Electric Powered Vehicle Service Parts Manual

Transcription

1 Electric Powered Vehicle ISSUED NOVEMBER 2011 REVISED APRIL 2014

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3 SERVICE PARTS MANUAL ELECTRIC 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 V ACCELERATOR PEDAL ASSEMBLY A - 1 BATTERY CHARGER B - 1 BODY - HAULER C - 1 BRAKES D - 1 BRAKES - FRONT DISC E - 1 ELECTRICAL SYSTEM F - 1 ELECTRONIC SPEED CONTROL G - 1 FRONT SUSPENSION - STEERING H - 5 MOTOR J - 1 REAR AXLE K - 1 REAR SUSPENSION L - 1 SEATING M - 1 WEATHER PROTECTION N - 1 WHEELS AND TIRES P - 1 Page iii

6 NOTES Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION ILLUSTRATED PARTS BREAKDOWN APPENDIX The first section, GENERAL INFORMATION, contains the following information: WARRANTY INFORMATION GENERAL INDEX HOW TO USE THE SERVICE PARTS MANUAL The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your vehicle. The third section, APPENDIX, contains a listing of specialty products and accessories. USE OF THE MANUAL To use this manual, consult the GENERAL INDEX to locate the information or illustration required. Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your situation and then contact the Service Parts Department. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its location) and note the complete number shown on the plate. Page v

8 Front of Vehicle ,88 81,86 84,89 82, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the General Index and select the most appropriate title. Turn to the page number indicated and locate the desired part on the illustration. From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying description for specific information regarding the part. 2. IF YOU KNOW THE PART NUMBER Locate the part number or description in the appropriate column on the parts list page. NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. Page vi

9 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 vii

10 ACCELERATOR 1 PEDAL BOX ASSEMBLY Includes Items To Direction Selector Harness Page A-1

11 ACCELERATOR ACCELERATOR PEDAL ASSEMBLY Includes Items Page A-2

12 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 G07 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2-37) G01 PEDAL BOX AND COVER (SEAL AND BEARING) G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" G01 PLUNGER SLEEVE G01 PLUNGER G01 PLUNGER CAM G01 ACCELERATOR ROD G4 LOCK NUT, 5/ G4 YOKE (ADJUSTABLE) G2 SPRING RETAINER, 3/8" G01 COMPRESSION SPRING G1 ACCELERATOR ROD BUSHING G1 SPRING RETAINER, 1/2" G02 MICRO SWITCH G01 SCREW, #4-20 X 5/8" LG G06 WIRING HARNESS (PEDAL BOX ASSEMBLY) G6 SCREW, #8-32 X 3/4" LG G02 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-16 X 1/2" LG G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 27-30) G04 ACCELERATOR PEDAL G01 ACCELERATOR PEDAL PAD G1 OVAL RIVET 3/16" X 7/16" LG Page A-3

13 ACCELERATOR When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 BUSHING G01 PEDAL PIVOT PIN G6 PUSHNUT, 9/32" I.D G3 CLEVIS PIN, 5/16" X 13/16" LG G1 TEFLON WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G2 BOLT, 5/16-18 X 13/16" LG G01 PEDAL PIVOT COVER... 1 Page A-4

14 ACCELERATOR Notes: Page A-5

15 ACCELERATOR Notes: Page A-6

16 BATTERY CHARGER DELTA-Q BATTERY CHARGER Includes Item 2-3 DELTA-Q BATTERY CHARGER Includes Item 7, DELTA-Q BATTERY CHARGER Includes Item 10, Page B-1

17 BATTERY CHARGER 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 V DELTA-Q BATTERY CHARGER WITH 10 DC CORD (INCLUDES ITEMS 2-3) G02 48V DC CABLE ASSEMBLY G01 AC POWER CORD (NOT SHOWN) G03 48V DELTA-Q BATTERY CHARGER WITH 10 DC CORD (INCLUDES ITEMS 7, 12-13) G02 48V DC CABLE ASSEMBLY, G04 48V DELTA-Q BATTERY CHARGER WITH 18 DC CORD (INCLUDES ITEMS 10, 12-13) G04 48V DC CABLE ASSEMBLY, G02 48V DELTA-Q BATTERY CHARGER G01 AC CORD (NOT SHOWN)... 1 Page B-2

18 BATTERY CHARGER Notes: Page B-3

19 BATTERY CHARGER Notes: Page B-4

20 F R P N F BODY < 14 25% < 14 25% P P ASHTRAY Page C-1

21 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 INSTRUMENT PANEL ASSEMBLY G2 RATCHET FASTENER, 1/4" X 3/4" LG UPPER FLOORPAN G11 RIVET (ALUMINUM), 3/16" X 9/16" LG OPERATOR INSTRUCTION DECAL GXX COWL G01 RIVET, 3/16" X 1" LG GRILL COVER G01 RIVET, 3/16 X 1" LG FENDER FLARE (DRIVER SIDE) FENDER FLARE (PASSENGER SIDE) G01 SELF-THREADING NUT, 3/16" X 19/ G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG G01 ASHTRAY G01 GASKET G02 BRACKET 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 Page C-2

