SERVICE PARTS MANUAL 602907

SERVICE PARTS MANUAL

602907

1 - INCLUDES ITEMS 3 - 16

Ref Fcv 1

ELECTRIC POWERED FLEET GOLF CARS &

PERSONAL VEHICLES

ISSUED DATE SEPTEMBER 2005 REVISED DATE JULY 2008

SERVICE PARTS MANUAL

ELECTRIC POWERED FLEET GOLF

CARS & PERSONAL VEHICLES

FLEET GOLF CAR

FLEET PDS GOLF CAR

FREEDOM SE

FREEDOM LE

FREEDOM SE PDS

FREEDOM LE PDS

SHUTTLE 2+2

STARTING MODEL YEAR: 2005

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 INCIDEN-

TAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124

OUTSIDE USA PHONE: 001-706-798-4311, FAX: 001-706-771-4609

E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906

Service Parts Manual Page i

NOTES

To obtain a copy of the limited warranty applicable to the vehicle, call or write a local

Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code.

The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.

Overfilling of batteries may void the warranty.

BATTERY PROLONGED STORAGE

All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C).

As with all electric vehicles, the batteries must be checked and recharged as required or at a minimum of 30 day intervals.

Page ii Service Parts Manual

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

BATTERY CHARGER - ON BOARD 36 VOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7

BATTERY CHARGER - EXPORT 36 VOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15

BODY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

BODY - MID SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

BODY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7

BODY - FOOTREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11

BODY - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

DIRECTION SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

ELECTRICAL SYSTEM - COMMON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

ELECTRICAL SYSTEM - PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9

ELECTRICAL SYSTEM - SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11

ELECTRONIC SPEED CONTROL - SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

ELECTRONIC SPEED CONTROL - PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

ELECTRONIC SPEED CONTROL - HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7

FRONT SUSPENSION/STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1

REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1

SEATING AND BAG HOLDER - GOLF CAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1

SEATING - SHUTTLE 2+2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3

SEATING - CONVERTIBLE CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-7

TOW BAR - PERMANENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1

TOW BAR - CASUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-5

WEATHER PROTECTION - GOLF CAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Service Parts Manual Page iii

TABLE OF CONTENTS

SECTION Page No.

WEATHER PROTECTION - SHUTTLE 2+2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-7

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1

SPECIALTY PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX A-1

OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX B-1

Page iv Service Parts Manual

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

• A LISTING OF OPTIONS/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.

Service Parts Manual v

HOW TO USE THE SERVICE PARTS MANUAL

Title Title

112

115

111

114

128 129

116

113

106

decal information

Front of Vehicle 102,104 107

103

79

105

92

62

91

69

82,87

81,86

83,88

84,89

95

96

65

66

94

63

64

71

98

99

100

101

62 - Includ es Items 63 -

66, 69 - 74

70 - Includ es Items 71 - 74

81 - Includes I tems 82 - 84

86 - Include

118 - Includ

126 - Include s Items 87 tems 112 - 114 es Items 11

9 - 121 s Items 127

- 131

74

120

70

123

67

121

118

122

119

72

73

130 131

127 126

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.

vi

Service Parts Manual

ILLUSTRATED PARTS BREAKDOWN

ILLUSTRATED PARTS BREAKDOWN


Page vii

ACCELERATOR

1 - Includes Items 3 - 19, 21, 23, 26 - 43

2 - Includes Items 3 - 17, 20, 21, 24 - 43

31 - Includes Items 32 - 35

33 - Includes Items 34, 35

13

12

14

11

26

3

19

20

A

21

15

16

17

9

7

8

4

5

A

3 23

24

To Harness from

Direction

Selector

23

24

28

29

Ref Acl 1-1

Page A-1 Service Parts Manual

ACCELERATOR

Ref Acl 1-2

38

46

34

35

37

41

32

37

42

43

39

45


To Harness from

Direction

Selector

Page A-2

ACCELERATOR

22

23

24

25

18

19

20

21

26

27

28

29

14

15

16

17

10

11

12

13

8

9

6

7

3

4

5

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.

1 2 3 4 5 DESCRIPTION

1

2

73333-G09

73333-G10

25853-G01

25854-G01

00983-G01

QTY.

PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3 - 19, 21, 23, 26 - 43) ...............

1

PEDAL BOX ASSEMBLY, PDS MODEL ONLY

(INCLUDES ITEMS 3 - 17, 20, 21, 24 - 43) ........................................................

1

PEDAL BOX AND COVER (SEAL AND BEARING).....................................

1

INDUCTIVE THROTTLE SENSOR ..............................................................

1

SELF THREADING NUT, 3/16" ....................................................................

2

25857-G01

28443-G01

28444-G01

73332-G01

00532-G4

10385-G4

17677-G2

73046-G01

17979-G1

17677-G1

25861-G01

25861-G02

01050-G01

25879-G03

25879-G05

00684-G6

70116-G02

01051-G01

PLUNGER SLEEVE......................................................................................

PLUNGER.....................................................................................................

PLUNGER CAM............................................................................................

ACCELERATOR ROD ..................................................................................

NUT, 5/16 - 24...............................................................................................

CLEVIS YOKE (ADJUSTABLE) ....................................................................

1

1

1

SPRING RETAINER, 3/8" .............................................................................

1

COMPRESSION SPRING ............................................................................

1

ACCELERATOR ROD BUSHING .................................................................

1

SPRING RETAINER, 1/2" .............................................................................

1

MICRO SWITCH...........................................................................................

MICRO SWITCH (PDS MODEL ONLY)........................................................

SCREW-PLASTITE, #4 - 20 X 5/8" LG.........................................................

WIRING HARNESS (PEDAL BOX ASSEMBLY) ..........................................

WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY) .......

SCREW, #8 - 32 X 3/4" LG (STAINLESS STEEL)........................................

ACCELERATOR PEDAL BRACKET.............................................................

SCREW, #8 - 16 X 1/2" LG ...........................................................................

1

1

1

1

1

2

1

1

2

1

4

Page A-3 Service Parts Manual

ACCELERATOR





ITEM PART NO.


39

40

41

42

35

36

37

38

43

44

45

46

30

31

32

33

34

25799-G03

*

27844-G01

27512-G01

15766-G1

17838-G1

74432-G01

12064-G6

10386-G3

17255-G1

10387-G3

00715-G2

70135-G01

QTY.

ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 32 - 35).............

1

ACCELERATOR PEDAL ........................................................................

1

ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 34, 35).............

1

ACCELERATOR PEDAL PAD .........................................................

1

OVAL RIVET 3/16" X 7/16" LG ........................................................

NYLON BUSHING ........................................................................................

PEDAL PIVOT PIN .......................................................................................

PUSHNUT, 9/32" I.D. ....................................................................................

CLEVIS PIN, 5/16" X 13/16" LG ...................................................................

TEFLON WASHER, 5/16".............................................................................

COTTER PIN, 3/32" X 3/4" LG .....................................................................

BOLT, 5/16 - 18 X 4/5" LG ...................................................................................

PEDAL PIVOT COVER .......................................................................................

6

3

1

1

1

1

1

4

1

Service Parts Manual Page A-4

BATTERY CHARGER - PORTABLE 36 VOLT

POWERWISE™

3

6

11

10

9 12

9

Transformer

8

Wire

8

9

13

7

9

10

11

4

5

B

15

Ref Bcp 1-1

Page B-1

POWERWISE™

+

74

75

70


76

71


2 - Includes Items 3 - 13, 18 - 63, 70 - 76


20

20

18

19

21

20

22

C

WHT from

Transformer

25

24

26

A

D

To Power

Input Board

To

Transformer

To Amp Fuse

To Black/

Control Board

To grounding

30

33, 66

E

29

Ref Bcp 1-2

Service Parts Manual Page B-2


POWERWISE™

A

RED to

Heat Sink

BLACK from

DC Plug

BLK from

Transformer

BLK from

AC Cord

WHT from

AC Cord

BLK from

Transformer

WHT

XF

57

GRN

16

GRN to

Ground

CONTROL / POWER INPUT

BOARD INSTALLATION

POWERWISE™

+

A

BRN from Control Board

ORN from Control Board

BLK from Transformer

BLK from Transformer

BLK from AC Cord

58

WHT from

AC Cord

BRN

ORN

YEL

WHT

XF

GRN

72

GRN to

Ground

POWER INPUT BOARD

INSTALLATION

B

Chassis

AMMETER INSTALLATION

45

WHT from DC Cord

54

50 48

51

52

48 49

50

53

55

46

47

0

53 51

51

48

53

Heat

Sink

C

TRANSFORMER

DETAIL

56

To

Capacitor

To Diodes

To Norm. Open on Power

Input Board To XF on Power Input Board

54

To

DC

Cord

53

55

28

27

GRN to

AC Cord

GRN to

Power

Input

Board

61

60

D

AC

Cord

Port

41

E

41

34

DC CABLE ASSEMBLY

37

36

38

39

35

Ref Bcp 1-3

Page B-3

62

63

Front of

Charger

GROUNDING DETAIL

43

67


66 - Includes Items 34 - 42, 67

40


42


79

85



25

26

27

28

29

21

22

23

24

17

18

19

20

13

14

15

16

10

11

12

8

9

6

7

3

4

5





ITEM PART NO.


1

2

28115-G01

28115-G02

*

00513-G6

00559-G4

11572-G3

28104-G01

00372-G4

00559-G4

00565-G4

00526-G1

28548-G01

28110-G01

QTY.

POWERWISE™ CHARGER (10' CORD) (INCLUDES ITEMS 3 - 63)................

1

POWERWISE™ + CHARGER (PORTABLE, 10' CORD) (INCLUDES ITEMS

3 - 13, 18 - 63, 70 - 76).......................................................................................

1

CHASSIS ......................................................................................................

1

SCREW, #8 - 18 X 1 3/4" LG ........................................................................

2

WASHER, #8 ................................................................................................

2

EXPANSION NUT.........................................................................................

2

HEAT SINK ...................................................................................................

1

SCREW, #8 - 32 X 1/2" LG ...........................................................................

4

WASHER, #8 ................................................................................................

4

LOCK WASHER, #8 .....................................................................................

4

NUT, #8 - 32..................................................................................................

4

DIODE...........................................................................................................

1

ELECTRICAL CLIP.......................................................................................

1

*

28667-G01

*

28102-G01

00614-G4

28136-G01

28136-G02

26979-G01

28109-G01

00969-G01

00414-G5

11027-G2

19388-G4

LABEL (POWERWISE™) ............................................................................

CONTROL / POWER INPUT BOARD ..........................................................

COVER .........................................................................................................

HANDLE .......................................................................................................

SCREW, #8 - 18 X 1/2" LG ...........................................................................

LABEL (VENTILATION) ................................................................................

LABEL (CORD CONDITION)........................................................................

CAPACITOR BRACKET ...............................................................................

1

1

1

1

6

1

1

1

CAPACITOR .................................................................................................

1

SCREW, #8 - 32 X 3/8" LG ...........................................................................

3

BOLT, 1/4 - 20 X 5/8" LG...............................................................................

3

LOCK NUT, 1/4 - 20 ......................................................................................

3

AC CORD .....................................................................................................

1

Page B-5 Service Parts Manual






ITEM PART NO.

13557-G2

1 2 3 4 5 DESCRIPTION QTY.

STRAIN RELIEF (AC)...................................................................................

1

54

55

56

57

50

51

52

53

58

59

46

47

48

49

43

44

45

39

40

41

42

35

36

37

38

30

31

32

33

34

73345-G01

73051-G11

73051-G12

73051-G27

73051-G14

73051-G08

73051-G15

73051-G16

73051-G10

73051-G17

73344-G01

28105-G01

01051-G01

00559-G4

01003-G01

22589-G2

00771-G6

00528-G4

28106-G01

00565-G5

00378-G4

00526-G3

28103-G01

27877-G01

17618-G1

DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34 - 43) ...........

PLUG (TOP HALF).................................................................................

PLUG (BOTTOM HALF).........................................................................

1

AUXILIARY CONTACT...........................................................................

1

MALE PIN...............................................................................................

2

SCREW, #10 - 32 X 1/2" LG (BRASS) ...................................................

2

MAGNET ................................................................................................

1

SCREW, #6 - 32 X 1/2" LG (STAINLESS STEEL) .................................

2

LOCK NUT, #6 - 32 ................................................................................

4

SCREW, #6 - 32 X 1" LG (STAINLESS STEEL) ....................................

2

DC CORD, 10' LG ..................................................................................

AMMETER ....................................................................................................

1

1

1

1

SCREW, #8 - 16 X 1/2" LG ...........................................................................

2

WASHER, #8 ................................................................................................

2

WASHER, #10 (BRASS)...............................................................................

4

SHOULDER WASHER, #10 .........................................................................

1

NYLON WASHER, 3/8".................................................................................

1

NUT, #10 - 32 (BRASS) ................................................................................

3

50 AMP FUSE...............................................................................................

1

LOCK WASHER, #10 ...................................................................................

4

SCREW, #10 - 24 X 1/2" LG .........................................................................

2

NUT, #10 - 24................................................................................................

2

TRANSFORMER ..........................................................................................

1

SPACER SUPPORT .....................................................................................

4

WIRE TIE ......................................................................................................

2



79

80

81

82

75

76

77

78

70

71

72

73

74

83

84

85

86

87

88

60

61

62

63

64

65





ITEM PART NO.


00372-G3

25977-G32

00565-G4

00526-G1

QTY.

SCREW, #8 - 32 X 3/8" LG ..........................................................................

1

16 GA WIRE (GREEN 4") ............................................................................

1

LOCK WASHER, #8.....................................................................................

1

NUT, #8 - 32 .................................................................................................

1

28115-G07

66

67

68

69

73345-G03

73344-G03

28115-G08

POWERWISE™ CHARGER (PORTABLE, 18' CORD) (INCLUDES ITEMS

3 - 31, 45 - 63, 66, 67) ........................................................................................

1

DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34 - 42, 67) ....

1

DC CORD, 18' LG..................................................................................

1

*

28667-G02

28667-G03

POWERWISE™ + CHARGER (PORTABLE, 18' CORD) (INCLUDES ITEMS

3 - 13, 18 - 31, 45 - 63, 66, 67, 70 - 76)..............................................................

1

LABEL (POWERWISE™ +) ........................................................................

1

CONTROL BOARD......................................................................................

1

POWER INPUT BOARD ..............................................................................

1

01005-G01

00559-G3

28111-G01

605747

604320

605493

605607

605608

606296

605748

604320

605494

605607

SCREW, #TEFLON-PLT-30-ZP #6-20 X 5/16".............................................

WASHER, #6................................................................................................

3

SUPPORT SPACER ....................................................................................

3

POWERWISE QE (DELTA), 10’ CORD 36 VOLT CHARGER ...........................

KIT, AC CORD, 9’ , POWERWISE QE.........................................................

KIT, 10’ DC CORD, 36V POWERWISE QE .................................................

KIT, PCB/EMI BRD, 36-48V PWISE QE ......................................................

KIT, CHARGER OVER/HNDLE, 36V PW QE ..............................................

CHARGER HANDLE-POWERWISE QE......................................................

POWERWISE QE(DELTA), 18’ CORD 36 VOLT CHARGER.............................

KIT, AC CORD, 9’, POWERWISE QE..........................................................

KIT, 18’ DC CORD, 36V POWERWISE QE .................................................

KIT, PCB/EMI BRD, 36V PWISE QE ...........................................................

