Gasoline Powered Vehicle Service Parts Manual

Transcription

1 Gasoline Powered Vehicle ISSUED SEP 2011 REVISED MAY 2014

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3 SERVICE PARTS MANUAL GASOLINE POWERED UTILITY VEHICLE SHUTTLE 2 SHUTTLE 4 SHUTTLE 6 STARTING MODEL YEAR 2012 DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically E-Z-GO, and therefore is subject to change without notice. E-Z-GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE- QUENTIAL DAMAGES RESULTING FROM THE USE OF THE INFORMATION AND MATERIALS IN THIS MANUAL. TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: , FAX: SERVICE PARTS PHONE: GET-EZGO ( ), FAX: INTERNATIONAL: PHONE: , FAX: E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA Page i

4 GENERAL INFORMATION To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Overfilling of batteries may void the warranty. BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75 F (-60 C). As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals. Page ii

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

6 NOTES Page iv Service Service Parts Parts Manual Manual

7 NOTES Page v

8 NOTES Page vi Service Service Parts Parts Manual Manual

9 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. Page vii

10 ,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 General Index and select the most appropriate title. Turn to the page number indicated and locate the desired part on the illustration. From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying description for specific information regarding the part. 2. IF YOU KNOW THE PART NUMBER Locate the part number or description in the appropriate column on the parts list page. NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. Page viii

11 HOW TO USE THE SERVICE PARTS MANUAL 3. COLOR CODE FOR BODY COMPONENTS The last two digits of the part number for the body part will denote the color code, locate the part number for the cowl, rear body, seat pod, side panel or seat wrap then locate your color in the list below, replace the last ** or XX with the two digit color code. CODE # DESCRIPTION CODE # DESCRIPTION 01 NO PAINT 53 MOSSY OAK NEW BREAK UP - DIPPED 02 SPECIAL COLOR 54 MOSSY OAK OBSESSION - DIPPED 05 JACOBSEN ORANGE 55 REALTREE ADVANTAGE MAX 4 - DIPPED 06 LIGHT GOLD PEARL 56 REALTREE HARDWOOD BROWN - DIPPED 07 SILVER PEARL METALIC 57 REALTREE AP HOT PINK - DIPPED 11 BLACK 58 BLACK / SILVER MARBLE - DIPPED 12 EMERALD GREEN PEARL 59 RED / SILVER MARBLE - DIPPED 13 CLOUD GRAY 60 HOT PINK / SILVER MARBLE - DIPPED 14 VIPER BLUE METALLIC 61 REALTREE AP 19 PATRIOT BLUE PEARL 62 REALTREE MAX 4 20 INFERNO RED METALLIC 63 MOSSY OAK BREAKUP 23 ADVANTAGE CLASSIC CAMO 64 MOSSY OAK TREESTAND 24 NATURAL 65 REALTREE APG 25 VIVID NEW HOLLAND BLUE 66 REALTREE MAX 1 26 STEEL BLUE PEARL 67 REALTREE AP PINK 27 BRIGHT SILVER METALLIC 68 REALTREE AP - DIPPED 29 PRIMER ONLY 69 MONSTER GREEN 30 HD ADVANTAGE CAMO 74 BARLEY GOLD 31 METALLIC CHARCOAL 75 OASIS GREEN 32 LIGHT ALMOND PEARL 76 JAVA BROWN 33 TIMBERLINE GREEN 34 DEEP MOLTEN RED 35 SAFETY YELLOW 36 IVORY 37 FOREST GREEN 38 BRIGHT WHITE 39 FLAME RED 40 BLACK 41 ELECTRIC BLUE 42 PLATINUM 43 BURGUNDY 44 ALMOND 45 BLACK 46 FLAME RED 47 BURLINGTON GREEN 48 BLACK 49 FLAME RED 50 RECON GREEN 51 SUNBURST ORANGE 52 BRITISH RACING GREEN Page ix

12 ACCELERATOR 1 PEDAL BOX ASSEMBLY includes items To Governor Part of Frame Page A-1

13 ACCELERATOR FOR VEHICLES MANUFACTURED FROM APRIL Differential Page A-2

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. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2-34) G02 ACCELERATOR PEDAL BRACKET G01 PAN HEAD PHILIPS SCREW, #8-16 X 1/2" LG G03 PEDAL BOX AND COVER G6 TRUSS HEAD PHILLIPS SCREW (SS), #8-32 X 3/4" LG G01 MICRO SWITCH G01 PAN HEAD TORX SCREW, #4-20 X 5/8" LG G01 MICRO SWITCH CAM G1 LOCK NUT, 5/16" G3 SOCKET HEAD SCREW, 1/4" - 20 X 3/8" LG G4 HEX NUT, 5/16" 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" 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

15 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. ACCELERATOR ITEM PART NO DESCRIPTION QTY G1 OVAL RIVET, 3/16" X 7/16" LG G01 ACCELERATOR PEDAL PAD * ACCELERATOR PEDAL G2 HEX HEAD BOLT, 5/16" - 18 X 4/5" LG CHOKE CABLE ASSY G4 LOCK WASHER, 9/16" G4 JAM NUT, 9/16" G01 CHOKE CABLE ADAPTER G02 RETAINER (SHUTTLE -2) G01 RETAINER (SHUTTLE 4-6) UPPER GOVERNOR BRACKET LOWER GOVERNOR BRACKET HEX HEAD BOLT, M6-1 X 12MM LG HEX HEAD BOLT, M6-1 X 30MM LG HEX NUT, M GOVERNOR LEVER BUSHING GOVERNOR ROD GOVERNOR ROD GUARD HEX HEAD BOLT, M6-1 X 20MM LG HEX HEAD BOLT, M X 16MM LG GOVERNOR CABLE / DIRECTION SELECTOR BRACKET FLANGED HEX HEAD BOLT, M X 16MM LG G11 RIVET 3/16" X 9/16" GOVERNOR WARNING DECAL G1 FLAT WASHER, 1/4" GOVERNOR COVER G1 NYLON CLAMP GOVERNOR CABLE / DIRECTION SELECTOR BRACKET (FOR VEHICLES MANUFACTURED FROM APRIL 2014)... 1 Page A-4

16 ACCELERATOR Notes: Page A-5

17 ACCELERATOR Notes: Page A-6

18 AIR FILTER AIR CLEANER ASSEMBLY Includes Items Carburetor 5 2 Page B-1

19 AIR FILTER 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 LOCK WASHER, 8 MM G1 HOSE CLAMP, HEXAGONAL HEAD BOLT M8, 25 X G7 HOSE CLAMP, AIR FILTER HOSE AIR CLEANER ASSEMBLY (INCLUDES ITEMS 7-11) G01 DUST EJECTOR VALVE G01 AIR CLEANER CLIP G01 AIR CLEANER COVER G01 AIR FILTER AIR CLEANER... 1 Page B-2

20 AIR FILTER Notes: Page B-3

21 AIR FILTER Notes: Page B-4

22 BODY ASHTRAY Page C-1

23 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 INSTRUMENT PANEL ASSEMBLY OPERATOR INSTRUCTION DECAL G2 RATCHET FASTENER, 1/4" X 3/4" UPPER FLOORPAN G11 RIVET (ALUMINUM), 3/16" X 9/16" GXXX COWL G01 RIVET, 3/16" X 1" GRILL COVER G01 RIVET, 3/16" X 1" FENDER FLARE (DRIVER SIDE) FENDER FLARE (PASSENGER SIDE) G01 SELF THREADING NUT, 3/16" X 19/32" G01 VINYL TRIM G01 RIVET, 3/16" X 1" G01 ASHTRAY G01 GASKET (ASHTRAY) G02 BRACKET (ASHTRAY) G4 SELF TAPPING SCREW, #10-16 X 1/2" LG CUSHMAN COWL DECAL BRUSHGUARD G2 HEX HEAD BOLT, 5/16" - 18 X 2 1/4" LG G6 HEX HEAD BOLT, 5/16" - 18 X 2 3/4" LG G04 SPACER, 1" G01 SPACER, 1/2"... 2 Page C-2