22 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 G6 HEX HEAD BOLT, 5/16" - 18 X 2 3/4" LG G04 SPACER, 1" G01 SPACER, 1/2" G8 FLAT WASHER, 5/16" G8 LOCK WASHER, 5/16" FRONT FASCIA G02 FRONT SHIELD BRACE G1 FENDER WASHER, 9/32" I.D. X 1 1/4" O.D G01 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G1 RIVET (ALUMINUM), 3/16" X 4/9" LG FASCIA BRACKET G6 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG G4 HEX NUT, 1/4" Page C-3

23 BODY Notes: Page C-4

24 BODY Page C-5

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

26 BODY Page C-7

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 G02 BATTERY TRAY (PASSENGER SIDE) G01 BATTERY TRAY (DRIVER SIDE) G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG G02 FENDER (PASSENGER SIDE) G01 FENDER (DRIVER SIDE) G2 RATCHET FASTENER G17 RIVET, 3/16" X 9/16" LG G01 FENDER (DRIVER SIDE) (SHUTTLE 2) G02 FENDER (PASSENGER SIDE) (SHUTTLE 2) G0XX REAR BODY WITH LNR and WITH LIGHT (See COLOR CODE in HOW TO USE SECTION) G01 J-TYPE NUT RETAINER, 1/4" G01 HINGE PLATE G11 RIVET (SS), 3/16" X 3/4" LG 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" LG G10 RIVET (SS), 5/32" X 9/16" LG G1 RATCHET FASTENER, 1/4" X 3/4" LG G1 PLASTIC DRIVE RIVET, 1/4" X 9/16" LG G02 COVER PLATE G01 RIVET (ALUMINUM), 3/16" X 1" LG G03 HEX HEAD BOLT, 1/4" - 20 X 11/16" LG G02 REAR BUMPER G01 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG G2 FLAT WASHER, 5/16" G01 BUMPER PLUG... 4 Page C-8

28 BODY 124 FOOT REST ASSEMBLY includes items 125 & Page C-9

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 G02 FOOT REST ASSEMBLY (INCLUDES ITEMS 125 & 126) G01 FOOT REST G01 FLOORMAT G1 END CAP G01 REFLECTOR REAR SEAT FACING WARNING LABEL G2 CARRIAGE BOLT, 3/8" - 16 X 1 1/4" LG G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G6 HEX HEAD BOLT, 3/8" - 16 X 1 3/4" LG G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/16" Page C-10

30 BODY Page C-11

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 FLAT 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 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G01 VALANCE PANEL G2 RATCHET FASTENER, 1/4" X 3/4" LG CUSHMAN - LABEL (SHUTTLE 4) CUSHMAN - LABEL (SHUTTLE 6) Page C-12

32 BODY Page C-13

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 G01 HOLD DOWN BRACKET G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/16" 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" DOUBLE SIDED TAPE... 40" G01 LATCH G6 SELF TAPPING SCREW, #10-16 X 3/4" LG G02 FRONT/REAR CARGO RACK G01 SIDE CARGO RACK G01 TAILGATE RETAINER BRACKET G6 TAPPING SCREW, #10-12 X 3/4" LG G1 NYLON BUSHING,.5" G4 HEX HEAD BOLT, 5/16" - 18 X 2 1/2" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" G01 BED LATCH, WARNING LABEL (SHUTTLE 4) G01 LOAD BED, WARNING LABEL (SHUTTLE 4) Page C-14

34 BODY Front of Vehicle Page C-15

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 ROCKER PANEL (DRIVER SIDE) (SHUTTLE 2) ROCKER 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, 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 BOLT, 5/16" - 18 X 3/4" LG G8 FLAT WASHER, 5/16" G6 LOCK NUT, 5/16" Page C-16

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 G01 BED MOUNT BRACKET G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG G7 FLAT WASHER, 1/4" G2 LOCK NUT, 1/4" G01 BULKHEAD 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... 40" 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 TYPE FASTENER, 1/4 X 57/ Page C-17

37 BODY Notes: Page C-18

38 BODY SHUTTLE Page C-19

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 CUSHMAN - LABEL (SHUTTLE 2) SEAT FRAME G01 SIDE PANEL (DRIVER SIDE) G02 SIDE PANEL (PASSENGER SIDE) G11 RIVET (SS), 3/16" X 3/4" LG G01 SEAT HINGE G01 SEAT WRAP PANEL G10 RIVET (SS), 5/32" X 9/16" LG G10 RIVET (SS), 5/32" X 9/16" LG G10 RIVET (SS), 5/32" X 9/16" LG G12 RIVET, 1/4" X 9/16" LG 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 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" Page C-20

40 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 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" G01 TRUSS HEAD TORX SCREW, 3/8" - 16 X 3/4" LG... 2 Page C-21

