SERVICE PARTS MANUAL

Transcription

1 INCLUDES ITEMS G01 SERVICE PARTS MANUAL Ref Fcv 19 GASOLINE POWERED UTILITY VEHICLE STARTING MODEL YEAR: 2004

2 SERVICE PARTS MANUAL GASOLINE POWERED UTILITY VEHICLE E-Z-GO ST 4X4 E-Z-GO Division of TEXTRON, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. E-Z-GO Division of TEXTRON, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: FAX: OUTSIDE USA PHONE: , FAX: E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA Page i

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

4 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 - FRONT C-1 BODY - MID C-5 BODY - REAR C-7 BRAKES D-1 BRAKES - PARK D-5 DIRECTION AND DRIVE SELECTOR E-1 DRIVETRAIN - FRONT F-1 DRIVETRAIN - MID F-3 DRIVETRAIN - REAR F-7 ELECTRICAL G-1 EXHAUST H-1 FRONT SUSPENSION I-1 FUEL SYSTEM J-1 HITCH K-1 REAR SUSPENSION L-1 SEAT M-1 STEERING N-1 TRUCK BED, PLASTIC O-1 WHEELS & TIRES P-1 SPECIALTY PRODUCTS APPENDIX A-1 OPTIONS/ACCESSORIES APPENDIX B-1 INDEX OF MAJOR COMPONENTS INDEX-1 Page iii

5 TABLE OF CONTENTS Notes: Page iv

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

7 ,87 67 Front of Vehicle 83,88 81,86 84, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the INDEX OF MAJOR COMPONENTS and select the most appropriate component description. Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying description for specific information regarding the part that was not shown in the index. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. 2. IF YOU KNOW THE PART NUMBER Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on. Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying description for specific information regarding the part. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts. The asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. Page vi

8 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

9 ACCELERATOR Includes Items Includes Items Part of Frame Part of Carburetor Ref Acl Page A-1

10 ACCELERATOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 ACCELERATOR PEDAL G01 PEDAL PAD SCREW, 1/2-13 X 3 1/ G3 WASHER, 1/2" G01 BUSHING G01 INNER PIVOT TUBE LOCK NUT, 1/ G01 SPRING G01 ACCELERATOR CABLE G3 CLEVIS PIN, 5/16" X 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG G3 PUSH NUT, 3/16" G01 ACCELERATOR AND GOVERNOR CABLE BRACKET SCREW, 3/8-16 X G1 WASHER, 3/8" LOCK NUT, 3/ G01 GOVERNOR CABLE G01 GOVERNOR LEVER ASSEMBLY G01 GOVERNOR LEVER G1 BALL JOINT G5 LOCK NUT, # Page A-2

11 ACCELERATOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 GOVERNOR BRACKET ASSEMBLY (INCLUDES ITEMS 32-35) G1 GOVERNOR ROD G1 COMPRESSION SPRING G1 GOVERNOR ADJUSTER G4 NUT, # G4 LOCK NUT, 1/ G4 SETSCREW, 1/4-20 X 1/2" LG G01 SPRING G01 GOVERNOR CABLE AND CHOKE BRACKET G01 BOLT, M X 20MM LG G01 BALL STUD G5 LOCK NUT, # G01 EXTENSION SPRING G01 CHOKE CABLE G01 CHOKE CABLE ADAPTER G02 ADAPTER RETAINER G4 LOCK WASHER, 9/16" G4 JAM NUT, 9/ G01 CHOKE LINKAGE G01 CHOKE PIVOT PLATE... 1 Page A-3

12 ACCELERATOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 BOLT, 1/4-20 X 1 1/4" LG G7 WASHER, 1/4" G01 BUSHING G7 SPACER, 9/16" G1 TORSION SPRING G4 LOCK NUT, 1/ G01 BALL STUD G2 LOCK NUT, 1/ Page A-4