24 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G8 FLAT WASHER, 5/16" G8 LOCK WASHER, 5/16" FRONT FASCIA G02 FRONT SHIELD BRACE G1 FENDER WASHER, 1 1/4" G01 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G1 RIVET (ALUMINUM), 3/16" X 4/9" FASCIA BRACKET G6 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G4 LOCK NUT, 1/4" Page C-3

25 BODY Notes: Page C-4

26 BODY Page C-5

27 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 LOWER FLOOR PANEL G01 ACCESS COVER G01 REAR FLOOR PANEL G10 RIVET (SS), 5/32" X 9/16" G02 FLOORMAT WITH HORN HOLES G04 FLOOR MAT WITH HORN HOLES, 1/8" (SHUTTLE 2 ONLY) SEAT FRAME WELDMENT G01 SEAT FRAME WELDMENT G02 BATTERY RACK G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 TORX TRUSS HEAD SCREW, 3/8" - 16 X 3/4" LG ROCKER PANEL (DRIVER SIDE) (SHUTTLE 4 & 6 ONLY) ROCKER PANEL (PASSENGER SIDE) (SHUTTLE 4 & 6 ONLY) G2 TRUSS HEAD PHILLIPS SCREW, #10-24 X 1 1/4" LG G10 LOCK NUT, # G1 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1" LG G4 LOCK NUT, 1/4" G5 FLAT WASHER # G4 SPACER, 5/16" G7 FLAT WASHER,.577" (SHUTTLE 2) G6 RIVET (ALUMINUM), 3/16" X 15/16" Page C-6

28 BODY 118 REAR BUMPER ASSEMBLY includes items Page C-7

29 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SPLASH PAN (PASSENGER SIDE) G02 SPLASH PAN (DRIVER SIDE) G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G02 FENDER (PASSENGER SIDE) G01 FENDER (DRIVER SIDE) G2 RATCHET FASTENER,.25" X.887" G17 RIVET, 3/16" X 5/8" G01 FENDER (DRIVER SIDE) (SHUTTLE 2) G02 FENDER (PASSENGER SIDE) (SHUTTLE 2) G0XX REAR BODY (See COLOR CODE IN HOW TO USE SECTION) G01 HINGE PLATE G11 RIVET (SS), 3/16" X 3/4" G01 PLUG G01 ACCESS PANEL G01 PAN HEAD TORX SCREW, #8 X 5/8" LG G02 J CLIP, # G12 RIVET (ALUMINUM), 1/4" X 9/16" G10 RIVET (SS), 5/32" X 9/16" G1 PLASTIC DRIVE RIVET, 1/4" X 9/16" G02 COVER PLATE G01 RIVET (ALUMINUM), 3/16" X 1" G01 REAR BUMPER ASSEMBLY (INCLUDES ITEMS ) * REAR BUMPER G01 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G2 FLAT WASHER, 5/16" G01 BUMPER PLUG G03 HEX HEAD BOLT, 1/4" - 20 X 11/16" LG G01 J - TYPE NUT RETAINER, 1/4" Page C-8

30 BODY Page C-9

31 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 VERTICAL FRAME SUPPORT (PASSENGER SIDE) G02 VERTICAL FRAME SUPPORT (DRIVER SIDE) G4 HEX HEAD BOLT, 3/8" - 16 X 1 1/2" LG (SHUTTLE 4) G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/8" G01 SEAT BACK SUPPORT (SHUTTLE) G01 SPACER, 8.45" X 2" (SHUTTLE 6) G02 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG G8 HEX HEAD BOLT, 3/8" - 16 X 1" LG G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/8" G01 VALANCE PANEL G2 RATCHET FASTENER, 1/4" X 3/4" CUSHMAN LABEL (SHUTTLE 4) CUSHMAN LABEL (SHUTTLE 6) Page C-10

32 BODY Page C-11

33 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 LOCK NUT, 5/16" G01 ADJUSTABLE BUMPER G01 HOLD DOWN BRACKET G01 CARGO DECK (SHUTTLE 4) G1 NOISE SUPPRESSOR G01 STEEL DECK G01 CARGO BED MAT G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG G4 LOCK NUT, 1/4" TAPE (DOUBLE SIDED)... 40" G01 LATCH G6 HEX HEAD BOLT, #10-16 X 3/4" LG G02 FRONT/REAR CARGO RACK G01 SIDE CARGO RACK G01 TAILGATE RETAINER BRACKET G6 TAPPING SCREW (SS), #10-12 X 3/4" LG G1 NYLINER BUSHING G4 HEX HEAD BOLT, 5/16" - 18 X 2 1/2" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 LABEL (WARNING) (BED LATCH - SHUTTLE 4) G01 LABEL (WARNING) (LOAD BED - SHUTTLE 4)... 1 Page C-12

34 BODY Front of Vehicle Page C-13

35 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY ROKER PANEL (DRIVER SIDE) (SHUTTLE 2) ROKER PANEL (PASSENGER SIDE) (SHUTTLE 2) G01 PEDAL PIVOT COVER G01 CARGO DECK (SHUTTLE 2) G01 HINGE G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG G9 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1 1/4" LG G7 FLAT WASHER, 1/4" G7 FLAT WASHER, 1/4" G2 LOCK NUT, 1/4" G5 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 2" LG G1 FENDER WASHER, 1/4" G01 BED FRAME G01 HEX HEAD BOLT, 3/8" - 16 X 2 3/4" LG G3 FLAT WASHER, 3/8" G6 HEX HEAD BOLT, 5/16" - 18 X 1 3/4" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 BRACKET G6 HEX HEAD CAP SCREW, 5/16" - 18 X 3/4" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 BED MOUNT BRACKET G3 HEX HEAD BOLT (SS), 1/4" - 20 X 3/4" LG G7 FLAT WASHER, 1/4" G2 LOCK NUT, 1/4" G01 BULKHEAD... 1 Page C-14

36 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG G7 FLAT WASHER, 1/4" G2 LOCK NUT, 1/4" G1 FOAM TAPE... A/R G01 FENDER (DRIVER SIDE) G02 FENDER (PASSENGER SIDE) G03 FENDER WITH TAILLIGHT (DRIVER SIDE) G04 FENDER WITH TAILLIGHT (PASSENGER SIDE) G01 REAR PANEL G2 RATCHET FASTENER, 1/4 X 57/ Page C-15

37 BODY Notes: Page C-16

38 BODY SHUTTLE Page C-17

39 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SEAT FRAME CUSHMAN LABEL (SHUTTLE 2) G01 TORX TRUSS HEAD SCREW, 3/8" - 16 X 3/4" LG G01 SIDE PANEL (DRIVER SIDE) G02 SIDE PANEL (PASSENGER SIDE) G11 RIVET (SS), 3/16" X 3/4" G01 SEAT HINGE G01 SEAT WRAP PANEL G10 RIVET (SS), 5/32" X 9/16" G10 RIVET (SS), 5/32" X 9/16" G10 RIVET (SS), 5/32" X 9/16" G12 RIVET, 1/4" X 9/16" G01 FENDER WASHER, 1/4" SEAT FRAME WELDMENT G8 HEX HEAD BOLT, 5/16" - 18 X 1"LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G01 TORX TRUSS SCREW, 3/8" - 16 X 3/4" LG SEAT BACK BRACKET G8 HEX HEAD BOLT, 3/8" - 16 X 1" LG G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/8" G01 SEAT FRAME G02 BATTERY RACK WELDMENT G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G8 HEX HEAD BOLT, 5/16" - 18 X 1" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G6 LOCK NUT, 5/16" Page C-18

