3 SERVICE PARTS MANUAL GASOLINE POWERED UTILITY VEHICLE CLAYS CAR CLAYS CAR CARB ST SPORT 2+2 ST SPORT 2+2 CARB ST CUSTOM STARTING MODEL YEAR 2005 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 INCIDEN- TAL AND CONSEQUENTIAL 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., 1451 MARVIN GRIFFIN RD., 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. 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. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ILLUSTRATED PARTS BREAKDOWN vii ACCELERATOR A-1 AIR FILTER B-1 BODY C-1 BRAKES D-1 CARBURETOR AND CHOKE E-1 CLUTCH F-1 DIRECTION SELECTOR G-1 ELECTRICAL SYSTEM H-1 ENGINE AND MUFFLER J-1 ENGINE MOUNTING K-1 FRONT SUSPENSION L-1 FUEL SYSTEM M-1 REAR AXLE N-1 REAR SUSPENSION P-1 SEATING Q-1 STARTER / GENERATOR R-1 STEERING S-1 WEATHER PROTECTION T-1 WHEELS AND TIRES U-1 SPECIALTY PRODUCTS APPENDIX A-1 OPTIONS AND 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 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. 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 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. vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR 1 - Includes Items Ref Acl 11-1 Page A-1

11 ACCELERATOR To Governor Ref Acl 11-2 Page A-2

12 ACCELERATOR To Carburetor Timing Belt Cover on Engine To Pedal Box 62 Existing Bolt Accelerator Cable Ref Acl 11-3 Page A-3

13 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 G04 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3-45) G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 4-7) G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 5-6) G1 OVAL RIVET, 3/16" X 7/16" LG G01 ACCELERATOR PEDAL PAD * ACCELERATOR PEDAL G1 NYLON BUSHING G01 PEDAL PIVOT PIN G6 PUSH NUT, 9/32" G3 CLEVIS PIN, 5/16" X 13/16" LG G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G4 CLEVIS YOKE (ADJUSTABLE) G4 NUT, 5/ G01 ACCELERATOR ROD G2 SPRING RETAINER, 3/8" G01 COMPRESSION SPRING G1 ACCELERATOR ROD BUSHING G1 SPRING RETAINER, 1/2" G01 MICRO SWITCH CAM G3 SETSCREW, 1/4-20 X 3/8" LG G1 LOCK NUT, 5/ G03 PEDAL BOX AND COVER G01 SCREW, #8-16 X 1/2" LG G6 SCREW, #8-32 X 3/4" LG (STAINLESS STEEL)... 2 Page A-4

14 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 G01 MICRO SWITCH G01 SCREW, #4-20 X 5/8" LG G04 WIRE HARNESS (PEDAL BOX) G1 FLEX LOOM (BULK)... AR G1 WIRE TIE G01 ACCELERATOR CABLE G01 ACCELERATOR CABLE BUSHING G01 COMPRESSION SPRING G02 CUP WASHER, 1/5" G5 LOCK NUT, # G02 ACCELERATOR PEDAL BRACKET G2 BOLT, 5/16-18 X 4/5" LG G01 PEDAL PIVOT COVER G02 ACCELERATOR CABLE MOUNTING BRACKET G01 LOCK NUT, M8 X 1.25 MM G02 THROTTLE CABLE MOUNTING BRACKET G01 LOCK NUT, M8 X 1.25 MM G01 GOVERNOR ARM G01 LOCK NUT, M8 X 1.25 MM G01 LOCK NUT, M8 X 1.25 MM Page A-5

15 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 G02 ACCELERATOR CABLE BRACKET G1 WIRE TIE G02 GOVERNOR COVER/DECAL ASSEMBLY (INCLUDES ITEMS 65, 66) G02 GOVERNOR COVER G1 LABEL (WARNING - GOVERNOR) G1 BONDED WASHER, 1/4" G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 THROTTLE CABLE G1 WIRE TIE G01 PEDAL GUARD G6 BOLT 1/4-20 X 3/4" LG G01 WASHER, 1/4" (STAINLESS STEEL) G2 LOCK NUT, 1/4-20 (STAINLESS STEEL)... 2 Page A-6

16 AIR FILTER 10 - Includes Items Carburetor Front of Vehicle 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 G02 AIR FILTER BRACKET (CABLE ACTUATED CARBURETOR) G3 BOLT, M6 X 1MM X 20MM LG G7 LOCK WASHER, 1/4" G7 WASHER, 1/4" G2 BOLT, 1/4-20 X 1 1/4" LG G7 WASHER, 1/4" G4 LOCK NUT, 1/ G11 RIVET G1 BONDED WASHER G01 AIR CLEANER CANISTER ASSEMBLY (INCLUDES ITEMS 11-14) G01 AIR CLEANER CANISTER G01 AIR CLEANER COVER G01 AIR CLEANER LATCH G01 AIR CLEANER DUST COLLECTOR G01 AIR CLEANER ELEMENT G7 HOSE CLAMP G01 HOSE (AIR FILTER TO CARBURETOR) G6 HOSE CLAMP G01 CARBURETOR GASKET G02 CHOKE / THROTTLE BRACKET G02 CHOKE / THROTTLE COVER G01 CARBURETOR ADAPTER G01 PCV HOSE G11 CARBURETOR MOUNTING SPACER G7 WASHER, 1/4" G1 NUT, M6 X G01 CARBURETOR BAFFLE G01 STUD G1 BOLT AND WASHER, M8 X 1.25 X 18 MM... 2 Page B-2