13 AIR FILTER Includes Items Front of Vehicle See DRIVETRAIN - MID Section Ref Air 19 Page B-1

14 AIR FILTER 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 AIR CLEANER CANISTER ASSEMBLY (INCLUDES ITEMS 2-4) * AIR CLEANER CANISTER G01 AIR CLEANER COVER G01 AIR CLEANER O-RING * AIR CLEANER LATCH G01 AIR CLEANER ELEMENT G01 SCREW, M X 30MM LG LOCK WASHER, M G01 AIR FILTER BRACKET G01 BOLT, M x 12MM LG G01 BOLT, M x 20MM LG G01 AIR INTAKE PLENUM TO CARBURETOR SEAL G01 AIR INTAKE PLENUM G01 SPACER G1 WASHER, 1/4" G01 BOLT, M x 60MM LG G01 REMOTE AIR INTAKE G01 RIVET, 3/16" X 1" LG (ALUMINUM) G2 HOSE CLAMP, 2 1/16" G01 HOSE (CONVOLUTED) G7 HOSE CLAMP, 1 9/16" G01 HOSE (AIR FILTER TO PLENUM) G7 HOSE CLAMP, 1 9/16" G01 SEALANT... A/R Page B-2

15 BODY - FRONT Mounts To Frame Part of Item Mounts To Frame Ref Bod Page C-1

16 BODY - FRONT 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 G** COWL G01 COWL FRAME G01 FRONT COWL BRACKET G5 LOCK WASHER, # G01 SCREW, #10-16 X 3/4" G01 HOOD LATCH G4 SCREW, #10-24 X 1/2" LG G10 LOCK NUT, # G9 RIVET, 3/16" X 9/16" LG (STAINLESS STEEL) G01 LABEL (E-Z-GO) G01 COWL LATCH G01 BOLT, 3/8-16 X 1 1/8" G4 NYLON WASHER, 1/2" G4 SPACER, 5/16" LOCK NUT, 3/ G01 LABEL (LATCH WARNING) G2 CLEVIS PIN, 5/16" X 1 1/8" LG G3 COTTER PIN, 3/32" X 3/4" LG Page C-2

17 BODY - FRONT 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 COWL SUPPORT BRACKET (DRIVER SIDE) G02 COWL SUPPORT BRACKET (PASSENGER SIDE) G3 LOCK SCREW, 5/16-18 X 1" LG LOCK NUT, 5/ G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G01 INSTRUMENT PANEL G01 CUP HOLDER G01 HAND RADIO HOLDER G01 BOLT, 3/8-16 X 1 1/8" G5 LOCK NUT, 3/ G01 INSTRUMENT PANEL SUPPORT BRACKET G02 BOLT, 1/4-20 X 1/2" LG G01 HAND RAIL G01 HAND RAIL MOUNT G4 BOLT, 5/16-18 X 2 1/2" LG LOCK NUT, 5/ Page C-3

18 BODY - FRONT 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 BRUSH GUARD G4 BOLT, 7/16-14 X 1 1/2" LG G3 WASHER, 1/2" G1 LOCK NUT, 7/ G01 BRUSH GUARD SIDE (DRIVER SIDE) G02 BRUSH GUARD SIDE (PASSENGER SIDE) G4 LOCK SCREW, 3/8-16 X 1" LG G2 WASHER, 5/16" G4 LOCK NUT, 3/ G01 LABEL (COLD STARTING)... 1 Page C-4

19 BODY - MID Mounts To Items 31 & 32 In BODY - FRONT Mounts To Frame Ref Bod 19-2 Page C-5

20 BODY - MID 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 FENDER WELL G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G8 WASHER, 5/16" LOCK NUT, 1/ G01 HOLE PLUG G01 FRONT VALANCE G01 BOLT, 3/8-16 X 1 1/8" G5 LOCK NUT, 3/ G01 FLOORPAN G4 NOISE SUPPRESSION STRIP, 6" G7 NOISE SUPPRESSION STRIP, 2" G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) LOCK NUT, 1/ G01 ROCKER PANEL (DRIVER SIDE) G02 ROCKER PANEL (PASSENGER SIDE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) LOCK NUT, 1/ G01 LABEL (WARNING)... 1 Page C-6

21 BODY - REAR See SEATING Section for Crossmember 4 Attaches To Frame Ref Bod 19-3 Page C-7

22 BODY - REAR 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 G** LOWER SIDE PANEL (DRIVER SIDE) G** LOWER SIDE PANEL (PASSENGER SIDE) G** SEAT SUPPORT PANEL G1 RETAINER NUT ('J' TYPE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G01 REAR FENDER (DRIVER SIDE) G02 REAR FENDER (PASSENGER SIDE) G9 LOCK SCREW, 1/4-20 X 3/4" LG G3 WASHER, 5/16" LOCK NUT, 1/ G2 RATCHET FASTENER, 1/4" X 3/4" LG G01 SEAT PANEL (DRIVER SIDE) G01 SEAT PANEL (PASSENGER SIDE) G1 RETAINER NUT ('J' TYPE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G01 LABEL (PARK BRAKE) G01 LABEL (HOT EXHAUST) G01 LABEL (WARNING) G1 LABEL (GOVERNOR WARNING) G01 LABEL (ST 4X4) G01 LABEL (TILT WARNING PICTOGRAM)... 2 Page C-8