40 BODY VEHICLES MANUFACTURED FROM MARCH Taillight Page C-19

41 BODY When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G0XX REAR BODY W/LIGHTS (See COLOR CODE IN HOW TO USE SECTION) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) BAGWELL LINER (FOR VEHICLES MANUFACTURED FROM MARCH 2014) RIVET (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G2 RATCHET RIVET,.25" X.887" (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G0XX REAR BODY W/O LIGHTS(See COLOR CODE IN HOW TO USE SECTION) (FOR VEHICLES MANUFACTURED FROM MARCH 2014)... 1 Page C-20

42 BODY Notes: Page C-21

43 BODY Notes: Page C-22

44 BRAKES - FRONT DISC Part of Frame Accelerator Pedal COMPENSATOR ASSEMBLY includes items BRAKE PEDAL ASSEMBLY includes items Page D-1

45 BRAKES - FRONT DISC 53 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) includes items WHT BLK BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) 54 Page D-2

46 BRAKES - FRONT DISC SPINDLE ASSEMBLY (DRIVER SIDE) includes items SPINDLE ASSEMBLY (PASSENGER SIDE) includes items , Front Brake Line Disc Hub Caliper Page D-3

47 BRAKES - FRONT DISC Front of Vehicle FRONT DISC BRAKE ACTUATOR ASSEMBLY includes items Page D-4

48 BRAKES - FRONT DISC 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 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-11) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" G01 BRAKE PEDAL PARK BRAKE PEDAL G01 BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 15/32" LG G1 TEFLON WASHER, 3/8" G01 SHOULDER BOLT, 3/8" - 16 X 4" LG G01 FLANGED BUSHING G01 TORSION SPRING G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/8" G2 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED) G01 BRAKE COMPENSATOR BUMPER BRAKE CABLE (DRIVER SIDE), 65.06" LG BRAKE CABLE (PASSENGER SIDE), 74.81" LG G01 RETAINING RING (SS) G3 CLEVIS PIN, 5/16" X 1" G3 COTTER PIN, 3/32" X 3/4"... 3 Page D-5

49 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 BRAKES - FRONT DISC G01 KICK-OFF LINK G1 NYLON BUSHING G1 TEFLON WASHER, 3/8" G8 FLAT WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW WITH PATCH LOCK, 1/4" - 20 X 1/2" LG G4 SPACER, 1.25" G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/16" G02 CATCH BRACKET G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G4 LOCK NUT, 1/4" G01 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-81) G01 BRAKE PEDAL PARK BRAKE PEDAL G01 BRAKE PAD G01 PARK BRAKE PAD G1 OVAL RIVET, 3/16" X 15/32" LG G1 LOCTITE (262) (NOT ILLUSTRATED)... A/R G03 BRAKE PEDAL PLATE... 1 Page D-6

50 BRAKES - FRONT DISC 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 PARKING BRAKE PEDAL PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 PHILLIPS FLAT HEAD MACHINE SCREW, #10-24 X 1" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 LIMIT SWITCH (3 POLE) G2 PHILLIPS PAN HEAD MACHINE SCREW, #6-32 X 1 1/4" LG G5 FLAT WASHER, # G3 FLAT WASHER, # G3 LOCK WASHER, # G5 HEX NUT, # G1 PHILLIPS PAN HEAD MACHINE SCREW, #6-32 X 7/32" LG G1 TEFLON WASHER, 3/8" G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE G8 FLAT WASHER, # G02 SPRING PLATE (PASSENGER SIDE) G01 SPRING PLATE (DRIVER SIDE) G01 FOUR LINK ROD HEX NUT, M BRAKE LINE G01 SWAGEFORM SCREW, 1/4" - 20 X 1/2" LG G01 WIRE RETAINER SPINDLE, CALIPER AND DISC HUB ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS ) DISC BRAKE SPINDLE (DRIVER SIDE) Page D-7

51 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. BRAKES - FRONT DISC ITEM PART NO DESCRIPTION QTY G1 SLOTTED NUT, 1" G01 DRIVE FLANGE STUD, 1.5" G2 ROLLER BEARING G1 BEARING RACE DISC BRAKE HUB G01 FLANGED BEARING G1 LOCK WASHER, 3/8" G8 HEX HEAD BOLT, 3/8" - 16 X 1" LG G01 BEARING G8 COTTER PIN, 5/32" X 1 3/4" G1 GREASE SEAL G02 CALIPER (DRIVER SIDE) SPINDLE, CALIPER AND DISC HUB ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS , 106) DISC BRAKE SPINDLE (PASSENGER SIDE) G01 KINGPIN TUBE G01 THRUST WASHER (SS), 0.995" I.D X 1.38" O.D G3 FLAT WASHER, 1/2" G6 LOCK NUT, 1/2" G6 HEX HEAD SHOULDER BOLT, 1/2" - 13 X 6" LG G01 CALIPER (PASSENGER SIDE) FRONT DISC BRAKE ACTUATOR ASSEMBLY (INCLUDES ITEMS ) G3 COTTER PIN, 3/32" X 3/4" G3 CLEVIS PIN, 5/16" X 1" UPPER ACTUATOR PIVOT G02 ACETAL BUSHING G01 ACTUATOR PIVOT BOLT, 3/4" - 16 X 4 3/4" LG Page D-8

52 BRAKES - FRONT DISC 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 HEX HEAD BOLT, 1/2" - 13 X 6" LG G6 LOCK NUT, 5/16" MASTER CYLINDER MASTER CYLINDER BRACKET G5 LOCK NUT, 3/8" G1 LOCK WASHER (SS), 3/8" LOWER ACTUATOR PIVOT ACTUATOR ASSEMBLY COVER G01 SWAGEFORM SCREW, 1/4" - 20 X 1/2" LG G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G4 LOCK NUT, 1/4" G3 COTTER PIN, 3/32" X 3/4" G1 NYLON BUSHING ACTUATOR LINKAGE G5 FLAT WASHER, 3/8" (NOT ILLUSTRATED) G1 BRAKE FLUID (NOT ILLUSTRATED)... A/R CRUSH WASHER, M BANJO BOLT, M10-1" X 20" LG COMPENSATOR ASSEMBLY (INCLUDES ITEMS ) G4 HEX NUT, 1/4" HEX NUT, 5/16" G01 EQUALIZER BRACKET G1 FLAT WASHER, 5/16" G1 ACCELERATOR ROD BUSHING... 1 Page D-9

53 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. BRAKES - FRONT DISC ITEM PART NO DESCRIPTION QTY G2 TUBE G1 COMPRESSION SPRING G01 BRAKE YOKE G9 LOCK NUT, 5/16" COMPENSATOR LINK ROD... 1 Page D-10

54 BRAKES - FRONT DISC Notes: Page D-11

55 BRAKES - FRONT DISC Notes: Page D-12

56 BRAKES - MECHANICAL Part of Frame Accelerator Pedal BRAKE PEDAL ASSEMBLY - includes items COMPENSATOR ASSEMBLY - includes items Page E-1

57 BRAKES - MECHANICAL Front of Vehicle BRAKE ASSEMBLY (DRIVER SIDE) includes items BRAKE ASSEMBLY (PASSENGER SIDE) includes items BRAKE SHOE KIT includes item BRAKE SPRING KIT includes items BRAKE ADJUSTER KIT (DRIVER SIDE) includes items BRAKE ADJUSTER KIT (PASSENGER SIDE) includes items BRAKE DRUM ASSEMBLY includes items Page E-2

