SERVICE PARTS MANUAL

Transcription

1 INCLUDES ITEMS SERVICE PARTS MANUAL Ref Fcv 17 ELECTRIC POWERED COASTAL FLEET GOLF CARS ISSUED APRIL 2006 REVISED DECEMBER 2007

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3 SERVICE PARTS MANUAL ELECTRIC POWERED COASTAL FLEET GOLF CARS COASTAL FLEET SERIES GOLF CAR COASTAL FLEET PDS GOLF CAR STARTING MODEL YEAR DISCLAIMER: The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice. The E-Z-GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON- SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: FAX: OUTSIDE USA PHONE: , FAX: TEXTRON GOLF, TURF & SPECIALTY PRODUCTS, P.O.BOX 388, 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 manufacture date code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Page ii

5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL v ILLUSTRATED PARTS BREAKDOWN vii ACCELERATOR A-1 BATTERY CHARGER - PORTABLE 36 VOLT B-1 BODY - FRONT C-1 BODY - MID SECTION C-5 BODY - REAR C-7 BODY - ACCESSORIES C-11 BODY - ACCESSORIES CONTINUED C-13 BODY - ACCESSORIES CONTINUED C-15 BRAKES D-1 DIRECTION SELECTOR E-1 ELECTRICAL SYSTEM - COMMON F-1 ELECTRICAL SYSTEM - PDS F-5 ELECTRICAL SYSTEM - SERIES F-7 ELECTRONIC SPEED CONTROL - SERIES G-1 ELECTRONIC SPEED CONTROL - PDS G-3 ELECTRIC MOTOR H-1 FRONT SUSPENSION/STEERING J-1 REAR AXLE K-1 REAR SUSPENSION L-1 SEATING AND BAG HOLDER - GOLF CAR M-1 TOW BAR - PERMANENT N-1 TOW BAR - CASUAL N-5 WEATHER PROTECTION - GOLF CAR P-1 WHEELS AND TIRES Q-1 SPECIALTY PRODUCTS APPENDIX A-1 OPTIONS/ACCESSORIES APPENDIX B-1 Page iii

6 TABLE OF CONTENTS Notes: Page iv

7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle APPENDIX Contains a listing of specialty products and options/accessories USE OF THE MANUAL To use this manual, consult the TABLE OF CONTENTS (page iii) to locate the information or illustration required. Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your situation. Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its location) and note the complete number shown on the plate. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components. 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 ,87 67 Front of Vehicle 83,88 81,86 84, , *See Body Section for decal information 79 HOW TO USE THE SERVICE PARTS MANUAL Title Title 62 - Includes Items 63-66, Includes Items Includes Items Includes Items Includes Items 95, Includes Items Includes Items Includes Items Left hand illustration page (continued on right hand page if required) Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required. Turn to the INDEX OF MAJOR COMPONENTS and select the most appropriate component description. Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying description for specific information regarding the part that was not shown in the index. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. 2. IF YOU KNOW THE PART NUMBER Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on. Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying description for specific information regarding the part. From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page. Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is found. The part number is the lowest assembly sold by Service Parts. The asterisk (*) indicates that the part depicted is not available for purchase. NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the assembly that it is used on. This process is repeated until the highest final assembly is reached. To facilitate the maintenance and repair of the vehicle, a Technician s Repair and Service Manual is available from the Service Parts Department. Page vi

9 ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN Page vii

10 ACCELERATOR 1 - Includes Items 3-19, 21, 23, Includes Items 3-17, 20, 21, Includes Items Includes Items 34, A A To Harness from Direction Selector Ref Acl 1-1 Page A-1

11 ACCELERATOR To Harness from Direction Selector Ref Acl 1-2 Page A-2

12 ACCELERATOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G09 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3-19, 21, 23, 26-43) G10 PEDAL BOX ASSEMBLY, PDS MODEL ONLY (INCLUDES ITEMS 3-17, 20, 21, 24-43) G01 PEDAL BOX AND COVER (SEAL AND BEARING) G01 INDUCTIVE THROTTLE SENSOR G01 SELF THREADING NUT, 3/16" PLUNGER G01 ACCELERATOR ROD G4 NUT, 5/ G4 CLEVIS YOKE (ADJUSTABLE) G2 SPRING RETAINER, 3/8" G01 COMPRESSION SPRING G1 ACCELERATOR ROD BUSHING G1 SPRING RETAINER, 1/2" G01 MICRO SWITCH G02 MICRO SWITCH (PDS MODEL ONLY) G01 SCREW, #4-14 X 5/8" LG G03 WIRING HARNESS (PEDAL BOX ASSEMBLY) G05 WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY) G6 SCREW, #8-32 X 3/4" LG (STAINLESS STEEL) G02 ACCELERATOR PEDAL BRACKET G01 SCREW, #8-16 X 1/2" LG... 4 Page A-3

13 ACCELERATOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 32-35) * ACCELERATOR PEDAL G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 34, 35) G01 ACCELERATOR PEDAL PAD G1 OVAL RIVET 3/16" X 7/16" LG G1 NYLON 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 4/5" LG G01 PEDAL PIVOT COVER... 1 Page A-4

14 BATTERY CHARGER - PORTABLE 36 VOLT POWERWISE Transformer 8 Wire B Includes Items Includes Items 3-13, 18-63, POWERWISE Ref Bcp 1-1 Page B-1

15 BATTERY CHARGER - PORTABLE 36 VOLT C WHT from Transformer 25 To Amp Fuse To Transformer To grounding To Black/ Control Board A D To Power Input Board 33, 66 E 29 Ref Bcp 1-2 Page B-2

16 BATTERY CHARGER - PORTABLE 36 VOLT POWERWISE POWERWISE + A RED to Heat Sink BLACK from DC Plug BLK from Transformer BLK from AC Cord WHT from AC Cord BLK from Transformer 58 A BRN from Control Board ORN from Control Board BLK from Transformer BLK from Transformer BLK from AC Cord WHT from AC Cord WHTXF BRN ORN YEL GRN GRN to Ground CONTROL / POWER INPUT BOARD INSTALLATION WHT XF GRN GRN to 72 Ground POWER INPUT BOARD INSTALLATION B Chassis AMMETER INSTALLATION WHT from DC Cord DC AMPERES Heat Sink C TRANSFORMER DETAIL To Capacitor 56 To Diodes To Norm. Open on Power Input Board To XF on Power Input Board To DC Cord GRN to Power Input Board GRN to AC Cord D AC Cord Port 41 E DC CABLE ASSEMBLY Ref Bcp GROUNDING DETAIL Front of Charger Includes Items Includes Items 34-42, Page B-3