41 BODY Notes: Page C-22

42 BODY VEHICLES MANUFACTURED FROM MARCH Taillight Page C-23

43 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 (WITH LIGHTS) (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 (FOR VEHICLES MANUFACTURED FROM MARCH 2014)... 1 Page C-24

44 BODY Notes: Page C-25

45 BODY Notes: Page C-26

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

47 BRAKES WHT BLK BRAKE PEADAL ASSEMBLY includes items Brake Pedal (Vehicle With Brake Lights) Page D-2

48 BRAKES BRAKE ASSEMBLY (DRIVER SIDE) includes items BRAKE ASSEMBLY (PASSENGER SIDE) includes itmes 84-89, 93 BRAKE DRUM ASSEMBLY includes items TOP PULL ADJUSTER ASSEMBLY Page D-3

49 BRAKES BOTTOM PULL TENSION PIN ADJUSTER ASSEMBLY BRAKE ASSEMBLY includes items BRAKE ASSEMBLY includes itmes 84-89, 93 BRAKE DRUM ASSEMBLY includes items 101, 102 Page D-4

50 BRAKES 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 PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-10) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" G02 BRAKE PEDAL G01 PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 7/16" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) G01 FLANGED BUSHING G01 TORSION SPRING G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/ G01 SWAGEFORM SCREW, 1/4-20 (NOT ILLUSTRATED) G2 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED) G01 BRAKE COMPENSATOR BUMPER BRAKE CABLE (DRIVER SIDE) BRAKE CABLE (PASSENGER SIDE) G01 RETAINING RING, 13/32" (STAINLESS STEEL) Page D-5

51 BRAKES 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 CLEVIS PIN, 5/16" X 13/16" LG G3 COTTER PIN, 3/32" X 3/4" LG G2 CLEVIS PIN, 5/16" X 5/8" 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, 1/4-20 (STAINLESS STEEL) G02 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) (INCLUDES ITEMS 54-80) G02 BRAKE PEDAL G01 PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PAD... 1 Page D-6

52 BRAKES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 OVAL RIVET, 3/16" x 7/16" LG G03 SERVICE BRAKE PEDAL PLATE G01 PIVOT PIN G01 TORSION SPRING G01 PUSHNUT, 5/16" G8 SCREW, #10-24 X 7/8" LG G1 RUBBER NUT, # G01 BRAKE PEDAL STANDOFF G01 CONICAL SPRING G10 LOCK NUT, # G8 MICRO SWITCH G2 BOLT, # 6-32 X 1 1/4" LG G5 FLAT WASHER, # G3 FLAT WASHER, # G3 LOCK WASHER, # G5 NUT, # G1 SCREW AND LOCK WASHER, # G8 FLAT WASHER # 4-5/ G1 FASTON TAB G1 WIRE HARNESS (BRAKE LIGHT) G1 WIRE TIE BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84-92) BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 84-91, 93) BRAKE SHOE, L BRAKE SHOE, T DUST COVER BRAKE SPRING BRAKE SPRING... 1 Page D-7

53 BRAKES 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 SHOE CLAMP GEAR ADJUSTER GEAR ADJUSTER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 FLAT WASHER, 13/16" G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS ) G1 BRAKE DRUM G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 FLAT WASHER, 1 3/8" O.D. X 21/32" CASTELLETED NUT, 5/ G1 COTTER PIN, 1/8" X 1 1/2" LG G01 SPINDLE CAP BRAKE CABLE BRACKET (PASSENGER SIDE) BRAKE CABLE BRACKET (DRIVER SIDE) COMPENSATOR ASSEMBLY (INCLUDES ITEMS ) G4 HEX NUT HEX NUT, 5/ G01 EQUALIZER BRACKET G1 FLAT WASHER - 5/ Page D-8

54 BRAKES 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 ACCELERATOR ROD BUSHING G2 TUBE G1 COMPRESSION SPRING G01 BRAKE YOKE G9 HEX LOCK NUT, 5/ COMPENSATOR LINK ROD... 1 Page D-9

55 BRAKES Notes: Page D-10

56 BRAKES - FRONT DISC Part of Frame Accelerator Pedal COMPENSATOR ASSEMBLY includes items BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) includes items Page D - 11

57 BRAKES - FRONT DISC 44 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) includes items WHT BLK BRAKE PEDAL (VEHICLE WITH BRAKE LIGHTS) Page D - 12

58 BRAKES - FRONT DISC SPINDLE ASSEMBLY (DRIVER SIDE) includes items SPINDLE ASSEMBLY (PASSENGER SIDE) includes items 81-91, 93, Disc Hub 81 Brake Line Assembly Caliper Page D - 13

59 BRAKES - FRONT DISC 111 Front of Vehicle FRONT DISC BRAKE ACTUATOR ASSEMBLY includes items BRAKE ACTUATOR ASSEMBLY 6 Page D - 14

