1 - INCLUDES ITEMS 3-16 SERVICE PARTS MANUAL GASOLINE POWERED PERSONNEL CARRIERS ISSUED APRIL 2008

Transcription

1 INCLUDES ITEMS SERVICE PARTS MANUAL GASOLINE POWERED PERSONNEL CARRIERS ISSUED APRIL 2008

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3 SERVICE PARTS MANUAL GASOLINE POWERED PERSONNEL CARRIERS AND GOLF CARS ST SHUTTLE 4 ST SHUTTLE 6 STARTING MODEL YEAR 2008 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 INCI- DENTAL 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., 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 ACCELERATOR A-1 Pedal Cover Pedal Box Assembly Accelerator Pedal Assembly AIR FILTER B-1 Air Cleaner Element Air Filter Housing Air Cleaner Hose BODY C-1 Front Bumper Front Splash Shield Cowl Instrument Panel Rocker Panels Rear Body Seat Support BRAKES - MECHANICAL D-1 Brake Pedal Pad Brake Pedal Brake Cable Brake Drum Assembly CARBURETOR E-1 Carburetor Main Jet Choke Cable CLUTCH F-1 Drive Clutch Driven Clutch 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 Page iii

6 TABLE OF CONTENTS SECTION Page No. ENGINE MOUNTING K-1 Engine Pan Mount Front Engine Mount FRONT SUSPENSION AND STEERING L-1 Strut Spindle 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 Q-1 Seat Bottom Seat Back Hip Restraints Seat Back Support Seat Bottom, Rear Facing Seat STARTER / GENERATOR R-1 Starter Starter Belt Starter Tensioner CARGO BED S-1 WOOD STAKE PLASTIC BED WEATHER PROTECTION T-1 Sun Top Windshield WHEELS AND TIRES U-1 Tire & Wheel Assembly Lug Nuts SPECIALTY PRODUCT APPENDIX A-1 OPTIONS/ACCESSORIES APPENDIX B-1 Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle. 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. Page v

8 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 vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR AND CHOKE 1 - Includes Items To Governor Part of Frame Page A-1

11 ACCELERATOR AND CHOKE Differential Page A-2

12 ACCELERATOR AND CHOKE 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 G02 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-16 X 1/2" LG G03 PEDAL BOX AND COVER G6 SCREW, #8-32 X 3/4" LG (STAINLESS STEEL) G01 MICRO SWITCH G01 SCREW, #4-20 X 5/8" LG G01 MICRO SWITCH CAM G1 LOCK NUT, 5/ G3 SETSCREW, 1/4-20 X 3/8" LG G4 NUT, 5/ G1 SPRING RETAINER G1 ACCELERATOR ROD BUSHING G01 COMPRESSION SPRING G2 SPRING RETAINER G01 ACCELERATOR ROD G4 CLEVIS YOKE (ADJUSTABLE) G3 CLEVIS PIN, 5/16" X 13/16" LG G1 NYLON BUSHING G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 PEDAL PIVOT PIN G6 PUSH NUT, 9/32" G1 WHEEL BEARING GREASE (NOT ILLUSTRATED)... A/R G04 WIRE HARNESS (PEDAL BOX) ACCELERATOR CABLE G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 31-33) G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 32-33)... 1 Page A-3

13 ACCELERATOR AND CHOKE 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 OVAL RIVET, 3/16" X 7/16" LG G01 ACCELERATOR PEDAL PAD * ACCELERATOR PEDAL G2 BOLT, 5/16-18 X 4/5" LG CHOKE CABLE ASSY ( TS - 4, TS - 6) G4 LOCK WASHER, 9/16" G4 JAM NUT, 9/ G01 CHOKE CABLE ADAPTER G02 RETAINER 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 G11 RIVET GOVERNOR WARNING DECAL G1 WASHER GOVERNOR COVER G1 NYLON CLAMP... 2 Page A-4

14 E-Z-GO AIR FILTER Page B-1

15 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 (INCLUDES ITEMS 2-6) BODY & BRACKET ASSEMBLY G01 AIR CLEANER COVER G01 AIR CLEANER CLIP G01 AIR FILTER G01 VALVE DUST EJECTOR G7 HOSE CLAMP HOSE G1 HOSE CLAMP G1 BOLT AND WASHER, M8 X 1.25 X 18 MM... 2 Page B-2