58 BRAKES - MECHANICAL 53 1 BRAKE PEDAL ASSEMBLY includes items WHT BLK BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Page E-3

59 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. BRAKES - MECHANICAL 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" G02 BRAKE PEDAL G02 PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 3/8" LG G2 NYLON WIRE TIE G01 SHOULDER BOLT, 3/8-16 X 4" LG G01 FLANGED BUSHING G01 TORSION SPRING G1 LOCK WASHER, 3/8" G5 LOCK NUT, 3/ COMPENSATOR ASSEMBLY (INCLUDES ITEMS 18-27) G4 HEX NUT 5/ HEX SPHERICAL NUT 5/ G01 EQUALIZER BRACKET G1 FLAT WASHER 3/8" G1 ACCELERATOR ROD BUSHING G2 TUBE G1 COMPRESSION SPRING G01 BRAKE YOKE G9 HEX LOCK NUT 5/ COMPENSATOR LINK ROD G01 RETAINING RING, S.S G01 BRAKE COMPENSATOR BUMPER G3 CLEVIS PIN, 5/16" X 1" LG... 3 Page E-4

60 BRAKES - MECHANICAL 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 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 FLAT 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 G4 LOCK NUT, 1/ BRAKE CABLE (PASSENGER SIDE) BRAKE CABLE (DRIVER SIDE) G02 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-80) G02 BRAKE PEDAL G02 PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PAD G1 OVAL RIVET, 3/16" x 3/8" LG G03 BRAKE PEDAL PLATE... 1 Page E-5

61 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. BRAKES - MECHANICAL ITEM PART NO DESCRIPTION QTY 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 G2 SCREW, #6-32 X 1 1/4" LG G5 FLAT WASHER, # G3 FLAT WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 SCREW AND LOCK WASHER, #6-32 X 7/ G8 FLAT WASHER, 5/16" G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84-92) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES 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 * PIN * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 94, 95)... 1 Page E-6

62 BRAKES - MECHANICAL When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCLUDES 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/ OUTER BRAKE DRUM WASHER SLOTTED NUT, 3/ G1 COTTER PIN, 1/8" X 1 1/2" LG SPINDLE CAP BRAKE CABLE BRACKET (PASSENGER SIDE) BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page E-7

63 BRAKES - MECHANICAL Notes: Page E-8

64 CARBURETOR Page F-1

65 CARBURETOR Page F-2

66 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 3-21) MAIN JET (#104) PILOT JET (#44) PLUG NEEDLE VALVE FLOAT FLOAT PIN FLOAT BOWL GASKET FLOAT CHAMBER BOWL SCREW BOWL GASKET BREATHER TUBE CLAMP, INTAKE TUBE CLAMP CYLINDER HEAD TUBE INTAKE TUBE CHOKE GASKET NUT, M6 X THROTTLE ROD ATTACHMENT BUSHING MAIN JET (#102) (FOR ELEVATIONS OF 6000 FT FT) MAIN JET (#104) (FOR ELEVATIONS OF 3000 FT FT) CARBURETOR MOUNT GASKET CARBURETOR INSULATOR... 1 Page F-3

67 CARBURETOR Notes: Page F-4

68 PRIMARY TEAM CLUTCH includes items SECONDARY TEAM CLUTCH includes items CLUTCH Page G-1

69 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 PRIMARY TEAM CLUTCH (INCLUDES ITEMS 2-10) PRIMARY STARTER PULLY, SVC STATIONARY ASSEMBLY MOVEABLE PRIMARY ASSEMBLY SHIFT ROLLER ASSEMBLY SHIM, 39.5 X PRIMARY SPIDER ASSEMBLY PRIMARY DUST COVER ASSEMBLY BOLT, 1/4-20 X DRIVE BELT SECONDARY TEAM CLUTCH (INCLUDES ITEMS 13-20) * SECONDARY STATIONARY, * MOVEABLE SECONDARY, INNER RETAINER SPRING COMPRESSION SPRING, 2.70 OD OUTER SPRING RETAINER RETAINER RING THRUST WASHER, x x CONICAL WASHER, M G3 SPRING TYPE LOCK WASHER HEX BOLT, M X HEX BOLT, M X CLUTCH WASHER Page G-2

70 CLUTCH Notes: Page G-3

71 CLUTCH Notes: Page G-4

72 DIRECTION SELECTOR 1 DIRECTION SELECTOR ASSEMBLY includes items FOR VEHICLES MANUFACTURED FROM APRIL Governor Cable Bracket Page H-1

73 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. DIRECTION SELECTOR ITEM PART NO DESCRIPTION QTY DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 2-26) DIRECTION SELECTOR BRACKET G4 FLIP LOK BUSHING,.25" FNR BRACKET G01 DIRECTION SELECTOR SHAFT DIRECTION SELECTOR CAM G1 LOCK NUT, 3/8" G2 BUSHING, 1/2" X.75" LG G01 NEUTRAL LOCK PIN G01 COMPRESSION SPRING, 3/8" X 5/8" LG G01 NEUTRAL LOCK BRACKET G2 LOCK NUT, 1/4" G01 EXTENSION SPRING G01 BALL STUD, 1/4" G5 LOCK NUT, # G01 MICRO SWITCH G01 SLOTTED MACHINED SCREW, #4-40 X 1" LG G1 LOCK WASHER, 5/8" G1 LOCK WASHER, 3/4" G2 HEX NUT, # PUSH/PULL SHIFTER CABLE G01 CUP WASHER, 1/4" G01 COMPRESSION SPRING, 19/32" X 1" LG G5 LOCK NUT, # G01 SOCKET HEAD SCREW, 1/4" - 20 X 7/8" LG G2 LOCK NUT, 1/4" G01 DIRECTION SELECTOR HANDLE G4 TRUSS HEAD PHILLIPS SCREW (SS), #10-32 X 1/2" LG... 1 Page H-2

74 DIRECTION SELECTOR 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 FLANGED HEX HEAD BOLT, M6-1 X 30MM LG HEX NUT, M G01 RIVET 3/16" X.38" GRIP MOUNTING BRACKET DIRECTION SELECTOR PIVOT BRACKET (FOR VEHICLES MANUFACTURED FROM APRIL 2014)... 1 Page H-3

75 DIRECTION SELECTOR Notes: Page H-4

76 ELECTRICAL SYSTEM Front of Vehicle See Body Section See Starter Generator Section Page J-1

77 ELECTRICAL SYSTEM BLACK 35 To Key Switch Control Harness RED To F2 On Starter/ Generator ELECTRICAL PLATE ASSEMBLY includes items Page J-2

78 ELECTRICAL SYSTEM FUSE BLOCK GRN HORN BUTTON Floorboard HORN 63 HORN Front of Vehicle Seatwrap Support 60 YEL BLK 57 Page J-3

79 ELECTRICAL SYSTEM HEAD LIGHT AND TURN SIGNAL TURN SIGNAL KIT includes items Page J-4

80 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) Page J-5

81 ELECTRICAL SYSTEM CONSOLE INSERT PLATE (WITH POWER OUTLET SHOWN) ASSEMBLY CONSOLE INSERT includes items 120, 122 POWER OUTLET 12V includes items ON OFF FUEL 102 Front of Vehicle HOUR METER KIT includes items HOUR METER KIT includes items KEY SWITCH, INDICATOR LIGHT(S), AND FUEL GAUGE 125 Front of Vehicle FNR MOUNTING SCREWS 129 SEAT SUPPORT SOLENOID COVER HOUR METER FNR Page J-6