23 BRAKES 51 - Includes Items Includes Items Includes Items Includes Items Mounts To Frame To Passenger Side Caliper 1 Mounts To Frame Mounts 18 To Frame Ref Brh Page D-1

24 BRAKES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 ROTOR G01 CALIPER (INCLUDES PADS) G01 BRAKE PADS (SET OF 4) G01 BOLT, 3/8-24 x 1" LG G1 LOCK WASHER, 3/8" G01 FRONT BRAKE LINE G8 BOLT, 1/4-20 X 2" LG G7 WASHER, 1/4" G4 LOCK NUT, 1/ G01 CLAMP G01 REAR BRAKE LINE G8 BOLT, 1/4-20 X 1" LG G7 WASHER, 1/4" G4 LOCK NUT, 1/ G9 INSULATED CABLE CLAMP, 5/16" G01 BANJO BOLT G01 COPPER GASKET G01 MASTER CYLINDER G1 BOLT, 5/16-18 X 1 1/8" LG LOCK NUT, 5/ Page D-2

25 BRAKES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 BRAKE PEDAL COVER, PEDAL PAD G01 BUSHING G01 INNER PIVOT TUBE SCREW, 1/2-13 X 3 1/2" LG LOCK NUT, 1/ G01 EXTENSION SPRING G10 CLEVIS YOKE (ADJUSTABLE) G2 JAM NUT, 1/ G01 BUSHING G4 CLEVIS PIN, 3/8" X 15/16" G1 COTTER PIN, 1/16" X 1" LG G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 53-63) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 53-63) G01 BRAKE SHOE G** PARK BRAKE WHEEL LEVER G01 WHEEL CYLINDER * WHEEL CYLINDER BOLT * UPPER RETURN SPRING * LOWER RETURN SPRING * CUP AND SPRING * ADJUSTER... 2 Page D-3

26 BRAKES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 61 * WASHER * BOLT, 1/4-28 X 1/2" LG * DUST COVER G01 ADJUSTER KIT (INCLUDES ITEMS 60-63) G01 HARDWARE KIT (INCLUDES ITEMS 56-59) G01 BRAKE DRUM... 2 Page D-4

27 BRAKES - PARK Pulley Includes Items Mounts To Frame Mounts 50 To Frame Ref Brp 19 Page D-5

28 BRAKES - PARK 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 PARK BRAKE LEVER ASSEMBLY (INCLUDES ITEMS 2-5) G01 PARK BRAKE LEVER G02 PARK BRAKE CABLE G1 CLEVIS PIN, 3/8" X 1 1/8" LG G2 COTTER PIN, 3/32" X 1" LG G3 LOCK SCREW, 5/16-18 X 1" LG LOCK NUT, 5/ G01 PULLEY MOUNT BRACKET (DRIVER SIDE) G01 PULLEY MOUNT BRACKET (PASSENGER SIDE) G01 PULLEY, 2" DIA G4 BOLT, 5/16-18 X 1 1/2" LG LOCK NUT, 5/ G01 EQUALIZER BRACKET G01 SPHERICAL NUT, 5/ G4 NUT, 5/ G01 BRAKE COMPENSATOR BUMPER G01 PARK BRAKE CABLE (DRIVER SIDE) G02 PARK BRAKE CABLE (PASSENGER SIDE) LOCK NUT, 3/ G01 RETAINING RING, 25/64" (STAINLESS STEEL) G3 CLEVIS PIN, 5/16" X 1" LG G3 COTTER PIN, 3/32" X 3/4" LG... 2 Page D-6

29 BRAKES - PARK 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 CLAMP G01 SENSOR ASSEMBLY (INCLUDES ITEMS 39-41) G01 PROXIMITY SENSOR SWITCH G01 SENSOR BRACKET G3 RIVET, 1/8" X 17/32" LG (ALUMINUM) G3 LOCK SCREW, 5/16-18 X 1" LG LOCK NUT, 5/ G01 PARK BRAKE FRAME G6 BOLT, 5/16-18 X 3/4" LG LOCK NUT, 5/ G6 BOLT, 3/8-16 X 3/4" LG LOCK NUT, 3/ G01 PARK BRAKE BOOT G1 WIRE TIE G01 GROMMET... 1 Page D-7