60 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 NYLON BUSHING G3 COTTER PIN, 3/32" X 3/4" G3 CLEVIS PIN, 5/16" X 1" ACTUATOR COVER G01 SWAGEFORM SCREW WITH DOGPOINT, 1/4" - 20 X 3/4" LG G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG G4 LOCKNUT, 1/4" ACTUATOR LINKAGE G5 FLAT WASHER, 3/8" (NOT ILLUSTRATED) G1 BRAKE FLUID (NOT ILLUSTRATED)... A/R G01 SHOULDER BOLT, 3/8" - 16 X 4" LG G01 ACETAL BUSHING G01 TORSION SPRING G1 FLAT 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" G01 KICK-OFF LINK G1 NYLON BUSHING G1 NYLON WASHER, 3/8"... 2 Page D - 15

61 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 G8 FLAT WASHER, 5/16" 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 1/4" LG 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 45-70) G01 BRAKE PEDAL PARK BRAKE PEDAL G8 FLAT WASHER, 5/16" G01 SERVICE BRAKE PAD G01 PARK BRAKE PAD G1 OVAL RIVET, 3/16" X 15/32" LG G03 BRAKE PEDAL PLATE G01 PIVOT 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... 2 Page D - 16

62 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 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 G02 SPRING PLATE (PASSENGER SIDE) G01 SPRING PLATE (DRIVER SIDE) G01 FOUR LINK ROD FLANGED HEX NUT, M BRAKE LINE G01 SWAGEFORM SCREW WITH DOGPOINT, 1/4" - 20 X 1/2" LG G01 WIRE RETAINER SPINDLE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 79-91) DISC BRAKE SPINDLE (DRIVER SIDE) G02 CALIPER (DRIVER SIDE) G1 SLOTTED NUT, 1" G01 DRIVE FLANGE STUD, 1.5" LG G2 ROLLER BEARING G1 BEARING RACE DISC BRAKE HUB G01 FLANGED BEARING G1 LOCK WASHER, 3/8" G6 HEX HEAD BOLT, 3/8" - 16 X 1" LG G01 BEARING G8 COTTER PIN 5/32" X 1 3/4" G1 GREASE SEAL... 1 Page D - 17

63 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 SPINDLE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 81-91, 93, 94) DISC BRAKE SPINDLE (PASSENGER SIDE) G01 CALIPER (PASSENGER SIDE) G01 KINGPIN TUBE G01 THRUST WASHER (SS), 0.995" I.D. X 1.38" O.D G3 FLAT WASHER, 1/2" G6 LOCKNUT, 1/2" G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG FRONT DISC BRAKE ACTUATOR ASSEMBLY (INCLUDES ITEMS ) MASTER CYLINDER WELDMENT G5 PLASTIC LOCK NUT, 3/8" G1 FLAT WASHER (SS), 3/8" G01 ACTUATOR PIVOT BOLT, 3/8" - 16 X 4 1/2" LG G02 ACETAL BUSHING WELDMENT BRACKET, UPPER BRAKE WELDMENT BRAKCET, LOWER BRAKE MASTER CYLINDER G1 HEX HEAD BOLT, 5/16" - 18 x 1 1/8" LG G6 LOCK NUT, 5/16" G3 CLEVIS PIN, 5/16" X 1" G3 COTTER PIN, 3/32" X 3/4" CRUSH WASHER, M BANJO BOLT, M10-1" X 20" LG COMPENSATOR ASSEMBLY (INCLUDES ) G4 HEX NUT, 1/4" HEX NUT, 5/16" Page D - 18

64 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 EQUALIZER BRACKET G1 FLAT WASHER, 5/16" G1 ACCELERATOR ROD BUSHING G2 TUBE G1 COMPRESSION SPRING G01 BRAKE YOKE G9 HEX LOCK NUT, 5/16" COMPENSATOR LINK ROD G01 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS ) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" G01 BRAKE PEDAL PARK BRAKE PEDAL G01 SERVICE BRAKE PAD G01 PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 15/32" LG G1 TEFLON WASHER, 3/8"... 2 Page D - 19

65 BRAKES - FRONT DISC Notes: Page D - 20

66 ELECTRICAL SYSTEM 23 A2 F CHARGER HARNESS Includes Items 2-11 CHARGER HARNESS RECEPTACLE Includes Items A1 F Page F-1

67 ELECTRICAL SYSTEM RED GRN/BLK OFF ON Page F-2

68 ELECTRICAL SYSTEM BLU/WHT ORN/WHT RED GRN 51 FLOOR MOUNTED HORN BUTTON Floorboard HORN 64 Front of Vehicle YEL BLK Page F-3

69 ELECTRICAL SYSTEM HEAD LIGHT & TURN SIGNAL TAILLIGHT Rear Fender 79 TURN SIGNAL KIT Includes items Page F-4

70 ELECTRICAL SYSTEM HOUR METER 94 Hour Meter Passenger Side Seat Support 93 Front of Vehicle HOUR METER Includes Items Electrical Components Cover Seat Support (+) (-) Solenoid Note: Hold lower nut when tightening top nut. DC TO DC CONVERTER KIT For Models after 02 October 2013 For Models before 02 October DC TO DC CONVERTOR KIT Includes Items 35-40, 100 & 101 Page F-5