82 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY GA WIRE (BLACK 6", F1 - A2) G01 TERMINAL COVER G1 BATTERY, 12V * BOLT, 5/16" - 18 X 1 1/4" LG * LOCK WASHER (SILICON BRONZE), 5/16" * LOCK NUT (SILICON BRONZE), 5/16" G02 BATTERY HOLD DOWN G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G8 LOCK WASHER, 5/16" G2 FLAT WASHER (SS), 5/16" G03 GROUND CABLE G19 14 GA WIRE (BLACK 6") G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG G1 LOCK NUT, 5/16" G01 FLANGED BOLT M6 X 1.0 X 23MM GA WIRE (42" LONG) WIRE HARNESS (CONTROL) G1 WIRE TIE (NOT ILLUSTRATED )... AR G01 COVER FNR G1 FLAT WASHER, 1/4" G6 HEX WASHER HEAD TAPPING SCREW, 1/4" - 14 X 3/4" LG ELECTRICAL PLATE ASSEMBLY (INCLUDES ITEMS 32-49)... 1 Page J-7

83 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. ELECTRICAL SYSTEM ITEM PART NO DESCRIPTION QTY G01 BRACKET G01 VOLTAGE REGULATOR G4 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G2 LOCK NUT, 1/4" G33 WIRE ASSEMBLY 6 GA RELAY G8 HEX HEAD BOLT, 1/4" - 20 X 1" LG SOLENOID * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/16" * NUT, 5/16" G7 LOCK WASHER (EXTERNAL TOOTH TYPE), 1/4" G1 HEX NUT, 1/4" G01 FUSE HOLDER ASSEMBLY G2 LOCK NUT, 1/4" 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 HEX HEAD BOLT, 1/4" - 20 X 5/8" LG G7 LOCK WASHER (SS), 1/4" G4 LOCK NUT, 1/ G1 HORN SWITCH... 1 Page J-8

84 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT G1 HORN SWITCH LABEL G01 ALUMINUM RIVET, 3/16" X 1" LG PASSENGER SIDE HEAD LIGHT ASSEMBLY DRIVER SIDE HEADLIGHT ASSEMBLY G01 SELF THREADING NUT 5 X 10 X 15 MM LED HEADLIGHT W/O TURN SIGNAL (PASSENGER SIDE) LED HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) TURN SIGNAL KIT (INCLUDES ITEMS 76-82) G1 NYLON CLAMP G3 STEERING COLUMN COVER TURN SIGNAL SWITCH ASSEMBLY TURN SIGNAL BULB G3 FLEX ZIP LOOM G1 FLASHER UNIT G1 HEX HEAD BOLT, 5/16" - 18 X 1 1/8" LG (NOT ILLUSTRATED) G01 SPACER,.328" X.75" X.50" (NOT ILLUSTRATED) G6 LOCK NUT, 5/16" - 18 (NOT ILLUSTRATED) G1 TAIL LIGHT ASSEMBLY COMPLETE Page J-9

85 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 ELECTRICAL SYSTEM WIRE HARNESS, LONG (ACCESSORY) G01 IGNITION SWITCH (WITH LIGHTS) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/4" 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 CONSOLE INSERT PLATE ASSY (INCLUDES ITEMS 120, 122) G02 RIVET, BLACK PLATIC 3/16 X 3/ POWER OUTLET 12V (INCLUDES ITEMS ) WIRE HARNESS, POWER OUTLET 12V G02 RIVET, BLACK PLATIC 3/16 X 3/ G01 OUTLET, POWER 12V G10 ALUMINUM RIVET, 5/32" G03 CONSOLE PLATE (E-COAT) G01 FUSE, AUTOMTIVE ATC TYPE, 15A G01 HOLE PLUG G1 NYLON CLAMP HOUR METER KIT (INCLUDES ITEMS )... 1 Page J-10

86 ELECTRICAL SYSTEM When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY HOUR METER HOUR METER BRACKET WIRE HARNESS (HOUR METER) HOUR METER KIT (INCLUDES ITEMS ) G1 NYLON CLAMP 15.5" (NOT ILLUSTRATED)... A/R G03 CONTINUOUS TONE POTTED BUZZER G01 BULBEX RIVET, 5/32" DIA BEZEL, TAILLIGHT (DRIVER SIDE) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) BEZEL, TAILLIGHT (PASSENGER SIDE) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G02 "J" TYPE NUT, #8 (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G4 PAN HEAD PHILLIPS SCREW, #8 X 1.5" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G1 TAILLIGHT ASSEMBLY (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 TAPPING SCREW, #8-18 X.75" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G11 RIVET, 3/16" X 9/16" (FOR VEHICLES MANUFACTURED FROM MARCH 2014)... 2 Page J-11

87 ELECTRICAL SYSTEM Notes: Page J-12

88 ENGINE AND MUFFLER 1 GAS ENGINE includes items Page K-1

89 ENGINE AND MUFFLER Page K-2

90 ENGINE AND MUFFLER FOR VEHICLES MANUFACTURED FROM APRIL Front of Vehicle 11 Page K-3

91 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. ENGINE AND MUFFLER ITEM PART NO DESCRIPTION QTY ENGINE, GAS, 13HP, NON-GOLF (INCLUDES ITEMS 3-6) DIP STICK OIL FILTER SPARK PLUG (BPR2ES) OIL DRAIN PLUG O RING, 16MM MUFFLER EXHAUST PIPE LOCK WASHER, 8MM HEX JAM NUT, M8 X HEX NUT, M HEX HEAD BOLT, M X 25MM LG HEX HEAD BOLT, M X 30MM LG EXHAUST GASKET MUFFLER (FOR VEHICLES MANUFACTURED FROM APRIL 2014)... 1 Page K-4

92 ENGINE AND MUFFLER Notes: Page K-5

93 ENGINE AND MUFFLER Notes: Page K-6

94 FRONT FRONT FRONT MOUNT BRACKET ASSEMBLY includes items ENGINE MOUNTING 3 10 Page L-1

95 ENGINE MOUNTING FOR VEHICLES MANUFACTURED FROM APRIL Page L-2

96 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 HEX HEAD BOLT, M X 25MM LG HEX NUT, M NUT PLATE HEX HEAD BOLT, M X 45MM LG FLAT WASHER, M10 X 22MM - 2.5MM HEX NUT, M HEX HEAD BOLT, M X 34MM LG FLAT HEAD TORX SCREW, M6-1 X 12MM LG DIFFERENTIAL PLATE G01 TUBE SPACER G8 HEX HEAD CAPSCREW, 3/8" - 16 X 2.75" LG G5 PLASTIC INSERT LOCK NUT 3/8" - 16" FRONT MOUNT BRACKET ASSEMBLY (INCLUDES ITEMS 16-19) FRONT MOUNT BRACKET RUBBER BUMPER G01 HEX - NUT M10 X SPLIT LOCK WASHER, 10MM G02 CROSSMEMBER BRACE G7 HEX HEAD CAPSCREW, 5/16" - 18 X 7/8" LG G8 FLAT WASHER 5/16" G01 LOCK NUT, 5/16" G1 FLAT WASHER, 3/8" X 1 X.063" ENGINE PAN (FOR VEHICLES MANUFACTERED FROM APRIL 2014)... 1 Page L-3

97 ENGINE MOUNTING Notes: Page L-4

98 FRONT SUSPENSION / STEERING 96 Front of Vehicle *Truck Models Only 30* 31* 29 Part of Frame Part of Frame LUG *NOTE: Tie Rod Not Shown for Clarity SPINDLE AND HUB ASSEMBLY includes items 4-10 WHEEL HUB ASSEMBLY WITH RACES includes item LUG SPINDLE AND HUB ASSEMBLY includes items 5-10, 13 SPINDLE AND HUB ASSEMBLY includes items WHEEL HUB ASSEMBLY WITH RACES includes item 19 SPINDLE AND HUB ASSEMBLY includes items Page M-1