17 BATTERY CHARGER - PORTABLE 36 VOLT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 POWERWISE CHARGER (10' CORD) (INCLUDES ITEMS 3-63) G02 POWERWISE + CHARGER (PORTABLE, 10' CORD) (INCLUDES ITEMS 3-13, 18-63, 70-76) * CHASSIS G6 SCREW, #8-18 X 1 3/4" LG G4 WASHER, # G3 EXPANSION NUT G01 HEAT SINK G4 SCREW, #8-32 X 1/2" LG G4 WASHER, # G4 LOCK WASHER, # G1 NUT, # G01 DIODE G01 ELECTRICAL CLIP * LABEL (POWERWISE ) G01 CONTROL / POWER INPUT BOARD * COVER G01 HANDLE G4 SCREW, #8-18 X 1/2" LG G01 LABEL (VENTILATION) G02 LABEL (CORD CONDITION) G01 CAPACITOR BRACKET G01 CAPACITOR G01 SCREW, #8-32 X 3/8" LG G5 BOLT, 1/4-20 X 5/8" LG G2 LOCK NUT, 1/ G4 AC CORD... 1 Page B-4

18 BATTERY CHARGER - PORTABLE 36 VOLT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 STRAIN RELIEF (AC) G3 STRAIN RELIEF (DC) G01 DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34-43) G11 PLUG (TOP HALF) G12 PLUG (BOTTOM HALF) G27 AUXILARY CONTACT G14 MALE PIN G08 SCREW, #10-32 X 1/2" LG (BRASS) G15 MAGNET G16 SCREW, #6-32 X 1/2" LG (STAINLESS STEEL) G10 LOCK NUT, # G17 SCREW, #6-32 X 1" LG (STAINLESS STEEL) G01 DC CORD, 10' LG G01 AMMETER G01 SCREW, #8-16 X 1/2" LG G4 WASHER, # G01 WASHER, #10 (BRASS) G2 SHOULDER WASHER, # G6 NYLON WASHER, 3/8" G4 NUT, #10-32 (BRASS) G01 50 AMP FUSE G5 LOCK WASHER, # G4 SCREW, #10-24 X 1/2" LG G3 NUT, # G01 TRANSFORMER G01 SPACER SUPPORT G1 WIRE TIE Page B-5

19 BATTERY CHARGER - PORTABLE 36 VOLT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G3 SCREW, #8-32 X 3/8" LG G32 16 GA WIRE (GREEN 4") G4 LOCK WASHER, # G1 NUT, # G07 POWERWISE CHARGER (PORTABLE, 18' CORD) (INCLUDES ITEMS 3-31, 45-63, 66, 67) G03 DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34-42, 67) G03 DC CORD, 18' LG G08 POWERWISE + CHARGER (PORTABLE, 18' CORD) (INCLUDES ITEMS 3-13, 18-31, 45-63, 66, 67, 70-76) * LABEL (POWERWISE +) G02 CONTROL BOARD G03 POWER INPUT BOARD G01 SCREW, #6-19 X 5/16" LG G3 WASHER, # G01 SUPPORT SPACER... 3 Page B-6

20 BODY - FRONT Includes Items Ref Bod 17-1 Page C-1

21 BODY - FRONT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 2-5) G01 BALL DEFLECTOR (PASSENGER SIDE) G01 BALL DEFLECTOR (DRIVER SIDE) G5 SCREW, #8-18 X 5/8" LG G01 INSTRUMENT PANEL INSERT (4 CUP HOLDER) G01 VINYL TRIM G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 SPLASH PANEL G2 RIVET, 1/4" X 3/4" LG G01 LABEL (SAFETY) G01 LABEL (ANTI-ROLLBACK) G01 BOLT, 1/4-20 X 11/16" LG G1 WASHER, 1/4" G01 RIVET, 1/4" X 1" LG G04 FRONT SHIELD G02 FRONT SHIELD BRACE G** COWL G01 RIVET, 3/16" X 1" LG (ALUMINUM)... 9 Page C-2

22 BODY - FRONT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G6 BOLT, 5/16-18 X 3/4" LG (WITH TOP) G2 WASHER, 5/16" (STAINLESS STEEL) (WITH TOP) G02 VINYL TAPE G02 E-Z-GO NAMEPLATE (GOLD) G01 PUSHNUT, 3/16"... 2 Page C-3

23 BODY - FRONT Page C-4

24 BODY - MID SECTION Ref Bod 1-2 Page C-5

25 BODY - MID SECTION Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 UPPER FLOORPAN G01 LOWER FLOORPAN G01 ACCESS COVER G11 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 FLOORMAT G01 SEAT FRAME G2 BOLT, 5/16-18 X 13/16" LG G02 BATTERY RACK G2 BOLT, 5/16-18 X 13/16" LG G6 BOLT, 5/16-18 X 3/4" LG G8 WASHER, 5/16" G6 LOCK NUT, 5/16-18 (STAINLESS STEEL) G01 SCREW, 3/8-16 X 3/4" LG G02 BRACKET G01 BOLT, 1/4-20 X 5/8" LG G01 WASHER, 1/4" (STAINLESS STEEL) G2 LOCK NUT, 1/ G03 SPLASH PANEL G2 BOLT, 5/16-18 X 13/16" LG G01 FENDER LINER (PASSENGER SIDE) G02 FENDER LINER (DRIVER SIDE) G2 RIVET, 1/4" X 3/4" LG... 8 Page C-6

26 BODY - REAR 1 - Includes Items 3, LABELS Ref Bod 17-3 Page C-7

27 BODY - REAR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G0** REAR BODY (WITHOUT TAILLIGHTS) (INCLUDES ITEMS 3, 4) G01 BAGWELL LINER G1 RATCHET FASTENER, 1/4" X 9/16" LG G10 RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) G12 RIVET, 1/4" X 9/16" LG (ALUMINUM) G1 RIVET, 1/4" X 3/4" LG G01 FENDER SCUFFGUARD (DRIVER SIDE) G02 FENDER SCUFFGUARD (PASSENGER SIDE) G2 RIVET, 1/4" X 3/4" LG G01 ACCESS PANEL G02 'J' CLIP G01 SCREW, #8 X 5/8" LG (STAINLESS STEEL) G01 SEAT HINGE PLATE G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G01 REAR BUMPER G2 WASHER, 5/16" G01 BOLT, 1/4-20 X 3/4" LG... 4 Page C-8