16 BODY Page C-1

17 BODY Includes Items Includes Items , 110, 112 ASH TRAY Ref Bod 7-2 Page C-2

18 BODY Includes Items 42, Includes Items 57, Ref Bod Page C-3

19 BODY Foot Rest Front of Vehicle Includes Items Page C-4

20 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 INSTRUMENT PANEL ASSEMBLY G01 SPLASH PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 UPPER FLOORPAN G01 LOWER FLOORPAN G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ACCESS COVER G01 LABEL (TEE HOLDER COVER) G01 REAR FLOORPAN G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G0* FLOORMAT G0xx COWL G01 NAMEPLATE (E-Z-GO) (OVAL) G01 RIVET, 3/16 X 1" LG G01 RIVET, 3/16 X 1" LG G01 FENDER FLARE (DRIVER SIDE) G02 FENDER FLARE (PASSENGER SIDE) G02 COWL SUPPORT BRACKET G02 SELF TAPPING SCREW, 1/4-20 X 1/2" LG G01 RIVET, 3/16 X 1 1/8" LG G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG G2 WASHER, 5/16 (WITHOUT SUN TOP) SEAT FRAME G2 BOLT, 5/16-18 X 13/16" LG Page C-5

21 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 SPLASH PAN (PASSENGER SIDE) G03 SPLASH PAN (DRIVER SIDE) G2 BOLT, 5/16-18 X 13/16" LG GXX COWL FENDER LINER (PASSENGER SIDE) FENDER LINER (DRIVER SIDE) G2 RATCHET FASTENER, 1/4" X 3/4" LG CONSOL PICTOGRAM LABEL G17 RIVET G** REAR BODY ASSEMBLY (W/OUT TAILLIGHTS) (INCLUDES ITEMS 42, 43) G01 BAGWELL LINER G1 RATCHET FASTENER, 1/4" X 9/16" LG G01 HINGE PLATE G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 PLUG G01 ACCESS PANEL G01 SCREW, #8 X 5/8" LG 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 9/16" LG G01 SEAT SUPPORT G02 REAR BUMPER ASSEMBLY (INCLUDES ITEMS 69 & 70) * REAR BUMPER * STAY G01 BOLT, 1/4-20 X 1 1/4" LG G2 WASHER, 5/16"... 4 Page C-6

22 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 BUMPER PLUG G03 BOLT, 1/4-20 x 11/16" LG G01 J-TYPE NUT RETAINER, 1/ G01 LABEL (WARNING) G01 SPACER G01 ROCKER PANEL (FRONT, DRIVER SIDE) G02 ROCKER PANEL (FRONT, PASSENGER SIDE) G01 ROCKER PANEL (REAR, DRIVER SIDE) G02 ROCKER PANEL (REAR, PASSENGER SIDE) G01 SILL PLATE (PASSENGER SIDE) G02 SILL PLATE (DRIVER SIDE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G4 SPACER, 5/16" G4 LOCK NUT, 1/ G6 RIVET, 3/16" X 15/16" LG (ALUMINUM) E-Z-GO LOGO LARGE LABEL G01 PEDAL PIVOT COVER LABEL (ST EXPRESS) G01 FENDER SCUFFGUARD (DRIVER SIDE) G02 FENDER SCUFFGUARD (PASSENGER SIDE) G2 RATCHET FASTENER, 1/4" x 3/4 " LG G04 SPACER, 1" G2 WASHER, 5/ G8 LOCK WASHER G01 SPACER G02 BOLT 5/16-18 X BRUSH GUARD G03 FOOTREST ASSEMBLY (INCLUDES 89-96) G1 END CAP, 1" G01 LABEL (WARNING)... 1 Page C-7