3

1

1

1

1

1

1

1

1

1

1







ITEM PART NO.


89

90

605608

606296

QTY.

KIT, CHARGER CVER/HNDLE, 36V PW QE ...............................................

1

CHARGER HANDLE-POWERWISE QE ......................................................

1


BATTERY CHARGER - ON BOARD 36 VOLT

POWERWISE™

3

4

5

2

B

6

11

10

9

A

12

9

Transformer

8

Wire

8

9

13

7

9

10

11

43

42

41


40

Ref Bco 1-1


20

Ref Bco 1-2

21

77

22


76

20

20

19

18

D

WHT from

Transformer

25

24

26

E

C



30 34

36

29

Page B-8

37

35

31


Pin 1 - Wire 67 to Input Board "COM"

Pin 2 - Tab Adapter 73, RED wire from Control Board

Pin 3 - Wire 68 to Input Board "WHT"

Pin 4 - Wire 69 to Heat Sink Clip

Pin 5 - Wire 70 to DC Cord RED Wire

A

63

65 70

68

67

64

69 73

RED from Control Board

RELAY INSTALLATION

B

Chassis

AMMETER INSTALLATION

45

48 49

50 48

WHT from DC Cord

53

51

52

50

54

55

46

47

0

53 51

51

48

53

Heat

Sink

Page B-9

Ref Bco 1-3

59

GRN from

AC Cord

58

AC Cord

Port

C

60

61

GROUNDING

DETAIL

Front of

Charger



D

TRANSFORMER

DETAIL

56

To Diodes 53

71

54

55

To

DC

Cord

28

To

Capacitor

To Norm. Open on Power

Input Board

To XF on Power Input Board

BATTERY CHARGER INSTALLATION

83

82

27

POWERWISE™

E

WHT from

Relay Pin 3

RED to

Heat Sink

BLK to

DC Plug

BLK from

Transformer

BLK from

AC Cord

WHT from

AC Cord

BLK from

Transformer

16

WHT

XF

GRN

15

72

GRN to

Ground

CONTROL / POWER INPUT

BOARD INSTALLATION

Front of Vehicle

81

79

Ref Bco 1-4

86

85

CHARGER RECEPTACLE COVER



25

26

27

28

21

22

23

24

29

30

17

18

19

20

14

15

16

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


28115-G11

*

*

00513-G6

00559-G4

11572-G3

28104-G01

00372-G4

00559-G4

00565-G4

00526-G1

28548-G01

28110-G01

QTY.

POWERWISE™ CHARGER (ON BOARD) (INCLUDES ITEMS 2 - 74).............

1

LABEL (POWERWISE™) .............................................................................

1

CHASSIS ......................................................................................................

1

SCREW, #8 - 18 X 1 3/4" LG ........................................................................

2

WASHER, #8 ................................................................................................

2

EXPANSION NUT.........................................................................................

2

HEAT SINK ...................................................................................................

1

SCREW, #8 - 32 X 1/2" LG ...........................................................................

4

WASHER, #8 ................................................................................................

6

LOCK WASHER, #8 .....................................................................................

4

NUT, #8 - 32..................................................................................................

4

DIODE...........................................................................................................

1

ELECTRICAL CLIP.......................................................................................

1

28667-G01

27877-G01

*

28102-G01

00614-G4

28136-G01

28136-G02

26979-G01

28109-G01

00969-G01

00414-G5

11027-G2

19388-G5

13557-G2

CONTROL / POWER INPUT BOARD ..........................................................

SPACER SUPPORT .....................................................................................

COVER .........................................................................................................

HANDLE .......................................................................................................

SCREW, #8 - 18 X 1/2" LG ...........................................................................

LABEL (VENTILATION) ................................................................................

LABEL (CORD CONDITION)........................................................................

CAPACITOR BRACKET ...............................................................................

1

4

1

1

4

1

1

1

CAPACITOR .................................................................................................

1

SCREW, #8 - 32 X 3/8" LG ...........................................................................

3

BOLT, 1/4 - 20 X 5/8" LG...............................................................................

3

LOCK NUT, 1/4 - 20 ......................................................................................

3

AC CORD .....................................................................................................

1

STRAIN RELIEF (AC)...................................................................................

1







ITEM PART NO.

13557-G3


STRAIN RELIEF (DC)...................................................................................

1

55

56

57

58

51

52

53

54

59

60

47

48

49

50

44

45

46

40

41

42

43

36

37

38

39

31

32

33

34

35

73344-G06

28107-G01

11343-G3

11343-G1

17064-G2

*

22009-G2

00559-G7

00565-G7

00532-G1

28105-G01

01051-G01

00559-G4

01003-G01

22589-G2

00771-G6

00528-G4

28106-G01

00378-G4

00565-G5

00526-G3

28103-G01

00372-G3

25977-G32

00565-G4

DC CORD ASSEMBLY (INCLUDES ITEMS 34 - 38) ...................................

DC CORD...............................................................................................

RING TERMINAL, 3/16" .........................................................................

RING TERMINAL, 5/16" .........................................................................

2

FEMALE TERMINAL ..............................................................................

2

HEAT SHRINK TUBING ......................................................................... A/R

ISOLATION MOUNT.....................................................................................

WASHER, FL-A-N-CP 1/4.............................................................................

WASHER-LK-SP-CP-1/4 ..............................................................................

NUT, 1/4 - 20.................................................................................................

AMMETER ....................................................................................................

SCREW, #8 - 16 X 1/2" LG ...........................................................................

TRANSFORMER ..........................................................................................

SCREW, #8 - 32 X 3/8" LG ...........................................................................

1

1

2

4

4

4

4

1

2

WASHER, #8 ................................................................................................

2

WASHER, #10 (BRASS)...............................................................................

4

SHOULDER WASHER, #10 .........................................................................

1

NYLON WASHER, 3/8".................................................................................

1

NUT, #10 - 32 (BRASS) ................................................................................

3

50 AMP FUSE...............................................................................................

1

SCREW, #10 - 24 X 1/2" LG .........................................................................

2

LOCK WASHER, #10 ...................................................................................

4

NUT, #10 - 24................................................................................................

2

1

1

16 GA WIRE (GREEN 4").............................................................................

1

LOCK WASHER, #8 .....................................................................................

1







ITEM PART NO.

00526-G1


NUT, #8 - 32..................................................................................................

1

81

82

83

84

85

86

77

78

79

80

74

75

76

70

71

72

73

66

67

68

69

61

62

63

64

65

21971-G4

00138-G4

14390-G9

25977-G38

25977-G37

25978-G161

25978-G162

25978-G163

17902-G1

28305-G01

71968-G02

00106-G6

11027-G2

73368-G01

00438-G6

11027-G1

73173-G01

14601-G10

RELAY ..........................................................................................................

SCREW, #6 - 32 X 1/2" LG ...........................................................................

LOCK NUT, #6 - 32 .......................................................................................

16 GA WIRE (BLACK 4") ..............................................................................

16 GA WIRE (WHITE 5") ..............................................................................

18 GA WIRE (BLUE 6") ................................................................................

1

1

1

18 GA WIRE (YELLOW 6")...........................................................................

1

18 GA WIRE (BLACK 7") ..............................................................................

1

ADAPTER TAB .............................................................................................

1

ADAPTER TERMINAL, 1/4" X 3/16".............................................................

1

SHIELD ...............................................................................................................

SCREW, #12 - 24 X 3/4" LG................................................................................

LOCK NUT, 1/4 - 20 ............................................................................................

CORD REEL .......................................................................................................

BOLT, 5/16 - 18 X 3/4" LG ...................................................................................

LOCK NUT, 5/16 - 18 ..........................................................................................

COVER PLATE ...................................................................................................

RIVET, 1/8" X 7/16" LG (ALUMINUM) .................................................................

1

2

2

1

2

2

1

2

2

1

4




BATTERY CHARGER - EXPORT 36 VOLT

1

2

Page B-15

Ref Bcl 1


BATTERY CHARGER - EXPORT 36 VOLT





ITEM PART NO.


1

2

28516-G01

28516-G03

BATTERY CHARGER, LESTER, 36 VOLT, PORTABLE WITH POWERWISE

CONNECTOR, CE APPROVED (OPTIONAL)

BATTERY CHARGER, LESTER, 36 VOLT, ON-BOARD, CE APPROVED

(OPTIONAL)

QTY.

For service or replacement parts, contact:

Lester Electrical

625 West “A” Street

Lincoln, NE 68522

Phone: (402) 477-8988, FAX: (402) 474-1769

Always provide the following information when requesting information or ordering replacement parts:

Model Number:

Serial Number: (stamped into housing)


BODY - FRONT

13

42

41

5

30 40 4

2

3

29

37

38

12

20

32

34

33

35

31

22

23

24

25

Ref Bod 1-1

Page C-1

26

18

1

9

8

16


Upper

Section

Lower Leg

Section


45

Self

Drilling

Screws

Self

Drilling

Screws

BODY - FRONT

26

27

28

29

22

23

24

25

30

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


71151-G01

71153-G01

71154-G01

00614-G5

71158-G01

QTY.

INSTRUMENT PANEL ASSEMBLY (INCLUDES ITEMS 2 - 5) ..........................

1

DEFLECTOR (PASSENGER SIDE) .............................................................

1

DEFLECTOR (DRIVER SIDE) ......................................................................

1

SCREW, #8 - 18 X 5/8" LG ...........................................................................

6

INSTRUMENT PANEL INSERT (4 CUP HOLDER)......................................

1

71115-G01

71055-G01

71413-G01

16816-G2

608465

74443-G01

01038-G01

16469-G1

01057-G01

27166-G04

70725-G02

71051-G**

71055-G01

VINYL TRIM ........................................................................................................

RIVET, 3/16" X 1" LG (ALUMINUM) ....................................................................

SPLASH PANEL..................................................................................................

RATCHET FASTENER, 1/4" X 3/4" LG ...............................................................

LABEL (SAFETY) ................................................................................................

LABEL (ANTI-ROLLBACK) .................................................................................

2

10

1

5

1

1

BOLT, 1/4 - 20 X 11/16" LG .................................................................................

4

WASHER, 1/4" ....................................................................................................

2

RIVET, 1/4" X 1" LG ............................................................................................

2

FRONT SHIELD ..................................................................................................

1

FRONT SHIELD BRACE.....................................................................................

COWL..................................................................................................................


2

1

9

Service Parts Manual Page C-2

BODY - FRONT

40

41

42

43

36

37

38

39

44

45

31

32

33

34

35





ITEM PART NO.


10570-G11

71056-G01

00570-G2

00438-G6

00571-G2

QTY.

RIVET, 3/16" X 3/4" LG (STAINLESS STEEL) ....................................................

2

BOLT, 5/16 - 18 X 5/8" LG ...................................................................................

4

WASHER, 5/16....................................................................................................

4

BOLT, 5/16 - 18 X 3/4" LG (WITH TOP) ..............................................................

2

WASHER, 5/16" ..................................................................................................

2

71037-G02

71597-G01

74239-G01

E-Z-GO NAMEPLATE (GOLD)............................................................................

NUT, SELF-THREADING, 5MM STUD x 10MM HEX .........................................

INSTRUMENT PANEL WOODGRAIN APPLIQUE KIT.......................................

1

2

1

Page C-3 Service Parts Manual

BODY - FRONT


BODY - MID SECTION

5

6

Ref Bod 2-2

Page C-5

1

4

2

3

19

20

9

18

10

15

14

13


BODY - MID SECTION

10

11

12

13

8

9

6

7

1

4

5

2

3

18

19

20

14

15

16

17





ITEM PART NO.


70662-G01

70451-G01

70452-G01

14601-G11

70995-G01

70995-G02

QTY.

UPPER FLOORPAN............................................................................................

1

LOWER FLOORPAN...........................................................................................

1

ACCESS COVER ................................................................................................

1

RIVET, 3/16" X 9/16" LG (ALUMINUM) ...............................................................

16

FLOORMAT.........................................................................................................

1

FLOORMAT WITH HORN HOLE ........................................................................

1

70440-G04

00715-G2

600496

70244-G03

00715-G2

71812-G01

71812-G02

16816-G2

SEAT FRAME......................................................................................................

BOLT, 5/16 - 18 X 4/5" LG ...................................................................................

BATTERY TRAY..................................................................................................

1

SPLASH PANEL..................................................................................................

1

BOLT, 5/16 - 18 X 4/5" LG ...................................................................................

4

FENDER LINER (PASSENGER SIDE) ...............................................................

FENDER LINER (DRIVER SIDE)........................................................................


1

2

1

1

8


BODY - REAR



51

52

53

54

55

6

47 45

46

LABELS

72

24

23

13 11

5

17

19

12

3

18 4

7

32

GOLF

CAR

29

30

31

28

68

Ref Bod 2-3

Page C-7

59, 60,

61, 62,

63

SHUTTLE 2+2 AND CONVERTIBLE CARRIER

40

41

39

29

37 38

36


BODY - REAR

26

27

28

29

22

23

24

25

30

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


71912-G4**

71334-G0**

71318-G01

16816-G1

10570-G10

10570-G12

18436-G1

QTY.

REAR BODY (WITHOUT TAILLIGHTS) (INCLUDES ITEMS 3, 4) .....................

1

REAR BODY (WITH TAILLIGHTS) (INCLUDES ITEMS 3, 4).............................

1

BAGWELL LINER .........................................................................................

1

RATCHET FASTENER, 1/4" X 9/16" LG ......................................................

26

RIVET, 5/32" X 9/16" LG (STAINLESS STEEL) ..................................................

6

RIVET, 1/4" X 9/16" LG (ALUMINUM) .................................................................

4

RIVET, 1/4" X 3/4" LG .........................................................................................

2

75126-G01

75126-G02

16816-G2

71320-G01

71364-G02

01107-G01

71609-G01

10570-G11

71578-G01

00571-G2

71102-G01

FENDER SCUFFGUARD (DRIVER SIDE) .........................................................

FENDER SCUFFGUARD (PASSENGER SIDE).................................................


ACCESS PANEL .................................................................................................

1

1

8

'J' CLIP ................................................................................................................

1

SCREW, #8 X 5/8" LG (STAINLESS STEEL) .....................................................

5

SEAT HINGE PLATE...........................................................................................


REAR BUMPER ..................................................................................................

WASHER, 5/16" ..................................................................................................

BOLT, 1/4 - 20 X 3/4" LG .....................................................................................

1

2

4

1

4

4


BODY - REAR

56

57

58

59

52

53

54

55

60

48

49

50

51

44

45

46

47

40

41

42

43

36

37

38

39

31

32

33

34

35





ITEM PART NO.


71514-G01

14601-G17

QTY.

BUMPER PLUG ..................................................................................................

4

RIVET, 3/16" X 9/16" LG (ALUMINUM) ...............................................................

4

71456-G01

71398-G01

71455-G01

71102-G01

71554-G01

71455-G01

71501-G01

71502-G01

15058-G6

71507-G01

71507-G02

16705-G1

23726-G4

14390-G4

75960-G01

75962-G01

REAR BUMPER (SHUTTLE 2+2) .......................................................................

BOLT, 1/4 - 20 X 1 1/4" LG ..................................................................................

BUMPER PLUG ..................................................................................................

BOLT, 1/4 - 20 X 3/4" LG .....................................................................................

'J' TYPE NUT RETAINER....................................................................................

BUMPER STAY ...................................................................................................

ROCKER PANEL (PASSENGER SIDE)..............................................................

ROCKER PANEL (DRIVER SIDE) ......................................................................