30 BRAKES - PARK Page D-8

31 DIRECTION AND DRIVE SELECTOR 1 - Includes Items Levers On Transfer Case 20 Ref Dsl 19 Page E-1

32 DIRECTION AND DRIVE 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 G01 FNR & 2WD/4WD SHIFTER ASSEMBLY (INCLUDES ITEMS 2-21) G01 SHIFTER HOUSING G01 DIRECTION SELECTOR HANDLE (INCLUDES ITEMS 4-9) G01 FLANGED BUSHING, 5/16" G01 TORSION SPRING G01 SHOULDER BOLT, 1/ G4 LOCK NUT, 1/ G01 BALL STUD G2 LOCK NUT, 1/ G01 TWO/FOUR WHEEL DRIVE SELECTOR HANDLE (INCL. ITEMS 11-15) G01 COMPRESSION SPRING G01 DETENT PIN G5 LOCK NUT G01 BALL STUD G2 LOCK NUT G01 PIVOT SHAFT G1 LOCK NUT, 3/ G01 TWO/FOUR WHEEL DRIVE SELECTOR CABLE (INCLUDES ITEM 20) G01 DIRECTION SELECTOR CABLE (INCLUDES ITEM 20) G01 CABLE END SOCKET G01 PROXIMITY SENSOR SWITCH G9 RIVET, 1/8" X 11/32" LG (ALUMINUM) G1 BOLT, 5/16-18 X 1 1/8" LG LOCK NUT, 5/ G01 HAND CONTROL COVER PLATE G01 LABEL (HAND CONTROLS) G01 RIVET, 3/16" X 1" LG (ALUMINUM) Page E-2

33 DIRECTION AND DRIVE 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 G01 BALL STUD G2 LOCK NUT, 1/ G01 KNOB G02 CLAMP... 2 Page E-3

34 DIRECTION AND DRIVE SELECTOR Page E-4

35 DRIVETRAIN - FRONT Ref Dtf 19 Page F-1

36 DRIVETRAIN - FRONT 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 DIFFERENTIAL G01 FRONT UNDERCARRIAGE G01 HALF SHAFT G8 BOLT, 3/8-16 X 1" LG G1 WASHER, LOCK 3/ G4 LOCK SCREW, 3/8-16 X 1" LG LOCK NUT, 3/ G01 FRONT DRIVE SHAFT G8 LOCK WASHER, 5/16" BOLT, 5/16-24 X 1 1/2" LG G01 SOLENOID SCREW, 1/4-28 X 5/8" LG G7 LOCK WASHER, 1/4" G01 DIFFERENTIAL LOCK LINKAGE G01 SHOULDER BOLT, # G10 LOCK NUT, # G01 FRONT DIFFERENTIAL GUARD... 1 Page F-2

37 DRIVETRAIN - MID Front of Vehicle View From Underneath Vehicle Ref Dtm Page F-3

38 DRIVETRAIN - MID 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 POH-305PE OIL FILTER ZGR5A SPARK PLUG (NGK) J16CR-U SPARK PLUG (DENSO) G01 ENGINE HONDA 18 HP SCREW, 7/16-14 X 2" LG G3 WASHER, 7/16" G1 LOCK NUT, 7/ G01 INDICATOR SWITCH G01 TRANSFER CASE SCREW, 3/8-16 X 4" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 ENGINE SUB-FRAME G01 ISOLATION MOUNT G6 BOLT, 5/16-18 X 3/4" LG G6 LOCK NUT, 5/ G8 BOLT 3/8-16 X 2" LG G02 WASHER, 3/8" LOCK NUT, 3/ Page F-4

39 DRIVETRAIN - MID Ref Dtm 19-2 Page F-5

40 DRIVETRAIN - MID 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 BACK PLATE G01 LOCK WASHER, 5/16" G01 SCREW, 5/16-24 X 3/4" LG G7 LOCK WASHER, 1/4" G6 BOLT, 1/4-20 X 3/4" LG G01 DRIVE BELT G01 DRIVE CLUTCH G1 PILOT WASHER G2 LOCK WASHER, 7/16" G01 BOLT, M10 X 1.25 X 160MM LG G01 DRIVEN CLUTCH G1 RETAINING WASHER G8 LOCK WASHER, 5/16" SCREW, 5/16-18 X 3 1/2" LG G01 CVT COVER G01 BOLT, 1/4-20 X 7/8" LG Page F-6