18 BODY Includes Items Ref Bod Page C-1

19 BODY Includes Items ASH TRAY FLOOR MOUNT GUN HOLDER Ref Bod 11-2 Page C-2

20 BODY Includes Items Includes Items Ref Bod 11-3 Page C-3

21 BODY Foot Rest Includes Items Front of Vehicle BOX COOLER AND BRACKET Ref Bod 11-4 Page C-4

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 G03 INSTRUMENT PANEL ASSEMBLY G01 INSTRUMENT PANEL INSERT (FOUR CUP) G01 LABEL (SAFETY) G01 GLOVE BOX DOORS (BOTH SIDES) G02 GLOVE BOX DOOR (DRIVER SIDE) G03 GLOVE BOX DOOR (PASSENGER SIDE) G** COWL G01 SPLASH PANEL G01 COWL SUPPORT BRACKET G02 BOLT, 1/4-20 X 1/2" LG G02 RIVET, 3/16" X 1 1/8" LG (ALUMINUM) G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG (ALUMINUM) G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 LABEL (ANTI-ROLLBACK) G01 LABEL (TEE HOLDER COVER) * SERIAL NUMBER PLATE * CAPACITY PLATE G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 NAMEPLATE (E-Z-GO) (OVAL) G01 FENDER FLARE (DRIVER SIDE) G02 FENDER FLARE (PASSENGER SIDE) G01 RIVET, 3/16" X 1" LG (ALUMINUM)... 6 Page C-5

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 G01 UPPER FLOORPAN (FRAME MOUNTED STEERING) G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 LOWER FLOORPAN G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ACCESS COVER BAR CHROME BRUSH GUARD (ST CUSTOM) G02 BUMPER G01 SPACER TUBE G1 END CAP, 3/4" G01 SPACER, 1/2" G2 WASHER, 5/16" G8 LOCK WASHER, 5/16" G02 BOLT, 5/16-18 X 2 1/2" LG G02 FRONT BASKET ASSEMBLY (INCLUDES ITEMS 48-53) G01 FRONT BASKET G01 BASKET MOUNTING BRACKET (DRIVER SIDE) G02 BASKET MOUNTING BRACKET (PASSENGER SIDE) G1 CARRIAGE BOLT, 3/8-16 X 1" LG (STAINLESS STEEL) G1 LOCK NUT, 3/ G01 LABEL, FRONT BASKET (WARNING) G01 GUN HOLDER, FLOOR MOUNT G06 FLOORMAT WITH HORN HOLES (1/8") G03 SEAT FRAME (FOR SINGLE CABLE DIRECTION SELECTOR) G2 BOLT, 5/16-18 X 4/5" LG G04 SEAT FRAME (ST CUSTOM) G01 ROCKER PANEL (PASSENGER SIDE) G01 ROCKER PANEL (DRIVER SIDE)... 1 Page C-6

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 G6 RIVET, 3/16" X 15/16" LG (ALUMINUM) G01 SILL PLATE (PASSENGER SIDE) G02 SILL PLATE (DRIVER SIDE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G4 SPACER, 5/16" G2 LOCK NUT, 1/4-20 (STAINLESS STEEL) G03 SPLASH PANEL (ST CUSTOM) G02 SPLASH PANEL G01 BATTERY TRAY G2 BOLT, 5/16-18 X 4/5" LG G01 FENDER LINER, EXTENDED (PASSENGER SIDE) G01 FENDER LINER, EXTENDED (DRIVER SIDE) G2 RATCHET FASTENER, 1/4" X 3/4" LG G17 RIVET G4** REAR BODY (WITHOUT TAILLIGHTS) (INCLUDES ITEMS 81, 82) G0** REAR BODY (WITH TAILLIGHTS) (INCLUDES ITEMS 81, 82) G01 BAGWELL LINER G1 RATCHET FASTENER, 1/4" X 9/16" LG G01 ACCESS PANEL G01 SCREW, #8 X 3/8" LG (STAINLESS STEEL) G02 "J" CLIP G12 RIVET, 1/4" X 9/16" LG (ALUMINUM) G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G1 PLASTIC DRIVE RIVET, 1/4" X 3/4" LG G01 SEAT HINGE PLATE... 2 Page C-7

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 G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G2 WASHER, 5/16" G01 NOTCHED REAR BUMPER G01 BOLT, 1/4-20 X 1 1/4" LG G01 BUMPER PLUG G01 BOLT, 1/4-20 x 11/16" LG G01 J-TYPE NUT RETAINER, 1/ G01 BUMPER STAY G01 LABEL (CLAYS CAR) G01 VERTICAL FRAME SUPPORT (PASSENGER SIDE) G02 VERTICAL FRAME SUPPORT (DRIVER SIDE) G6 BOLT, 3/8-16 X 1 1/2" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G2 CARRIAGE BOLT, 3/8-16 X 1 1/4" LG G8 BOLT, 3/8-16 X 1" LG G01 FOOTREST ASSEMBLY (INCLUDES ITEMS ) G1 END CAP, 1" G01 LABEL (WARNING) G01 FLOORMAT G01 FOOTREST G01 LABEL (LOAD BED LIMIT WARNING) G01 SUPPORT TUBE SELF THREADING SCREW, #12-24 X 3/4" LG G1 END CAP, 3/4"... 4 Page C-8

26 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 G2 HOLE PLUG, 1/2" G01 BOX COOLER AND BRACKET (INCLUDES HARDWARE) G02 ASH TRAY KIT (INCLUDES ITEMS ) G01 ASH TRAY G01 GASKET G02 BRACKET G4 SCREW, #10-16 X 1/2" LG G01 GUN HOLDER (SWIVEL MOUNT) (NOT ILLUSTRATED)... 1 Page C-9

27 BODY Page C-10

28 BRAKES Part of Frame Accelerator Pedal Includes Items 19, Includes Items Ref Brk 6-1 Page D-1

29 BRAKES WHT BLK Includes Items Includes Items BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Ref Brk 6-2 Page D-2

30 BRAKES Front of Vehicle Includes Items Includes Items Includes Items Includes Items Includes Items 94, Includes Items 94, Includes Items 101, Ref Brk 6-3 Page D-3

31 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" * BRAKE PEDAL G02 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 8-10) * SERVICE BRAKE PAD * PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 3/8" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG 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 * BRAKE CABLE (DRIVER SIDE) * BRAKE CABLE (PASSENGER SIDE) G01 RETAINING RING, S.S Page D-4