99 FRONT SUSPENSION / STEERING 86 Front of Vehicle RACK AND PINION UNIT includes items RACK BALL JOINT includes items STEERING COLUMN KIT includes items STEERING COLUMN KIT includes items STEERING COLUMN KIT includes items 61, 63-65, TIE ROD ASSEMBLY includes items Page M-2

100 FRONT SUSPENSION / STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRONT AXLE FRONT AXLE WITH FRONT DISC BRAKES G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 4-10) G04 SPINDLE ASSEMBLY (PASSENGER SIDE) G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G01 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 8) G1 LUG BOLT, 1/2" - 20 X 1 3/16" LG G1 CASTELLATED NUT, 1" G8 COTTER PIN, 5/32" X 1 3/4" LG G2 SPINDLE CAP G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 5-10, 13) G04 SPINDLE ASSEMBLY (DRIVER SIDE) SPINDLE AND HUB ASSEMBLY WITH FRONT DISC BRAKES (PASSENGER SIDE)(INCLUDES ITEMS 16-21) G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G01 WHEEL HUB ASSEMBLY WITH RACES, (INCLUDES ITEM 19) G1 LUG BOLT, 1/2" - 20 X 1 7/32" LG G1 CASTELLATED NUT, 1" G8 COTTER PIN, 5/32" X 1 3/4" LG SPINDLE AND HUB ASSEMBLY, WITH FRONT DISC BRAKES (DRIVER SIDE)(INCLUDES ITEMS 15-20) G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG G3 FLAT WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER (SS), 1" G6 LOCK NUT, 1/2" G01 SHOCK ABSORBER... 2 Page M-3

101 FRONT SUSPENSION / STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SHOCK ABSORBER BOOT G1 WIRE TIE G1 SHOCK ABSORBER WASHER G1 RUBBER BUSHING G6 HEX NUT, 3/8" G03 CANTILEVER LEAF SPRING (HEAVY DUTY) G03 SPRING PLATE G1 LOCK NUT, 7/16" G11 HEX HEAD BOLT, 7/16" - 14 X 1 3/4" LG G01 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 41-52) G01 STEERING RACK COVER & BEARING * STEERING BOX INSTALLATION TAG G01 RACK EXTENSION * JAM NUT, 1/2" G01 RACK BOOT G2 WIRE TIE G8 CLAMP, 1 13/16" - 2 3/8" G01 PINION SEAL G01 TIE ROD END - OUTER * GROMMET - TIE ROD END * CASTELLATED NUT, 7/ G3 GREASE FITTING, STRAIGHT G2 COTTER PIN, 3/32" X 1" LG G8 HEX HEAD BOLT, 7/16" - 14 X 2 3/4" LG G01 HEX HEAD BOLT, 7/16" - 14 X 3 1/2" LG G02 SPACER, 1.21" LG G04 STEERING HOUSING SPACER G7 HEX NUT, 7/16" G2 FLAT WASHER, 7/16" G1 LOCK NUT, 7/16" Page M-4

102 FRONT SUSPENSION / STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 STEERING SHAFT G06 STEERING COLUMN KIT (INCLUDES ITEMS 63-65) G03 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 HEX WASHER HEAD, SCREW, #6-20 X 5/16" LG G08 STEERING COLUMN KIT (HORN) (INCLUDES ITEMS 67-69) G04 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 HEX WASHER HEAD, SCREW, #6-20 X 5/16" LG G01 HEX WASHER HEAD BOLT, 3/8" - 16 X 1 1/4" LG G1 LOCK WASHER, 3/8" G01 COVER G01 RIVET, 3/16" X 1" LG (ALUMINUM) G05 STEERING COLUMN KIT (INCLUDES ITEMS 61, 63-65, 75-81) G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 75, 76) G01 HEX HEAD BOLT, M8 X G G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER CUSHMAN STEERING WHEEL DECAL G01 STEERING WHEEL COVER STEERING WHEEL CLIPBOARD G01 HUB COVER G2 LOCK NUT, 5/8" G02 TIE ROD ASSEMBLY (INCLUDES ITEMS 90-94) G02 THREADED ROD (24" LG) G01 TIE ROD END (LEFT HAND THREADS)... 1 Page M-5

103 FRONT SUSPENSION / STEERING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 JAM NUT, M12 X (LEFT HAND THREADS) G02 TIE ROD END (RIGHT HAND THREADS) G02 JAM NUT, M12 X (RIGHT HAND THREADS) G1 LOCK NUT, 7/16" G01 VINYL CAP... 4 Page M-6

104 FRONT SUSPENSION / STEERING Notes: Page M-7

105 FRONT SUSPENSION / STEERING Notes: Page M-8

106 FUEL SYSTEM Front of Vehicle DEZGPNHEQR Air Filter Part of Frame To Carburetor 34 1 CARB FUEL TANK ASSEMBLY (Use with sending unit) includes items CARB FUEL TANK, FLUOR (W/SWITCH) includes item 11 Page N-1

107 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) (INCLUDES ITEMS 4-14) G01 SIPHON TUBE GROMMET G3 SIPHON TUBE ASSEMBLY ROLLOVER VALVE GROMMET EPA FUEL TANK LABEL ROLLOVER VALVE FUEL TANK CAP (RATCHET) CARB FUEL TANK, (W/SWITCH) (INCLUDES ITEM 11) FUEL TANK, W/ SENDER UNIT G01 FUEL TANK ADAPTER G01 FLAT HEAD MACHINE SCREW 6-32 X 1/2" G2 FUEL LEVEL SENDER LOW PRESSURE FUEL HOSE, 3/16" I.D. X 3/8 O.D. X LONG (CARB) LOW PRESSURE FUEL HOSE, 3/16" I.D. X 3/8 O.D. X LONG (CARB) G6 BLACK TRIM, 6.25" LONG G1 NYLON CLAMP TUBING CLAMP, 3/16" I.D G8 HEX HEAD BOLT, 5/16" - 18 X 1" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 SPACER, 5/16" HOSE REDUCER - ID 1/4" X 3/16" FUEL SHUT-OFF VALVE G1 HOSE CLAMP,.50 DIAMETER FUEL SYSTEM HOSE, ID 6.35, 2.00" G01 FUEL LINE FILTER... 1 Page N-2

108 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 FUEL SYSTEM HOSE,.25 I.D. X.50 O.D. X 8.00 LONG G4 HOSE CLAMP, DIA CARB FUEL SYSTEM HOSE,.25 I.D. X.50 O.D. X LONG FUEL PUMP G6 HEX WASHER HEAD SLOTTED TAPPING SCREW, 1/4" - 14 X.75" LG CARBON CANISTER MOUNTING BRACKET G11 RIVET, 3/16" DIA X CARBON CANISTER EVAP LABEL... 1 Page N-3

109 FUEL SYSTEM Notes: Page N-4

110 REAR AXLE 1 REAR AXLE includes items Page P-1

111 REAR AXLE FOR VEHICLES MANUFACTURED FROM APRIL Page P-2

112 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 (INCLUDES ITEMS 2-16) G01 OIL DRAIN PLUG G01 GASKET, 14 MM G01 OIL SEAL, 28 X 47 X 9 MM G01 FLANGED HEX HEAD BOLT, M8 X 1.25 X 100MM LG G01 FLANGED HEX HEAD BOLT, M10 X 1.5 X 23MM LG AXLE TUBE (PASSENGER SIDE) AXLE TUBE (DRIVER SIDE) AXLE SHAFT (PASSENGER SIDE) AXLE SHAFT (DRIVER SIDE) G01 BALL BEARING G01 SNAP RING, 52 MM SLOTTED NUT, M22 X REAR AXLE, 11.47:1 (FOR VEHICLES MANUFACTURED FROM APRIL 2014) REAR AXLE WITH LSD, 11:47.1 (FOR VEHICLES MANUFACTURED FROM APRIL 2014)... 1 Page P-3