RIVET, 3/16" X 15/16" LG (ALUMINUM) .............................................................

SILL PLATE (PASSENGER SIDE) ......................................................................

1

SILL PLATE (DRIVER SIDE)...............................................................................

1

SCREW, 1/4 - 20 X 1" LG (STAINLESS STEEL) ................................................

4

SPACER, 5/16"....................................................................................................

4

LOCK NUT, 1/4 - 20 ............................................................................................

4

LABEL (FREEDOM) ............................................................................................

LABEL (FREEDOM SE) ......................................................................................

1

2

4

2

2

4

1

1

4

2

2

Page C-9 Service Parts Manual

BODY - REAR

70

71

72

66

67

68

69

61

62

63

64

65





ITEM PART NO.


75964-G01

35434-G01

35430-G19

QTY.

LABEL (FREEDOM LE) ......................................................................................

2

LABEL (SHUTTLE) .............................................................................................

2

LABEL (TXT 2+2) ................................................................................................

2

*

74024-G01

LABEL (SERIAL NUMBER) ................................................................................

SEAT WRAP MOUNTED NOISE SUPPRESSOR ..............................................

1

1


BODY - FOOTREST

Items 1 - 22 Are For Use On

Shuttle 2+2 and Convertible Carrier Models Only

VIEWED FROM

FRONT OF

VEHICLE

21

Convertible Carrier Only

19

20

22

4

16

14

8

9

Vertical

Frame

Support

10

11

13

11

Foot

Rest

12

11

13

5

17

1

2

3 ef Bod 2-4

Page C-11

TWO BAG ATTACHMENT


30

27

29

28


BODY - FOOTREST

26

27

28

29

22

23

24

25

30

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


70361-G01

70633-G01

70362-G01

19853-G1

74074-G01

QTY.

FOOTREST ASSEMBLY (INCLUDES ITEMS 2 - 5) ...........................................

1

FOOTREST ..................................................................................................

1

FLOOR MAT .................................................................................................

1

END CAP, 1" .................................................................................................

2

LABEL (WARNING) ......................................................................................

1

74126-G01

74126-G02

00427-G6

00560-G1

00769-G2

11098-G5

01006-G02

74149-G01

16816-G2

75268-G01

606882

19859-G1

20271-G2

75183-G01

75188-G01

22238-G2

17255-G1

75187-G01

VERTICAL FRAME SUPPORT (PASSENGER SIDE) ........................................

VERTICAL FRAME SUPPORT (DRIVER SIDE).................................................

END CAP, 3/4".....................................................................................................

HOLE PLUG, 1/2" ................................................................................................

1

1

BOLT, 3/8 - 16 X 1 1/2" LG ..................................................................................

2

WASHER, 3/8" ....................................................................................................

10

CARRIAGE BOLT, 3/8 - 16 X 1 1/4" LG ..............................................................

2

LOCK NUT, 3/8 - 16 ............................................................................................

10

BOLT, 3/8 - 16 X 1" LG ........................................................................................

VALANCE PANEL ...............................................................................................


2

1

4

SUPPORT ...........................................................................................................

1

SELF THREADING SCREW, #12 - 24 X 3/4" LG ...............................................

2

2

2

TWO BAG ATTACHMENT KIT (INCLUDES ITEMS 27 - 30) ..............................

1

TWO BAG ATTACHMENT ............................................................................

1

KNOB, 3/8 - 16 X 1 1/2" LG ..........................................................................

1

TEFLON WASHER, 5/16" .............................................................................

1

SUPPORT BRACKET...................................................................................

1


BODY - ACCESSORIES

7

4

BASKET DIVOT REPAIR KIT

Reinforcing Plate (Part of holder)

2 1 - Includes Items 2 - 4

3

SAND BOTTLE DIVOT REPAIR KIT

A

12

13

Ref Bod 2-5

Page C-13

SIDE

BASKET

KIT

11


18

19

17

20

A


CENTER BASKET KIT


BODY - ACCESSORIES

10

11

12

13

8

9

6

7

1

4

5

2

3

18

19

20

14

15

16

17





ITEM PART NO.


28661-G01

71102-G01

28660-G01

28659-G01

QTY.

SAND BOTTLE DIVOT REPAIR KIT (INCLUDES ITEMS 2 - 4) .........................

1

BOLT, 1/4 - 20 X 3/4" LG...............................................................................

1

SAND BOTTLE HOLDER .............................................................................

1

SAND BOTTLE .............................................................................................

1

23300-G01

75007-G02

75460-G01

71102-G01

00793-G2

75003-G02

75461-G01

71102-G01

00793-G2

01105-G01

BASKET DIVOT REPAIR KIT (INCLUDES SCOOP) ..........................................

SIDE BASKET KIT (INCLUDES ITEMS 11 - 13).................................................

SIDE BASKET ..............................................................................................

BOLT, 1/4 - 20 X 3/4" LG...............................................................................

FLAT WASHER, 1/4" (STAINLESS STEEL) .................................................

CENTER BASKET KIT (INCLUDES ITEMS 17 - 20) ..........................................

CENTER BASKET ........................................................................................

1

1

1

3

3

1

1

BOLT, 1/4 - 20 X 3/4" LG...............................................................................

2

FLAT WASHER, 1/4" (STAINLESS STEEL) .................................................

2

SCREW, #10 X 5/8" LG (STAINLESS STEEL) .............................................

2


BODY - ACCESSORIES CONTINUED

Front of Vehicle

MESSAGE

HOLDER

1

OR

2

COOLER JUG

AND BRACKET

5

BOX COOLER

AND BRACKET

11 12

10

9

RAKE HOLDER AND RAKE

Ref Bod 2-6

Page C-15

6



10

11

12

8

9

6

7

1

4

5

2

3





ITEM PART NO.


75509-G01

75496-G01

QTY.

MESSAGE HOLDER (ONE PIECE)....................................................................

1

MESSAGE HOLDER...........................................................................................

1

75495-G01

75344-G01

25885-G01

00989-G06

11027-G2

14735-G1

COOLER JUG AND BRACKET KIT ....................................................................

BOX COOLER AND BRACKET KIT ...................................................................

RAKE HOLDER...................................................................................................

1

1

1

SQUARE HEAD BOLT, 1/4 - 20 X 3/4" LG..........................................................

2

LOCK NUT, 1/4 - 20 ............................................................................................

2

RAKE...................................................................................................................

1



2

A

4

3

FOUR BAG ATTACHMENT KIT


18

A

E

11

14 15

13

16

17

12

10

E

B

C

5

B

8

6

C

7

8

D

D

7

8

9

9

9

ASH TRAY

Ref Bod 2-7

Page C-17

24

25

23

26

27



22

23

24

25

26

27

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


75335-G01

*

*

17651-G2

28129-G01

17651-G2

17651-G3

00559-G8

28129-G01

*

00560-G1

*

13728-G1

00150-G6

00559-G5

00565-G5

00526-G3

*

QTY.

FOUR BAG ATTACHMENT KIT (INCLUDES ITEMS 2 - 18) ..............................

1

TOP ASSEMBLY ..........................................................................................

1

BOTTOM ASSEMBLY ..................................................................................

1

CLEVIS PIN, 5/16 X 1 1/8" LG......................................................................

1

PUSH NUT, 5/16"..........................................................................................

1

CLEVIS PIN, 5/16 X 1 1/8" LG......................................................................

1

CLEVIS PIN, 5/16 X 1/2" LG.........................................................................

2

WASHER, 5/16" ............................................................................................

3

PUSH NUT, 5/16"..........................................................................................

3

CLEVIS PIN 3/8 X 1 1/4" LG.........................................................................

2

WASHER, 3/8" ..............................................................................................

2

PUSH NUT, 3/8"............................................................................................

2

RUBBER BUMPER.......................................................................................

2

SCREW, #10 - 24 X 3/4" LG .........................................................................

2

WASHER, #10 ..............................................................................................

2

LOCK WASHER, #10 ...................................................................................

2

NUT, #10 - 24................................................................................................

2

LABEL (WARNING) ......................................................................................

1

75109-G02

27731-G01

27736-G01

75108-G02

00100-G4

ASH TRAY KIT (INCLUDES ITEMS 24 - 27) ......................................................

ASH TRAY ....................................................................................................

GASKET .......................................................................................................

BRACKET .....................................................................................................

SCREW, #10 - 16 X 1/2" LG .........................................................................

1

1

1

1

4



6

5

4

3

10

2

DOUBLE SANDMUG MOUNTING KIT

ITEM 1 INCLUDES 2 TO 6

9

8

Page C-19

SINGLE SANDMUG MOUNTING KIT

ITEM 7 INCLUDES 8 TO 10







ITEM PART NO.


8

9

6

7

10

1

4

5

2

3

606986

606988

71102-G01

606950

*

606949

606951

71102-G01

606950

606949

QTY.

DOUBLE SANDMUG MOUNTING KIT ( INCLUDES 2-6 ) .................................

1

MOUNTING PLATE, SAND MUG - HOLDER..............................................

1

BOLT 1/4 - 20 X 3/4 .....................................................................................

2

SAND MUG HOLDER...................................................................................

2

BOLT 1/4 - 20 X 1/2 ...............................................................................

4

SAND MUG...................................................................................................

2

SINGLE SANDMUG MOUNTING KIT (INCLUDES 8-10 ) ..................................

1

BOLT 1/4 - 20 X 3/4 .....................................................................................

1

SAND MUG HOLDER...................................................................................

1

SAND MUG...................................................................................................

1


BRAKES

43

50

41

42

35

39

46

45

36

37 38

16

15

14

9

10

7

8

4

3

1

2

40

48

49

30

31

6

5

18

12

24

19

20

13

23

38

37

36

35

34

Accelerator

Pedal

28

26



Part of Frame

25

28

31

32

Ref Brk 1-1

Page D-1


Ref Brk 1-2

BRAKES

78

79

70

55

62

63

64

68

67

75

74

73

69

72

71

66

61

65

54

76 77



59

58

56

57

BRAKE PEDAL

(VEHICLE WITH BRAKE LIGHTS)


Page D-2

Ref Brk 1-3

Page D-3

BRAKES

107

101

106

105

102

Front of Vehicle 89

98

87

90

88

85

94

95

96

91

92

93

82 - Includes Items 84 - 92, 94, 95

83 - Includes Items 84 - 91, 93 - 95

84 - Includes Items 85





97

110

111


BRAKES

19

20

21

22

15

16

17

18

11

12

13

14

8

9

10

27

28

29

23

24

25

26





ITEM PART NO.


1

2

5

6

3

4

7

70612-G01

70681-G01

70682-G01

01071-G01

*

70611-G02

70274-G01

*

*

15766-G1

QTY.

BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS)

(INCLUDES ITEMS 2 - 10)..................................................................................

1

TORSION SPRING.......................................................................................

2

PIVOT PIN ....................................................................................................

1

PUSHNUT, 5/16" ..........................................................................................

2

BRAKE PEDAL .............................................................................................

1

PARK BRAKE PEDAL ..................................................................................

1

BRAKE/PARK BRAKE PEDAL PAD KIT

(INCLUDES ITEMS 8 - 10) ...........................................................................

1

SERVICE BRAKE PAD ..........................................................................

1

PARK BRAKE PEDAL PAD ...................................................................

1

OVAL RIVET, 3/16" X 7/16" LG..............................................................

9

70582-G01

70581-G01

70676-G01

00643-G1

11098-G5

70272-G04

00963-G01

11098-G9

70969-G03

28082-G01

28083-G01

*

*

01111-G01

SHOULDER BOLT, 3/8 - 16 X 4" LG (STAINLESS STEEL)...............................

FLANGED BUSHING ..........................................................................................

TORSION SPRING .............................................................................................

WASHER, 3/8" ....................................................................................................

LOCK NUT, 3/8 - 16 ............................................................................................

COMPENSATOR ASSEMBLY (INCLUDES ITEMS 19, 20) ...............................

SPHERICAL NUT, 5/16 - 24 .........................................................................

1

LOCK NUT, 5/16 - 24....................................................................................

1

EQUALIZER AND BRAKE CABLE ASSEMBLY (INCLUDES ITEMS 23 - 26) ...

1

2

1

1

1

1

1

EQUALIZER BRACKET................................................................................

1

BRAKE COMPENSATOR BUMPER ............................................................

2

BRAKE CABLE (DRIVER SIDE)...................................................................

1

BRAKE CABLE (PASSENGER SIDE)..........................................................

1

RETAINING RING, 4/5" (STAINLESS STEEL) ...................................................

4


Page D-4

BRAKES

40

41

42

43

36

37

38

39

30

31

32

33

34

35

48

49

50

51

44

45

46

47

52

53





ITEM PART NO.


10386-G3

10387-G3

14443-G2

QTY.

CLEVIS PIN, 5/16" X 13/16" LG..........................................................................

1

COTTER PIN, 3/32" X 3/4" LG............................................................................

3

CLEVIS PIN, 5/16" X 5/8" LG..............................................................................

2

54

55

56

57

58

70601-G01

17838-G1

20835-G1

00559-G8

10387-G3

70098-G01

10097-G6

70587-G01

71215-G01

14134-G4

70113-G01

11027-G1

70080-G02

00414-G6

00891-G2

70690-G02

*

70611-G02

70274-G01

*

*

KICK-OFF LINK...................................................................................................

NYLON BUSHING...............................................................................................

KICK-OFF CAM...................................................................................................

SETSCREW, 1/4 - 20 X 1/2" LG .........................................................................

SPACER..............................................................................................................

ADJUSTABLE BUMPER.....................................................................................

LOCK NUT, 5/16 - 18 ..........................................................................................

CATCH BRACKET ..............................................................................................

BOLT, 1/4 - 20 X 3/4" LG ....................................................................................

NUT, 1/4 - 20 NYLOCK .......................................................................................

1

2

TEFLON WASHER, 3/8" .....................................................................................

2

WASHER, 5/16" ..................................................................................................

2

COTTER PIN, 3/32" X 3/4" LG............................................................................

2

KICK-OFF CAM PIVOT.......................................................................................

1

FLANGED BEARING ..........................................................................................

2

1

2

1

1

1

1

2

2

BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS)

(INCLUDES ITEMS 54 - 79)................................................................................

1

BRAKE PEDAL .............................................................................................

1

PARK BRAKE PEDAL ..................................................................................

1

BRAKE/PARK BRAKE PEDAL PAD KIT (INCLUDES ITEMS 57 - 59) ........

1

SERVICE BRAKE PAD ..........................................................................

1

PARK BRAKE PAD ................................................................................

1

Page D-5


BRAKES





ITEM PART NO.

15766-G1


OVAL RIVET, 3/16" x 7/16" LG ..............................................................

9

77

78

79

80

73

74

75

76

81

82

83

69

70

71

72

65

66

67

68

59

60

61

62

63

64

84

85

86

87

70258-G03

70682-G01

70681-G01

01071-G01

00737-G8

00739-G1

74535-G01

27137-G01

14390-G10

10606-G8

00957-G1

00559-G5

00559-G3

00565-G3

00525-G5

13514-G1

14628-G1

24605-G1

17618-G1

70998-G01

70998-G02

70794-G01

*

27944-G01

*

BRAKE PEDAL PLATE.................................................................................

1

PIVOT PIN ....................................................................................................

1

TORSION SPRING.......................................................................................

2

PUSHNUT, CAP WASHER TYPE 5/16".......................................................

1

SCREW, #10 - 24 X 7/8" LG.........................................................................

4

RUBBER NUT, #10 - 24 ...............................................................................