23 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 FLOORMAT G01 FOOTREST G01 FOOTREST MOUNTING TUBE G2 HOLE PLUG G1 END CAP, 3/ SCREW, 1/4-20 X G2 CARRIAGE BO-LT, 3/8-16 X 1 1/4" LG G5 LOCK NUT, 3/ G1 WASHER, 3/8" G4 BOLT, 3/8-16 X 1-3/ G01 VERTICAL FRAME SUPPORT (PASSENGER SIDE) G02 VERTICAL FRAME SUPPORT (DRIVER SIDE) G8 BOLT, 3/8-16 X 1" LG G02 ASH TRAY KIT (INCLUDES ITEMS ) G01 ASH TRAY G01 GASKET G02 BRACKET G4 SCREW, #10-16 x 1/2" LG G01 ASH TRAY KIT (INCLUDES ITEMS ( , 110,112) G02 BRACKET (E-COAT) G1 BAGWELL NOISE SUPPRESSOR SEAT WRAP FOAM G01 SEATWRAP NOISE SUPPRESSOR G01 FENDER NOISE SUPPRESSOR G01 FENDER NOISE SUPPRESSOR (DRIVER SIDE, FRONT) G01 SEATWRAP NOISE SUPPRESSOR (DRIVER SIDE, SIDE)... 1 Page C-8

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

25 BRAKES - MECHANICAL WHT BLK Includes Items Includes Items BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Page D-2

26 BRAKES - MECHANICAL Includes Items 84-92, 94, Includes Items 84-91, Includes Items Includes Items Includes Items 94, Includes Items 94, Includes Items 101, 102 Page D-3

27 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 BRAKES - MECHANICAL G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) G01 FLANGED BUSHING G01 TORSION SPRING G1 WASHER, 3/8" G5 LOCK NUT, 3/ G04 COMPENSATOR ASSEMBLY (INCLUDES ITEMS 19, 20) G01 SPHERICAL NUT, 5/ G9 LOCK NUT, 5/ G06 EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23-24) G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER G08 BRAKE CABLE 58.31" G09 BRAKE CABLE 68.00" G01 RETAINING RING, 13/32" (STAINLESS STEEL) G3 CLEVIS PIN, 5/16" X 13/16" LG... 3 Page D-4

28 BRAKES - MECHANICAL 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 COTTER PIN, 3/32" X 3/4" LG G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 WASHER, 5/16" G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW, 1/4-20 X 1/2" LG G4 SPACER G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G02 CATCH BRACKET G6 BOLT, 1/4-20 X 3/4" LG G4 LOCK NUT, 1/4-20 (STAINLESS STEEL) 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 G1 OVAL RIVET, 3/16" x 7/16" LG... 9 Page D-5

29 THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 60 BRAKES - MECHANICAL G03 BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 7/8" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 MICRO SWITCH G1 BOLT, #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, 94, 95) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 84-91, 93-95) 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

30 BRAKES - MECHANICAL 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 G2 LUG BOLT, 1/2-20 X 1 3/16" LG OUTER BRAKE DRUM WASHER SLOTTED NUT, M22 X G1 COTTER PIN, 1/8" X 1 1/2" LG G01 SPINDLE CAP SPINDLE CAP ADAPTER BRAKE CABLE BRACKET (PASSENGER SIDE) BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-7

31 BRAKES - MECHANICAL Notes: Page D-8

32 CARBURETOR Page E-1

33 CARBURETOR 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 CARBURETOR (INCLUDES ITEMS 3-22) MAIN JET (#106) PILOT JET (#52) PLUG NEEDLE VALVE FLOAT FLOAT PIN FLOAT BOWL GASKET FLOAT CHAMBER BOWL SCREW BOWL GASKET CHOKE BRACKET BREATHER TUBE CLAMP, INTAKE TUBE CLAMP CYLINDER HEAD TUBE INTAKE TUBE CHOKE GASKET NUT, M6 X THROTTLE ROD ATTACHMENT BUSHING STUD BOLT MAIN JET (#102) (FOR ELEVATIONS OF 6000 FT FT) MAIN JET (#104) (FOR ELEVATIONS OF 3000 FT FT)... 1 Page E-2

34 CLUTCH 7 - Includes items 8 to Page F-1

35 CLUTCH 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 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

36 DIRECTION SELECTOR 1 - includes Items (16, 23-26, 33-34) 2 - includes Items (4-21) Page G-1

37 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 CABLE ASSEMBLY (INCLUDES ITEMS 16, 23-26, 33-34) DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 4, 6, 7-21, 23-33) DIRECTION SELECTOR BRACKET WITH BUSHING (INCLUDES ITEM 9) DIRECTION SELECTOR SHAFT DIRECTION SELECTOR CAM G1 LOCK NUT, 3/ * 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 G8 RIVET G01 SCREW, 1/4-20 X 7/8" LG G2 LOCK NUT, 1/ G01 DIRECTION SELECTOR HANDLE... 1 Page G-2