32 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 1" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 3/4" 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 G2 LOCK NUT, 1/ G02 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-80) * BRAKE PEDAL G02 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 57-59) * SERVICE BRAKE PAD * PARK BRAKE PAD... 1 Page D-5

33 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 G1 OVAL RIVET, 3/16" x 3/8" LG G03 BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 1" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 MICRO SWITCH G1 SCREW, #6-32 X 1 1/4" LG G5 WASHER, # G3 WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 SCREW AND LOCK WASHER, # G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84-92) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCL. ITEMS 84-91, 93) G01 BRAKE SHOE KIT (INCLUDES ITEM 85) * BRAKE SHOE G01 BRAKE SPRING KIT (INCLUDES ITEMS 87-91) * UPPER SPRING * LOWER SPRING... 1 Page D-6

34 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. 89 * PIN * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 94, 95) G02 BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCL ITEMS 94, 95) * ADJUSTER * TEFLON WASHER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 INNER BRAKE DRUM WASHER, 1 5/16" OD X 1" ID X 1/32" G2 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS ) * BRAKE DRUM G1 LUG BOLT, 1/ G2 SPINDLE CAP ADAPTER G1 OUTER BRAKE DRUM WASHER G8 SLOTTED NUT, 3/ G1 COTTER PIN, 1/8" X 1 1/2" LG G2 SPINDLE CAP G04 BRAKE CABLE BRACKET (PASSENGER SIDE) G03 BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-7

35 BRAKES Page D-8

36 CARBURETOR AND CHOKE Includes Items Page E-1

37 CARBURETOR AND CHOKE 40 See AIR CLEANER Section Ref Cac 2-2 Page E-2

38 CARBURETOR AND CHOKE 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 G02 CARBURETOR (FOR VEHICLES ORIGINALLY EQUIPPED WITH 350cc (EH35C)) (INCLUDES ITEMS 2-28) G01 NUT G05 MAIN JET (#82) G05 PILOT JET (#42) G01 PLUG G01 GASKET G01 NEEDLE VALVE G01 FLOAT G01 FLOAT PIN G01 FLOAT BOWL GASKET G01 FLOAT CHAMBER G01 BOWL SCREW G01 BOWL GASKET G01 DRAIN SCREW G01 VENT TUBE G01 SCREW G01 BUSHING G01 COLLAR G01 SPRING, CHOKE RETURN G01 CHOKE SHAFT ASSY G01 SCREW * CHOKE VALVE G01 SCREW G01 OV RING G01 COLLAR G01 THROTTLE RETURN SPRING G01 THROTTLE SHAFT ASSY G01 THROTTLE VALVE G04 MAIN JET (#78) (FOR ELEVATIONS OF 5000 FT FT)... 1 Page E-3

39 CARBURETOR AND CHOKE 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 CARBURETOR MOUNT GASKET G01 CARBURETOR INSULATOR (FOR FUJI ENGINE EH35C) G04 CHOKE CABLE (22 1/4" LG WITH NUTS) G01 CHOKE CABLE (60 1/4" LG WITH NUTS) G02 CHOKE CABLE (31 1/2" LG WITH NUTS) G4 LOCK WASHER, 9/16" G4 JAM NUT, 9/ G02 RETAINER G01 CHOKE CABLE ADAPTER G4 JAM NUT, 5/ Page E-4

40 CLUTCH Ref Clt 11 Page F-1

41 CLUTCH 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 DRIVE CLUTCH G9 BOLT, 7/16-20 X 6 1/2" LG G2 LOCK WASHER, 7/16" G1 PILOT WASHER G03 DRIVEN CLUTCH ASSEMBLY (INCLUDES ITEMS 8-15) * MOVABLE SHEAVE (INCLUDES ITEMS 9-10) G01 SCREW, #10-24 X 7/8" LG G01 RAMP BUTTON * CAM G1 SPACER, 1 1/2" G01 COMPRESSION SPRING * SHEAVE AND POST G01 HEAVY DUTY RETAINING RING G8 BOLT, 5/16-18 X 4" LG G8 LOCK WASHER, 5/16" G1 RETAINING WASHER G01 DRIVE BELT (SEVERE DUTY)... 1 Page F-2

42 DIRECTION SELECTOR Top of Seat Support Panel Includes Items Ref Dsl To Shifter Input Shaft Page G-1

43 DIRECTION SELECTOR 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 DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 2-33) G02 DIRECTION SELECTOR BRACKET G01 DIRECTION SELECTOR SHAFT G01 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 LATCH 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, # G03 REVERSE WARNING BUZZER G01 SCREW, #6-32 X 3/8" LG G GA WIRE (RED 7") G01 SHIFTER CABLE G01 CUP WASHER, 1/4"... 4 Page G-2

44 DIRECTION SELECTOR 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 COMPRESSION SPRING, 19/32" X 1" LG G01 SHIFTER ARM WITH BUSHING G5 LOCK NUT, # G4 BUSHING, FLIP LOK, G01 SCREW, 1/4-20 X 7/8" LG G2 LOCK NUT, 1/ G01 LOCK NUT, M8 X 1.25 MM G01 DIRECTION SELECTOR HANDLE G4 SCREW, #10-32 X 1/2" LG (STAINLESS STEEL) G1 WIRE TIE G01 CABLE CLIP... 2 Page G-3

45 DIRECTION SELECTOR Page G-4

46 ELECTRICAL SYSTEM 1 - Includes Item Includes Items Front of Vehicle See BODY Section See Starter/Generator Section F2 DF A2 GRN 40 F1 A Ref Ele 2-1 Page H-1

47 ELECTRICAL SYSTEM 47 - Includes Items BLACK RED To F2 On Starter/ Generator Ref Ele 2-2 Page H-2

48 ELECTRICAL SYSTEM FUSE BLOCK GRN 76 HORN BUTTON Floorboard HORN HORN Front of Vehicle Seatwrap Support 84 YEL BLK 81 Ref Ele 11-3 Page H-3