2

BRAKE PEDAL STANDOFF.........................................................................

2

CONICAL SPRING .......................................................................................

2

NUT, NYLOCK #10 - 24...............................................................................

2

MICRO SWITCH...........................................................................................

1

BOLT, #6 - 32 X 1 1/4" LG............................................................................

2

WASHER, #10 ..............................................................................................

2

WASHER, #6 ................................................................................................

4

LOCK WASHER, #6 .....................................................................................

2

NUT, #6 - 32 .................................................................................................

2

SCREW AND LOCK WASHER, #6 - 32 X 1/4" (BRASS) .............................

2

PUSH ON MALE TERMINAL........................................................................

WIRE HARNESS (BRAKE LIGHT) ...............................................................

WIRE TIE ......................................................................................................

2

1

3

BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84 - 92, 94, 95)........

1

BRAKE ASSEMBLY (PASSENGER SIDE)

(INCLUDES ITEMS 84 - 91, 93 - 95) ..................................................................

1

BRAKE SHOE KIT (INCLUDES ITEM 85)....................................................

2

BRAKE SHOE ........................................................................................

2

BRAKE SPRING KIT (INCLUDES ITEMS 87 - 91).......................................

2

UPPER SPRING ....................................................................................

1


Page D-6

BRAKES

98

99

100

101

94

95

96

97

88

89

90

91

92

93

106

107

108

109

102

103

104

105

110

111





ITEM PART NO.


*

*

*

*

72582-G01

72582-G02

*

*

17083-G2

15126-G1

15485-G1

QTY.

LOWER SPRING ...................................................................................

1

PIN .........................................................................................................

2

CUP AND SPRING ................................................................................

2

ADJUSTER SPRING..............................................................................

1

BRAKE ADJUSTER KIT (DRIVER SIDE) (INCLUDES ITEMS 94, 95) ........

1

BRAKE ADJUSTER KIT (PASSENGER SIDE) (INCLUDES ITEMS 94, 95) 1

ADJUSTER ............................................................................................

1

TEFLON WASHER ................................................................................

2

BOLT, 5/16 - 24 X 1" LG .....................................................................................

8

LOCK NUT, 5/16 - 24 ..........................................................................................

8

WASHER, 13/16" ................................................................................................

2

19186-G01

*

19862-G1

15487-G1

15483-G1

10387-G1

72036-G03

72036-G04

BRAKE DRUM ASSEMBLY (INCLUDES ITEMS 101 - 102) ..............................

BRAKE DRUM ..............................................................................................

LUG BOLT, 1/2 - 20 X 1 3/16" LG ................................................................

WASHER, 1 3/8" O.D. X 21/32" ..........................................................................

2

CASTELLATED NUT, 5/8 - 18 ............................................................................

2

COTTER PIN, 1/8" X 1 1/2" LG...........................................................................

2

BRAKE CABLE BRACKET (PASSENGER SIDE) ..............................................

BRAKE CABLE BRACKET (DRIVER SIDE) .......................................................

2

1

4

1

1

Page D-7


BRAKES


Page D-8

DIRECTION SELECTOR

2

*NOTE: For PDS Direction Selector See ELECTRICAL SYSTEM Section

20

1

3

21



6

4

5

9

12

13

11

32

33

25

34 26

22

36

37

17

16

41

28

24

23

22

29

45

49

50

48

30 31

44

46

47

37

38

40

39

15

35

42

34

26

8

9

7

25

27

Ref Dsl 1-1

Page E-1



27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2





ITEM PART NO.


71205-G01

00740-G4

70233-G01

25664-G2

70334-G01

70313-G01

70232-G03

22754-G3

14390-G1

QTY.

DIRECTION SELECTOR HANDLE.....................................................................

1

SCREW, #10 - 32 X 1/2" LG (STAINLESS STEEL)............................................

1

DIRECTION SELECTOR SHAFT .......................................................................

1

BUSHING ............................................................................................................

1

OFFSET SHIFT LINKAGE ARM .........................................................................

1

LINKAGE ROD....................................................................................................

1

SHIFT LINKAGE ARM ........................................................................................

1

BUSHING ............................................................................................................

2

LOCK NUT, 3/8 - 24 ............................................................................................

2

73049-G01

00114-G6

16469-G1

00438-G6

00571-G2

11098-G6

70578-G02

73027-G01

12835-G1

10606-G2

00645-G7

73048-G01

00565-G3

14628-G1

00525-G5

00645-G5

12806-G1

00560-G1

DIRECTION SELECTOR COVER ......................................................................

SCREW, 1/4 - 14 X 3/4" LG ................................................................................

WASHER, 1/4" ....................................................................................................

BOLT, 5/16 - 18 X 3/4" LG ..................................................................................

WASHER FLAT, 5/16" ........................................................................................

NUT, NYLOCK 5/16 - 18 ....................................................................................

DIRECTION SELECTOR ASSEMBLY (INCLUDES ITEMS 20 - 50) ..................

DIRECTION SELECTOR SHAFT .................................................................

CAM ..............................................................................................................

MICRO SWITCH...........................................................................................

SCREW, #6 - 32 X 2" LG..............................................................................

COVER BRACKET .......................................................................................

LOCK WASHER, #6 .....................................................................................

PUSH ON MALE TERMINAL........................................................................

NUT, #6 - 32 .................................................................................................

SCREW, #6 - 32 X 5/8" LG...........................................................................

SPACER .......................................................................................................

WASHER, 3/8"..............................................................................................

1

1

1

2

2

2

1

1

1

2

4

1

6

3

6

2

4

1


Page E-2


41

42

43

44

37

38

39

40

31

32

33

34

35

36

45

46

47

48

49

50





ITEM PART NO.


14390-G1

25978-G37

13514-G1

00567-G3

25978-G343

00414-G8

00559-G7

00565-G7

00532-G1

15461-G1

73031-G02

73290-G02

QTY.

LOCK NUT, 3/8 - 24......................................................................................

1

18 GA WIRE (RED 4") ..................................................................................

1

SCREW.........................................................................................................

4

LOCK WASHER, #6 .....................................................................................

4

18 GA WIRE (RED 6") ..................................................................................

1

SCREW, 1/4-20X1" LG.................................................................................

2

WASHER, 1/4 ...............................................................................................

4

LOCK WASHER, 1/4" ...................................................................................

2

NUT, 1/4 - 20 ................................................................................................

2

SUPPORT BRACKET...................................................................................

1

DIRECTION SELECTOR MOUNTING BRACKET .......................................

1

REVERSE WARNING BUZZER (CONTINUOUS TONE) ............................

1

14651-G1

24940-G1

00565-G7

00414-G6

18888-G1

00565-G8

00544-G3

CONTACT BOARD ASSEMBLY (INCLUDES ITEMS 45 - 50).....................

1

STOP......................................................................................................

2

LOCK WASHER, 1/4" (STAINLESS STEEL) .........................................

2

BOLT, 1/4 - 20 X 3/4" LG .......................................................................

2

CONTACT STUD, 5/16 - 18 ...................................................................

4

LOCK WASHER, 5/16"...........................................................................

4

NUT, 5/16 - 18........................................................................................

4

Page E-3




Page E-4

ELECTRICAL SYSTEM - COMMON

27

17

CHARGER

RECEPTACLE 14 20

19

16 22

A


21

15

28

1

A

9 11

5

4

6

Control Harness

(See Electronic

Speed Control

Section)

Controller (See

Electronic Speed

Control Section)

10

38

39

40 PDS

41 Only

34

32

33 Power Harness

(See Electronic

Speed Control

Section)

Clamp

(See

REAR AXLE

Section)

Ref Ele 1-1

Page F-1 Service Parts Manual

66

HOUR METER DETAIL


63

64

67

65

HORN BUTTON

Floorboard

59 58 56

HORN

57

55

56


71, 72

73, 74

75

OFF ON

77

76

KEY SWITCH AND KEY SET

85

TURN SIGNALS


82

89

46

45

83

84

81

52

47

GRN

51

Ref Ele 1-2

53

54

Service Parts Manual Page F-2


Rear

Fender

93

94

96

95

98

97

TAILLIGHTS

99

WHT to BLK from Harness - Both Sides

BLK to BLU/WHT from Harness - Both Sides

RED to WHT from Harness - Driver Side

RED to YEL from Harness - Passenger Side

RED TO BRN from Harness - (W/O Turn Signals)

103

105

109 104

108

107

LIGHT BAR

106

Page F-3

Ref Ele 1-3

115

Driver Side

114

113

114

Passenger Side

115

BLK RED

YEL BLK

BLK BLU BLK BLU

RED

BLK

BLK

GRN







ITEM PART NO.


XXXXX-GXX 6 VOLT BATTERY ...............................................................................................

6

25

26

27

28

21

22

23

24

29

30

17

18

19

20

14

15

16

10

11

12

13

8

9

6

7

1

4

5

2

3

01101-G01

70045-G01

11027-G1

00702-G2

607651

607590

73063-G01

*

*

73051-G05

73051-G06

73051-G08

73051-G09

73051-G10

*

71055-G01

17618-G1

HOLD DOWN BOLT (STAINLESS STEEL).........................................................

BATTERY RETAINER .........................................................................................

LOCK NUT, 5/16 - 18 ..........................................................................................

NUT, 5/16 - 18 ..................................................................................................... 12

4 GA WIRE, GREEN 10".....................................................................................

1

4 GA WIRE, GREEN 7".......................................................................................

5

CHARGER RECEPTACLE ASSEMBLY (INCLUDES ITEMS 14 - 23)................

SCREW, #10 - 32 X 1/2" LG (BRASS) .........................................................

SCREW, #6 - 32 X 1 3/4" LG (STAINLESS STEEL).....................................

LOCK NUT, #6 - 32 .......................................................................................

WIRE HARNESS (CHARGER).....................................................................


WIRE TIE ............................................................................................................

2

1

2

1

RECEPTACLE COVER ................................................................................

1

RECEPTACLE BOTTOM ..............................................................................

1

FEMALE CONNECTOR ...............................................................................

2

INSULATOR SLEEVE...................................................................................

1

2

3

3

1

4

3







ITEM PART NO.


55

56

57

58

51

52

53

54

59

60

47

48

49

50

44

45

46

40

41

42

43

36

37

38

39

31

32

33

34

35

27327-G01

10570-G11

17618-G1

00993-G01

28418-G01

00993-G02

28418-G02

22674-G1

01041-G01

18392-G1

32860-G1

00414-G5

00559-G7

14390-G4

17318-G1

17318-G2

27068-G01

19233-G1

71055-G01

CABLE CLAMP ...................................................................................................


WIRE TIE ............................................................................................................

QTY.

1

1

11

LOCK WASHER, 5/16" (SILICON BRONZE) ...................................................... AR

NUT, 5/16 - 18 (BRASS)...................................................................................... AR

LOCK WASHER, 1/4" (SILICON BRONZE) ........................................................

NUT, 1/4 - 20 (BRASS)........................................................................................

FUSE BLOCK......................................................................................................

RIVET, 1/8" X 13/16" LG .....................................................................................

2

2

1

2

15 AMP FUSE ..................................................................................................... AR

HORN..................................................................................................................

1

BOLT, 1/4 - 20 X 5/8" LG .....................................................................................

1

WASHER, 1/4" FL ...............................................................................................

1

LOCK NUT, 1/4 - 20 ............................................................................................

1

HORN SWITCH...................................................................................................

1

HORN SWITCH CAP AND NUT .........................................................................

1

HORN SWITCH BOOT .......................................................................................

1

HORN SWITCH LABEL ......................................................................................

1


2







ITEM PART NO.


85

86

87

88

81

82

83

84

89

90

77

78

79

80

74

75

76

70

71

72

73

66

67

68

69

61

62

63

64

65

75113-G02

74665-G02

74716-G01

74696-G01

10570-G11

75117-G01

17421-G1

17955-G1

18027-G1

33639-G**

00568-G6

17137-G1

17063-G1

75107-G02

17867-G1

21640-G1

32307-G3

17618-G1

20965-G3

73043-G01

HOUR METER KIT (INCLUDES ITEMS 63 - 67)................................................

HOUR METER..............................................................................................

HOUR METER BRACKET............................................................................

RETAINER CLIP ...........................................................................................

RIVET ...........................................................................................................

WIRE HARNESS (HOUR METER)...............................................................

KEY SWITCH KIT (W/O LIGHTS - STANDARD - WITH HARDWARE) ..............

1

KEY SWITCH (WITHOUT LIGHTS - NON STANDARD) ....................................

1

KEY SWITCH (WITHOUT LIGHTS - INDIVIDUALLY KEYED) ...........................

KEY SWITCH (WITH LIGHTS) ...........................................................................

1

LOCK WASHER, 3/4"..........................................................................................

1

FACE NUT, 3/4 - 20.............................................................................................

KEY (SET)...........................................................................................................

TURN SIGNAL KIT (INCLUDES ITEMS 81 - 85)................................................

WIRE HARNESS (ACCESSORY).......................................................................

QTY.

1

1

1

1

2

1

1

1

1

1

TURN SIGNAL (WITH MOUNTING HARDWARE).......................................

1

TURN SIGNAL FLASHER......................................................................

1

FLEX LOOM, 3/8" X 8" LG............................................................................

1

WIRE TIE ......................................................................................................

2

STEERING COLUMN COVER .....................................................................

1

1







ITEM PART NO.


111

112

113

114

115

104

105

106

107

108

109

110

100

101

102

103

96

97

98

99

91

92

93

94

95

74371-G01

74371-G02

71364-G02

71425-G01

22288-G2

14601-G11

21759-G1

74236-G03

74236-G04

01038-G01

00414-G6

11027-G2

74001-G01

00114-G6

74004-G01

74005-G01

74006-G01

BEZEL (DRIVER SIDE).......................................................................................

BEZEL (PASSENGER SIDE) ..............................................................................

'J' CLIP ................................................................................................................

COUNTERSUNK SCREW, #8 ............................................................................

8

BRAKE / TAILLIGHT LAMP.................................................................................

1

RIVET, 3/16" X 9/16" LG (ALUMINUM)...............................................................

4

TAILLIGHT BULB ................................................................................................ AR

HEADLIGHT MOUNT BRACKET (PASSENGER SIDE).....................................

QTY.

1

1

8

1

HEADLIGHT MOUNT BRACKET (DRIVER SIDE) .............................................

1

BOLT, 1/4 - 20 X 11/16" LG .................................................................................

2

BOLT, 1/4 - 20 X 3/4" LG .....................................................................................

2

LOCK NUT, 1/4 - 20 ............................................................................................

2

HEADLIGHT AND TURN SIGNAL LIGHT ..........................................................

1

SCREW, 1/4 - 14 X 3/4" LG.................................................................................

4

HEAD LIGHT BULB ............................................................................................ AR

MARKER LIGHT BULB ....................................................................................... AR

TURN SIGNAL BULB.......................................................................................... AR




ELECTRICAL SYSTEM - PDS

Control

Harness

18

OFF

ON

1

5

2

6

7

17

19

13

9

DASH MOUNTED DIRECTION SELECTOR,

STATE OF CHARGE METER, LABEL AND PLATE

REVERSE BUZZER

RED

23

GRN/

BLK

24

Ref Ele 1-4


ELECTRICAL SYSTEM - PDS

17

18

19

20

13

14

15

16

21

22

23

24

8

9

10

11

12

1

4

5

2

3

6





ITEM PART NO.


73030-G05

74316-G01

QTY.