28 BODY - REAR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 BUMPER PLUG G17 RIVET, 3/16" X 9/16" LG (ALUMINUM) G01 ROCKER PANEL (PASSENGER SIDE) G01 ROCKER PANEL (DRIVER SIDE) G6 RIVET, 3/16" X 15/16" LG (ALUMINUM) G01 SILL PLATE (PASSENGER SIDE) G02 SILL PLATE (DRIVER SIDE) G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G4 SPACER, 5/16" G04 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 LABEL (PRECISION DRIVE SYSTEM )... AR * LABEL (SERIAL NUMBER) G01 LABEL (E-SHIELD) G01 HOLE PLUG (DASH MOUNTED DIRECTION SELECTOR SWITCH ONLY)... 1 Page C-9

29 BODY - REAR Page C-10

30 BODY - ACCESSORIES 4 Reinforcing Plate (Part of holder) Includes Items SAND BOTTLE DIVOT REPAIR KIT 7 BASKET DIVOT REPAIR KIT A SIDE BASKET KIT 10 - Includes Items Includes Items A CENTER BASKET KIT Ref Bod 2-5 Page C-11

31 BODY - ACCESSORIES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SAND BOTTLE DIVOT REPAIR KIT (INCLUDES ITEMS 2-4) G01 BOLT, 1/4-20 X 3/4" LG G01 SAND BOTTLE HOLDER G01 SAND BOTTLE G01 BASKET DIVOT REPAIR KIT (INCLUDES SCOOP) G02 SIDE BASKET KIT (INCLUDES ITEMS 11-13) G01 SIDE BASKET G01 BOLT, 1/4-20 X 3/4" LG G2 FLAT WASHER, 1/4" (STAINLESS STEEL) G02 CENTER BASKET KIT (INCLUDES ITEMS 17-20) G01 CENTER BASKET G01 BOLT, 1/4-20 X 3/4" LG G2 FLAT WASHER, 1/4" (STAINLESS STEEL) G01 SCREW, #10 X 5/8" LG (STAINLESS STEEL)... 2 Page C-12

32 BODY - ACCESSORIES CONTINUED Front of Vehicle ASH TRA Y MESSAGE HOLDER 1 OR COOLER JUG AND BRACKET 5 10 BOX COOLER AND BRACKET RAKE HOLDER AND RAKE 9 6 Ref Bod 2-6 Page C-13

33 BODY - ACCESSORIES CONTINUED Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 MESSAGE HOLDER (ONE PIECE) G01 MESSAGE HOLDER G01 COOLER JUG AND BRACKET KIT G01 BOX COOLER AND BRACKET KIT G01 RAKE HOLDER G6 SQUARE HEAD BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/ G1 RAKE G02 ASH TRAY KIT (INCLUDES ITEMS 17-20) G01 ASH TRAY G01 GASKET G02 BRACKET G4 SCREW, #10-16 X 1/2" LG... 4 Page C-14

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

35 BRAKES Front of Vehicle Includes Items 55-63, 65, Includes Items 55-62, Includes Items Includes Items Includes Items 65, Includes Items 65, Includes Items 72, 73 Ref Brk 1-3 Page D-2

36 BRAKES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) (INCLUDES ITEMS 2-10) G01 TORSION SPRING G01 PIVOT PIN G01 PUSHNUT, 5/16" * BRAKE PEDAL G02 PARK BRAKE PEDAL G01 BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 8-10) * SERVICE BRAKE PAD * PARK BRAKE PEDAL PAD G1 OVAL RIVET, 3/16" X 7/16" LG G01 SHOULDER BOLT, 3/8-16 X 4" LG (STAINLESS STEEL) G01 FLANGED BUSHING G01 TORSION SPRING G1 WASHER, 3/8" G5 LOCK NUT, 3/ G04 COMPENSATOR ASSEMBLY (INCLUDES ITEMS 19, 20) G01 SPHERICAL NUT, 5/ G9 LOCK NUT, 5/ G03 EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23-26) G01 EQUALIZER BRACKET G01 BRAKE COMPENSATOR BUMPER * BRAKE CABLE (DRIVER SIDE) * BRAKE CABLE (PASSENGER SIDE) G01 RETAINING RING, 4/5" (STAINLESS STEEL) Page D-3

37 BRAKES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY 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 WASHER, 5/16" G3 COTTER PIN, 3/32" X 3/4" LG G01 KICK-OFF CAM PIVOT G6 FLANGED BEARING G01 KICK-OFF CAM G01 SETSCREW, 1/4-20 X 1/2" LG G4 SPACER G01 ADJUSTABLE BUMPER G1 LOCK NUT, 5/ G02 CATCH BRACKET G6 BOLT, 1/4-20 X 3/4" LG G2 LOCK NUT, 1/4-20 (STAINLESS STEEL) G01 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 55-63, 65, 66) G02 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 55-62, 64-66) G01 BRAKE SHOE KIT (INCLUDES ITEM 56) * BRAKE SHOE G01 BRAKE SPRING KIT (INCLUDES ITEMS 58-62) * UPPER SPRING... 1 Page D-4

38 BRAKES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 59 * LOWER SPRING * PIN * CUP AND SPRING * ADJUSTER SPRING G01 BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 65, 66) G02 BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCLUDES ITEMS 65, 66) 1 65 * ADJUSTER * TEFLON WASHER G2 BOLT, 5/16-24 X 1" LG G1 LOCK NUT, 5/ G1 WASHER, 13/16" G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS 72-73) * BRAKE DRUM G1 LUG BOLT, 1/2-20 X 1 3/16" LG G1 WASHER, 1 3/8" O.D. X 21/32" G1 CASTELLATED NUT, 5/ G1 COTTER PIN, 1/8" X 1 1/2" LG G01 SPINDLE CAP G03 BRAKE CABLE BRACKET (PASSENGER SIDE) G04 BRAKE CABLE BRACKET (DRIVER SIDE)... 1 Page D-5

39 BRAKES Page D-6

40 DIRECTION SELECTOR *NOTE: For PDS Direction Selector See ELECTRICAL SYSTEM Section Includes Items Includes Items Ref Dsl 1-1 Page E-1