49 ELECTRICAL SYSTEM Includes Items Ref Ele 11-4 Page H-4

50 ELECTRICAL SYSTEM TAILLIGHT Rear Fender 110 WHT to BLU/WHT from Harness - Both Sides BLK to BLK from Harness - Both Sides RED to BRN from Harness - Both Sides (without Turn Signals) RED to WHT from Harness - Driver Side (with Turn Signals) RED to YEL from Harness - Passenger Side (with Turn Signals) 117 TURN SIGNAL Includes Items Ref Ele 11-5 Page H-5

51 ELECTRICAL SYSTEM CONSOLE INSERT PLATE (WITH POWER OUTLET SHOWN) Includes Items OFF ON 133 E FUEL F KEY SWITCH, INDICATOR LIGHT(S), AND FUEL GAUGE Includes Items HOUR METER HOUR METER 153 BLACK Front of Vehicle YELLOW Ref Ele 11-6 (+) (-) Solenoid Page H-6

52 ELECTRICAL SYSTEM 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 G02 IGNITION PICKUP ASSEMBLY (INCLUDES ITEM 2) G01 BOLT AND WASHER ASSEMBLY, M5 X 0.8 X 10 MM LG G01 IGNITION COIL ASSEMBLY (INCLUDES ITEMS 6-10) * IGNITION COIL * SPACER * LOCK WASHER * NUT * SCREW G1 NUT, M6 X G01 6 GA WIRE (BLACK 6", F1 - A2) G1 TERMINAL COVER G* BATTERY, 12V G1 BOLT, 5/16-18 X 1 1/4" LG G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 NUT, 5/16-18 (SILICON BRONZE) G02 BATTERY HOLD DOWN G6 BOLT, 5/16-18 X 3/4" LG G8 LOCK WASHER, 5/16" G2 WASHER, 5/16" (STAINLESS STEEL) G03 GROUND CABLE G19 14 GA WIRE (BLACK 6")... 1 Page H-7

53 ELECTRICAL SYSTEM 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 G6 BOLT, 5/16-18 X 3/4" LG G1 LOCK NUT, 5/ G01 FLANGED BOLT, M6 X 1 X 23 MM LG G85 6 GA WIRE (BLACK 23", F2 - SOL) G01 WIRE HARNESS (CONTROL) G1 WIRE TIE... AR G01 COVER G1 WASHER, 1/4" G6 SCREW, 1/4-14 X 3/4" LG G01 ELECTRICAL PLATE ASSEMBLY (INCLUDES ITEMS 48-73) G01 BRACKET G01 VOLTAGE REGULATOR G2 BOLT, 1/4-20 X 1 1/4" LG G2 LOCK NUT, 1/ G01 IGNITOR G8 BOLT, 1/4-20 X 1" LG G5 BOLT, 1/4-20 X 5/8" LG G01 SOLENOID G2 LOCK NUT, 1/ Page H-8

54 ELECTRICAL SYSTEM 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 FASTON TAB, G01 FASTON TAB, #10 X 1/4" G5 LOCK WASHER, # G4 NUT, # G56 18 GA WIRE (BLACK 5 3/4") G01 IN-LINE FUSE HOLDER G8 LOCK WASHER, 5/16" G4 NUT, 5/ G1 FUSE BLOCK G01 RIVET, 1/8" X 13/16" LG G1 15 AMP FUSE G1 HORN G5 BOLT, 1/4-20 x 5/8" LG G7 WASHER, 1/4" (STAINLESS STEEL) G2 LOCK NUT, 1/4-20 (STAINLESS STEEL) G1 HORN SWITCH G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT G1 HORN SWITCH LABEL G01 RIVET, 3/16" X 1" LG (ALUMINUM)... 2 Page H-9

55 ELECTRICAL SYSTEM 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 HEADLIGHT (INCLUDES ITEM 94) G6 SCREW, #10-16 X 1" LG G01 JUMPER WIRE (HEADLIGHT) G3 TURN SIGNAL LIGHT ASSEMBLY (INCLUDES ITEMS ) G3 TURN SIGNAL LIGHT G7 WASHER, 1/4" (STAINLESS STEEL) G1 WIRE ASSEMBLY G7 LOCK WASHER, 1/4" G1 NUT, 1/ G1 PUSH-ON TERMINAL (MALE) G5 LENS, AMBER G5 SCREW, #6-18 X 5/8" LG G01 TURN SIGNAL JUMPER, RED/BLACK (PASSENGER SIDE) G02 TURN SIGNAL JUMPER, GREEN/BLACK (DRIVER SIDE) G2 TAILLIGHT ASSEMBLY (COMPLETE) G01 TURN SIGNAL KIT (INCLUDES ITEMS ) G1 TURN SIGNAL (WITH MOUNTING HARDWARE) (INCLUDES ITEM 114) G1 TURN SIGNAL FLASHER G3 FLEX LOOM, 3/8 X 8" LG G1 WIRE TIE G3 STEERING COLUMN COVER G01 WIRE HARNESS (ACCESSORY) Page H-10

56 ELECTRICAL SYSTEM 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 IGNITION SWITCH (WITH LIGHTS, INDIVIDUALLY KEYED) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/ G1 IGNITION KEY G01 WIRE HARNESS (KEY SWITCH) G04 PLATE (FUEL GAUGE AND OIL LIGHT) G01 LABEL (OIL LIGHT AND FUEL GAUGE WITH HEADLIGHTS) G1 FUEL GAUGE G1 INDICATOR LIGHT G01 HARNESS (OIL LIGHT/FUEL GAUGE) G GA WIRE (RED 6") G02 DRIVE RIVET, 3/16" X 3/8" LG G01 CONSOLE INSERT ASSEMBLY (INCLUDES ITEMS ) G03 CONSOLE INSERT PLATE G01 LABEL (CONSOLE INSERT PLATE) G01 POWER OUTLET (12 VOLT) G10 RIVET, 3/16" X 7/16" LG (ALUMINUM) G01 DRIVE RIVET, 3/16" X 3/8" LG G01 WIRE HARNESS (POWER OUTLET) Page H-11