PLATE (KEY SWITCH, DIRECTION SELECTOR) .............................................

1

LABEL (KEY SWITCH WITHOUT LIGHTS, DIRECTION SELECTOR)..............

1

7

73030-G06

74320-G01

74322-G01

PLATE (KEY SWITCH, DIRECTION SELECTOR, CHARGE METER) ..............

1

LABEL (KEY SWITCH WITHOUT LIGHTS, DIRECTION SELECTOR,

CHARGE METER) ..............................................................................................

1

LABEL (KEY SWITCH WITH LIGHTS, DIRECTION SELECTOR,

CHARGE METER) ..............................................................................................

1

33623-G02

74323-G01

33636-G04

74018-G01

25978-G74

73290-G02

01041-G01

DRIVE RIVET, 3/16" X 3/8" LG ...........................................................................

DIRECTION SELECTOR SWITCH (DASH MOUNTED).....................................

STATE OF CHARGE METER (VERTICAL) ........................................................

WIRE HARNESS (STATE OF CHARGE METER) ..............................................

18 GA WIRE (RED 6").........................................................................................

REVERSE WARNING BUZZER (CONTINUOUS TONE) ...................................

RIVET, 1/8" X 13/16" LG .....................................................................................

2

1

1

1

1

1

2


ELECTRICAL SYSTEM - SERIES

21

22

Controller (See

Electronic Speed

Control Section)

Ref Ele 1-5

Page F-11

Control Harness

(See Electronic

Speed Control

Section)

12

16

OFF

ON

1

5

2

6

7

17

15

9

STATE OF CHARGE METER, LABEL AND PLATE


ELECTRICAL SYSTEM - SERIES

10

11

12

13

8

9

6

7

1

4

5

2

3

17

18

19

20

14

15

16

21

22





ITEM PART NO.


73030-G01

71145-G01

QTY.

PLATE (KEY SWITCH ONLY) .............................................................................

1

LABEL (KEY SWITCH ONLY) .............................................................................

1

73030-G02

71123-G02

71129-G02

33623-G02

73041-G01

33636-G01

74018-G01

25978-G74

00565-G8

00532-G3

PLATE (KEY SWITCH, STATE OF CHARGE METER) ......................................

LABEL (KEY SWITCH W/O LIGHTS, STATE OF CHARGE METER) ................

1

LABEL (KEY SWITCH W/ LIGHTS, STATE OF CHARGE METER) ...................

1

DRIVE RIVET, 3/16" X 3/8" LG ...........................................................................

WIRE HARNESS (KEY SWITCH).......................................................................

STATE OF CHARGE METER .............................................................................

WIRE HARNESS (STATE OF CHARGE METER) ..............................................

18 GA WIRE (RED 6").........................................................................................

LOCK WASHER, 5/16"........................................................................................

NUT, 5/16 - 18 .....................................................................................................

1

2

1

1

1

1

4

4


ELECTRONIC SPEED CONTROL - SERIES

A

7

ORN to

MS4 (NC)

BLK to

Tab on

Direction

Selector

RED to

Solenoid

LT. GRN to

Key Switch

To Pedal

Box Connector

B+ to Direction

Selector A

SOL

B- to Negative

Battery Terminal

B+

B-

M- to

A1 Motor

M-

12

BLK

20

23

BLK

WHT

24

29

11

To B+

15

1 - Includes Items 3-27

2 - Includes Items 3-10 & 12-29

16

25

A

17

26 27

19

8

10

4 3

RED

*

6

BLK

12

3

13 10 8

4

WHT

From Power

Harness 19

From Control

Harness

* Silver line on diode (6) must be oriented as shown

22 21

19

18

19

Ref Esc 1-1

Page G-1 Service Parts Manual

ELECTRONIC SPEED CONTROL - SERIES

26

27

28

29

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


73056-G04 ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 3-27) .....

1

73056-G06 ELECTRONIC SPEED CONTROL-II ASSY (INCLUDES ITEMS 3-10; 12-29).

1

* LOCK WASHER, #10 ...................................................................................

2

*

30353-G1

NUT, 10 - 32 .................................................................................................

DIODE, 3 AMP..............................................................................................

2

1

21764-G1

73103-G02

*

RESISTOR....................................................................................................

1

WIRE HARNESS (CONTROL) .....................................................................

1

NUT, 5/16 - 24...............................................................................................

2

*

607591

25978-G10

800706

27855-G01

73471-G01

25864-G09

73190-G01

71102-G01

73028-G01

31539-G1

73053-G01

71102-G03

607656

25866-G01

00270-G5

11027-G1

607656

LOCK WASHER, 5/16" .................................................................................

4 GA WIRE, GREEN, 11.5"...........................................................................

18 GA WIRE (SOL - B-) ................................................................................

LOCK NUT, 1/4 - 20 ......................................................................................

SOLENOID, 36 VOLT ...................................................................................

HEATSINK ....................................................................................................

ELECTRONIC SPEED CONTROLLER ........................................................

LOCK NUT, 5/16 - 18 ....................................................................................

4 GA WIRING HARNESS, GREEN ..............................................................

2

1

1

2

1

1

1

THERMAL MOUNTING PAD ........................................................................

1

BOLT, 1/4 - 20 X 3/4" LG...............................................................................

5

COVER .........................................................................................................

1

WIRE TIE ......................................................................................................

1

DOUBLE TUBE CLAMP ...............................................................................

1

BOLT, 1/4 - 20 X 1 3/16" LG..........................................................................

3

4 GA WIRING HARNESS, GREEN ..............................................................

1

SOLENOID BRACKET ................................................................................

1

BOLT, 5/16 - 18 X 5/8" LG.............................................................................

3

3

1

Service Parts Manual Page G-2

ELECTRONIC SPEED CONTROL - PDS

A

44

48, 49, 50, 51

5 Pin Performance Option

25

Inline Connector

4 Pin Tow/Maintenance

Box Connector

43

11

F2

BLK

WHT

B+

F1

B-

A1

27




34

39

33

4 Pin Accelerator

Inline Connector

See ACCELERATOR

3 Pin Speed Sensor

Inline Connector

See ELECTRIC MOTOR

24

31

A

28

19

17

16

29

38

36

C From Power

37

Harness 15

8

10

41

40

3 2

6

YEL

BLU

From Control

Harness

2

3

13 10 8

RED

From Control

Harness

19 22 21

19

18

46

Ref Esp 1-1



26

27

28

29

22

23

24

25

30

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


73276-G02

*

*

QTY.

ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2 - 44)......

1

LOCK WASHER, #10 ...................................................................................

2

NUT, 10 - 32..................................................................................................

2

21764-G1

*

*

607591

800706

27855-G01

73471-G01

73326-G07

73190-G01

71102-G01

31539-G1

73053-G01

71102-G01

73106-G01

74324-G02

00270-G5

11027-G1

RESISTOR....................................................................................................

NUT, 5/16 - 24...............................................................................................

LOCK WASHER, 5/16" .................................................................................

4 GA WIRE, GREEN 11.5"............................................................................

LOCK NUT, 1/4 - 20 ......................................................................................

SOLENOID, 36 VOLT ...................................................................................

HEATSINK ....................................................................................................


THERMAL MOUNTING PAD ........................................................................

BOLT, 1/4 - 20 X 3/4" LG...............................................................................

WIRE TIE ......................................................................................................

DOUBLE TUBE CLAMP ...............................................................................

BOLT, 1/4 - 20 X 3/4" LG...............................................................................

WIRE HARNESS (POWER) .........................................................................


BOLT, 5/16 - 18 X 5/8" LG.............................................................................

LOCK NUT, 5/16 - 18 ....................................................................................

1

2

2

1

2

1

1

1

1

5

1

1

4

1

1

3

3



40

41

42

43

36

37

38

39

31

32

33

34

35

48

49

50

51

44

45

46

47





ITEM PART NO.


25866-G01

73089-G01

73028-G02

73093-G01

QTY.

SOLENOID BRACKET .................................................................................

1

COVER ASSEMBLY (INCLUDES ITEMS 33 - 41) .......................................

1

COVER (WITH GASKET) ......................................................................

1

LABEL (TOW SWITCH) .........................................................................

1

73125-G01

*

*

73139-G01

73138-G02

17618-G1

607592

607593

71102-G01

73272-G01

73272-G02

73272-G03

73272-G04

TOGGLE SWITCH WITH SEAL (INCLUDES ITEMS 37 - 39) ...............

SCREW, #5 - 40...............................................................................

NUT, 15/32 - 32................................................................................

SEALED NUT, 15/32 - 32.................................................................

WIRE HARNESS (TOW SWITCH).........................................................

WIRE TIE ...............................................................................................

4 GA WIRE, GREEN 28" ..............................................................................

4 GA WIRE, GREEN 37" ..............................................................................

BOLT, 1/4 - 20 X 3/4" LG .....................................................................................

PERFORMANCE OPTION (FREEDOM) (NOT AVAILABLE FOR FLEET).........

PERFORMANCE OPTION (STEEP HILL) ..........................................................

PERFORMANCE OPTION (MILD HILL) .............................................................

PERFORMANCE OPTION (ALL TERRAIN) .......................................................

1

4

1

1

1

1

1

1

4

1

1

1

1




ELECTRONIC SPEED CONTROL - HD

COVER INSTALLATION


18

20

19

22

23

2

M-

A2

SO

L

27

26

25

Ref Esh 1

Page G-7

4

5

3

30

16

29

6

6

12

11

8

SOLENOID DETAILS

17

14

13

10


ELECTRONIC SPEED CONTROL - HD





ITEM PART NO.


1

4

5

8

9

6

7

2 73060-G05

3 74014-G02

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

26

27

28

29

30

73055-G02

00414-G5

00559-G7

11027-G2

20468-G1

21764-G1

*

*

*

*

73095-G04

28325-G01

25978-G88

607591

25978-G10

00438-G6

11027-G1

23723-G2

16469-G1

14419-G1

00414-G5

11027-G2

QTY.

ELECTRONIC SPEED CONTROL ASSEMBLY (INCLUDES ITEMS 2 - 23).....

1


1

CONTROLLER 1

BOLT, 1/4 - 20 X 5/8" LG...............................................................................

4

WASHER, 1/4" .............................................................................................

4

LOCK NUT, 1/4 - 20 ......................................................................................

6

SOLENOID ...................................................................................................

RESISTOR....................................................................................................

1

LOCK WASHER, #10 ...................................................................................

2

NUT, #10 - 32................................................................................................

2

WASHER, 5/16" ............................................................................................

2

NUT, 5/16 - 24...............................................................................................


WIRE HARNESS (POWER) .........................................................................

BOLT, 5/16 - 18 X 3/4" LG.............................................................................

LOCK NUT, 5/16 - 18 ....................................................................................

COVER................................................................................................................

2

1

1

18 GA WIRE (RED 9") ..................................................................................

1

4 GA WIRE, GREEN 11.5"............................................................................

1

18 GA WIRE(BLK 6", SOL - B-) ....................................................................

1

1

WASHER, 1/4" ....................................................................................................

1

WING NUT, 1/4 - 20 ............................................................................................

1

BOLT, 1/4 - 20 X 5/8" LG .....................................................................................

LOCK NUT, 1/4 - 20 ............................................................................................

1

4

4

4

4


FRONT SUSPENSION/STEERING

Front of Vehicle

33

34

35

44

43

45

*Truck

Models

Only 42*

40

41*

Part of

Frame

1

36

11

4 LUG

10

25

5 LUG

9

6

24

52

53

50

53

Part of

Frame

7

4,15

19,30

34

37

48, 49

21

3,14

8

6

5

23

53

*NOTE: Tie Rod Not

Shown for

Clarity

21

22 18, 29

20

52

3 - Includes Items 4 -10

7 - Includes Item 8



22 - Includes Item 23


Ref Fss 1-1

Page H-1 Service Parts Manual


Ref Fss 1-2

96

117

114

Front of Vehicle

109

113

116

OR

111

112

79

110

115

82

97

93

92

56

81

83

84

76

63

101

102

60

100

108

107

105

106

58

59

68







64

65

61

75 74

73

62

72

125

67

66

71

70

124

123

120

119

121

122

Service Parts Manual Page H-2


22

23

24

25

19

20

21

26

27

28

10

11

12

13

14

8

9

6

7

4

5





ITEM PART NO.


602513

QTY.

FRONT AXLE......................................................................................................

1 1

2

3 70942-G01

70942-G02

25146-G1

50892-G1

70895-G01

19862-G1

12093-G1

00798-G8

12091-G2

SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE)

(INCLUDES ITEMS 4 - 10) .................................................................................

1

SPINDLE ASSEMBLY (PASSENGER SIDE) ...............................................

1

GREASE SEAL.............................................................................................

1

ROLLER BEARING AND RACE ASSEMBLY ..............................................

2

WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 8) ......

1

LUG BOLT, 1/2 - 20 X 1 3/16" LG ..........................................................

4

CASTELLATED NUT, 1 - 14 .........................................................................

1

COTTER PIN, 5/32" X 1 3/4" LG ..................................................................

1

SPINDLE CAP ....................................................................................................

2

70673-G01

70673-G02

SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE)

(INCLUDES ITEMS 5 - 10, 15) ...........................................................................

1

SPINDLE ASSEMBLY (DRIVER SIDE)........................................................

1 15

16

17

18 70943-G01

70942-G02

12092-G1

50892-G1

70772-G01

30143-G1

12093-G1

00798-G8

SPINDLE AND HUB ASSEMBLY, 5 LUG (PASSENGER SIDE)

(INCLUDES ITEMS 19 - 25) ...............................................................................

1

SPINDLE ASSEMBLY (PASSENGER SIDE) ...............................................

1

GREASE SEAL.............................................................................................

1

ROLLER BEARING AND RACE ASSEMBLY ..............................................

2

WHEEL HUB ASSEMBLY WITH RACES, 5 LUG (INCLUDES ITEM 23) ....

1

LUG BOLT, 1/2 - 20 X 1 7/32" LG ..........................................................

5

CASTELLATED NUT, 1 - 14 .........................................................................

1

COTTER PIN, 5/32" X 1 3/4" LG ..................................................................

1



52

53

54

55

56

57

48

49

50

51

44

45

46

47

40

41

42

43

36

37

38

39

30

31

32

33

34

35





ITEM PART NO.


29 70797-G01

70673-G02

QTY.

SPINDLE AND HUB ASSEMBLY, 5 LUG (DRIVER SIDE)

(INCLUDES ITEMS 20 - 25, 30) .........................................................................

1

SPINDLE ASSEMBLY (DRIVER SIDE) .......................................................

1

00407-G6

00560-G3

70745-G01

70754-G01

14390-G6

76419-G01

70509-G01

31539-G1

10435-G1

10194-G1

00532-G6

70990-G02

70989-G03

70163-G03

00734-G1

00463-G11

70964-G02

*

BOLT, 1/2 - 13 X 6" LG .......................................................................................

WASHER, 1/2" ....................................................................................................

KING PIN TUBE .................................................................................................

THRUST WASHER, 1" (STAINLESS STEEL) ....................................................

LOCK NUT, 1/2 - 13 ............................................................................................

SHOCK ABSORBER ..........................................................................................

SHOCK ABSORBER BOOT...............................................................................

WIRE TIE............................................................................................................

SHOCK ABSORBER WASHER .........................................................................

RUBBER BUSHING ...........................................................................................

NUT, 3/8 - 24.......................................................................................................

LEAF SPRING (SEE PART NUMBER ON SPRING) .........................................

LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING) ...............