41 DRIVETRAIN - REAR Includes Item Ref Dtr 19 Page F-7

42 DRIVETRAIN - REAR 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 REAR AXLE (INCLUDES ITEM 2) G01 LUG BOLT, 1/ G01 REAR DRIVE SHAFT G8 LOCK WASHER, 5/16" BOLT, 5/16-24 X 1 1/2" LG G01 SOLENOID SCREW, 1/4-28 X 5/8" LG G7 LOCK WASHER, 1/4" G01 DIFFERENTIAL LOCK LINKAGE G01 SHOULDER SCREW G10 LOCK NUT, # G01 REAR DIFFERENTIAL GUARD G01 BOLT, 3/8-16 X 1 1/8" LOCK NUT, 3/ Page F-8

43 ELECTRICAL HEADLIGHT FUSE BLOCK Ref Ele Page G-1

44 ELECTRICAL 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 HEADLIGHT (RECTANGULAR) (INCLUDES ITEM 2) G6 SCREW, #10-16 X 1" LG G01 JUMPER WIRE (HEADLIGHT) G4 LENS, AMBER G5 SCREW, #6-32 X 5/8" LG G9 LOCK NUT, # G1 WIRE TIE ADHESIVE BASE G1 WIRE TIE G1 WIRE TIE G01 CLAMP, 1/2" G02 FUSE BLOCK (12 POSITION) G2 SCREW, #10-24 X 1 1/4" LG G5 WASHER, # G10 LOCK NUT, # G01 FUSE, 15 AMP G03 FUSE, 25 AMP G4 NUT, # G01 IN-LINE FUSE COVER G01 RIVET, 3/16" X 1" LG (ALUMINUM)... 1 Page G-2

45 ELECTRICAL SWITCHES AND GAUGE CLUSTER Ref Ele 19-2 Page G-3

46 ELECTRICAL 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 GAUGE PLATE - OPTIONS G02 GAUGE PLATE - NO OPTIONS G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 GAUGE CLUSTER G01 LIGHT SWITCH... AR G01 LIGHT SWITCH DELETE HOLE PLUG... AR G01 BED DUMP SWITCH G01 BED DUMP SWITCH DELETE HOLE PLUG G11 HOLE PLUG, 5/8" G01 LABEL (HEADLIGHT) G01 LABEL (HORN) G01 LABEL (BED LIFT) G01 LABEL (ACCESSORY LIGHTS) G02 ROCKER SWITCH G01 POWER OUTLET G01 RIVET, 5/32" X 3/4" LG G01 KEY SWITCH (OFF-ON-START) G01 PLATE, KEY G01 LABEL (KEY START) Page G-4

47 ELECTRICAL UNDER COWL DRIVER SIDE BEHIND SIDE PANEL DRIVER SIDE BEHIND SIDE PANEL 30 Wire From Positive (+) Battery Post Ref Ele Page G-5

48 ELECTRICAL 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 BATTERY G01 SCREW, 5/16-18 X 1" LG G01 LOCK WASHER, 5/16" (SILICON BRONZE) G01 NUT, 5/16-18 (SILICON BRONZE) G01 LABEL (BATTERY DISPOSAL - CE) G01 BATTERY TRAY G8 BOLT, 5/16-18 X 1" LG G4 BOLT, 5/16-18 X 2 1/2" LG G2 WASHER, 5/16" LOCK NUT, 5/ G01 BATTERY RETAINER G8 BOLT, 5/16-18 X 1" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/ G144 6 GA WIRE (BLACK 94") (B+ / SOL) G145 6 GA WIRE (BLACK 20") (B- / GRD) G8 BOLT, 5/16-18 X 1" LG LOCK NUT, 5/ G146 6 GA WIRE (BLACK 26") (GRD / ENG) G6 BOLT, 3/8-16 X 3/4" LG G1 WASHER, 3/8" LOCK NUT, 3/ G01 VOLTAGE REGULATOR G8 BOLT, 1/4-20 X 1" LG G4 LOCK NUT, 1/ G1 WIRE TIE... 1 Page G-6