38 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 G4 SCREW, #10-32 X 1/2" LG (STAINLESS STEEL) BOLT, M X NUT, M BRACKET * BUSHING, FLIP LOK, MOUNTING BRACKET... 1 Page G-3

39 DIRECTION SELECTOR Notes: Page G-4

40 ELECTRICAL SYSTEM Front of Vehicle See Body Section See Starter Generator Section Page H-1

41 ELECTRICAL SYSTEM BLACK To Key Switch Control Harness RED To F2 On Starter/ Generator Includes Items Page H-2

42 ELECTRICAL SYSTEM FUSE BLOCK GRN 51 HORN BUTTON Floorboard HORN HORN Front of Vehicle Seatwrap Support 60 YEL BLK 57 Page H-3

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

44 ELECTRICAL SYSTEM TAILLIGHT Rear Fender 87 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) 95 TURN SIGNAL Includes Items Ref Ele 11-5 Page H-5

45 ELECTRICAL SYSTEM CONSOLE INSERT PLATE (WITH POWER OUTLET SHOWN) Includes Items Front of Vehicle OFF ON E FUEL F KEY SWITCH, INDICATOR LIGHT(S), AND FUEL GAUGE Includes Items FNR MOUNTING SCREWS 126 SEAT SUPPORT SOLENOID COVER Ref Ele Front of Vehicle FNR HOUR METER Page H-6

46 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 GA WIRE (BLACK 6", F1 - A2) G01 TERMINAL COVER G* BATTERY, 12V * BOLT, 5/16-18 X 1 1/4" LG * LOCK WASHER, 5/16" (SILICON BRONZE) * 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") G6 BOLT, 5/16-18 X 3/4" LG G1 LOCK NUT, 5/ G01 FLANGED BOLT GA WIRE (42" LONG) WIRE HARNESS (CONTROL) G1 WIRE TIE (NOT ILLUSTRATED )... AR G01 COVER FNR G1 WASHER, 1/4" G6 SCREW, 1/4-14 X 3/4" LG Page H-7

47 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 ELECTRICAL PLATE ASSEMBLY (INCLUDES ITEMS 32-49) G01 BRACKET G01 VOLTAGE REGULATOR G4 BOLT, 1/4-20 X 1 1/4" LG G2 LOCK NUT, 1/ G33 WIRE ASSEMBLY 6 GA RELAY G8 BOLT, 1/4-20 X 1" LG G01 SOLENOID * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/16" * NUT, 5/ G7 LOCK WASHER - SS -.255/ G1 NUT, 1/ G01 FUSE HOLDER ASSEMBLY G2 LOCK NUT, 1/ G01 FASTON TAB, G56 18 GA WIRE (BLACK 5 3/4") G1 FUSE BLOCK G01 RIVET, 1/8" X 13/16" LG G1 15 AMP FUSE G33 #6 GA WIRE ASSEMBLY G1 16 GA WIRE (RED) G1 HORN G5 BOLT, 1/4-20 x 5/8" LG G7 WASHER, 1/4" (STAINLESS STEEL) G4 LOCK NUT, 1/ Page H-8

48 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 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) G01 HEADLIGHT (INCLUDES ITEM 70) G6 SCREW, #10-16 X 1" LG G01 JUMPER WIRE (HEADLIGHT) SPACER G3 TURN SIGNAL LIGHT ASSEMBLY (INCLUDES ITEMS 75-80) 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) G4 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) TURN SIGNAL KIT (INCLUDES ITEMS 91-95)... 1 Page H-9

49 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 G1 TURN SIGNAL (WITH MOUNTING HARDWARE) (INCLUDES ITEM 106) G1 TURN SIGNAL FLASHER G3 FLEX LOOM, 3/8 X 8" LG G1 WIRE TIE G3 STEERING COLUMN COVER WIRE HARNESS (ACCESSORY) G01 IGNITION SWITCH (WITH LIGHTS) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/ G1 IGNITION KEY 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 G02 CONSOLE INSERT ASSEMBLY (INCLUDES ITEMS ) G03 CONSOLE INSERT PLATE G10 PLUG G02 DRIVE RIVET, 3/16" X 3/8" LG... 3 Page H-10