SPRING PLATE ..................................................................................................

LOCK NUT, 7/16 - 14 ..........................................................................................

BOLT, 7/16 - 14 X 1 3/4" LG ...............................................................................

RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 57 - 68) .............

STEERING BOX INSTALLATION TAG ........................................................

2

4

2

2

2

2

2

4

8

8

4

2

2

4

11

11

1

1



83

84

85

86

79

80

81

82

87

75

76

77

78

71

72

73

74

67

68

69

70

63

64

65

66

58

59

60

61

62





ITEM PART NO.


70694-G01

*

70961-G01

12416-G2

11391-G8

70638-G01

70695-G01

50641-G1

50209-G2

10387-G2

10389-G3

QTY.

RACK EXTENSION ......................................................................................

1

JAM NUT, 1/2 - 20.........................................................................................

1

RACK BOOT.................................................................................................

1

WIRE TIE ......................................................................................................

1

CLAMP, 1 13/16 - 2 3/8"................................................................................

1

PINION SEAL ...............................................................................................

1

RACK BALL JOINT (INCLUDES ITEMS 65 - 68) .........................................

1

RUBBER BOOT .....................................................................................

1

CASTELLATED NUT, 7/16 - 20 ..............................................................

1

COTTER PIN, 3/32" X 1" LG ...............................................................................

1

GREASE FITTING, STRAIGHT...........................................................................

1

00464-G6

01068-G01

70667-G02

70667-G03

00532-G7

00560-G2

00734-G1

70607-G01

70758-G05

70610-G03

28569-G01

01022-G01

BOLT, 7/16 - 14 X 2 3/4" LG ................................................................................

2

BOLT, 7/16 - 14 X 3 1/2" LG ................................................................................

1

SPACER ..............................................................................................................

2

SPACER (SHORT) ..............................................................................................

1

NUT, 7/16 - 14 .....................................................................................................

1

FLAT WASHER, 7/16" .........................................................................................

4

LOCK NUT, 7/16 - 14 ..........................................................................................

3

STEERING SHAFT .............................................................................................

STEERING COLUMN KIT (INCLUDES ITEMS 82 - 84) .....................................

STEERING COLUMN ...................................................................................

STEERING COLUMN BUSHING..................................................................

SCREW, #6 - 20 X 5/16" LG .........................................................................

1

1

1

1

1







ITEM PART NO.


113

114

115

116

109

110

111

112

117

105

106

107

108

101

102

103

104

97

98

99

100

93

94

95

96

88

89

90

91

92 01006-G01

00879-G1

70997-G01

71055-G01

70580-G01

01055-G01

00565-G8

70751-G01

70888-G01

15112-G1

70887-G01

71146-G01

71147-G01

71047-G01

74405-G01

602979

607925

71949-G01

14390-G2

608529

BOLT, 3/8 - 16 X 1 1/4" LG ..................................................................................

LOCK WASHER, 3/8"..........................................................................................

COVER................................................................................................................


INTERMEDIATE SHAFT (INCLUDES ITEMS 101, 102).....................................

QTY.

4

4

1

1

1

BOLT, M8 X 1.25 - 05 LG..............................................................................

2

LOCK WASHER, 5/16" .................................................................................

2

RETAINING RING (INTERNAL) ..........................................................................

1

RETAINING RING (EXTERNAL).........................................................................

1

BALL BEARING ..................................................................................................

1

WAVE WASHER..................................................................................................

1

STEERING WHEEL ............................................................................................

1

STEERING WHEEL COVER ..............................................................................

1

LABEL (E-Z-GO) .................................................................................................

1

LABEL (CUSHMAN)............................................................................................

1

STEERING WHEEL ............................................................................................

1

CLIPBOARD........................................................................................................

1

HUB COVER .......................................................................................................

1

LOCK NUT, 5/8 - 18 ............................................................................................

1

WARNING LABEL ...............................................................................................

1







ITEM PART NO.


118

119

120

121

122

123

124

125

70876-G02

70897-G02

70902-G01

01069-G01

70902-G02

01069-G02

00734-G1

TIE ROD ASSEMBLY (INCLUDES ITEMS 120 - 124) ........................................

THREADED ROD (24" LG)...........................................................................

TIE ROD END (LEFT HAND THREADS) .....................................................

JAM NUT, M12 X 1.25 - 05 (LEFT HAND THREADS)..................................

TIE ROD END (RIGHT HAND THREADS)...................................................

JAM NUT, M12 X 1.25 - 05 (RIGHT HAND THREADS) ...............................

LOCK NUT, 7/16 - 14 ..........................................................................................

QTY.

1

1

1

1

1

1

2




MOTOR

Ref Mtr 1

30


2 - Includes Items 3 - 11 and 14


4

18

5

19

6

20

9

23

10

2

X

1

X

2

A

1

A

8

22

7

21

A

11

3

17

12

14

24

A

26

27 28

25 PDS Only 29

Page J-1


MOTOR

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2





ITEM PART NO.


73124-G02

73124-G03

73120-G01

73120-G03

73120-G15

73120-G25

73120-G07

73120-G06

73120-G09

73120-G08

73120-G16

73120-G29

QTY.

MOTOR (SERIES, FLEET SPEED) (INCLUDES ITEMS 3 - 12) ........................

1

MOTOR (SERIES, HIGH SPEED) (INCLUDES ITEMS 3 - 11, 14) ....................

1

ARMATURE..................................................................................................

1

BRUSH SPRING...........................................................................................

4

BRUSH PLATE AND BOX............................................................................

1

BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) ...........................

1

BEARING......................................................................................................

1

SNAP RING ..................................................................................................

1

COVER PLATE AND SCREW......................................................................

1

COMMUTATOR END HOUSING .................................................................

1

CAP...............................................................................................................

1

FRAME AND FIELD COIL (G02 MOTOR) (INCLUDES HARDWARE) ........

1

73120-G30 FRAME AND FIELD COIL (G03 MOTOR) (INCLUDES HARDWARE) ........

1

73124-G08 MOTOR (SEPARATELY EXCITED) (PDS) (INCLUDES ITEMS 17 - 29)...........

1

73120-G18 ARMATURE..................................................................................................

1

73120-G03 BRUSH SPRING...........................................................................................

4

73120-G15

73120-G25

73120-G07

73120-G06

73120-G09

73120-G31

73120-G19

73328-G01

01037-G02

73277-G01

73327-G01

24261-G1

BRUSH PLATE AND BOX............................................................................

BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) ...........................

BEARING......................................................................................................

SNAP RING ..................................................................................................

COVER PLATE AND SCREW......................................................................

FRAME AND FIELD COIL (INCLUDES HARDWARE).................................

COMMUTATOR END HOUSING .................................................................

MAGNET.......................................................................................................

SCREW, #10 - 32 X 1/2" LG.........................................................................

RETAINING RING ........................................................................................

SPEED SENSOR..........................................................................................

SPLINE BUMPER ...............................................................................................

1

1

1

1

1

1

1

1

1

2

1

1


Page J-2

3

REAR AXLE


NOTE: Apply a light coat of moly grease to

male spline before assembly. Reference

part number 15.

11

14 13

12

7

6

5

4

9

2

Ref Rax 1

Page K-1


REAR AXLE

11

12

13

14

7

8

9

10

15

5

6

3

4

1

2





ITEM PART NO.


73500-G01

20377-G12

20377-G11

*

28610-G01

15558-G1

73050-G01

QTY.

REAR AXLE ASSEMBLY (INCLUDES ITEMS 2 - 7) ..........................................

1

AXLE SHAFT (PASSENGER SIDE).............................................................

1

AXLE SHAFT (DRIVER SIDE)......................................................................

1

DIFFERENTIAL COVER...............................................................................

1

FILL PLUG WITH 'O' RING...........................................................................

1

BOLT, 5/16 - 18 X 3/4" LG............................................................................ 10

VENT ............................................................................................................

1

72763-G01 SCUFF GUARD ..................................................................................................

1

XXXXX-XXX SPLINE BUMPER (SEE ELECTRIC MOTOR) ...................................................

1

00797-G2

00565-G7

00559-G7

28095-G01

BOLT, 1/4 - 20 X 1 1/4" LG .................................................................................

LOCK WASHER, 1/4" .........................................................................................

WASHER FLAT, 1/4" ..........................................................................................

3

3

3

MOLY LUBE, 2 OZ.............................................................................................. AR


Page K-2

REAR SUSPENSION

4

2

3

18

3

2

1

19

10

9

2

3

6

7

16

12

13

14

15

Ref Rsp 1

Page L-1

8

4

3

2


REAR SUSPENSION

10

11

12

13

8

9

6

7

1

4

5

2

3

14

15

16

17

18

19





ITEM PART NO.


76418-G01

10435-G1

10194-G1

00532-G6

QTY.

SHOCK ABSORBER...........................................................................................

2

SHOCK ABSORBER WASHER ..........................................................................

8

RUBBER BUSHING ............................................................................................

8

NUT, 3/8 - 24 .......................................................................................................

4

603109

74207-G01

72618-G01

00560-G1

11098-G5

70289-G02

70291-G01

70290-G02

00665-G9

11098-G5

14158-G1

12262-G1

REAR LEAF SPRINGS (REPLACE LEFT & RIGHT SPRINGS SIMULTANEOUSLY)2

LEAF SPRING, 4 LEAF .......................................................................................

2

'U' BOLT, 3/8 - 16 X 2" X 2 1/2" LG ....................................................................

4

WASHER, 3/8" ....................................................................................................

8

LOCK NUT, 3/8 - 16 ............................................................................................

SPACER ..............................................................................................................

FLANGED BUSHING (LEAF SPRING) ...............................................................

SHOULDER BOLT, 3/8 - 16 X 3 1/4" LG .............................................................

LOCK NUT, 3/8 - 16 ............................................................................................

8

4

12

SHACKLE PLATE ...............................................................................................

4

BOLT, 3/8 - 16 X 3 1/2" LG (STAINLESS STEEL)...............................................

4

LOCK NUT, 3/8 - 16 ............................................................................................

4

2

2

Service Parts Manual Page L-2

SEATING AND BAG HOLDER - GOLF CAR


Front of Vehicle

22

21

20

29

19

28

14

17

15

16

24 25

27

26

Part of

Frame


2

5

Ref Sgc 1

3

10

11

4

Page M-1

8


6

7

SEATING AND BAG HOLDER - GOLF CAR

27

28

29

23

24

25

26

19

20

21

22

16

17

18

12

13

14

15

8

9

10

11

6

7

4

5

1

2

3





ITEM PART NO.


71611-G**

71602-G**

71012-G01

17074-G1

604912-G**

71701-G01

71702-G01

71204-G01

QTY.

SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 2 - 4) .....................................

1

VINYL SEAT BOTTOM COVER ...................................................................

1

VINYL TRIM (SEAT BOTTOM).....................................................................

1

RUBBER PAD...............................................................................................

2

TWO TONE VINYL SEAT BOTTOM ...................................................................

1

HIP RESTRAINT (PASSENGER SIDE) ..............................................................

1

HIP RESTRAINT (DRIVER SIDE).......................................................................

1

BOLT, 1/4 - 20 X 7/8" LG .....................................................................................

8

71610-G01

00720-G08

71751-G**

71753-G**

71752-G01

01107-G01

604916-G**

71811-G03

00661-G8

00664-G7

01075-G01

71851-G01

71856-G01

71853-G01

16816-G1

01102-G01

11027-G2

SEAT HINGE.......................................................................................................

SCREW, #12 - 14 X 1" LG (STAINLESS STEEL) ...............................................

SEAT BACK ASSEMBLY (INCLUDES ITEMS 14 - 16).......................................

VINYL SEAT BACK COVER ........................................................................

PLASTIC SEAT BACK COVER ....................................................................

SCREW, #8 X 5/8" LG (STAINLESS STEEL)...............................................

TWO TONE VINYL SEAT BACK.........................................................................

SEAT SUPPORT BRACKET...............................................................................

BOLT, 1/4 - 20 X 1" LG (STAINLESS STEEL).....................................................

LOCK WASHER, 1/4" (STAINLESS STEEL) ......................................................

SCREW, 3/8 - 16 X 2 1/2" LG..............................................................................

BAG HOLDER BRACKET...................................................................................

BAG RETAINER CLAMP.....................................................................................

BAG RETAINER STRAP.....................................................................................

2

4

1

1

1

4

1

2

4

4

4

1

2

1

RATCHET FASTENER, 1/4" X 9/16" LG.............................................................

2

CARRIAGE BOLT, 1/4 - 20 X 1 1/2" LG (STAINLESS STEEL)...........................

2

LOCK NUT, 1/4 - 20 ............................................................................................

2

Service Parts Manual Page M-2

SEATING - SHUTTLE 2+2


Front of Vehicle

23

30

29

28

24

25

22

17

18

19

27

26

26

27

24

25

Ref Ssh 1-1

Page M-3


2

3

12

13

4


9

7

8


49

50

45



Ref Ssh 1-2

35

36

40

48

42

50

49

51

55

54

53


37

41

Page M-4


27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2





ITEM PART NO.


71611-G**

71602-G**

71012-G01

17074-G1

QTY.

SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 2 -4) .....................................

1


1

VINYL TRIM (SEAT BOTTOM).....................................................................

1

RUBBER PAD...............................................................................................

2

71701-G01

71702-G01

00661-G8

71610-G01

00720-G08

71751-G**

71753-G**

71752-G01

01107-G01

70364-G01

74111-G01

01006-G02

00560-G1

70113-G01

11027-G1

74508-G02

00661-G8

00664-G7

HIP RESTRAINT (PASSENGER SIDE)..............................................................


BOLT, 1/4 - 20 X 1" LG(STAINLESS STEEL).....................................................

SEAT HINGE.......................................................................................................

SCREW, #12 - 14 X 1" LG (STAINLESS STEEL)...............................................

SEAT BACK ASSEMBLY (INCLUDES ITEMS 17 - 19) ......................................

1


1


SCREW, #8 X 5/8" LG (STAINLESS STEEL) ..............................................

SPACER..............................................................................................................

1

1

8

2

6

1

4

2

SEAT BACK SUPPORT .....................................................................................

2

BOLT, 3/8 - 16 X 1 1/2" LG .................................................................................

4

WASHER, 3/8" ....................................................................................................

4

ADJUSTABLE BUMPER.....................................................................................

4

LOCK NUT, 5/16 - 18 ..........................................................................................

6

LATCH BRACKET - LEFT...................................................................................

1

BOLT, 1/4 - 20 X 1" LG (STAINLESS STEEL)....................................................

4


4

Page M-5







ITEM PART NO.


49

50

51

52

45

46

47

48

53

54

55

41

42

43

44

37

38

39

40

31

32

33

34

35

36

74139-G**

71602-G**

74140-G01

71012-G01

71702-G01

71701-G01

00661-G8

71751-G**

74117-G01

00661-G8

00664-G7

17838-G1

00440-G4

00559-G8

11098-G6

SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 42 - 44) ................................

1

VINYL COVER (SEAT BOTTOM).................................................................

1

TRIM .............................................................................................................

TRIM .............................................................................................................


HIP RESTRAINT (PASSENGER SIDE)..............................................................

1

BOLT, 1/4 - 20 X 1" LG (STAINLESS STEEL)....................................................

8

SEAT BACK ASSEMBLY (INCLUDES ITEMS 17 - 19) ......................................

SEAT SUPPORT BRACKET...............................................................................