57 ELECTRICAL SYSTEM 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 G02 HOUR METER KIT (INCLUDES ITEMS ) G1 HOUR METER G02 HOUR METER BRACKET G4 SCREW, #10-24 X 1/2" LG G10 LOCK NUT, # G01 WIRE HARNESS (HOUR METER)... 1 Page H-12

58 ENGINE AND MUFFLER See ELECTRICAL Section See CARBURETOR AND CHOKE Section Part of Rear Engine Mount Ref Emf 2 Page J-1

59 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 G01 ENGINE (FOR VEHICLES ORIGINALLY EQUIPPED WITH 295cc (EH29C) (INCLUDES ITEMS 3-9, 12-22) G02 ENGINE (FOR VEHICLES ORIGINALLY EQUIPPED WITH 350cc (EH35C) (INCLUDES ITEMS 3-8, 10-20, 23) G01 TIMING BELT G01 TIMING BELT COVER G01 TIMING BELT COVER GROMMET G01 BOLT, M6 X 1 X 12 MM LG DIP STICK (10 DEGREES) G01 IGNITION COIL BRACKET (295cc) G01 IGNITION COIL BRACKET (350cc) G02 SPARK PLUG (NGK B?P? or?k?r4es - RESISTOR) (295cc) G01 SPARK PLUG (NGK B?P? or?k?r5es - RESISTOR) (350cc) G01 VALVE COVER G01 VALVE COVER GASKET G01 FLANGED BOLT, M6 X 1 X 23 MM LG G01 OIL FILLER CAP G01 OIL FILLER 'O' RING G01 OIL FILTER G01 OIL FILTER 'O' RING G01 BOLT AND WASHER, M6 X 1 X 12 MM LG G01 STUD, M6 X 1 X 115MM LG G01 MUFFLER G01 EXHAUST GASKET * NUT G1 BOLT AND WASHER, M8 X 1.25 X 18 MM LG G8 BOLT, 5/16-18 X 1" LG G8 LOCK WASHER, 5/16" G8 WASHER, 5/16"... 1 Page J-2

60 ENGINE MOUNTING OIL Part of Frame Ref Emt 2 Page K-1

61 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 G01 FRONT ENGINE MOUNT G01 REAR ENGINE MOUNT G4 BOLT, 7/16-14 X 1 1/2" LG G2 LOCK WASHER, 7/16" G3 WASHER, 7/16" G6 BOLT, 3/8-16 X 2 3/4" LG G01 SPACER G01 CROSSMEMBER BRACE G01 MOUNT BRACKET G1 WASHER, 3/8" G5 LOCK NUT, 3/ G7 BOLT, 5/16-18 X 7/8" LG G03 WASHER, 5/16" (STAINLESS STEEL) G01 LOCK NUT, 5/16-18 (STAINLESS STEEL) G4 BOLT, 3/8-16 X 4 1/2" LG G1 WASHER, 3/8" G01 PLASTIC WASHER, 2 1/4" OD X 5/8" ID X 1/8" G01 WASHER, 2 1/2" OD X 5/8" ID X 1/8" G01 ISOLATION MOUNT G02 WASHER, 3/8" G5 LOCK NUT, 3/ G01 ENGINE GUARD G4 BOLT, 7/16-14 X 1 1/2" LG G2 LOCK WASHER, 7/16"... 4 Page K-2

62 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 G3 WASHER, 7/16" G2 BOLT, 5/16-18 X 1 1/8" LG G6 LOCK NUT, 5/16-18 (STAINLESS STEEL) G02 STRAP, DIFFERENTIAL - GAS MED/TXT G01 SPACER G01 'U' BOLT, 7/16-14 X 3 7/16" X 3 9/16" LG G3 WASHER, 7/16" G1 LOCK NUT, 7/ Page K-3

63 ENGINE MOUNTING Page K-4

64 FRONT SUSPENSION 14 - Includes Items 5-12 and 15 3, , Part of Frame Part of Frame Ref Fsp 10 Page L-1

65 FRONT SUSPENSION 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 FRONT AXLE G03 SPINDLE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 4-12) * SPINDLE (DRIVER SIDE) G1 BEARING G3 GREASE FITTING, STRAIGHT G1 GREASE SEAL G01 WHEEL HUB ASSEMBLY WITH RACES (INCLUDES ITEMS 9) G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 BEARING AND RACE ASSEMBLY (COMPLETE) G1 SLOTTED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG G03 SPINDLE ASSEMBLY (PASSENGER SIDE) (INCL ITEMS 5-12, 15) * SPINDLE (PASSENGER SIDE) G2 SPINDLE CAP G01 BOLT, 1/2-13 X 5" LG G5 WASHER, 1/2" G01 KING PIN TUBE G1 THRUST WASHER, 7/8" G6 LOCK NUT, 1/ G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER BUSHING G6 NUT, 3/ G01 SHOCK ABSORBER BOOT... 2 Page L-2

66 FRONT SUSPENSION 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 G1 WIRE TIE G01 LEAF SPRING (HEAVY DUTY) G03 SPRING PLATE G1 LOCK NUT, 7/ G11 BOLT, 7/16-14 X 1 3/4" LG G01 WINCH RECEIVER G01 VINYL CAP... 2 Page L-3

67 FRONT SUSPENSION Page L-4

68 FUEL SYSTEM 2 Front of Vehicle To Carburetor To Crankcase Pulse Fitting 1 Part of Frame 12 Page M-1

69 FUEL 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 G02 FUEL TANK (FOR ELECTRIC FUEL GAUGE) G01 FUEL TANK CAP G01 FUEL LEVEL SENDER ADAPTER G01 SCREW, #6-32 X 1/2" LG G2 FUEL LEVEL SENDER (ELEC. FUEL GAUGE) (INCLUDES ITEMS 6, 7) * GASKET G01 SCREW, #10-32 x 3/4" LG G8 BOLT, 5/16-18 X 1" LG G8 WASHER, 5/16" G01 SPACER G6 LOCK NUT, 5/16-18 (STAINLESS STEEL) G01 FUEL FILTER G1 FUEL SYSTEM TUBING, 1/4" ID X 1/2" OD X 3 1/4" LG (BULK) G1 CLAMP G01 FUEL PUMP G6 SCREW, 1/4-14 X 3/4" LG G1 FUEL SYSTEM TUBING, 1/4" ID X 1/2" OD X 16" LG (BULK)... A/R G4 HOSE CLAMP, 1/4" G01 TUBING, 1/4" ID X 1/2" OD X 16" LG (BULK)... A/R G1 WIRE TIE G1 VINYL TRIM, 6 1/4" LG (BULK)... A/R 30 Page M-2