50 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 WIRE HARNESS (POWER OUTLET) HOUR METER KIT (INCLUDES ITEMS ) HOUR METER HOUR METER BRACKET WIRE HARNESS (HOUR METER) G1 NYLON CLAMP 15.5" (NOT ILLUSTRATED)... AR G03 CONT TONE POTTED BUZZER (NOT SHOWN)... 1 Page H-11

51 ELECTRICAL SYSTEM Notes: Page H-12

52 ENGINE AND MUFFLER Page J-1

53 ENGINE AND MUFFLER Page J-2

54 ENGINE AND MUFFLER 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 ENGINE, GAS, 13HP, NON-GOLF 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

55 ENGINE AND MUFFLER Notes: Page J-4

56 ENGINE MOUNTING FRONT 21 FRONT 5 Page K-1

57 ENGINE MOUNTING 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 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 ISO MOUNT BOLT, M X BOLT, M RUBBER WASHER DELRIN WASHER G2 CAP ADAPTER COMPRESSION SPRING WASHER, M X Page K-2

58 FRONT SUSPENSION/STEERING 2 - Includes Items Includes Item Includes Items 4-9, Part of Frame Front of Vehicle Front of Vehicle Part of Frame LUG , *NOTE: Tie Rod Not Shown for Clarity 23 Page L-1

59 FRONT SUSPENSION/STEERING Front of Vehicle Includes Items Includes Items Includes Items 47,48, Includes Items 51, Includes Items Page L-2

60 FRONT SUSPENSION/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 FRONT AXLE G01 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 3-9) G01 SPINDLE ASSEMBLY (PASSENGER SIDE) G1 GREASE SEAL G2 ROLLER BEARING AND RACE ASSEMBLY G01 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 7) G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 CASTELLATED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG G01 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 4-9, 11) G01 SPINDLE ASSEMBLY (DRIVER SIDE) G6 BOLT, 1/2-13 X 6" LG G3 WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER, 1" (STAINLESS STEEL) G6 LOCK NUT, 1/ G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER BUSHING G6 NUT, 3/ G03 LEAF SPRING (HEAVY DUTY) G03 SPRING PLATE G1 LOCK NUT, 7/ G11 BOLT, 7/16-14 X 1 3/4" LG G01 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 26-37) * STEERING BOX INSTALLATION TAG G01 RACK EXTENSION * JAM NUT, 1/ G01 RACK BOOT... 1 Page L-3

61 FRONT SUSPENSION/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 G2 WIRE TIE G8 CLAMP, 1 13/16-2 3/8" G01 PINION SEAL G01 RACK BALL JOINT (INCLUDES ITEMS 34-37) G1 RUBBER BOOT G2 CASTELLATED NUT, 7/ G2 GREASE FITTING, STRAIGHT G3 COTTER PIN, 3/32" X 1" LG G6 BOLT, 7/16-14 X 2 3/4" LG G01 VINYL CAP G02 SPACER G1 NYLON CLAMP G01 SHOCK ABSORBER BOOT G2 FLAT WASHER, 7/16" G1 LOCK NUT, 7/ G01 STEERING SHAFT G05 STEERING COLUMN KIT (INCLUDES ITEMS 47,48 & 69) G03 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 50, 51) G01 BOLT, M8 X G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER STEERING WHEEL G01 CLIPBOARD G2 LOCK NUT, 5/ G02 TIE ROD ASSEMBLY (INCLUDES ITEMS 60-64)... 1 Page L-4

62 FRONT SUSPENSION/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 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/ G01 BOLT, 3/8-16 x 1 1/4" LG G1 LOCK WASHER, 3/8" G01 SCREW #6-20 x 5/16" LG G01 FLANGED BEARING G01 BEARING STEERING RACK COVER G1 RIVET G01 STEERING WHEEL COVER... 1 Page L-5

63 FRONT SUSPENSION/STEERING Notes: Page L-6

64 FUEL SYSTEM Front of Vehicle Air Filter Part of Frame To Crankcase To Carburetor Carb Fuel Tank Assembly for Fuel Level Sending Unit includes items 4-8 Fuel Tank Assembly includes items 4, 5 & 9 Fuel Tank Assembly for Fuel Level Sending Unit includes items 4, 5 & 10 Fuel Level Sending Unit includes items 14 & Page M-1