1

1

1

2

BOLT, 1/4 - 20 X 1" LG (STAINLESS STEEL).................................................... 12

LOCK WASHER, 1/4" (STAINLESS STEEL) ...................................................... 12

NYLON BUSHING...............................................................................................

4

BOLT, 5/16 - 18 X 2 1/4" LG ...............................................................................

WASHER, 5/16" ..................................................................................................

LOCK NUT, 5/16 - 18 ..........................................................................................

QTY.

1

2

2

2


Page M-6

SEATING - CONVERTIBLE CARRIER


Front of Vehicle

23

30

29

24

25

22

17

18

19

27

26

26

27

24

25

Ref Scc 1-1

Page M-7


2

3

12

13

4


9

7

8

Ref Scc 1-2



Front of Vehicle

35

36

34 33

70

Handrail

69

SIDE BASKET

62

65

64 63

38

39

37

41

55

56

57

47

42

51

45

48



46

54

53 52

59

66

58

60 61



26

27

28

29

22

23

24

25

30

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3





ITEM PART NO.


71611-G**

71602-G**

71012-G01

17074-G1

QTY.

SEAT BOTTOM ASSEMBLY (INCLUDES ITEMS 2 - 4) .....................................

1


1

VINYL TRIM (SEAT BOTTOM) .....................................................................

1

RUBBER PAD ...............................................................................................

2

71701-G01

71702-G01

71204-G01

71610-G01

00720-G08

71751-G**

71753-G**

71752-G01

01107-G01

70364-G01

74111-G01

01006-G02

00560-G1

70113-G01

11027-G1

00661-G8

00664-G7

HIP RESTRAINT (PASSENGER SIDE) ..............................................................


BOLT, 1/4 - 20 X 7/8" LG .....................................................................................

SEAT HINGE .......................................................................................................

SCREW, #12 - 14 X 1" LG (STAINLESS STEEL) ...............................................




SCREW, #8 X 5/8" LG (STAINLESS STEEL) ...............................................

SPACER ..............................................................................................................

SEAT BACK SUPPORT ......................................................................................

BOLT, 3/8 - 16 X 1 1/2" LG ..................................................................................

WASHER, 3/8" ....................................................................................................

ADJUSTABLE BUMPER .....................................................................................

LOCK NUT, 5/16 - 18 ..........................................................................................

BOLT, 1/4 - 20 X 1" LG (STAINLESS STEEL).....................................................


1

1

8

2

4

1

1

1

4

2

2

4

4

2

2

4

4

Page M-9 Service Parts Manual






ITEM PART NO.


56

57

58

59

52

53

54

55

60

48

49

50

51

44

45

46

47

40

41

42

43

36

37

38

39

31

32

33

34

35

71751-G**

75258-G01

00661-G8

00664-G7

16705-G6

00520-G1

75261-G01

71062-G01

71063-G**

75197-G**

75252-G**

00762-G4

17255-G01

00891-G3

19859-G1

71060-G01

00661-G6

00559-G8

75193-G01

00438-G8

00559-G8

11027-G1

00440-G4

17838-G1

00559-G8


SEAT BACK SUPPORT ......................................................................................

BOLT, 1/4 - 20 X 0.75" LG (STAINLESS STEEL)................................................


4

SCREW, 1/4 - 20 X 1 3/4" LG (STAINLESS STEEL) ..........................................

2

ACORN NUT, 1/4 - 20 (STAINLESS STEEL) ......................................................

2

CAP-TUBE - 3/4 X 11 GA..................................................................................

2

BED .....................................................................................................................

1

SEAT BOTTOM ASSEMBLY (INCLUDES ITEM 43)...........................................

1

SEAT BOTTOM (INCLUDES ITEM 44) ........................................................

VINYL SEAT BOTTOM COVER.............................................................

1

SCREW, 5/16 - 18 X 1 1/4" LG (STAINLESS STEEL) ........................................

2

WASHER, LK - SS - 5/16" ..................................................................................

4

NUT - ACCORN - SS - 5/16 - 18 .........................................................................

2

CAP-TUBE - 3/4 X 11 GA..................................................................................

BED FRONT (INCLUDES MAT)..........................................................................

QTY.

1

1

4

1

4

1

BOLT, 1/4 - 20 X 3/4" LG (STAINLESS STEEL)..................................................

4

WASHER - LK - SP - SS - 1/4"............................................................................

4

SUPPORT FRAME..............................................................................................

1

BOLT, 5/16 - 18 X 1" LG ......................................................................................

2

WASHER, 5/16" ..................................................................................................

2

LOCK NUT, 5/16 - 18 ..........................................................................................

2

BOLT, 5/16 - 18 X 2 1/2" LG ................................................................................

2

NYLON BUSHING...............................................................................................

4

WASHER, 5/16" ..................................................................................................

2



66

67

68

69

70

61

62

63

64

65





ITEM PART NO.


00654-G3

75196-G01

00762-G2

00664-G8

00520-G3

75261-G02

QTY.

LOCK NUT, 5/16 - 18 (STAINLESS STEEL) .......................................................

2

HANDRAIL ..........................................................................................................

2

SCREW, 5/16 - 18 X 1 1/4" LG (STAINLESS STEEL) ........................................

2

LOCK WASHER, 5/16" (STAINLESS STEEL) ....................................................

2

ACORN NUT, 5/16 - 18 (STAINLESS STEEL) ....................................................

2

END CAP, 1"........................................................................................................

4

75007-G01

00106-G6

SIDE BASKET (BLACK)......................................................................................

SELF THREADING SCREW, #12 - 24 X 3/4" LG ...............................................

2

4

Page M-11 Service Parts Manual



TOW BAR - PERMANENT

1

4

2

5

3

Ref Twb 1-1

Page N-1

20

19

9

18

10

11

15

16

12

13

14

25

26

27

24

17


23

22

21

28

29



49

48

Ref Twb 1-2

46

47



43

45

44

33

37

34

35

36

40

39

34

38

32

Service Parts Manual Page N-2






ITEM PART NO.


75318-G01

75319-G01

16705-G1

00891-G2

75338-G02

QTY.

MOUNTING PLATE.............................................................................................

1

STOP MOUNT PLATE ........................................................................................

1

SCREW, 1/4 - 20 X 1" LG (STAINLESS STEEL) ................................................

3

LOCK NUT, 1/4 - 20 (STAINLESS STEEL) .........................................................

3

FEMALE STOP ...................................................................................................

1

75304-G01

75299-G01

75302-G01

75291-G01

00410-G8

00675-G3

75339-G01

00571-G5

11098-G8

75362-G01

75340-G01

75360-G01

13571-G7

75303-G01

20852-G2

25661-G02

13005-G4

75370-G01

75338-G03

12547-G4

00565-G8

00520-G3

26

27

28

29

22

23

24

25

30

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

1

4

5

2

3

TOW BAR ASSEMBLY (TOWING VEHICLE) (INCLUDES ITEMS 9 - 29) .........

TOW BAR .....................................................................................................

CUP WASHER..............................................................................................

SHOULDER BOLT, 5/16 - 18 X 2" LG...........................................................

LABEL (WARNING) ......................................................................................

MALE STOP .................................................................................................

BOLT, 6MM X 1 X 30 MM LG.......................................................................

LOCK WASHER, 5/16" .................................................................................

ACORN NUT, 5/16 - 18 (STAINLESS STEEL) .............................................

1

1

UPPER PIVOT .............................................................................................

1

LOWER PIVOT ............................................................................................

1

BOLT, 1/2 - 20 X 3" LG. .................................................................................

1

WASHER, 1/2" (STAINLESS STEEL)...........................................................

1

SPRING WASHER .......................................................................................

1

WASHER, 1/2" ..............................................................................................

1

LOCK NUT, 1/2 - 20 ......................................................................................

1

LATCH STOP................................................................................................

1

WASHER, 3/8" ..............................................................................................

2

PIVOT PIN ....................................................................................................

1

SPRING PIN .................................................................................................

1

LATCH ..........................................................................................................

1

COMPRESSION SPRING ...........................................................................

1

1

1

1

1

1

1

1

Page N-3 Service Parts Manual


44

45

46

47

40

41

42

43

48

49

36

37

38

39

32

33

34

35





ITEM PART NO.


31 75308-G01

75305-G01

75292-G01

75309-G01

75342-G01

00518-G8

10387-G1

75307-G01

00566-G6

00533-G8

QTY.

TOW BAR HITCH ASSEMBLY (TOWED VEHICLE)

(INCLUDES ITEMS 32 - 49)................................................................................

1

HITCH ...........................................................................................................

1

PIVOT BOLT .................................................................................................

1

THRUST WASHER.......................................................................................

2

WASHER, 3/4" ..............................................................................................

1

CASTELLATED NUT, 3/4 - 16 ......................................................................

1

COTTER PIN, 1/8" X 1 1/2" LG ....................................................................

2

BEARING......................................................................................................

1

LOCK WASHER, 3/4" ...................................................................................

1

NUT, 3/4 - 16.................................................................................................

1

602981

603089

27205-G01

18434-G3

27205G02

18434-G4

50209-G2

10387-G2

TIE ROD ASSEMBLY (INCLUDES ITEMS 43 - 47) .....................................

THREADED ROD...................................................................................

COTTER PIN, 3/32" X 1" LG ........................................................................

1

1

TIE ROD END (LEFT HAND THREADS)...............................................

1

JAM NUT, M12 X 1.25-05 (LEFT HAND THREADS) .............................

1

TIE ROD END (RIGHT HAND THREADS) ............................................

1

JAM NUT, M12 X 1.25-05 (RIGHT HAND THREADS)...........................

1

CASTELLATED NUT, 7/16 - 20 ....................................................................

2

2

Service Parts Manual Page N-4

TOW BAR - CASUAL

10

11


3

Ref Tbc 1

Page N-5

14

4

9

13

15

2

5

6

7

8

12


TOW BAR - CASUAL





ITEM PART NO.


11

12

13

14

7

8

9

10

15

5

6

3

4

1

2

75033-G01

*

75034-G01

75060-G01

75058-G01

75065-G01

00922-G2

10387-G2

75068-G01

14869-G5

16783-G1

75067-G01

75035-G02

14869-G3

75091-G01

QTY.

CASUAL TOW BAR (INCLUDES ITEMS 2 - 15) ................................................

1

TOW BAR .....................................................................................................

1

TIE ROD (INCLUDES NUT AND COTTER PIN) ..........................................

1

COUPLING ..................................................................................................

1

LOCK PIN .....................................................................................................

1

COMPRESSION SPRING ............................................................................

1

WASHER, 3/8"..............................................................................................

1

COTTER PIN, 3/32" X 1" LG ........................................................................

1

SAFETY PIN .................................................................................................

1

WIRE ROPE .................................................................................................

1

FERRULE .....................................................................................................

3

FERRULE .....................................................................................................

1

HEX HEAD PLUG.........................................................................................

1

WIRE ROPE .................................................................................................

1

LABEL (WARNING) ......................................................................................

1


Page N-6

WEATHER PROTECTION - GOLF CAR

D

C

1 - Includes items 2 - 19

SUN TOP

B

15

16

2

Rear of Vehicle

17

19

16

18

DETAIL D

(REAR)

8

Driver Side

4

5

3

6

A

16

14

2

Front of Vehicle

3

17

DETAIL C

(FRONT)

16

18

8

12

Ref Wgc 1-1

Page P-1

DETAIL A

7


11

10

DETAIL B

11

13

Ref Wgc 1-2


Front Top

Strut

23

24

Setscrew

22

REAR VIEW MIRROR


27

Strut

33

28

44

43

42

Strut

31

Front of

Vehicle

29

30

FULL WINDSHIELD


32

Front of

Vehicle

FOLD DOWN WINDSHIELD


36

Front of

Vehicle

37

Strut

41

38

39

40


Page P-2


WEATHER ENCLOSURE

46

47

Page P-3

Ref Wgc 1-3


49

BAG AND RAIN CURTAIN


27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2





ITEM PART NO.

1 2 3 4 5 DESCRIPTION

75040-G**

27069-G**

75045-G05

000440-G2

00559-G8

75048-G01

00570-G2

75046-G02

QTY.

SUN TOP KIT (GOLF CAR) (INCLUDES ITEMS 2 - 19) ....................................

1

SUN TOP ......................................................................................................

1

FRONT STRUT.............................................................................................

1

SCREW - CAP - 5/16 - 18 X 2 1/4"...............................................................

4

WASHER - 5/16" FL - B - CP........................................................................

4

SPACER, 1/2"...............................................................................................

2

WASHER, 5/16"............................................................................................

6

REAR STRUT ...............................................................................................

2

00685-G7

01110-G03

17255-G1

01109-G01

00753-G5

00753-G6

01110-G01

75051-G01

00654-G2

19853-G1

19528-G2

19496-G1

19502-G2

19527-G1

75524-G01

*

EGWHC12

EGWHS12

EGWHW12

BOLT, 5/16 - 18 X 1 3/4" LG (STAINLESS STEEL) .....................................

REAR VIEW MIRROR KIT (INCLUDES ITEMS 22 - 24) ....................................

REAR VIEW MIRROR ..................................................................................

SUPPORT BRACKET...................................................................................

SCREW, #8 - 32 X 5/8" LG (STAINLESS STEEL) .......................................

WINDSHIELD KIT (GOLF CAR) (INCLUDES ITEMS 27 - 33)............................

4

WASHER, 5/16" (STAINLESS STEEL) ........................................................

8

TEFLON WASHER, 5/16".............................................................................

4

LOCK NUT, 5/16 - 18 (STAINLESS STEEL) ................................................

4

SCREW, 1/4 - 20 X 2" LG (STAINLESS STEEL) .........................................

2

SCREW, 1/4 - 20 X 2 1/4" LG (STAINLESS STEEL) ...................................

2

WASHER, 1/4" (STAINLESS STEEL) ..........................................................

8

SPACER .......................................................................................................

4

LOCK NUT, 1/4 - 20 (STAINLESS STEEL) ..................................................

4

END CAP, 1".................................................................................................

2

1

1

1

1

1

WINDSHIELD ...............................................................................................

1

SASH, 26" LG ...............................................................................................

2


2


4


Page P-4


41

42

43

44

37

38

39

40

45

46

31

32

33

34

35

36





ITEM PART NO.


EGWHG13

EGWHN12

EGWHL14

QTY.

RUBBER GROMMET ...................................................................................

2


2

LABEL (SAFETY) .........................................................................................

1

47

75077-G01

*

EGWHC10

EGWHS12

EGWHW12

EGWHG13

EGWHN12

137-010

136-008

EGWHL14

75078-G01

75079-G01

FOLD DOWN WINDSHIELD KIT (GOLF CAR) (INCLUDES ITEMS 36 - 44).....

WINDSHIELD ...............................................................................................

TOP GRIP, 3/4" X 2".....................................................................................

TOP GRIP FASTENER.................................................................................

LABEL (SAFETY) .........................................................................................

1

1

SASH, 12" LG ...............................................................................................

2


2


4

RUBBER GROMMET ...................................................................................

2


2

2

2

1

WEATHER ENCLOSURE (3 SIDED)

RECOMMENDED FOR VEHICLES WITH WINDSHIELDS................................

1

WEATHER ENCLOSURE (4 SIDED)

RECOMMENDED FOR VEHICLES WITHOUT WINDSHIELDS ........................

1

48

49 75191-G01 BAG COVER AND RAIN CURTAIN KIT .............................................................

1

For service or replacement windshield parts, contact:

Eagle Parts, Inc.