113 REAR AXLE Notes: Page P-4

114 REAR SUSPENSION Front of the Vehicle

115 REAR SUSPENSION ITEM PART NO DESCRIPTION QTY.

116 REAR SUSPENSION Notes:

117 REAR SUSPENSION Notes:

118 SEATING 17 1 SEAT BACK ASSEMBLY includes items FLIP FLOP SEAT BOTTOM ASSEMBLY includes items 56-59, SEAT BACK ASSEMBLY includes items 3-9, 122 & Front of Vehicle Front of Vehicle REAR FACING SEAT BOTTOM includes items SEAT BOTTOM ASSEMBLY includes items SEAT BOTTOM ASSEMBLY includes items SEAT BOTTOM ASSEMBLY includes items 22-36, 126 Front of Vehicle Front of Vehicle Page R-1

119 SEATING 80 HANDRAIL KIT, FLIP FLOP SEAT includes items HANDRAIL KIT, FLIP FLOP SEAT includes items 82-86, MAX 250 lbs. 110 kg MAX 4 in. 10 cm MAX 14 o / 25% Top of Vehicle Page R-2

120 SEATING 91 SAEAT BOTTOM ASSEMBLY includes items Floormat Page R-3

121 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 3-9) G02 GRAY 71751G03 OYSTER 71751G04 TAN 71751G06 BROWN 71751G07 BLACK WHITE WITH BLUE WHITE WITH RED RED WITH BLACK 2 3 * FLAT STAPLE G01 PLASTIC SEAT BACK COVER G01 SEAT BACK (WOOD) G01 PAN HEAD TORX SCREW, #8 X.63" LG PAN HEAD TORX SCREW, #8 X.88" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 FOAM PADDING (SEAT BACK) *** VINYL SEAT BACK COVER G02 GRAY 71753G03 OYSTER 71753G04 TAN 71753G06 BROWN 71753G07 BLACK G0102 WHITE/BLUE G0103 WHITE/RED G0304 RED/BLACK G8 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G7 LOCK WASHER,.255" X.263" SEAT BACK SUPPORT... 1 Page R-4

122 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 HEX HEAD BOLT, 1/4" - 20 X 7/8" LG G01 RIVET, 3/16" (NOT ILLUSTRATED) *** SEAT BACK ASSEMBLY G03 TAN 71274G04 GRAY 71274G05 OYSTER 71274G06 SPECIAL HEX HEAD BOLT, 1/4" - 20 X 1" LG *** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 22-36) G03 GRAY 71611G05 OYSTER 71611G07 TAN 71611G09 SPECIAL 71611G16 BROWN 71611G17 BLACK 71611G35 RED ON BLACK WHITE WITH RED WHITE WITH BLUE G1 RUBBER PAD * FLAT STAPLE * FLAT STAPLE G01 VINYL TRIM (SEAT BOTTOM) *** VINYL SEAT BOTTOM COVER G02 GREY 71602G03 OYSTER 71602G04 TAN 71602G05 SPECIAL 71602G06 BLACK Page R-5

123 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G07 BROWN G0103 WHITE ON RED G0102 WHITE/BLUE G02 FOAM PADDING (SEAT BOTTOM) G01 SEAT BOTTOM (WOOD) G01 HIP RESTRAINT (DRIVER SIDE) G01 HIP RESTRAINT (PASSENGER SIDE) G01 HEX HEAD BOLT, 1/4" - 20 X 7/8" LG G01 SEAT HINGE G08 FLAT HEAD PHILLIPS SCREW, #12-14 X 1" LG SEAT BOTTOM (WOOD) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) HIP RESTRAINT (DRIVER SIDE) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) HIP RESTRAINT (PASSENGER SIDE) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) *** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 38-50) G02 GRAY 74139G03 OYSTER 74139G04 TAN 74139G06 BROWN 74139G07 BLACK 38 * FLAT STAPLE * FLAT STAPLE *** VINYL SEAT BOTTOM COVER G02 GRAY 71602G03 OYSTER 71602G04 TAN 71602G07 BROWN 71602G06 BLACK G01 SEAT BOTTOM (WOOD) G02 FOAM PADDING (SEAT BOTTOM)... 1 Page R-6

124 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 VINYL TRIM FRONT G01 FLAT WASHER (SS), 1/4" G8 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G7 LOCK WASHER,.255" X.263" G01 VINYL TRIM (SEAT BOTTOM) G01 HIP RESTRAINT (DRIVER SIDE) G01 HIP RESTRAINT (PASSENGER SIDE) HEX HEAD BOLT, M X 24MM LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) MOUNTING BRACKET (NOT ILLUSTRATED) G01 HEX HEAD BOLT, 1/4" - 20 X 7/8" LG G01 RIVET, 3/16" (NOT ILLUSTRATED) *** REAR FACING SEAT BOTTOM (INCLUDES ITEMS 56-60) TAN WHITE/BLUE WHITE/RED RED/BLACK BLACK GRAY BROWN DECK BOARD ASSEMBLY G1 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1" LG SEAT STRAP G7 FLAT WASHER, 1/4" DECK BOARD ASSEMBLY (FOR VEHICLES MANUFACTURED FROM MARCH 2014) SEAT FRAME WELDMENT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) SEAT FRAME WELDMENT FOOTREST WELDMENT ARMREST, REAR SEAT... 2 Page R-7

125 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SEAT FRAME SUPPORT FOOTREST BRACKET (PASSENGER SIDE) FOOTREST BRACKET (DRIVER SIDE) G01 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG G4 HEX HEAD BOLT, 3/8" - 16 X 1 1/2" LG G2 HEX HEAD BOLT, 3/8" - 16 X 3 1/4" LG G9 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1 1/4" LG FLAT WASHER, 3/8" G01 FLAT WASHER, 1/4" G5 LOCK NUT, 3/8" G5 LOCK NUT, 3/8" G4 LOCK NUT, 1/4" G1 SQUARE CAP TUBE, 1" G2 HEX HEAD BOLT, 3/8" - 49 X 1.25" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) HANDRAIL KIT, FLIP FLOP SEAT (INCLUDES ITEMS 81-86) FOOTREST HANDLE WELDMENT G1 SQUARE CAP TUBE, 3/4" DECAL G8 HEX HEAD BOLT, 3/8" - 16 X 2" LG FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" HANDRAIL KIT, FLIP FLOP SEAT (INCLUDES ITEMS 82-86, 88) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) FOOTREST HANDLE WELDMENT G** SEAT BOTTOM (INCLUDES ITEMS 92-96) (SHUTTLE 4 & 6) G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 FLAT WASHER (SS), 1/4"... 8 Page R-8

126 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G7 LOCK WASHER (SS), 1/4" G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG REAR SEAT ARM REST (FOR VEHICLES MANUFACTURED FROM MARCH 2014) FOOTREST WELDMENT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G01 HAND GRIP WELDMENT G02 HEX HEAD BOLT, 1/4" - 20 X 2" LG SEAT BACK SUPPORT WELDMENT G6 TRIM (BLACK) G0XX SEAT POD (see COLOR CODES in HOW TO USE section) G01 ASHTRAY G5 ACORN NUT, 3/8" G4 SPACER, 5/16" G8 HEX HEAD BOLT, 3/8" - 16 X 2" LG G8 HEX HEAD BOLT, 5/16" - 18 X 2" LG G1 FLAT WASHER (SS), 3/8" G01 RUBBER WASHER, 5/8" G9 SPACER, 3/4" G6 LOCK NUT (SS), 5/16" G06 TRUSS HEAD PHILLIPS SCREW (SS), 5/16" - 18 X 3/4" LG G01 FLAT WASHER (SS), 1/4" G6 LOCK NUT (SS), 1/4" G01 VENT PLUG G0XX SEAT POD (see COLOR CODES in HOW TO USE section) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) *** FLIP FLOP SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 56-59, 120) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G G G G G G09 OYSTER TAN GRAY BLACK BROWN WHITE/BLUE Page R-9