65 FUEL 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 CARB FUEL TANK ASSEMBLY (use with sending unit) (inc items 4-8) G01 SIPHON TUBE GROMMET G3 SIPHON TUBE ASSEMBLY ROLLOVER VALVE GROMMET ROLLOVER VALVE CARB STANDARD FUEL TANK STANDARD FUEL TANK STANDARD FUEL TANK FOR USE WITH SENDING UNIT FUEL TANK ASSEMBLY (includes items 4, 5 & 9) FUEL TANK ASSEMBLY (use with sending unit) (inc items 4, 5 & 10) G2 FUEL LEVEL SENDING UNIT (includes items 14 & 15) * GASKET * STAINLESS STEEL HEX HEAD SCREW WITH SEALANT, #10-32 X 1/ G01 FUEL TANK ADAPTER G01 FLAT HEAD PHILLIPS SCREW, #6-32 X G01 FUEL FILL CAP CARB FUEL FILL CAP G8 HEX HEAD BOLT, 5/16-18 X G8 FLAT WASHER, 5/ G6 LOCK NUT, 5/ G01 SPACER BOLT, 5/ G1 HOSE CLAMP,.50 DIAMETER FUEL SYSTEM HOSE, 3.25" G01 FUEL LINE FILTER FUEL SYSTEM HOSE, 8"... 1 Page M-2

66 FUEL 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 G4 HOSE CLAMP, DIA CARB FUEL SYSTEM HOSE, 26.OO LONG FUEL PUMP G6 HEX WASHER HEAD SLOTTED TAPPING SCREW, 1/4-14 X CARBON CANNISTER MOUNTING BRACKET (CARB ONLY) G11 RIVET, 3/16 DIA X.70 (CARB ONLY) CARBON CANNISTER (CARB ONLY) HOSE CLAMP,.41 DIA (CARB ONLY) LOW PRESSURE FUEL HOSE, 3/16 I.D. X 17" LOW PRESSURE FUEL HOSE, 3/16 I.D. X 34" HOSE TO AIR FILTER FITTING,.156 I.D. WITH 1/8-27 NPT (CARB ONLY) G6 BLACK TRIM, 6.25 LONG G1 NYLON CLAMP CARB LABEL (NOT SHOWN IN ILLUSTRATION)... 1 Page M-3

67 FUEL SYSTEM Notes: Page M-4

68 REAR AXLE Page N-1

69 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 REAR AXLE G01 OIL DRAIN PLUG G01 GASKET G01 OIL SEAL 28 X 47 X G01 FLANGE BOLT M8 X 1.25 X G01 FLANGE BOLT M10 X 1.5 X AXLE TUBE (PASSENGER SIDE) AXLE TUBE (DRIVER SIDE) AXLE SHAFT (PASSENGER SIDE) AXLE SHAFT (DRIVER SIDE) G01 BALL BEARING G01 SNAP RING SLOTTED NUT... 2 Page N-2

70 REAR SUSPENSION Front of the Vehicle Page P-1

71 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 HEAVY DUTY LEAF SPRING LEAF SPRING BUSHING, FRONT G9 HEX HEAD BOLT, SS 3/8-16 X 3.5 LG G1 FLAT WASHER,.411 I.D. X 1.00 O.D. X G1 FLANGED LOCK NUT, 3/ G02 SPLIT STEEL SPACER G01 FLANGED URETHANE BUSHING G02 SHACKLE PLATE G9 HEX HEAD BOLT, SS 3/8-16 X 3.5 LG G5 LOCK NUT, 3/ SPRING PLATE, DRIVER SIDE SPRING PLATE, PASSENGER SIDE G01 RUBBER BUMPER G3 U-BOLT REAR SUSPENSION PLATE G1 FLAT WASHER,.411 I.D. X 1.00 O.D. X G5 LOCK NUT, 3/ G01 LOCK WASHER, M G01 HEX NUT, M G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK BUSHING G6 HEX NUT, 3/ G01 VINYL CAP... 4 Page P-2