41 DIRECTION SELECTOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 DIRECTION SELECTOR HANDLE G4 SCREW, #10-32 X 1/2" LG (STAINLESS STEEL) G01 DIRECTION SELECTOR SHAFT G2 BUSHING G01 OFFSET SHIFT LINKAGE ARM G01 LINKAGE ROD G03 SHIFT LINKAGE ARM G3 BUSHING G1 LOCK NUT, 3/ G01 DIRECTION SELECTOR COVER G6 SCREW, 1/4-14 X 3/4" LG G1 WASHER, 1/4" G6 BOLT, 5/16-18 X 3/4" LG G2 WASHER, 5/16" (STAINLESS STEEL) G6 LOCK NUT, 5/16-18 (STAINLESS STEEL) G02 DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 20-50) G01 DIRECTION SELECTOR SHAFT G1 CAM G2 MICRO SWITCH G7 SCREW, #6-32 X 2" LG G01 COVER BRACKET G3 LOCK WASHER, # G1 PUSH ON MALE TERMINAL G5 NUT, # G5 SCREW, #6-32 X 5/8" LG G1 SPACER G1 WASHER, 3/8"... 1 Page E-2

42 DIRECTION SELECTOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G1 LOCK NUT, 3/ G37 18 GA WIRE (RED 4") G1 SCREW G3 LOCK WASHER, # G GA WIRE (RED 6") G8 BOLT, 1/4-20 X 1" LG (STAINLESS STEEL) G7 WASHER, 1/4" (STAINLESS STEEL) G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G1 NUT, 1/ G1 SUPPORT BRACKET G02 DIRECTION SELECTOR MOUNTING BRACKET G02 REVERSE WARNING BUZZER (CONTINUOUS TONE) G1 CONTACT BOARD ASSEMBLY (INCLUDES ITEMS 45-50) G1 STOP G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G6 BOLT, 1/4-20 X 3/4" LG G1 CONTACT STUD, 5/ G8 LOCK WASHER, 5/16" G3 NUT, 5/ Page E-3

43 DIRECTION SELECTOR Page E-4

44 ELECTRICAL SYSTEM - COMMON CHARGER RECEPTACLE Includes Items A A 5 6 Control Harness (See Electronic Speed Control Section) Controller (See Electronic Speed Control Section) Power Harness (See Electronic Speed Control Section) PDS 41 Only Clamp (See REAR AXLE Section) Ref Ele 1-1 Page F-1

45 ELECTRICAL SYSTEM - COMMON 51, OFF ON KEY SWITCH AND KEY SET FUSE BLOCK AND FUSE GRN 47 Ref Ele 17-2 Page F-2

46 ELECTRICAL SYSTEM - COMMON Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. 1 XXXXX-GXX 6 VOLT BATTERY G01 HOLD DOWN BOLT (STAINLESS STEEL) G01 BATTERY RETAINER G1 LOCK NUT, 5/ GA WIRE, GREEN 10" GA WIRE, GREEN 7" G2 NUT, 5/ G01 CHARGER RECEPTACLE ASSEMBLY (INCLUDES ITEMS 14-23) * RECEPTACLE COVER * RECEPTACLE BOTTOM G05 FEMALE CONNECTOR G06 INSULATOR SLEEVE G08 SCREW, #10-32 X 1/2" LG (BRASS) G09 SCREW, #6-32 X 1 3/4" LG (STAINLESS STEEL) G10 LOCK NUT, # * WIRE HARNESS (CHARGER) G1 WIRE TIE G01 RIVET, 3/16" X 1" LG (ALUMINUM) G1 WIRE TIE Page F-3

47 ELECTRICAL SYSTEM - COMMON Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 CABLE CLAMP G11 RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) G1 WIRE TIE G01 LOCK WASHER, 5/16" (SILICON BRONZE)... AR G01 NUT, 5/16-18 (BRASS)... AR G02 LOCK WASHER, 1/4" (SILICON BRONZE) G02 NUT, 1/4-20 (BRASS) G1 FUSE BLOCK G01 RIVET, 1/8" X 13/16" LG G1 15 AMP FUSE... AR G1 KEY SWITCH KIT (W/O LIGHTS - STANDARD - WITH HARDWARE) G1 KEY SWITCH (WITHOUT LIGHTS - NON STANDARD) G6 LOCK WASHER, 3/4" G1 FACE NUT, 3/ G1 KEY (SET)... 1 Page F-4

48 ELECTRICAL SYSTEM - PDS REVERSE BUZZER RED 23 GRN/ BLK 24 Control Harness OFF ON 9 13 DASH MOUNTED DIRECTION SELECTOR, STATE OF CHARGE METER, LABEL AND PLATE Ref Ele 1-4 Page F-5

49 ELECTRICAL SYSTEM - PDS Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY PLATE (KEY SWITCH, DIRECTION SELECTOR) G01 LABEL (KEY SWITCH WITHOUT LIGHTS, DIRECTION SELECTOR) G06 PLATE (KEY SWITCH, DIRECTION SELECTOR, CHARGE METER) G01 LABEL (KEY SWITCH WITHOUT LIGHTS, DIRECTION SELECTOR, CHARGE METER) G02 DRIVE RIVET, 3/16" X 3/8" LG G01 DIRECTION SELECTOR SWITCH (DASH MOUNTED) G04 STATE OF CHARGE METER (VERTICAL) G01 WIRE HARNESS (STATE OF CHARGE METER) G74 18 GA WIRE (RED 6") G02 REVERSE WARNING BUZZER (CONTINUOUS TONE) G01 RIVET, 1/8" X 13/16" LG... 2 Page F-6

50 ELECTRICAL SYSTEM - SERIES Controller (See Electronic Speed Control Section) Control Harness (See Electronic Speed Control Section) OFF ON 9 15 STATE OF CHARGE METER, LABEL AND PLATE Ref Ele 17-5 Page F-7

51 ELECTRICAL SYSTEM - SERIES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY PLATE (KEY SWITCH ONLY) G01 LABEL (KEY SWITCH ONLY) G02 PLATE (KEY SWITCH, STATE OF CHARGE METER) G02 LABEL (KEY SWITCH W/O LIGHTS, STATE OF CHARGE METER) G02 DRIVE RIVET, 3/16" X 3/8" LG G01 WIRE HARNESS (KEY SWITCH) G01 STATE OF CHARGE METER G01 WIRE HARNESS (STATE OF CHARGE METER) G74 18 GA WIRE (RED 6") G8 LOCK WASHER, 5/16" G3 NUT, 5/ Page F-8

52 ELECTRONIC SPEED CONTROL - SERIES A B+ to Direction Selector A B- to Negative Battery Terminal SOL M- to A1 Motor 7 B+ B- M- ORN to MS4 (NC) 12 BLK BLK to Tab on Direction Selector RED to Solenoid LT. GRN to Key Switch To Pedal Box Connector RED RED 24 BLK WHT Includes Items 2-29 A To B * 6 RED BLK From Control Harness WHT From Power Harness 19 * Silver line on diode (6) must be oriented as shown Ref Esc 1-1 Page G-1