71 ELECTRICAL SYSTEM TAILLIGHT Rear Fender 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 F-6

72 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 G03 CHARGER HARNESS / RECEPTACLE (INCLUDES ITEMS 2-11) CHARGER HARNESS G30 CHARGER HARNESS RECEPTACLE (INCLUDES ITEMS 4-11) G22 RECEPTACLE BOTTOM G21 RECEPTACLE COVER G08 BINDING HEAD BRASS SCREW, #10-32 X 1/2" LG G09 PHILLIPS HEAD SCREW, #6-32 X 1 3/4" LG G10 LOCK NUT, # G25 RED JUMPER WIRE, 18 GA G23 FEMALE CONTACT G24 FEMALE CONTACT, INSULATED G01 RIVET, 3/16" X 1" LG G01 POWER HARNESS G01 LOCK WASHER, 5/16" G01 HEX NUT, 5/16" G0* CLAMP G11 RIVET (SS), 3/16" X 3/4" LG XXXXXG** 6 VOLT BATTERY BATTERY RETAINER G01 HOLD DOWN BOLT G1 LOCK NUT, 5/16" G01 HOLD DOWN BOLT G01 BATTERY RETAINER G18 4 GA WIRE (BLK 6") G16 4 GA WIRE (BLK 19")... 1 Page F-7

73 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 G13 4 GA WIRE (BLK 10 1/2") G2 HEX NUT, 5/16" DC TO DC CONVERTER KIT (INCLUDES ITEMS 35-40, 100 & 101) DC TO DC CONVERTER (FOR MODELS AFTER 02 OCTOBER 2013) BRACKET DC TO DC WIRING HARNESS PHILIPS PAN HEAD SCREW, #10-24 X 1/2" LG (FOR MODELS AFTER 02 OCTOBER 2013) G5 CHRISTMAS TREE RIVET,.187" X 0.55" LG G2 HEX HEAD BOLT, 5/16" - 18 X.80" LG (NOT ILLUSTRATED) G1 IGNITION SWITCH G6 LOCK WASHER, 3/4" G1 FACE NUT G1 IGNITION SWITCH (WITHOUT LIGHTS, NON-STANDARD KEY) G1 IGNITION SWITCH (WITHOUT LIGHTS, INDIVIDUALLY KEYED) G01 IGNITION SWITCH (WITH LIGHTS, STANDARD KEY) G02 IGNITION SWITCH (WITH LIGHTS, NON-STANDARD KEY) G03 IGNITION SWITCH (WITH LIGHTS, INDIVIDUALLY KEYED) G1 FUSE BLOCK G01 RIVET, 5/32" X 3/8" LG G1 FUSE, 15 AMP WIRE HARNESS (ACCESSORY) G06 CONSOLE INSERT PLATE G01 LABEL, DIRECTION SELECTOR AND STATE OF CHARGE METER G01 LABEL, LIGHTS, DIRECTION SELECTOR & STATE OF CHARGE METER G01 DIRECTION SELECTOR SWITCH G05 STATE OF CHARGE METER (VERTICAL) G02 RIVET, 3/16" X 3/8" LG SOC FUSE HARNESS G01 HARNESS (CONTROL) G74 18 GA WIRE (RED 6")... 1 Page F-8

74 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 G02 BUZZER G01 RIVET, 5/32" X 3/4" LG G1 HORN HEADLIGHT W/O TURN SIGNAL (PASSENGER SIDE) HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) LED HEADLIGHT W/O TURN SIGNAL (PASSENGER SIDE) LED HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) G01 SELF THREADING NUT, 5 X 10X 15MM G02 VINYL TAPE WIRE HARNESS (ACCESSORY), 48V DC, SWB JUMPER PLUG, TAIL LIGHT G2 TAIL LIGHT TURN SIGNAL KIT (INCLUDES ITEMS 80-85) TURN SIGNAL BULB TURN SIGNAL SWITCH ASSEMBLY G3 FLEX LOOM, 3/8" X 8" LG G1 WIRE TIE G3 STEERING COLUMN COVER G01 FLASHER UNIT G1 HORN SWITCH G2 HORN SWITCH CAP AND NUT G01 HORN SWITCH BOOT HORN SWITCH LABEL G01 RIVET, 5/32" X 3/4" LG Page F-9

75 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 G06 HOUR METER KIT (INCLUDES ITEMS 94-98) G02 HOUR METER G01 HOUR METER BRACKET G01 RETAINER CLIP G11 RIVET, 3/16" X G04 WIRE HARNESS (HOUR METER) DC TO DC CONVERTER (FOR MODELS BEFORE 02 OCTOBER 2013) G4 PHILLIPS PAN HEAD SCREW, #10-24 X 1/2" LG (FOR MODELS BEFORE 02 OCTOBER 2013) G1 TAIL LIGHT ASSEMBLY COMPLETE 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 F-10