72 SEATING Includes Items Floormat Includes Items See Body Section Ref Sea Page Q-1

73 SEATING Front of Vehicle Handrail SIDE BASKET Includes Item Ref Sea 11-2 Page Q-2

74 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 BACK ASSEMBLY G** SEAT BOTTOM (INCLUDES ITEMS 4-8) (SHUTTLE 4 & 6) G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 WASHER, 1/4" (STAINLESS STEEL) G7 LOCKWASHER, 1/4" (STAINLESS STEEL) G2 BOLT, 1/4-20 X 1 1/4" LG G01 SEAT BACK REAR COVER G01 REAR HAND HOLD BAR G02 BOLT, 1/4-20 X 2" LG G01 SEAT BACK BRACKET G6 TRIM, BLACK G0** SEAT POD G01 ASHTRAY G5 ACORN NUT, 3/ G4 SPACER, 5/16" G8 BOLT, 3/8-16 X 2" LG G8 BOLT, 5/16-18 X 2" LG G1 WASHER, 3/8" (STAINLESS STEEL) G01 RUBBER WASHER, 5/8" G9 SPACER, 3/4" G6 LOCK NUT, 5/16-18 (STAINLESS STEEL)... 3 Page Q-3

75 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 G06 SCREW, 5/16-18 X 3/4" LG (STAINLESS STEEL) G01 WASHER, 1/4" (STAINLESS STEEL) G6 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 VENT PLUG G** SEAT BACK G8 BOLT, 1/4-20 X 1" LG (STAINLESS STEEL) G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G01 SEAT BACK SUPPORT SCREW 1/4-20 X G7 LOCK WASHER, 1/4" G** SEAT BOTTOM (INCLUDES ITEMS 45-51) (SHUTTLE 4 & 6) G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG (STAINLESS STEEL) G01 FRONT EDGE TRIM G01 BACK EDGE TRIM G01 HIP RESTRAINT (DRIVER SIDE) G01 HIP RESTRAINT (PASSENGER SIDE) G01 BOLT, 1/4-20 X 7/8" LG G6 SCREW, 5/16-18 X 1 1/2" LG G1 TEFLON WASHER, 5/16" G3 LOCK NUT, 5/ G1 END PLUG, 3/4" G02 END PLUG G01 BED FRONT G6 BOLT, 1/4-20 X 3/4" LG G7 WASHER, 5/16"... 4 Page Q-4

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 G01 LABEL (WARNING) (SHUTTLE 4) G8 BOLT, 5/16-18 X 1" LG G8 WASHER, 5/16" G13 SCREW, 1/4-20 X LG G4 BOLT, 5/16-18 X 2 1/2" LG G1 NYLON BUSHING G8 WASHER, 5/16" G1 ACORN NUT, 1/ G01 HANDRAIL G2 SCREW, 5/16-18 X 1 1/4" LG G8 LOCK WASHER 5/16" G3 ACORN NUT, 5/ G** TWO TONE VINYL SEAT BACK G6 BOLT, 1/4-20 X 3/4" LG SEAT BOTTOM CONV CARRIER (INCLUDES ITEM 77) G** TWO TONE VINYL SEAT BOTTOM G01 WASHEER 1/4" G01 SUPPORT FRAME G01 BED ASSEMBLY G01 END PLUG, 3/4"... 2 Page Q-5

77 SEATING Notes: Page Q-6

78 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

79 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 G01 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

80 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 BOLT, 1/2-13 X 8" LG NUT, 1/ STARTER / GENERATOR ADJUSTER JAM NUT, 3/ NUT, 3/ G4 PUSH NUT, 5/16" STARTER / GENERATOR BELT... 1 Page R-3

81 STARTER / GENERATOR Notes: Page R-4

82 CARGO BED A B 7 6 A 3 8 B Page S-1

83 CARGO BED A B C 24 A B C Page S-2

84 CARGO BED Part of Truck Bed Page S-3

85 CARGO BED Page S-4

86 CARGO BED 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 BED ASSEMBLY (INCLUDES ITEMS 2-11) G01 PLASTIC BED, 36" G01 PIVOT SHAFT G01 SHOULDER BOLT, 1/4-20 X 3/4" LG G01 TAILGATE G01 BOWED ANGLE G2 SCREW, 1/4-20 X 5/8" LG (STAINLESS STEEL) G01 EXTRUSION CHANNEL G02 TAILGATE CABLE G2 SCREW, 1/4-20 X 1 1/4" LG G01 LOAD BED DECAL G01 RIVET G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/ G01 BED LATCH G01 LATCH TORSION SPRING G02 KEEPER PLATE G02 RETAINER BRACKET G01 SCREW, 1/4-20 X 5/8" LG G01 HANDLE GRIP E-Z-GO LABEL G01 CLEVIS PIN G1 COTTER PIN G01 BUSHING... 4 Page S-5