53 ELECTRONIC SPEED CONTROL - SERIES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G04 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-31) * LOCK WASHER, # * NUT, G1 DIODE, 3 AMP G1 RESISTOR G02 WIRE HARNESS (CONTROL) * NUT, 5/ * LOCK WASHER, 5/16" GA WIRE GREEN 11.5" G10 18 GA WIRE (SOL - B-) LOCK NUT, 1/ G01 SOLENOID, 36 VOLT G01 HEATSINK G05 ELECTRONIC SPEED CONTROLLER G01 THERMAL MOUNTING PAD G01 BOLT, 1/4-20 X 3/4" LG G01 COVER G1 WIRE TIE G01 DOUBLE TUBE CLAMP G03 BOLT, 1/4-20 X 1 3/16" LG GA WIRE HARNESS, GREEN G5 BOLT, 5/16-18 X 5/8" LG G1 LOCK NUT, 5/ G01 SOLENOID BRACKET... 1 Page G-2

54 ELECTRONIC SPEED CONTROL - PDS A BLK BLK WHT B+ B+ F2 F2 F1 F1 B- B- A1 A Includes Items Includes Items Includes Items , 49, Pin Pin Performance Option Inline Connector 4 4 Pin Pin Tow/Maintenance Box Box Connector Pin Pin Accelerator 3 3 Pin Pin Speed Sensor Inline Connector Inline Connector See See ACCELERATORSee See ELECTRIC MOTOR A C C From Power Harness YEL YEL 2 BLU 3 3 From Control RED From Control Harness Harness Ref Ref Esp Esp Page G-3

55 ELECTRONIC SPEED CONTROL - PDS Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2-44) * LOCK WASHER, # * NUT, G1 RESISTOR * NUT, 5/ * LOCK WASHER, 5/16" GA WIRE, GREEN 11.5" LOCK NUT, 1/ G02 SOLENOID, 36 VOLT G01 HEATSINK G07 ELECTRONIC SPEED CONTROLLER G01 THERMAL MOUNTING PAD G01 BOLT, 1/4-20 X 3/4" LG G1 WIRE TIE G01 DOUBLE TUBE CLAMP G03 BOLT, 1/4-20 X 1 3/16" LG G01 WIRE HARNESS (POWER) G02 WIRE HARNESS (CONTROL) G5 BOLT, 5/16-18 X 5/8" LG G1 LOCK NUT, 5/ Page G-4

56 ELECTRONIC SPEED CONTROL - PDS Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SOLENOID BRACKET G01 COVER ASSEMBLY (INCLUDES ITEMS 33-41) G02 COVER (WITH GASKET) G01 LABEL (TOW SWITCH) G01 TOGGLE SWITCH WITH SEAL (INCLUDES ITEMS 37-39) * SCREW, # * NUT, 15/ G01 SEALED NUT, 15/ G02 WIRE HARNESS (TOW SWITCH) G1 WIRE TIE GA WIRE, GREEN 28" GA WIRE, GREEN 37" G01 BOLT, 1/4-20 X 3/4" LG G02 PERFORMANCE OPTION (STEEP HILL) G03 PERFORMANCE OPTION (MILD HILL)... 1 Page G-5

57 ELECTRONIC SPEED CONTROL - PDS Page G-6

58 ELECTRIC MOTOR 1 - Includes Items Includes Items 3-11 and Includes Items X1 X2 A2 A A A PDS Only 29 Ref Mtr 1 Page H-1

59 ELECTRIC MOTOR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 MOTOR (SERIES, FLEET SPEED) (INCLUDES ITEMS 3-12) G02 MOTOR (SERIES, HIGH SPEED) (INCLUDES ITEMS 3-11, 14) G01 ARMATURE G03 BRUSH SPRING G15 BRUSH PLATE AND BOX G25 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G09 COVER PLATE AND SCREW G08 COMMUTATOR END HOUSING G16 CAP G29 FRAME AND FIELD COIL (G02 MOTOR) (INCLUDES HARDWARE) G31 FRAME AND FIELD COIL (G03 MOTOR) (INCLUDES HARDWARE) G02 MOTOR (SEPARATELY EXCITED) (PDS) (INCLUDES ITEMS 17-29) G18 ARMATURE G03 BRUSH SPRING G15 BRUSH PLATE AND BOX G25 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) G07 BEARING G06 SNAP RING G09 COVER PLATE AND SCREW G31 FRAME AND FIELD COIL (INCLUDES HARDWARE) G19 COMMUTATOR END HOUSING G01 MAGNET G02 SCREW, #10-32 X 1/2" LG G01 RETAINING RING G01 SPEED SENSOR G1 SPLINE BUMPER... 1 Page H-2

60 FRONT SUSPENSION/STEERING f Front of Vehicle Part of Frame , Part of Frame LUG ,16 Ref Fss Includes Items Includes Item Includes Items 7-13, 17 *NOTE: Tie Rod Not Shown for Clarity Page J-1

61 FRONT SUSPENSION/STEERING Front of Vehicle OR ,88 81,86 84,89 82, Includes Items Includes Items Includes Items Includes Items 101, Includes Items Ref Fss 17-2 Page J-2

62 41- Includes Items FRONT SUSPENSION/STEERING Page J-3

63 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY FRONT AXLE G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE) (INCLUDES ITEMS 4-13) G04 SPINDLE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 5-6) G01 BEARING G01 BEARING, DP G1 GREASE SEAL G1 ROLLER BEARING AND RACE ASSEMBLY G1 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 10) G1 LUG BOLT, 1/2-20 X 1 7/32" LG G1 SLOTTED NUT, G8 COTTER PIN, 5/32" X 1 3/4" LG G2 SPINDLE CAP G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE) (INCLUDES ITEMS 7-13 & 17) G02 SPINDLE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 5-6) G6 BOLT, 1/2-13 X 6" LG G3 WASHER, 1/2" G01 KING PIN TUBE G01 THRUST WASHER (STAINLESS STEEL) G6 LOCK NUT, 1/ G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER SHOCK ABSORBER BUSHING... 8 Page J-4