76 ELECTRICAL SYSTEM Notes: Page F-11

77 ELECTRICAL SYSTEM Notes: Page F-12

78 RUN l P/N G01 ELECTRONIC SPEED CONTROL 1 ELECTRONIC SPEED CONTROL ASSEMBLY Includes Items 2-16, Walkaway Fuse Walkaway Relay 34 #10 Black From Motor F2 (Power Harness) PURPLE From Walkaway Fuse To Solenoid (+) #4 Black From Motor A1 (Power Harness) #4 Black From Motor A2 (Power Harness) 2 4 J3 F2 J2 J1 F1 B+ M- B- 37 #18 Yellow From J1 Pin 5 (Control Harness) #18 Blue From J1 Pin 17 (Control Harness) #18 Red From Tow Switch and Reverse Buzzer (Control Harness) #10 White From Charger Receptacle Speed Sensor Harness 25 Charger Receptacle Harness Red FromWalkaway Relay To Solenoid (-) #4 Black From Charger (Charger Harness) #18 Red/White From Tow Switch (Control Harness) To Ignition Interlock (Charger Receptacle) #4 Black From Motor A1 (Power Harness) 26 #4 Black From Battery (-) (Power Harness Power Harness 29 Code Fault Code Symptoms Corrective Action 1-1 HW FAILSAFE Vehicle will not run Check motor wiring, replace controller 1-2 THROTTLE FAULT 1 Vehicle will not run Check pedal box adjustment, connections, replace ITS 1-3 SPEED SENSOR FAULT Vehicle runs slowly Check speed sensor connection, and wiring, replace sensor if required 1-4 HPD Vehicle will not run Release and reapply pedal. Check pedal box, linkage, switch and key switch 1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage 2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries WARNING Always select 'TOW / MAINTENANCE' position before towing. TOWING MAINTENANCE TOW MAINTENANCE Possibility of electrical arc and battery explosion. Before removing/connecting batteries or electrical components turn switch to 'TOW/MAINTENANCE' position. To disable electrical system place switch in 'TOW/MAINTENANCE' position and remove battery wire. After reconnecting batteries, allow a minimum of 30 seconds before selecting 'RUN' position 73340G OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC 2-3 THERMAL CUTBACK Vehicle performance reduced Allow controller to cool 2-4 MAIN DRIVER ON Vehicle runs slowly Solenoid driver defective, replace controller 2-5 VDD FAULT Vehicle will not run Replace controller 3-1 MAIN DRIVER OFF Solenoid does not close Replace controller 3-2 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid 3-3 PRECHARGE FAULT Vehicle will not run Check for additional electronics attached to B+, replace controller 3-4 FIELD MISSING Solenoid closes, vehicle will Check wiring. not run Replace power harness and motor if required. 3-5 FIELD OVERCURRENT Vehicle will not run Field windings or power harness shorted. Verify, replace motor if necessary. 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller 4-4 AUX CONT DNC Vehicle will not run Replace controller 4-5 WELDED AUX CONT Vehicle runs slowly Replace controller 5-1 EEPROM FAILSAFE Vehicle will not run Replace controller 5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring. Replace solenoid if necessary 5-3 MAIN CONT DNC Vehicle will not run Check all solenoid wiring. Replace solenoid if necessary 5-5 MISSING CONTACTOR Vehicle stops Check all solenoid wiring. Replace solenoid if necessary Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close), HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor), M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault) DIAGNOSTIC FAULT CODES The LED will flash a diagnostic fault code when a fault is detected Some faults may only be detected by operating the vehicle with the rear of the vehicle raised and supported on safety stands Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery compartment) to the 'TOW/MAINTENANCE' position before performing any repairs or maintenance to the vehicle Select 'RUN' before returning the vehicle to service Page G-1

79 ELECTRONIC SPEED CONTROL 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 G04 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-16, 31-37) G01 CONTROLLER MOUNT ELECTRONIC SPEED CONTROLLER G01 48 VOLT SOLENOID (INCLUDES ITEMS 7-10) * LOCK WASHER, # * NUT, # * LOCK WASHER, 5/16" * JAM NUT, 5/ G01 FASTON TAB G2 LOCK NUT, 1/ G17 4 GA WIRE (BLK 9") G01 DOUBLE TUBE CLAMP G2 LOCK NUT, 1/ G01 CONTROLLER COVER G01 BOLT, 8MM X 16MM LG G01 LOCK WASHER, 5/16" G01 BOLT, 6MM X 1 X 12MM LG G02 LOCK WASHER, 1/4" G01 CONTROL HARNESS G06 4 GA WIRE (BLK 59 1/2") (SOL - BATTERY +) G01 TOW-MAINTENANCE SWITCH (SHUTTLE 4/6) G03 TOW-MAINTENANCE SWITCH (SHUTTLE 2) G01 RIVET, 5/32" X 3/4" LG G01 DIAGNOSTIC LABEL (FAULT CODE)... 1 Page G-2