49 ELECTRICAL Oil Pressure Switch Mounted On Passenger Side Of Engine Front of Vehicle 6 DRIVER SIDE FRONT OF VEHICLE PASSENGER SIDE OF ENGINE Existing Engine Parts Ref Ele Page G-7

50 ELECTRICAL 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 WIRE HARNESS G01 CLAMP, 1/2" G02 CLAMP, 3/4" G1 PUSH ON MALE TERMINAL G01 ALTERNATOR BELT ALTERNATOR G01 ALTERNATOR MOUNTING SHAFT LOCK NUT, 3/ G8 BOLT, 5/16-18 X 1" LG G2 WASHER, 5/16" G01 ALTERNATOR BRACKET G8 BOLT, 3/8-16 X 1" LG LOCK NUT, 3/ G01 PTO SHAFT G01 WASHER, M G01 BOLT, M8 X 1.25 X 18MM LG PULLEY WOODRUFF KEY G01 WIRE HARNESS (ALTERNATOR) G GA WIRE (BLACK 3") G7 LOCK WASHER, 1/4" G1 NUT, 1/ G5 LOCK WASHER, # G4 NUT, # Page G-8

51 EXHAUST Includes Item Ref Exh 19 Page H-1

52 EXHAUST 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 MUFFLER G01 SPRING G01 EXHAUST PIPE G01 EXHAUST MANIFOLD G01 GASKET NUT G01 MOUNTING BRACKET (INCLUDES ITEM 11) * BUSHING BOLT, 1/2-13 X 3 1/2" LG G3 WASHER, 1/2" G01 INNER PIVOT TUBE LOCK NUT, 1/ G01 SPARK ARRESTER (SCREW INCLUDED)... 1 Page H-2

53 FRONT SUSPENSION To Steering Tie Rod End Ref Fsp Page I-1

54 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 G8 LOCK NUT, 1/ G01 STRUT WASHER G01 STRUT BUSHING G01 SPHERICAL BALL G01 BALL SEAT G01 STRUT G02 KNUCKLE (DRIVER SIDE) G01 KNUCKLE (PASSENGER SIDE) G8 BOLT, 3/8-16 X 2" LG G4 LOCK NUT, 3/ G01 BALL JOINT G8 LOCK WASHER, 5/16" (STAINLESS STEEL) G01 BOLT, M X 30MM LG G01 CASTLE NUT G1 COTTER PIN, 1/16" X 1" LG G01 CONTROL ARM G01 FLANGED BUSHING SCREW, 1/2-13 X 4" LG G1 LOCK NUT, 1/ G01 BEARING G3 LOCK WASHER, 1/2" G01 BOLT, M X 40MM LG G1 OUTER BRAKE WASHER LOCK NUT, 3/ G2 SPINDLE CAP Page I-2

55 FUEL SYSTEM Ref Fsy Page J-1

56 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 G01 PLATE FUEL TANK G6 BOLT, 3/8-16 X 3/4" LG LOCK NUT, 3/ G01 FUEL TANK ASSY G6 FUEL LEVEL SENDER G01 SCREW, #10-32 x 3/4" LG G01 FUEL TANK MOUNTING STRAP G5 VINYL EXTRUSION - 2FT G1 BOLT, 5/16-18 X 1 1/8" LG G8 LOCK WASHER, 5/16" G8 WASHER, 5/16" G01 FUEL CAP G01 TUBING, 1/4" I.D. X 1/2" O.D. (BULK)... AR G1 CLAMP G3 INSULATED CABLE CLAMP, 11/16" G01 TUBING, 3/16" I.D. X 3/8" O.D. (BULK)... AR G3 CLAMP, 3/8" G3 INSULATED CABLE CLAMP, 11/16" G01 BOLT, M x 20MM LG G1 WIRE TIE G01 FUEL FILTER G1 WIRE TIE... 1 Page J-2

57 HITCH Ref Hit 19 Page K-1

58 HITCH 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 REAR HITCH KIT (INCLUDES ITEMS 2-6) G01 REAR HITCH G01 BACKING PLATE G4 SCREW, 1/2-13 X 1 1/2" LG G3 WASHER, 1/2" G6 LOCK NUT, 1/ G01 LABEL (HITCH CAPACITY)... 1 Page K-2