70 REAR AXLE Includes Items OIL Ref Rax 11 Page N-1

71 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 (13.32:1) (INCLUDES ITEMS 3-30) G01 FLANGED BOLT, M8 X 1.25 X 100 MM LG G01 FLANGED BOLT, M8 X 1.25 X 110 MM LG G01 FLANGED BOLT, M8 X 1.25 X 120 MM LG G01 FLANGED BOLT, M8 X 1.25 X 130 MM LG G01 LOCK WASHER, 8 MM G01 NUT, M8 X 1.25 MM G01 OIL CHECK PLUG G01 GASKET, 8 MM G01 OIL DRAIN PLUG G01 GASKET, 14 MM G01 OIL FILLER PLUG G01 INPUT SHAFT SEAL G01 AXLE SHAFT SEAL G01 AXLE TUBE (DRIVER SIDE) G01 AXLE TUBE (PASSENGER SIDE) G01 AXLE SHAFT (DRIVER SIDE) G01 AXLE SHAFT (PASSENGER SIDE) G01 RETAINING RING G01 BALL BEARING G01 FLANGED BOLT, M10 X 1.5 X 23 MM LG G01 WASHER, 10 MM ******* BRAKE CABLE BRACKET (SEE BRAKES SECTION) ******* BRAKE CABLE BRACKET (SEE BRAKES SECTION) G02 DIFFERENTIAL SKID PLATE G01 FLANGED BOLT, M8 X 1.25 X 120 MM LG... 2 Page N-2

72 REAR SUSPENSION Ref Rsp Page P-1

73 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 HEAVY DUTY LEAF SPRING G02 SPRING PLATE G02 U BOLT, 3/8-16 X 2" X 2 1/8" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 FLANGED BUSHING G1 SHOULDER BOLT, 3/8-16 X 3 1/4" LG G1 LOCK NUT, 3/ G01 FLANGED BUSHING G02 SPACER G9 BOLT, 3/8-16 X 3 1/2" LG (STAINLESS STEEL) G02 SHACKLE PLATE G5 LOCK NUT, 3/ G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER BUSHING G6 NUT, 3/ Page P-2

74 SEATING Front of Vehicle Includes Items Ref Sea Page Q-1

75 SEATING 40 - Includes Items Front of Vehicle Handrail SIDE BASKET Includes Item 50, Includes Item Ref Sea 11-2 Page Q-2

76 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** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 2-9) * TEE NUT G1 RUBBER PAD * FLAT STAPLE * FLAT STAPLE G01 VINYL TRIM (SEAT BOTTOM) G** VINYL SEAT BOTTOM COVER * FOAM PADDING (SEAT BOTTOM) * SEAT BOTTOM (WOOD) G** TWO TONE VINYL SEAT BOTTOM SEAT BOTTOM (ST CUSTOM) G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 BOLT, 1/4-20 X 1" LG (STAINLESS STEEL) TORX HEAD SCREW G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG (STAINLESS STEEL) SEAT BACK (ST CUSTOM) G** SEAT BACK ASSEMBLY (INCLUDES ITEMS 23-29) * FLAT STAPLE G01 PLASTIC SEAT BACK COVER * SEAT BACK (WOOD) G01 SCREW, #8 X 3/8" LG (STAINLESS STEEL) * TEE NUT * FOAM PADDING (SEAT BACK) G** VINYL SEAT BACK COVER G** TWO TONE VINYL SEAT BACK... 1 Page Q-3

77 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 G01 SPACER G01 SEAT BACK SUPPORT G8 BOLT, 1/4-20 X 1" LG (STAINLESS STEEL) G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G02 BOLT, 3/8-16 X 1 1/2" LG G1 WASHER, 3/8" G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ SCREW 1/4-20 X 1" G** SEAT BACK ASSEMBLY (INCLUDES ITEMS 23-29) G01 SEAT BACK SUPPORT G8 BOLT, 1/4-20 X 1" LG (STAINLESS STEEL) G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G6 SCREW, 1/4-20 X 1 3/4" LG (STAINLESS STEEL) G1 ACORN NUT, 1/ G01 END PLUG, 3/4" G01 BED ASSEMBLY G** SEAT BOTTOM ASSEMBLY (INCLUDES ITEM 50, 51) G** SEAT BOTTOM (INCLUDES ITEM 51) G** VINYL SEAT BOTTOM COVER G4 SCREW, 5/16-18 X 1 1/2" LG (STAINLESS STEEL) G1 TEFLON WASHER, 5/16" G3 LOCK NUT, 5/16-18 (STAINLESS STEEL) G1 END CAP, 3/4" G01 BED FRONT (INCLUDES MAT) G6 BOLT, 1/4-20 X 3/4" LG (STAINLESS STEEL) G7 WASHER, 5/16"... 4 Page Q-4

78 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 G01 SUPPORT FRAME G8 BOLT, 5/16-18 X 1" LG G8 WASHER, 5/16" G3 LOCK NUT, 5/ G4 BOLT, 5/16-18 X 2 1/2" LG G1 NYLON BUSHING G8 WASHER, 5/16" G3 LOCK NUT, 5/16-18 (STAINLESS STEEL) G01 HANDRAIL G2 SCREW, 5/16-18 X 1 1/4" LG (STAINLESS STEEL) G8 LOCK WASHER, 5/16" (STAINLESS STEEL) G3 ACORN NUT, 5/ G02 END CAP, 1" G01 SIDE BASKET (BLACK) G6 SELF THREADING SCREW, #12-24 X 3/4" LG... 4 Page Q-5