80 ELECTRONIC SPEED CONTROL 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 ELECTRONIC SPEED CONTROLLER SVC KIT (Includes 4, 32-37) G1 NYLON WIRE TIE WALKAWAY RELAY HARNESS ASSEMBLY (includes 34) RELAY G5 RIVET, 0.18 X G2 RIVET, 0.25 X G01 FUSE COVER... 1 Page G-3

81 ELECTRONIC SPEED CONTROL Notes: Page G-4

82 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 H-1

83 FRONT SUSPENSION / STEERING 86 Front of Vehicle RACK AND PINION UNIT 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 H-2

84 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 H-3

85 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 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) 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 SPACER (SHORT), 0.69" LG G7 HEX NUT, 7/16" G2 FLAT WASHER, 7/16" G1 LOCK NUT, 7/16" Page H-4

86 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 H-5

87 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 H-6

88 FRONT SUSPENSION / STEERING Notes: Page H-7

89 FRONT SUSPENSION / STEERING Notes: Page H-8

90 MOTOR 1 MOTOR Includes Items Page J-1

91 MOTOR 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 G04 MOTOR (SEPARATELY EXCITED) (INCLUDES ITEMS 2-12) G36 ARMATURE G38 BRUSH SPRING G39 BRUSH G40 BRUSH BOX G41 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G43 HEADBAND G37 FRAME AND FIELD COIL (INCLUDES HARDWARE) G42 COVER COMMUTATOR END G01 RETAINING RING G02 SCREW, #10-32 X 1/2" LG G01 MAGNET G02 SPEED SENSOR... 1 Page J-2

92 MOTOR Notes: Page J-3

93 MOTOR Notes: Page J-4

94 REAR AXLE 1 REAR AXLE ASSEMBLY Includes Items 2-7 NOTE: Apply a light coat of moly grease to male spline before assembly. Reference part number Page K-1

95 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 G01 REAR AXLE ASSEMBLY 14.76:1 (INCLUDES ITEMS 2-7) AXLE SHAFT (PASSENGER SIDE) AXLE SHAFT (DRIVER SIDE) * DIFFERENTIAL COVER FILL PLUG WITH 'O' RING G1 BOLT, 5/16-18 X 3/4" LG G01 VENT G02 SCUFF GUARD G1 SPLINE BUMPER G2 BOLT, 1/4-20 X 1 1/4" LG G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G01 WASHER, 1/4" (STAINLESS STEEL) G1 ANTI-SIEZE.... AR Page K-2

96 REAR AXLE Notes: Page K-3

97 REAR AXLE Notes: Page K-4

98 REAR SUSPENSION Page L-1

99 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. REAR SUSPENSION ITEM PART NO DESCRIPTION QTY G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING G6 HEX NUT, 3/8" G03 LEAF SPRING (HEAVY DUTY) G01 U BOLT, 3/8" - 16 X 2" X 2 1/2" LG G1 FLAT WASHER, 3/8" G5 LOCK NUT, 3/8" G02 SPLIT STEEL SPACER FLANGED BUSHING G02 SHACKLE PLATE G9 HEX HEAD BOLT, 3/8" - 16 X 3 1/2" LG (STAINLESS STEEL) G5 LOCK NUT, 3/8" G1 SHOULDER BOLT, 3/8" - 16 X 3 1/4" LG G1 LOCK NUT, 3/8" G01 VINYL CAP... 2 Page L-2

100 REAR SUSPENSION Notes: Page L-3

101 REAR SUSPENSION Notes: Page L-4

102 SEATING 17 1 SEAT BACK ASSEMBLY includes items 3-6, 8 & SEAT BACK ASSEMBLY includes items 3-6, 8, 118 & FLIP FLOP SEAT BOTTOM ASSEMBLY includes items 57-60, Front of Vehicle SEAT BOTTOM ASSEMBLY includes items SEAT BOTTOM ASSEMBLY includes items 22-27, 32, , 112, 121 Front of Vehicle Front of Vehicle Page M-1

103 SEATING HANDRAIL KIT, FLIP FLOP SEAT includes items HANDRAIL KIT, FLIP FLOP SEAT includes items & MAX 250 lbs. 110 kg MAX 4 in. 10 cm MAX 14 o / 25% Top of Vehicle Page M-2

104 SEATING SHUTTLE 4 and 6 91 SEAT BOTTOM ASSEMBLY includes items Floormat Page M-3

105 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 3-6, 8 & 9) G01 WHITE 71751G02 GRAY 71751G03 OYSTER 71751G04 TAN 71751G06 BROWN 71751G07 BLACK RED/BLACK WHITE/BLUE WHITE/RED 3 * FLAT STAPLE G01 PLASTIC SEAT BACK COVER G01 SEAT BACK (WOOD) G01 PAN HEAD TORX SCREW, #8 X 5/8" LG PAN HEAD TORX SCREW, #8 X.88" LG G01 FOAM PADDING (SEAT BACK) *** VINYL SEAT BACK COVER G01 WHITE 71753G02 GRAY 71753G03 OYSTER 71753G04 TAN 71513G06 BROWN 71513G07 BLACK G0304 RED/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"... 4 Page M-4