127 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G G G G G G15 RED/BLACK WHITE/RED WHITE/BLACK WHITE/YELLOW GRAY/BLACK OYSTER/GARNET 120 *** FLIP FLOP VINYL SEAT BOTTOM COVER GRAY BROWN OYSTER TAN WHITE/BLUE WHITE/RED BLACK WHITE/YELLOW GRAY/BLACK WHITE/BLACK RED/BLACK WHITE/BLACK 121 *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 3-9, 122 & 123) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) WHITE/YELLOW GRAY/BLACK WHITE/BLACK OYSTER/GARNET SEAT BACK SUPPORT *** VINYL SEAT BACK COVER G0704 GRAY/BLACK G0108 WHITE/YELLOW G0304 RED/BLACK G0104 WHITE/BLACK G0506 OYSTER/GARNET *** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 22-36, 126) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) WHITE/YELLOW GRAY/BLACK 126 *** VINYL SEAT BOTTOM COVER G0108 WHITE/YELLOW G0704 GRAY/BLACK G0304 RED/BLACK G0104 WHITE/BLACK G0506 OYSTER/GARNET 127 Page R-10

128 SEATING When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SEAT FRAME SUPPORT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G6 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014)... 2 Page R-11

129 SEATING Notes: Page R-12

130 STARTER GENERATOR 1 STARTER / GENERATOR includes items Page S-1

131 STARTER GENERATOR Page S-2

132 STARTER GENERATOR FOR VEHICLES MANUFACTURED FROM APRIL Page S-3

133 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. STARTER GENERATOR ITEM PART NO DESCRIPTION QTY STARTER / GENERATOR (INCLUDES ITEMS 2-18) HEX NUT LOCKWASHER PULLEY FRONT COVER BEARING RETAINING RING KEY ARMATURE ASSEMBLY FRAME & FIELD ASSEMBLY BRUSH LEAD & TERMINAL SERVICE PKG BRUSH SPRING BRUSH BOX ASSEMBLY BRUSH 1 COVER BRUSH 2 COVER WAVY WASHER BEARING REAR COVER HEX HEAD SHOULDER BOLT, M X HEX NUT, M HEX HEAD BOLT, M X 20MM LG STARTER / GENERATOR BRACKET TENSIONER BRACKET HEX HEAD BOLT, M X 20MM LG HEX HEAD BOLT, M X 25MM LG HEX JAM NUT, M HEX FLANGE NUT, M Page S-4

134 STARTER GENERATOR 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 STARTER / GENERATOR BELT G6 PUSH NUT, 5/16" TENSIONER BOLT BRACKET (GUIDE CABLE) STARTER / GENERATOR SUPPORT BRACKET (FOR VEHICLES MANUFACTURED FROM APRIL 2014) WIRE ASSEMBLY, 6 AWG, 42" LG G01 RUBBER BOOT... 3 Page S-5

135 STARTER GENERATOR Notes: Page S-6

136 WEATHER PROTECTION D Rear of Vehicle Front Of Vehicle 5 (Driver Side Shown) D A C A B C Sun Top 15 Front Strut 21 B 1 2 SUN TOP KIT BLACK includes items 4-6, 7, SUN TOP KIT WHITE includes items 4-6, 8, SUN TOP KIT BEIGE includes items 4-6, 9, SUN TOP HARDWARE KIT includes items SUN TOP KIT WHITE includes items 4, 8, SUN TOP KIT BLACK includes items 4, 7, SUN TOP KIT BEIGE includes items 4, 9, Page T - 1

137 WEATHER PROTECTION WINDSHIELD Front Top Strut 38 Setscrew 37 REAR VIEW MIRROR KIT includes items REAR VIEW MIRROR WINDSHIELD Page T - 2

138 WEATHER PROTECTION When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY SUN TOP KIT, BLACK (INCLUDES ITEMS 4-6, 7, 10-25) SUN TOP KIT, WHITE (INCLUDES ITEMS 4-6, 8, 10-25) SUN TOP KIT, BEIGE (INCLUDES ITEMS 4-6, 9-25) FRONT SUPPORT REAR SUPPORT (DRIVER SIDE) REAR SUPPORT (PASSENGER SIDE) SUN TOP, BLACK SUN TOP, WHITE SUN TOP, BEIGE SUN TOP HARDWARE KIT (INCLUDES ITEMS 11-25) G2 HEX HEAD BOLT, 5/16" - 18 X 2 1/4" LG G8 LOCK WASHER, 5/16" G5 NYLON WASHER, 3/8" G01 SPACER, 1/2" G1 ALUMINIUM SPACER, 3" LG G8 HEX HEAD BOLT (SS), 3/8" - 16 X 5" LG G5 HEX HEAD BOLT, 3/8" - 16 X 1 3/4" LG G6 HEX HEAD BOLT, 3/8" - 16 X 2" LG G5 LOCK NUT, 3/8" G8 FLAT WASHER 5/16", BLACK G1 FLAT WASHER (SS), 5/8" G1 SPACER, 1/4" THICK G3 HEX HEAD BOLT, 3/8" - 16 X 2 1/2" LG G1 LOCK WASHER, 3/8" G1 END CAP, 1" REAR SUPPORT (SHUTTLE 2) CROSS REAR SUPPORT (SHUTTLE 2) SUN TOP KIT, WHITE (INCLUDES ITEMS 4, 8, 10-28) SUN TOP KIT, BLACK (INCLUDES ITEMS 4, 7, 10-28) SUN TOP KIT, BEIGE (INCLUDES ITEMS 4, 9, 10-28)... 1 Page T - 3

139 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. 32 WEATHER PROTECTION WINDSHIELD KIT SASH, 26" WINDSHIELD KIT SASH, 12" G2 REAR VIEW MIRROR KIT (INCLUDES ITEMS 38-40) G1 REAR VIEW MIRROR G2 SUPPORT BRACKET G1 HEX HEAD BOLT (SS), # 8-32 X 5/8" LG... 1 Page T - 4

140 WEATHER PROTECTION Notes: Page T - 5

141 WEATHER PROTECTION Notes: Page T - 6

142 WHEELS AND TIRES 1 TIRE AND HEEL ASSEM LY Includes Items 2 3 TIRE AND HEEL ASSEM LY Includes Items St le ti e m di e m ti e s n RONT REAR Page U-1

143 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. WHEELS AND TIRES ITEM PART NO DESCRIPTION QTY TIRE AND WHEEL ASSEMBLY (INCLUDES ITEMS 2, 3, 4)... AR KENDA TIRE WHEEL RIM G2 VALVE STEM G1 LUG NUT, 1/ AR G01 TIRE AND WHEEL ASSEMBLY (INCLUDES ITEMS 4, 7 AND 8) G06 TRAIL TIRE G01 WHEEL RIM G2 SPINDLE CAP G01 MOLDED DUST CAP G1 6"CHROME E-Z-GO WHEEL COVER HUB CAP SILVER HUB CAP GOLD... 4 Page U-2

144 WHEELS AND TIRES Notes: Page U-3

145

146 E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA s, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc. Technical Communications Department