79 SEATING Page Q-6

80 STARTER / GENERATOR Includes Items Includes Items Includes Items Includes Items Includes Items Includes Items Includes Items STARTER/GENERATOR MOUNTING Ref Stg 11 Page R-1

81 STARTER / GENERATOR 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 STARTER / GENERATOR (INCLUDES ITEMS 2-43) G01 ARMATURE (INCLUDES ITEMS 3-5) G01 REAR BALL BEARING G01 FRONT BALL BEARING G01 BEARING HOLDER G01 FIELD COIL G01 INSULATING BRUSH ASSEMBLY ( F ) (INCLUDES ITEMS 10-13) * NUT * LOCK WASHER * WASHER * INSULATOR G01 POLE CORE SETSCREW G01 FRONT COVER G01 REAR COVER G01 TERMINAL ASSEMBLY ( A ) (INCLUDES ITEMS 18-23) * TERMINAL * INSULATOR * INSULATOR * WASHER * LOCK WASHER * NUT G01 BRUSH HOLDER ASSEMBLY (INCLUDES ITEMS 26-28) G01 BRUSH G01 BRUSH SPRING G01 BRUSH CONNECTOR G01 KEY... 1 Page R-2

82 STARTER / GENERATOR 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. 31 * PULLEY G01 BRUSH AND PULLEY HARDWARE KIT (INCLUDES ITEMS 33-37) * NUT * LOCK WASHER * SCREW * SCREW * SCREW G01 BRUSH 1 COVER G01 BRUSH 2 COVER G01 HOUSING HARDWARE KIT (INCLUDES ITEMS 41-43) * BOLT * LOCK WASHER * WASHER G4 BOLT, 1/2-13 X 8" LG G3 WASHER, 1/2" G3 LOCK WASHER, 1/2" G1 NUT, 1/ G01 STARTER / GENERATOR ADJUSTER G5 JAM NUT, 3/ G5 NUT, 3/ G1 WASHER, 3/8" G4 PUSH NUT, 5/16" G01 STARTER / GENERATOR BELT... 1 Page R-3

83 STARTER / GENERATOR Page R-4

84 STEERING Includes Items Includes Items Includes Items Includes Items Includes Items Front of Vehicle STEERING SHAFT AND COLUMN Ref Str RACK, BELLOWS AND TENSIONER Page S-1

85 STEERING IDLER, TIE RODS AND MOUNTING To Passenger Side Front Spindle To Driver Side Front Spindle 74 Ref Str 10-2 Page S-2

86 STEERING 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 G02 STEERING BOX ASSEMBLY (COMPLETE) (INCLUDES ITEMS 2-34) G01 STEERING HOUSING (INCLUDES ITEMS 3-6) * SLEEVE BEARING * SLEEVE BEARING * FLANGED BEARING G3 GREASE FITTING, STRAIGHT G6 BOLT, 3/8-16 X 3/4" LG G1 GREASE FITTING, G01 RACK GUIDE COVER G01 GASKET G01 COMPRESSION SPRING G01 RACK GUIDE G1 HOSE CLAMP, 1 5/16" G01 RACK COVER G1 HOSE CLAMP, 1 5/16" G01 BELLOWS G5 HOSE CLAMP, 13/16" G01 STEERING GEAR KIT (INCLUDES ITEMS 21-28) G01 GEAR PINION G1 BALL BEARING G01 EXTERNAL RETAINING RING G01 STEERING RACK G01 RACK BALL END G8 JAM NUT, 7/ G1 GREASE FITTING, G01 RETAINER G01 IDLER... 1 Page S-3

87 STEERING 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 THRUST WASHER, 1 1/2" G01 THRUST WASHER, 7/8" G6 LOCK NUT, 7/ G8 COTTER PIN, 5/32" X 1 3/4" LG G01 STEERING SHAFT/COLUMN KIT (INCLUDES ITEMS 37-48) G6 STEERING SHAFT G01 COUPLING G1 LOCK NUT, 1/ G01 SCREW, 1/4-20 X 7/8" LG G01 GASKET G01 BOLT, 3/8-16 X 1 1/4" LG WITH PATCHLOCK G1 LOCK WASHER, 3/8" G01 RETAINER G01 STEERING COLUMN KIT (INCLUDES ITEMS 46-48) * STEERING COLUMN G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG G4 BOLT, 7/16-20 X 2 1/2" LG G3 LOCK NUT, 7/ G01 BOLT, 7/16-14 X 1 1/4" LG WITH PATCHLOCK G2 LOCK WASHER, 7/16" STEERING WHEEL Page S-4

88 STEERING 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 COVER G01 LABEL (E-Z-GO) G01 LABEL (CUSHMAN) G2 LOCK NUT, 5/ G04 TIE ROD ASSEMBLY (INCLUDES ITEMS 68-72) G03 THREADED ROD (10 1/8" 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/ G2 CASTELLATED NUT, 7/ G2 COTTER PIN, 3/32" X 1" LG... 1 Page S-5

89 STEERING Page S-6

90 WEATHER PROTECTION 14 Front of Vehicle D A C SUNTOP B 8 5 DETAIL D (REAR) , 3 (Passenger Side Shown) 1 - Includes items Front of Vehicle , 3 (Driver Side Shown) DETAIL B 15 5 (Outside Tubing On Sun Top) DETAIL A Ref Wea 11-1 Front of Vehicle 9 DETAIL C (FRONT) Page T-1

91 WEATHER PROTECTION Front Top Strut Setscrew REAR VIEW MIRROR 23 - Includes Items WEATHER ENCLOSURE 29 Strut Front of Vehicle Includes Items Ref Wea 11-2 Page T-2