64 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G6 NUT, 3/ G01 VINYL CAP G03 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) G03 SPRING PLATE G1 LOCK NUT, 7/ G11 BOLT, 7/16-14 X 1 3/4" LG G02 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 42-65) G01 STEERING RACK COVER & BEARING * STEERING BOX INSTALLATION TAG * JAM NUT, 1/ G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 PINION G01 RETAINING RING (INTERNAL) G01 SEAL PINION G01 RACK STEERING G01 SCREW, G01 RACK LOADER G01 SPRING COMPRESSION G01 GASKET RACK LOADER G01 COVER RACK LOADER G01 SCREW, 1/ G3 GREASE FITTING, STRAIGHT G01 RACK BALL JOINT (INCLUDES ITEMS 59-61) G1 RUBBER BOOT... 1 Page J-5

65 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 SLOTTED NUT, 7/ G2 COTTER PIN, 3/32" X 1" LG G01 ROD END (INNER) G01 RACK BOOT G2 WIRE TIE G8 WIRE TIE G6 BOLT, 7/16-14 X 2 3/4" LG G01 BOLT, 7/16-14 X 3 1/2" LG G02 SPACER G03 SPACER (SHORT) G7 NUT, 7/ G2 FLAT WASHER, 7/16" G1 LOCK NUT, 7/ G01 STEERING SHAFT G06 STEERING COLUMN KIT (INCLUDES ITEMS 82-84) G03 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG G08 STEERING COLUMN KIT (HORN) (INCLUDES ITEMS 87-89) G04 STEERING COLUMN G01 STEERING COLUMN BUSHING G01 SCREW, #6-20 X 5/16" LG... 1 Page J-6

66 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 BOLT, 3/8-16 X 1 1/4" LG G1 LOCK WASHER, 3/8" G01 COVER G01 RIVET, 3/16" X 1" LG (ALUMINUM) G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 101, 102) G01 BOLT, M8 X G8 LOCK WASHER, 5/16" G01 RETAINING RING (INTERNAL) G01 RETAINING RING (EXTERNAL) G1 BALL BEARING G01 WAVE WASHER STEERING WHEEL G01 STEERING WHEEL COVER G01 LABEL (E-Z-GO) STEERING WHEEL G2 LOCK NUT, 5/ G01 LABEL (JACOBSEN) G02 TIE ROD ASSEMBLY (INCLUDES ITEMS )... 1 Page J-7

67 FRONT SUSPENSION/STEERING Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G02 THREADED ROD (24" LG) G01 TIE ROD END (LEFT HAND THREADS) G01 JAM NUT, M12 X (LEFT HAND THREADS) G02 TIE ROD END (RIGHT HAND THREADS) G02 JAM NUT, M12 X (RIGHT HAND THREADS) G1 LOCK NUT, 7/ G01 FRENCH STEERING COLUMN SAFETY LABEL G02 FRENCH CLIPBOARD SAFETY LABEL (ELECTRIC) G02 FRENCH CLIPBOARD SAFETY LABEL (GAS)... 1 Page J-8

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

69 REAR AXLE Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 REAR AXLE ASSEMBLY (INCLUDES ITEMS 2-7) G12 AXLE SHAFT (PASSENGER SIDE) G11 AXLE SHAFT (DRIVER SIDE) * DIFFERENTIAL COVER G01 FILL PLUG WITH 'O' RING G1 BOLT, 5/16-18 X 3/4" LG G01 VENT G02 SCUFF GUARD XXXXX-XXX SPLINE BUMPER (SEE ELECTRIC MOTOR) G2 BOLT, 1/4-20 X 1 1/4" LG G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G7 WASHER, 1/4" (STAINLESS STEEL) G01 MOLY LUBE, 2 OZ... AR Page K-2

70 REAR SUSPENSION Ref Rsp 17 Page L-1

71 REAR SUSPENSION Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 SHOCK ABSORBER G1 SHOCK ABSORBER WASHER G1 RUBBER BUSHING G6 NUT, 3/ G01 VINYL CAP LEAF SPRING, 2 LEAF G03 LEAF SPRING, 4 LEAF G01 'U' BOLT, 3/8-16 X 2" X 2 1/2" LG G1 WASHER, 3/8" G5 LOCK NUT, 3/ G02 SPACER G01 FLANGED BUSHING (LEAF SPRING) G02 SHACKLE PLATE G9 BOLT, 3/8-16 X 3 1/2" LG (STAINLESS STEEL) G5 LOCK NUT, 3/ G1 SHOULDER BOLT, 3/8-16 X 3 1/4" LG G1 LOCK NUT, 3/ Page L-2

72 SEATING AND BAG HOLDER - GOLF CAR Front of Vehicle Part of Frame 1 - Includes Items Ref Sgc 1 Page M-1

73 SEATING AND BAG HOLDER - GOLF CAR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G** SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 2-4) G** VINYL SEAT BOTTOM COVER G01 VINYL TRIM (SEAT BOTTOM) G1 RUBBER PAD G** TWO TONE VINYL SEAT BOTTOM G01 HIP RESTRAINT (PASSENGER SIDE) G01 HIP RESTRAINT (DRIVER SIDE) G01 BOLT, 1/4-20 X 7/8" LG G01 SEAT HINGE G08 SCREW, #12-14 X 1" LG (STAINLESS STEEL) G** SEAT BACK ASSEMBLY (INCLUDES ITEMS 14-16) G** VINYL SEAT BACK COVER G01 PLASTIC SEAT BACK COVER G01 SCREW, #8 X 5/8" LG (STAINLESS STEEL) G** TWO TONE VINYL SEAT BACK G03 SEAT SUPPORT BRACKET G8 BOLT, 1/4-20 X 1" LG (STAINLESS STEEL) G7 LOCK WASHER, 1/4" (STAINLESS STEEL) G01 BOLT, 3/8-16 X 2 3/4" LG G01 BAG HOLDER BRACKET G01 BAG RETAINER CLAMP G01 BAG RETAINER STRAP G1 RATCHET FASTENER, 1/4" X 9/16" LG G01 CARRIAGE BOLT, 1/4-20 X 1 1/2" LG (STAINLESS STEEL) G2 LOCK NUT, 1/ Page M-2