59 REAR SUSPENSION Ref Rsp 19 Page L-1

60 REAR 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 LEAF SPRING, 265/500 LB G01 SHOCK MOUNTING BRACKET G01 LEAF SPRING PLATE G01 U-BOLT, 3/ G1 WASHER, 3/8" G5 LOCK NUT, 3/ G01 LEAF SPRING SHACKLE G01 FLANGED BUSHING SCREW, 1/2-13 X 4" LG G3 WASHER, 1/2" G6 LOCK NUT, 1/ G01 SHOCK ABSORBER, REAR G8 LOCK SCREW, 3/8-16 X 2" LG LOCK NUT, 3/ G01 RUBBER BUMPER G01 LOCK WASHER, 10MM G01 NUT, M10 X Page L-2

61 SEAT Ref Sea 19 Page M-1

62 SEAT 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 SEAT BOTTOM G01 SEAT BOTTOM FRAME G02 HINGE G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G01 HOUSING HALF HINGE G01 BOLT, 1/4-20 X 7/8" LG LOCK NUT, 1/ G01 HINGE PIN G01 SEAT BACK G01 SEAT BACK COVER PLATE G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G01 SEAT CROSSMEMBER G01 SEAT BACK SUPPORT BRACKET G01 BUMPER REST G2 BOLT, 3/8-16 X 1 1/4" LG LOCK NUT, 3/ Page M-2

63 SEAT 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 G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G01 BRACE G01 ADJUSTABLE BUMPER LOCK NUT, 5/ G01 SEAT FRAME G6 BOLT, 3/8-16 X 3/4" LG LOCK NUT, 3/ Page M-3

64 SEAT Page M-4

65 STEERING Includes Items 2-8 Ref Str 19 To Knuckle In FRONT SUSPENSION Section Page N-1

66 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 RACK & PINION ASSEMBLY (INCLUDES ITEMS 2-8) * TIE ROD END (DRIVER SIDE) * TIE ROD END (PASSENGER SIDE) G02 NUT, CASTLE M12 X G3 WASHER, 1/2" (STAINLESS STEEL) G1 COTTER PIN, 1/16" X 1" * BOOT (DRIVER SIDE) * BOOT (PASSENGER SIDE) G8 BOLT, 5/16-18 X 4" LG G3 LOCK SCREW, 5/16-18 X 1" LG G8 WASHER, 5/16" (STAINLESS STEEL) G6 LOCK NUT, 5/ G01 STEERING COLUMN G8 BOLT, 3/8-16 X 1" LG G1 WASHER, 3/8" G1 LOCK NUT, 3/ G01 BOLT, M8 X 1.25 X 30MM LG G8 LOCK WASHER, 5/16" G01 BUSHING G01 STEERING WHEEL G3 WASHER, 1/2" G03 LOCK NUT, 1/ G01 COVER, STEERING WHEEL... 1 Page N-2

67 TRUCK BED, PLASTIC Includes Items A B B A Ref Tbp Page O-1

68 TRUCK BED, PLASTIC A B C A B C Ref Tbp 19-2 Page O-2

69 TRUCK BED, PLASTIC 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 BED ASSEMBLY, 40" (INCLUDES ITEMS 2-11) G01 PLASTIC BED, 40" G01 PIVOT SHAFT G01 SHOULDER BOLT, 1/4-20 X 3/4" LG G01 TAILGATE G01 TAILGATE STIFFENER G2 SCREW, 1/4-20 X 5/8" LG (STAINLESS STEEL) G01 TAILGATE PROTECTOR G01 TAILGATE CABLE G01 TAILGATE CABLE SPACER G2 SCREW, 1/4-20 X 5/8" LG (STAINLESS STEEL) G04 LABEL (BED LOAD WARNING) G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 ADJUSTABLE RUBBER BUMPER G1 LOCK NUT, 5/ G01 BED LATCH G01 LATCH TORSION SPRING G02 KEEPER PLATE G02 RETAINER BRACKET G5 BOLT, 1/4-20 X 5/8" LG G7 LOCK WASHER, 1/4" G01 HANDLE GRIP Page O-3

70 TRUCK BED, PLASTIC 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 BUSHING G01 CLEVIS PIN G1 COTTER PIN, 15/32" X 2 13/16" LG G01 SPRING CHANNEL G5 SCREW, 1/4-20 X 5/8" LG G7 LOCK WASHER, 1/4" G7 WASHER, 1/4" G02 GAS SPRING G10 CLEVIS PIN, 1/2" X 2 27/32" LG G11 CLEVIS PIN, 1/2" X 1 3/4" LG G1 COTTER PIN, 15/32" X 2 13/16" LG G01 PLATE G1 RATCHET FASTENER, 1/4" X 9/16" LG G01 LABEL (ST E-Z-GO) G01 LABEL (ST 4X4) G01 HEAT SHIELD G7 WASHER, 1/4" G01 BOLT, 1/4-20 X 5/8" LG... 2 Page O-4