106 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 BACK SUPPORT G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG *** 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 22-33) G01 WHITE 71611G03 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 G01 WHITE 71602G02 GREY 71602G03 OYSTER Page M-5

107 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 G04 TAN 71602G05 SPECIAL 71602G06 BLACK 71602G07 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 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG G01 SEAT HINGE G08 FLAT HEAD PHILLIPS SCREW, #12-14 X 1" LG G01 HAND GRIP WELDMENT G02 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 2" LG SEAT BACK SUPPORT WELDMENT G6 TRIM (BLACK) G0** SEAT POD 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... 4 Page M-6

108 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 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG G01 VINYL TRIM FRONT *** FLIP FLOP SEAT BOTTOM GRAY TAN BROWN WHITE/RED WHITE/BLUE RED/BLACK BLACK 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 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" Page M-7

109 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 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 & 88) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) FOOTREST HANDLE WELDMENT G** SEAT BACK ASSEMBLY 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" G7 LOCK WASHER (SS), 1/4" G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG Page M-8

110 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 G5 ACORN NUT, 3/8" G4 SPACER, 5/16" 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) HEX HEAD BOLT, M X 24MM LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) REAR SEAT ARM REST (FOR VEHICLES MANUFACTURED FROM MARCH 2014) FOOTREST WELDMENT (FOR VEHICLES MANUFACTURED FROM MARCH 2014) *** FLIP FLOP SEAT BOTTOM ASSEMBLY (FOR VEHILCES MANUFACTURED FROM MARCH 2014) (INCLUDES ITEMS 57-60, 116) G01 OYSTER G03 TAN G04 GRAY G06 BLACK G07 BROWN G09 WHITE/BLUE G10 RED/BLACK G11 WHITE/RED G12 WHITE/BLACK G13 WHITE/YELLOW G14 GRAY/BLACK G15 OYSTER/GARNET 116 *** FLIP FLOP VINYL SEAT BOTTOM COVER GRAY BROWN OYSTER TAN WHITE/BLUE WHITE/RED BLACK WHITE/YELLOW GRAY/BLACK WHITE/BLACK Page M-9

111 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 RED/BLACK OYSTER/RUBY 117 *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 3-6, 8, 118 &119) (FOR VEHICELS 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 120 *** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 22-27, 32, , 112, 121) (FOR VEHICLES MANUFACTURED FROM MARCH 2014) WHITE/YELLOW GRAY/BLACK 121 *** VINYL SEAT BOTTOM COVER G0108 WHITE/YELLOW G0704 GRAY/BLACK G0304 RED/BLACK G0104 WHITE/BLACK G0506 OYSTER/GARNET 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) G2 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G8 HEX HEAD BOLT, 3/8" - 16 X 2 1/4" LG (FOR VEHICLES MANUFACTURED FROM MARCH 2014) G7 FLAT WASHER, 1/4" (FOR VEHICLES MANUFACTURED FROM MARCH 2014)... 4 Page M-10

112 SEATING Notes: Page M-11

113 SEATING Notes: Page M-12

114 WEATHER PROTECTION D Rear of Vehicle Front Of Vehicle 5 (Driver Side Shown) D A C A B C Sun Top 15 Front of Vehicle Front Strut 21 B 14 1 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 N-1

115 WEATHER PROTECTION WINDSHIELD Front Top Strut Setscrew 37 REAR VIEW MIRROR KIT includes items REAR VIEW MIRROR WINDSHIELD Page N-2

116 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 (SS), 3/8" - 16 X 1 3/4" LG G6 HEX HEAD BOLT (SS), 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 N-3

117 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 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 N-4

118 WEATHER PROTECTION Notes: Page N-5

119 WEATHER PROTECTION Notes: Page N-6

120 WHEELS AND TIRES 1 7 TIRE AND WHEEL ASSEMBLY Includes Items 2-4 TIRE AND WHEEL ASSEMBLY Includes Items (Style of tire may differ from tire shown) Page P-1

121 WHEELS AND TIRES When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 TIRE AND WHEEL ASSEMBLY (INCLUDES ITEMS 2, 3, 4) G01 TIRE, 18 X LINKS G01 WHEEL RIM G2 VALVE STEM G1 LUG NUT, 1/ TIRE AND WHEEL ASSEMBLY (INCLUDES ITEMS 2, 3, 4) TIRE, 18 X LINKS WHEEL RIM G2 VALVE STEM HUB CAP SILVER HUB CAP GOLD... 4 Page P-2

122 WHEELS AND TIRES Notes: Page P-3

123

124 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