74 TOW BAR - PERMANENT Includes Items Ref Twb 1-1 Page N-1

75 TOW BAR - PERMANENT Includes Items Includes Items Ref Twb 1-2 Page N-2

76 TOW BAR - PERMANENT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 MOUNTING PLATE G01 STOP MOUNT PLATE G1 SCREW, 1/4-20 X 1" LG (STAINLESS STEEL) G2 LOCK NUT, 1/4-20 (STAINLESS STEEL) G02 FEMALE STOP G01 TOW BAR ASSEMBLY (TOWING VEHICLE) (INCLUDES ITEMS 9-29) G01 TOW BAR G01 UPPER PIVOT G01 LOWER PIVOT G8 BOLT, 1/2-20 X 3" LG G3 WASHER, 1/2" (STAINLESS STEEL) G01 SPRING WASHER G5 WASHER, 1/2" G8 LOCK NUT, 1/ G01 LATCH STOP G01 WASHER, 3/8" G01 PIVOT PIN G7 SPRING PIN G01 LATCH G2 COMPRESSION SPRING G02 CUP WASHER G4 SHOULDER BOLT, 5/16-18 X 2" LG G01 LABEL (WARNING) G03 MALE STOP G4 BOLT, 6MM X 1 X 30 MM LG G8 LOCK WASHER, 5/16" G3 ACORN NUT, 5/16-18 (STAINLESS STEEL) Page N-3

77 TOW BAR - PERMANENT Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 TOW BAR HITCH ASSEMBLY (TOWED VEHICLE) (INCLUDES ITEMS 32-49) G01 HITCH G01 PIVOT BOLT G01 THRUST WASHER G01 WASHER, 3/4" G8 CASTELLATED NUT, 3/ G1 COTTER PIN, 1/8" X 1 1/2" LG G01 BEARING G6 LOCK WASHER, 3/4" G8 NUT, 3/ TIE ROD ASSEMBLY (INCLUDES ITEMS 43-47) THREADED ROD G01 TIE ROD END (LEFT HAND THREADS) G3 JAM NUT, M12 X (LEFT HAND THREADS) G02 TIE ROD END (RIGHT HAND THREADS) G4 JAM NUT, M12 X (RIGHT HAND THREADS) G2 CASTELLATED NUT, 7/ G2 COTTER PIN, 3/32" X 1" LG... 2 Page N-4

78 TOW BAR - CASUAL 1 - Includes Items Ref Tbc 1 Page N-5

79 TOW BAR - CASUAL Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 CASUAL TOW BAR (INCLUDES ITEMS 2-15) * TOW BAR G01 TIE ROD (INCLUDES NUT AND COTTER PIN) G01 COUPLING * LOCK PIN G01 COMPRESSION SPRING G2 WASHER, 3/8" G2 COTTER PIN, 3/32" X 1" LG G01 SAFETY PIN G5 WIRE ROPE G1 FERRULE G01 FERRULE G02 HEX HEAD PLUG G3 WIRE ROPE G01 LABEL (WARNING)... 1 Page N-6

80 WEATHER PROTECTION - GOLF CAR D 1 - Includes items 2-19 SUN TOP B C A Front of Vehicle 17 2 Rear of Vehicle DETAIL C (FRONT) Driver Side DETAIL D (REAR) Ref Wgc 1-1 DETAIL A DETAIL B Page P-1

81 WEATHER PROTECTION - GOLF CAR Front Top Strut 23 Setscrew REAR VIEW MIRROR 21 - Includes Items Strut Front of Vehicle FULL WINDSHIELD 26 - Includes Items FOLD DOWN WINDSHIELD 35 - Includes Items Front of Vehicle Strut 41 Ref Wgc Page P-2

82 WEATHER PROTECTION - GOLF CAR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY. For service or replacement parts, contact: Eagle Parts, Inc Marvin Griffin Rd. Augusta, GA Telephone (706) or FAX (706) G** SUN TOP KIT (GOLF CAR) (INCLUDES ITEMS 2-19) G** SUN TOP G05 FRONT STRUT G01 BOLT, 5/16-18 X 2 1/4" LG G8 LOCK WASHER, 5/16" G01 SPACER, 1/2" G2 WASHER, 5/16" G02 REAR STRUT G7 BOLT, 5/16-18 X 1 3/4" LG (STAINLESS STEEL) G03 WASHER, 5/16" (STAINLESS STEEL) G1 TEFLON WASHER, 5/16" G01 LOCK NUT, 5/16-18 (STAINLESS STEEL) G5 SCREW, 1/4-20 X 2" LG (STAINLESS STEEL) G6 SCREW, 1/4-20 X 2 1/4" LG (STAINLESS STEEL) G01 WASHER, 1/4" (STAINLESS STEEL) G01 SPACER G2 LOCK NUT, 1/4-20 (STAINLESS STEEL) G1 END CAP, 1" G3 REAR VIEW MIRROR KIT (INCLUDES ITEMS 22-24) G1 REAR VIEW MIRROR G3 SUPPORT BRACKET G1 SCREW, #8-32 X 5/8" LG (STAINLESS STEEL) Page P-3

83 WEATHER PROTECTION - GOLF CAR Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 WINDSHIELD KIT (GOLF CAR) (INCLUDES ITEMS 27-33) * WINDSHIELD EGWHC12 SASH, 26" LG EGWHS12 SCREW, 1/4-20 X 1 3/4" LG (STAINLESS STEEL) EGWHW12 WASHER, 1/4" (STAINLESS STEEL) EGWHG13 RUBBER GROMMET EGWHN12 LOCK NUT, 1/4-20 (STAINLESS STEEL) EGWHL14 LABEL (SAFETY) G01 FOLD DOWN WINDSHIELD KIT (GOLF CAR) (INCLUDES ITEMS 36-44) C WINDSHIELD A SASH, 12" LG EGWHS12 SCREW, 1/4-20 X 1 3/4" LG (STAINLESS STEEL) EGWHW12 WASHER, 1/4" (STAINLESS STEEL) EGWHG13 RUBBER GROMMET EGWHN12 LOCK NUT, 1/4-20 (STAINLESS STEEL) C TOP GRIP, 3/4" X 2" C BOTTOM GRIP LABEL (SAFETY) B BUMPERS... 2 Page P-4

84 WHEELS AND TIRES 1 - Includes Items Includes Items Includes Items Includes Items Includes Items Ref Whl 17 Page Q-1 SILVER / GOLD SPOKE HUBCAP 32, 34