71 WHEELS & TIRES 1 - Includes Items 2, 3, Includes Items 2, 3, Includes Items 14, 3, 4 4 Rotation Ref Whl 19 Page P-1

72 WHEELS & 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 G** TIRE AND WHEEL ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 2-4) G01 TIRE (AT489), 25 X G** WHEEL, 10" X 6" G1 VALVE STEM G** TIRE AND WHEEL ASSY. (PASSENGER SIDE) (INCLUDES ITEMS 2-4) G1 LUG NUT, 1/ G02 TIRE AND WHEEL ASSEMBLY (INCLUDES ITEMS 14, 3, 4) G01 TIRE (TURF CTR TREAD), 25 X Page P-2

73 WHEELS & TIRES Page P-3

74 SPECIALTY PRODUCTS SPECIALTY PRODUCTS Appendix A-1

75 SPECIALTY PRODUCTS SPECIAL TOOLS PART NO. CLUTCH PULLER (DRIVE) G2 CURRENT INDICATOR G2 DIGITAL MULTI-METER G01 COMPRESSION TESTER G01 FEELER GAUGE G01 TACHOMETER G01 ENGINE OIL PART NO. 4 CYCLE ENGINE OIL, 5 GALLON (19 LITER) G03 4 CYCLE ENGINE OIL, 12 QUART CASE G04 4 CYCLE ENGINE OIL, 1 QUART BOTTLE (950 ML) G06 TOUCH UP PAINT PART NO. PEN 3 OUNCE (89 ML) - RECON GREEN G** PEN 3 OUNCE (89 ML) - CAMOUFLAGE PAINT (THREE PENS) G01 AEROSOL 12 OUNCE (360 ML) - RECON GREEN G** MAINTENANCE PRODUCTS PART NO. PLEXUS CLEANER, 7 OUNCE (210 ML) (FOR WINDSHIELDS) G01 PLEXUS CLEANER, 13 OUNCE (380 ML) (FOR WINDSHIELDS) G02 BATTERY PROTECTOR, 14 OUNCE (410 ML) SPRAY G01 CARBURETOR & CHOKE CLEANER, 15 OUNCE (440 ML) SPRAY G01 WHITE LITHIUM GREASE, 14 OUNCE (410 ML) SPRAY G01 PENETRANT/LUBRICANT, 15 OUNCE (440 ML) SPRAY G01 MULTI-PURPOSE CLEANER & DEGREASER, 14 OUNCE (410 ML) SPRAY G01 MULTI-PURPOSE HAND CLEANER, 32 OUNCE (950 ML) LIQUID G01 BATTERY CLEANER, 32 OUNCE (950 ML) WITH TRIGGER SPRAYER G01 BIO-DEGRADEABLE CLEANER, 32 OUNCE (950 ML) WITH TRIGGER SPRAYER G01 MULTI-PURPOSE VALUE PACK G01 BATTERY PROTECTOR, 4 OUNCE (120 ML) SPRAY PENETRANT/LUBRICANT, 4 OUNCE (120 ML) SPRAY WHITE LITHIUM GREASE, 4 OUNCE (120 ML) SPRAY CARBURETOR & CHOKE CLEANER, 4 OUNCE (120 ML) SPRAY Appendix A-2

76 OPTIONS/ACCESSORIES OPTIONS/ACCESSORIES Appendix B-1

77 OPTIONS/ACCESSORIES ITEM KIT NO. SECTION HIGH OUTPUT ALTERNATOR KIT G Electrical FRONT BRUSH GUARD KIT G Body SIDE BRUSH GUARD KIT G Body REAR HITCH KIT G Hitch WINCH KIT G01 HIGH ALTITUDE CONVERSION KIT (5-8K FT) G01 HIGH ALTITUDE CONVERSION KIT (8-10K FT) G02 TURF TIRE AND WHEEL ASSEMBLY G Wheels And Tires FRONT DIFFERENTIAL GUARD G Drivetrain - Front REAR DIFFERENTIAL GUARD G Drivetrain - Rear Appendix B-2