87 CARGO BED 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 FLAT WASHER G5 LOCK NUT G4 SCREW 38/ G01 SPACER G02 SCREW FRONT BED SUPPORT BED SUPPORT BRACKET G1 SCREW 5/ G01 SEAT SUPPORT BED FRAME G01 SCREW G8 SCREW, 5/8-16" G8 FLAT WASHER G6 LOCK NUT G02 REAR SUPPORT FRAME (PASSENGER SIDE) G01 PANEL G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/ Page S-6

88 CARGO BED 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 RIVET G1 NYLON BUSHING G01 CARGO DECK G01 HOLD DOWN BRACKET G02 FRONT/REAR CARGO RACK G01 SIDE CARGO RACK G6 SCREW, #10-12 X 3/4" LG (STAINLESS STEEL) G01 STEEL DECK G3 SCREW, 1/4-20 X 3/4" LG (STAINLESS STEEL) G4 LOCK NUT, 1/ G1 NOISE SUPPRESSOR G01 CARGO BED MAT G02 TAILGATE RETAINER BRACKET G01 LATCH G6 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G8 WASHER, 5/16" G6 LOCK NUT, 5/16-18 (STAINLESS STEEL) G4 BOLT, 5/16-18 X 2 1/2" LG... 2 Page S-7

89 CARGO BED Notes: Page S-8

90 WEATHER PROTECTION WINDSHIELD Front Of Vehicle (Driver Side Shown) (Driver Side Rear Shown) B Front Of Vehicle A A 36 B C C Front Of Vehicle 31 D D 35 Page T-1

91 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 WINDSHIELD KIT SUN TOP KIT (INCLUDES ITEMS 24-42) SUN TOP KIT (INCLUDES ITEMS 24-42) G02 REAR SUPPORT (DRIVER SIDE) G01 REAR SUPPORT (PASSENGER SIDE) G5 BOLT, 3/8-16 X 1 3/4" LG (STAINLESS STEEL) G1 WASHER, 3/8" (STAINLESS STEEL) G5 NYLON WASHER, 3/8" G5 LOCK NUT, 3/ G1 END CAP, 1"... 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 FRONT SUPPORT G02 BOLT, 5/16-18 X 2 1/2" LG G8 LOCK WASHER, 5/16" G01 SPACER, 1/2" G1 LOCK WASHER, 3/8" G01 SUN TOP G10 SCREW, G2 WASHER, 5/16" G6 LOCK NUT, 5/ G2 BOLT, 5/16-18 X 2 1/4" LG G8 WASHER, 5/16" G11 BOLT, 5/16-18 X 3 1/4" LG... 4 Page T-3

93 WEATHER PROTECTION Notes: Page T-4

94 WHEELS AND TIRES 1 - Includes Items 2, 3, Includes Items 5, 6, (Style of tire may differ from tire shown) Page U-1

95 WHEELS AND TIRES 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 TIRE AND WHEEL ASSEMBLY... AR LUG NUT... AR CENTER CAP WHEEL ASSEMBLY TIRE 23 x 10.5 x WHEEL RIM VALVE STEM... 1 Page U-2

96 WHEELS AND TIRES Notes: 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. SECTION ASHTRAY KIT G See BODY ASHTRAY KIT G See BODY BALL HITCH KIT G See BODY HOUR METER KIT See ELECTRICAL SYSTEM REAR VIEW MIRROR KIT G See WEATHER PROTECTION SOFT ENCLOSURE G0* See WEATHER PROTECTION SUN TOP KIT See WEATHER PROTECTION SUN TOP KIT See WEATHER PROTECTION TURN SIGNAL KIT G See ELECTRICAL SYSTEM GOLD SPOKE WHEEL COVERS G* See WHEELS AND TIRES SILVER SPOKE WHEEL COVERS G* See WHEELS AND TIRES WINDSHIELD (FULL) See WEATHER PROTECTION FRONT SHIELD WITH WINCH RECIEVER MOUNT See STEERING SECTION WOOD STAKE BED RED/BLK See CARGO BED PLASTIC BED, RED/BLK See CARGO BED CONV CARRIER WHITE/BLUE See SEATING WOODSIDE BED WHITE/BLUE PLASTIC BED WHITE/BLUE Appendix B-2

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