85 WHEELS AND TIRES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G01 TIRE AND WHEEL ASSEMBLY (LINKS 1 18 X 8.5-8) (INCLUDES ITEMS 2-4) G01 LINKS 1 CARLISLE TIRE, 18 X G01 WHEEL RIM (4 LUG) G2 VALVE STEM G03 WHEEL AND TIRE ASSEMBLY (TURF SAVER 18 X 8.5-8) (INCLUDES ITEMS 7-9) G03 CARLISLE TIRE (TURF SAVER 18 X 8.5-8) G01 WHEEL RIM (4 LUG) G2 VALVE STEM G01 WHEEL AND TIRE ASSEMBLY SURE TRAIL 6-PLY 18.5 X 8.5-8) (INCLUDES ITEMS 12-14) G01 CARLISLE TIRE (SURE TRAIL, 6 PLY 18 X 8.5-8) G01 WHEEL RIM (4 LUG) G2 VALVE STEM G02 WHEEL AND TIRE ASSEMBLY (TURF GLIDE 18 X 8.5-8) (INCLUDES ITEMS ) G06 CARLISLE TIRE (TURF GLIDE 18 X 8.5-8) G1 WHEEL RIM (4 LUG) G2 VALVE STEM G04 WHEEL AND TIRE ASSEMBLY (FAIRWAY 18 X 8.5-8) (INCLUDES ITEMS 22-24) G08 CARLISLE TIRE (FAIRWAY 18 X 8.5-8) G1 WHEEL RIM (4 LUG) G2 VALVE STEM G1 LUG NUT, 1/ Page Q-2

86 WHEELS AND TIRES Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. G** Indicates consult Customer Service Department for additional information. ITEM PART NO DESCRIPTION QTY G2 GOLD SPOKE HUBCAP G1 SILVER SPOKE HUBCAP... 4 Page Q-3

87 SPECIALTY PRODUCTS SPECIALTY PRODUCTS Appendix A-1

88 SPECIALTY PRODUCTS SPECIAL TOOLS PART NO. BATTERY MAINTENANCE KIT G01 SEAL INSTALLATION TOOL (REAR AXLE SHAFT SEAL) G1 BATTERY SET DISCHARGER, 36 VOLT, 75 AMP G01 CURRENT INDICATOR G2 DIGITAL MULTI-METER G01 CRIMPING TOOL G01 TUBELESS TIRE REPAIR KIT TIRE PLUGGER REFILL PACK(50/BOX) TOUCH UP PAINT PART NO. PEN 3 OUNCE (89 ML) - HUNTER GREEN G02 PEN 3 OUNCE (89 ML) - CHAMPAGNE BEIGE G01 PEN 3 OUNCE (89 ML) - WHITE G05 PEN 3 OUNCE (89 ML) - INDUSTRIAL YELLOW G03 PEN 3 OUNCE (89 ML) - ORANGE G04 PEN 3 OUNCE (89 ML) - STEEL BLUE PEARL G** PEN 3 OUNCE (89 ML) - CAMOUFLAGE PAINT (THREE PENS) G01 AEROSOL 12 OUNCE (360 ML) - HUNTER GREEN G09 AEROSOL 12 OUNCE (360 ML) - CHAMPAGNE BEIGE G15 AEROSOL 12 OUNCE (360 ML) - INDUSTRIAL YELLOW G14 MAINTENANCE PRODUCTS PART NO. PLEXUS CLEANER, 13 OUNCE (380 ML) (FOR WINDSHIELDS) G02 BATTERY PROTECTOR, 14 OUNCE (410 ML) SPRAY G02 E-Z-GO ALL SURFACE CLEANER E-Z-GO FIBERGLASS/PLASTIC RESTORER W/SHIELD AND PLASTIC PROTECTOR OZ HAND CLEANER OZ HAND CLEANER Appendix A-2

89 SPECIALTY PRODUCTS Notes: Appendix A-3

90 OPTIONS/ACCESSORIES OPTIONS/ACCESSORIES Appendix B-1

91 OPTIONS/ACCESSORIES 2 BAG ATTACHMENT G Body -Footrest 4 BAG ATTACHMENT G Body - Accessories Continued 8" CHROME HUBCAP G* Wheels And Tires 6" CHROME HUBCAP G* Wheels And Tires GOLD SPOKE HUBCAP G* Wheels And Tires SILVER SPOKE HUBCAP G* Wheels And Tires ASHTRAY KIT G Body - Accessories Continued CENTER BASKET G Body - Accessories COOLER JUG AND BRACKET KIT G Body - Accessories Continued COOLER BOX AND BRACKET KIT G Body - Accessories Continued DIVOT REPAIR KIT G Body - Accessories MESSAGE HOLDER KIT (REQUIRES SUN TOP) G Body - Accessories Continued MESSAGE HOLDER KIT (REQUIRES SUN TOP) G Body - Accessories Continued REAR VIEW MIRROR (REQUIRES SUN TOP) G Weather Protection - Golf Car SAND BOTTLE G** Body - Accessories SAND RAKE G Body - Accessories Continued SAND RAKE HOLDER G Body - Accessories Continued SAND MUG - KIT, SINGLE Body - Accessories Continued SAND MUG - KIT, DOUBLE Body - Accessories Continued SIDE BASKET G** Body - Accessories SUN TOP KIT, GOLF CAR G** Weather Protection - Golf Car TOW BAR KIT (CASUAL) G Tow Bar - Casual TOW BAR KIT (PERMANENT) G Tow Bar - Permanent WINDSHIELD KIT, GOLF CAR G Weather Protection, Golf Car WINDSHIELD KIT, FOLD DOWN, GOLF CAR G Weather Protection, Golf Car TIRE DOMINATOR 20X Wheels and Tires PATHFINDER TIRE, BRUSHED WHEEL LH Wheels and Tires PATHFINDER TIRE, BRUSHED WHEEL RH Wheels and Tires PRO TOUR - POLISHED WHEEL Wheels and Tires PRO TOUR, TIRE 205/ Wheels and Tires V-STEM-BRUSHED SPOKED WHEEL Wheels and Tires PRO BRUSHED WHEEL Wheels and Tires DOMINATOR - POLISHED WHEEL Wheels and Tires Appendix B-2

92 OPTIONS/ACCESSORIES DOMINATOR - BRUSHED WHEEL Wheels and Tires CHROME CENTER CAP - SPOKED WHEEL Wheels and Tires NUT, LUG-CHROME Wheels and Tires V-STEM-POLISHED SPOKED WHEEL Wheels and Tires PATHFINDER TIRE 22X Wheels and Tires PATHFINDER TIRE, POLISHED WHEEL LH Wheels and Tires PATHFINDER TIRE, POLISHED WHEEL RH Wheels and Tires JACK-UP KIT G Wheels and Tires BFS INSTALLATION Electrical System NOZZLE GUN - BFS Electrical System Appendix B-3

93 OPTIONS/ACCESSORIES Notes: Appendix B-4

94

95 E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA TO CONTACT US North America: Technical Assistance & Warranty Phone: , FAX: Service Parts Phone: GET-EZGO ( ), FAX: International: Phone: , FAX: Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc. Technical Communications Department