92 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 G01 SUN TOP KIT (INCLUDES ITEMS 2-20) G01 REAR STRUT (DRIVER SIDE) G02 REAR STRUT (PASSENGER SIDE) G5 BOLT, 3/8-16 X 1 3/4" LG (STAINLESS STEEL) G1 WASHER, 3/8" (STAINLESS STEEL) G5 NYLON WASHER, 3/ G5 LOCK NUT, 3/ G1 END CAP, 1" G01 FRONT STRUT G2 BOLT, 5/16-18 X 2 1/4" LG G8 LOCK WASHER, 5/16" G01 SPACER, 1/2" G1 LOCK WASHER, 3/8" G01 SUN TOP G8 BOLT, 3/8-16 X 5" LG (STAINLESS STEEL) G1 SPACER G1 WASHER, 3/8" (STAINLESS STEEL) G3 BOLT, 3/8-16 X 2 1/2" LG (STAINLESS STEEL) G6 BOLT, 3/8-16 X 2" LG (STAINLESS STEEL) G1 SPACER, 1/4" G2 REAR VIEW MIRROR KIT (INCLUDES ITEMS 24-26) G1 REAR VIEW MIRROR G2 SUPPORT BRACKET G1 SCREW, #8-32 X 5/8" LG (STAINLESS STEEL) G01 WINDSHIELD KIT (LEXAN) (REQUIRES SUN TOP KIT) (INCLUDES ITEMS 29-35) * WINDSHIELD... 1 Page T-3

93 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 A SASH, 26" LG A SCREW, 1/4-20 X 1 3/4" LG (STAINLESS STEEL) B WASHER, 1/4" (STAINLESS STEEL) C RUBBER GROMMET D LOCK NUT, 1/4-20 (STAINLESS STEEL) LABEL (SAFETY) G01 WEATHER ENCLOSURE (3 SIDED)... 1 Replacement Parts for items may be obtained from: Eagle Parts, Inc 1811 Wilkinson Rd. Augusta, GA Telephone (706) Fax (706) Page T-4

94 WHEELS AND TIRES 1 - Includes Items 2, 3, Includes Items 8, 9, (Style of tire may differ from tire shown) Ref Whl 11 Page U-1

95 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 AND TIRE ASSEMBLY (INCLUDES ITEMS 2, 3, 4)... AR G02 TIRE, 20 X TURF SAVER G02 WHEEL RIM, BLACK (4 LUG) G1 VALVE STEM G1 LUG NUT, 1/ AR WHEEL ASSEMBLY (INCLUDES ITEM 8, 9, 10)... AR TERRA TRAC TIRE VALVE STEM WHEEL - POLISHED SPOKED CENTER CAP... AR NUT, LUG... AR Page U-2

96 WHEELS AND TIRES Page U-3

97 SPECIALTY PRODUCTS SPECIALTY PRODUCTS Appendix A-1

98 SPECIALTY PRODUCTS SPECIAL TOOLS PART NO. HIGH RESISTANCE SPARK PLUG WIRE SET G02 CLUTCH PULLER (DRIVE) G2 FLYWHEEL PULLER G01 CURRENT INDICATOR G2 DIGITAL MULTI-METER G01 TUBELESS TIRE REPAIR KIT TIRE PLUGGER REFIL PACK (50/BOX) 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 G24 PEN 3 OUNCE (89 ML) - OLIVE GREEN 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) - INDUSTRIAL YELLOW G14 MAINTENANCE PRODUCTS PART NO. PLEXUS CLEANER, 13 OUNCE (380 ML) (FOR WINDSHIELDS) G02 BATTERY PROTECTOR, 14 OUNCE (410 ML) SPRAY G02 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

99 OPTIONS/ACCESSORIES OPTIONS/ACCESSORIES Appendix B-1

100 OPTIONS/ACCESSORIES ITEM KIT NO. COMMENTS ASHTRAY KIT G See BODY BOX COOLER AND BRACKET KIT G See BODY DIFFERENTIAL GUARD G See REAR AXLE FRONT BASKET G See BODY GLOVE BOX DOOR G0* See BODY GUN HOLDER (FLOOR MOUNT) G See BODY GUN HOLDER (SWIVEL MOUNT) G See BODY HOUR METER KIT G See ELECTRICAL SYSTEM REAR VIEW MIRROR KIT G See WEATHER PROTECTION SOFT ENCLOSURE G See WEATHER PROTECTION SUN TOP KIT G See WEATHER PROTECTION TURN SIGNAL KIT G See ELECTRICAL SYSTEM WINDSHIELD (POLYCARBONATE) G See WEATHER PROTECTION TIRE DOMINATOR 20X Wheels and Tires PATHFINDER TIRE, BRUSHED WHEEL LH Wheels and Tires PATHFINDER TIRE, BRUSHED WHEEL RH Wheels and Tires V-STEM-BRUSHED SPOKED WHEEL Wheels and Tires DOMINATOR - POLISHED WHEEL Wheels and Tires DOMINATOR - BRUSHED WHEEL Wheels and Tires CHROME CENTER CAP - SPOKED WHEEL Wheels and Tires NUT, LUG-CHROME Wheels and Tires V-STEM-POLISHED SPOKED WHEEL Wheels and Tires PATHFINDER TIRE 22X Wheels and Tires PATHFINDER TIRE, POLISHED WHEEL LH Wheels and Tires PATHFINDER TIRE, POLISHED WHEEL RH Wheels and Tires WHEEL INSTL FRT/RR 20X9X10 STRYKER Wheels and Tires SEAT BTM COVER FRONT/REAR W/PIPPING GXXXX Seating SEAT BACK FRNT/RR COVER - W/PIPPING GXXXX Seating VINYL CVR-SEAT BTM CC W/PIPPING GXXXX Seating SEAT BOTTOM CONV-CARR W/PIPPING GXXXX Seating SEAT BACK CUST W/PIPPING GXXXX Seating SEAT BOTTOM FRONT W/PIPPING GXXXX Seating Appendix B-2

101 OPTIONS/ACCESSORIES ITEM KIT NO. COMMENTS SEAT BOTTOM REAR W/PIPPING GXXXX Seating Appendix B-3

102 OPTIONS/ACCESSORIES Appendix B-4

103 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