1411 Marvin Griffin Rd.

Augusta, GA 30906

Telephone (706) 790-6687 or FAX (706) 790-6066

Page P-5




Page P-6

WEATHER PROTECTION - SHUTTLE 2+2

D

SUNTOP

C

19 18

5

A

20

B

Rear of Vehicle

8 5

7

5

7

2, 3

(Passenger

Side Shown)

DETAIL D

(REAR)

1 - Includes items 2 - 20

12

10

11

9

13

DETAIL B

15

Front of Vehicle

6

7

5

5

14

(Outside Tubing

On Sun Top)

2, 3

(Driver Side Shown)

DETAIL A

5

4

Ref Wsh 1-1

Page P-7

16

Front of Vehicle

DETAIL C

(FRONT)


9

17 7

Ref Wsh 1-2


Front Top

Strut

25

26

Setscrew

24

REAR VIEW MIRROR


29

Strut

35

30

46

45

44

Strut

33

Front of

Vehicle

31

32

FULL WINDSHIELD


34

Front of

Vehicle

FOLD DOWN WINDSHIELD


38

Front of

Vehicle

39

Strut

43

40

41

42


Page P-8


75123-G01

75074-G01

75074-G02

00665-G5

00679-G1

00771-G5

00891-G5

19853-G1

75125-G01

00440-G2

00905-G8

75048-G01

00879-G1

27604-G01

00674-G8

18716-G1

00653-G1

00665-G3

00665-G6

24647-G1

27

28

29

30

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

5

6

3

4

1

2





ITEM PART NO.

1 2 3 4 5 DESCRIPTION QTY.

SUN TOP (SHUTTLE 2+2) (INCLUDES ITEMS 2 - 20)......................................

1

REAR STRUT (DRIVER SIDE).....................................................................

1

REAR STRUT (PASSENGER SIDE)............................................................

1

BOLT, 3/8 - 16 X 1 3/4" LG (STAINLESS STEEL) .......................................

4

WASHER, 3/8 (STAINLESS STEEL)............................................................ 18

WASHER, 3/8 ...............................................................................................

4

LOCK NUT, 3/8 - 16...................................................................................... 10

END CAP, 1".................................................................................................

2

FRONT STRUT.............................................................................................

1

SCREW - CAP - 5/16 - 18 X 2 1/4" ..............................................................

4

LOCK WASHER, 5/16" .................................................................................

4

SPACER, 1/2"...............................................................................................

2

LOCK WASHER, 3/8" ...................................................................................

4

SUN TOP ......................................................................................................

1

BOLT, 3/8 - 16 X 5" LG (STAINLESS STEEL) .............................................

2

SPACER .......................................................................................................

2


2

BOLT, 3/8 - 16 X 2 1/2" LG (STAINLESS STEEL) .......................................

2

BOLT, 3/8 - 16 X 2" LG (STAINLESS STEEL) .............................................

2

SPACER, 1/4"...............................................................................................

2

19528-G2

19496-G1

19502-G2

19527-G1

75524-G02

*

EGWHC12

REAR VIEW MIRROR KIT (INCLUDES ITEMS 24 - 26) ....................................

REAR VIEW MIRROR ..................................................................................

SUPPORT BRACKET...................................................................................

SCREW, #8 - 32 X 5/8" LG (STAINLESS STEEL) .......................................

WINDSHIELD KIT (SHUTTLE 2+2) (INCLUDES ITEMS 29 - 35).......................

WINDSHIELD ...............................................................................................

SASH, 26" LG ...............................................................................................

1

1

1

1

1

1

2

Page P-9



41

42

43

44

38

39

40

45

46

31

32

33

34

35

36

37





ITEM PART NO.


EGWHS12

EGWHW12

EGWHG13

EGWHN12

EGWHL14

QTY.


2


4

RUBBER GROMMET ...................................................................................

2


2

LABEL (SAFETY) .........................................................................................

1

75525-G02

*

EGWHC10

EGWHS12

EGWHW12

EGWHG13

EGWHN12

137-010

136-008

EGWHL14

FOLD DOWN WINDSHIELD KIT (SHUTTLE 2+2)

(INCLUDES ITEMS 38 - 46)................................................................................

1

WINDSHIELD ...............................................................................................

1

SASH, 12" LG ...............................................................................................

2


2


4

RUBBER GROMMET ...................................................................................

2


2

TOP GRIP, 3/4" X 2".....................................................................................

2

TOP GRIP FASTENER.................................................................................

2

LABEL (SAFETY) .........................................................................................

1

For service or replacement parts for windshields, contact:

Eagle Parts, Inc.

1411 Marvin Griffin Rd.

Augusta, GA 30906

Telephone (706) 790-6687 or FAX (706) 790-6066


Page P-10

WHEELS AND TIRES

19





4

9

14

26

3

8

13 2

7

12

18

21

22

17

6" CHROME HUBCAP

28

Page Q-1

8" CHROME HUBCAP

30


SILVER / GOLD SPOKE HUBCAP

32, 34


23

24

25

26

19

20

21

22

27

28

15

16

17

18

12

13

14

4

5

6

2

3





ITEM PART NO.


1 28757-G01

28764-G01

28759-G01

11657-G2

QTY.

TIRE AND WHEEL ASSEMBLY (LINKS 18 X 8.5 - 8)

(INCLUDES ITEMS 2 - 4)....................................................................................

1

TIRE (LINKS 18 X 8.5 - 8) ............................................................................

1

WHEEL RIM (4 LUG)....................................................................................

1

VALVE STEM................................................................................................

1

28757-G03

7

8

9

10

11

28764-G03

28759-G01

11657-G2

28842-G01

WHEEL AND TIRE ASSEMBLY (TURF SAVER 18 X 8.5 - 8)

(INCLUDES ITEMS 7 - 9)...................................................................................

1

TIRE (TURF-SAVER 18 X 8.5 - 8) ................................................................

1

WHEEL RIM (4 LUG)....................................................................................

1

VALVE STEM................................................................................................

1

28764-G08

28759-G01

11657-G2

WHEEL AND TIRE ASSEMBLY (SURE TRAIL 6-PLY 18.5 X 8.5 - 8)

(INCLUDES ITEMS 12 - 14)................................................................................

1

TIRE (SURE TRAIL 18.5 X 8.5 - 8)...............................................................

1

WHEEL RIM (4 LUG)....................................................................................

1

VALVE STEM................................................................................................

1

600599

601768

601766

601767

601353

601354

14723-G1

16042-G1

WHEEL AND TIRE ASSEMBLY (ALLOY WHEEL).............................................

1

TIRE (TOUR MAX 205 X 50 - 10).................................................................

1

WHEEL ALLOY RIM.....................................................................................

VALVE STEM................................................................................................

WHEEL ALLOY CAP...........................................................................................

WHEEL ALLOY LUG NUT ..................................................................................

1

1

1

4

LUG NUT, 1/2 - 20............................................................................................... 16

6" CHROME HUBCAP ........................................................................................

4

Service Parts Manual Page Q-2






ITEM PART NO.


32

33

34

35

29

30

31

16042-G2

14913-G1

14913-G2

19241-G2

19241-G4

19241-G1

19241-G3

QTY.

6" CHROME HUBCAP (SET OF FOUR).............................................................

1

8" CHROME HUBCAP ........................................................................................

4

8" CHROME HUBCAP (SET OF FOUR).............................................................

1

GOLD SPOKE HUBCAP.....................................................................................

4

GOLD SPOKE HUBCAP (SET OF FOUR) .........................................................

1

SILVER SPOKE HUBCAP...................................................................................

4

SILVER SPOKE HUBCAP (SET OF FOUR).......................................................

1

Page Q-3 Service Parts Manual

SPECIALTY PRODUCTS

SPECIALTY PRODUCTS

Service Parts Manual Appendix A-1

SPECIALTY PRODUCTS

SPECIAL TOOLS PART NO.

BATTERY MAINTENANCE KIT ........................................................................................................................ 25587-G01

SEAL INSTALLATION TOOL (REAR AXLE SHAFT SEAL) ............................................................................... 18739-G1

BATTERY SET DISCHARGER, 36 VOLT, 75 AMP .......................................................................................... 28251-G01

CURRENT INDICATOR ...................................................................................................................................... 16489-G2

DIGITAL MULTI-METER ................................................................................................................................... 27481-G01

CRIMPING TOOL ............................................................................................................................................ 27765-G01

TUBELESS TIRE REPAIR KIT ............................................................................................................................... 606009

TIRE PLUGGER REFILL PACK (50/BOX) ............................................................................................................. 606831

TOUCH UP PAINT PART NO.

PEN 3 OUNCE (89 ML) - HUNTER GREEN .................................................................................................... 28432-G02

PEN 3 OUNCE (89 ML) - CHAMPAGNE BEIGE .............................................................................................. 28432-G01

PEN 3 OUNCE (89 ML) - WHITE ..................................................................................................................... 28432-G05

PEN 3 OUNCE (89 ML) - INDUSTRIAL YELLOW............................................................................................ 28432-G03

PEN 3 OUNCE (89 ML) - ORANGE ................................................................................................................. 28432-G04

PEN 3 OUNCE (89 ML) - STEEL BLUE PEARL ............................................................................................... 28432-G**

PEN 3 OUNCE (89 ML) - CAMOUFLAGE PAINT (THREE PENS) .................................................................. 75831-G01

MAINTENANCE PRODUCTS PART NO.

PLEXUS ® CLEANER, 13 OUNCE (380 ML) (FOR WINDSHIELDS) ............................................................... 28433-G02

BATTERY PROTECTOR, 14 OUNCE (410 ML) SPRAY .................................................................................. 27619-G02

E-Z-GO ALL SURFACE CLEANER ........................................................................................................................ 606311

E-Z-GO FIBREGLASS/PLASTIC RESTORER....................................................................................................... 606313

WINDSHIELD AND PLASTIC PROTECTOR ......................................................................................................... 606314

64 OZ HANDCLEANER..........................................................................................................................................607636

4 OZ HAND CLEANER...........................................................................................................................................607637

Appendix A-2 Service Parts Manual

OPTIONS/ACCESSORIES


Service Parts Manual Appendix B-1


ITEM KIT NO.

COMMENTS

2 BAG ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . 75183-G01 . . . . . . . . . . Body -Footrest

4 BAG ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . 75335-G01 . . . . . . . . . . Body - Accessories Continued

8" CHROME HUBCAP. . . . . . . . . . . . . . . . . . . . . . . . . 14913-G* . . . . . . . . . . . Wheels And Tires

6" CHROME HUBCAP. . . . . . . . . . . . . . . . . . . . . . . . . 16042-G* . . . . . . . . . . . Wheels And Tires

GOLD SPOKE HUBCAP . . . . . . . . . . . . . . . . . . . . . . . 19241-G* . . . . . . . . . . . Wheels And Tires

SILVER SPOKE HUBCAP . . . . . . . . . . . . . . . . . . . . . . 19241-G* . . . . . . . . . . . Wheels And Tires

ASHTRAY KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75109-G02 . . . . . . . . . . Body - Accessories Continued

CENTER BASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75003-G01 . . . . . . . . . . Body - Accessories

COOLER JUG AND BRACKET KIT . . . . . . . . . . . . . . 75495-G01 . . . . . . . . . . Body - Accessories Continued

COOLER BOX AND BRACKET KIT . . . . . . . . . . . . . . 75344-G01 . . . . . . . . . . Body - Accessories Continued

DIVOT REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 23300-G1 . . . . . . . . . . . Body - Accessories

MESSAGE HOLDER KIT (REQUIRES SUN TOP) . . . 75509-G01 . . . . . . . . . . Body - Accessories Continued

MESSAGE HOLDER KIT (REQUIRES SUN TOP) . . . 75496-G01 . . . . . . . . . . Body - Accessories Continued

REAR VIEW MIRROR (REQUIRES SUN TOP) . . . . . 19528-G2 . . . . . . . . . . . Weather Protection - Golf Car

SAND BOTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28661-G** . . . . . . . . . . Body - Accessories

SAND RAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14735-G1 . . . . . . . . . . . Body - Accessories Continued

SAND RAKE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . 75006-G01 . . . . . . . . . . Body - Accessories Continued

SIDE BASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75007-G** . . . . . . . . . . Body - Accessories

SUN TOP KIT, GOLF CAR . . . . . . . . . . . . . . . . . . . . . 75040-G** . . . . . . . . . . Weather Protection - Golf Car

TOW BAR KIT (CASUAL) . . . . . . . . . . . . . . . . . . . . . . 75033-G01 . . . . . . . . . . Tow Bar - Casual

TOW BAR KIT (PERMANENT) . . . . . . . . . . . . . . . . . . 75304-G01 . . . . . . . . . . Tow Bar - Permanent

WINDSHIELD KIT, GOLF CAR . . . . . . . . . . . . . . . . . . 75524-G01 . . . . . . . . . . Weather Protection, Golf Car

WINDSHIELD KIT, FOLD DOWN, GOLF CAR . . . . . . 74910-G01 . . . . . . . . . . Weather Protection, Golf Car

TIRE DOMINATOR 20X11-10 . . . . . . . . . . . . . . . . . . . 605316 . . . . . . . . . . . . . Wheels and Tires

PATHFINDER TIRE, BRUSHED WHEEL LH . . . . . . . 605355 . . . . . . . . . . . . . Wheels and Tires

PATHFINDER TIRE, BRUSHED WHEEL RH . . . . . . . 605356 . . . . . . . . . . . . . Wheels and Tires

PRO TOUR - POLISHED WHEEL . . . . . . . . . . . . . . . . 605317 . . . . . . . . . . . . . Wheels and Tires

PRO TOUR, TIRE 205/50-10. . . . . . . . . . . . . . . . . . . . 605315 . . . . . . . . . . . . . Wheels and Tires

V-STEM-BRUSHED SPOKED WHEEL . . . . . . . . . . . . 605351 . . . . . . . . . . . . . Wheels and Tires

PRO BRUSHED WHEEL . . . . . . . . . . . . . . . . . . . . . . . 605318 . . . . . . . . . . . . . Wheels and Tires

DOMINATOR - POLISHED WHEEL . . . . . . . . . . . . . . 605319 . . . . . . . . . . . . . Wheels and Tires

Appendix B-2 Service Parts Manual


DOMINATOR - BRUSHED WHEEL . . . . . . . . . . . . . . . 605320 . . . . . . . . . . . . . Wheels and Tires

CHROME CENTER CAP - SPOKED WHEEL . . . . . . . 604929 . . . . . . . . . . . . . Wheels and Tires

NUT, LUG-CHROME . . . . . . . . . . . . . . . . . . . . . . . . . . 605310 . . . . . . . . . . . . . Wheels and Tires

V-STEM-POLISHED SPOKED WHEEL. . . . . . . . . . . . 605311 . . . . . . . . . . . . . Wheels and Tires

PATHFINDER TIRE 22X11-10 . . . . . . . . . . . . . . . . . . . 604928 . . . . . . . . . . . . . Wheels and Tires

PATHFINDER TIRE, POLISHED WHEEL LH . . . . . . . 604930 . . . . . . . . . . . . . Wheels and Tires

PATHFINDER TIRE, POLISHED WHEEL RH . . . . . . . 605228 . . . . . . . . . . . . . Wheels and Tires

JACK-UP KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74786-G02 . . . . . . . . . . Wheels and Tires

BFS - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 607108 . . . . . . . . . . . . . Electrical System

NOZZLE GUN - BFS-08 . . . . . . . . . . . . . . . . . . . . . . . 608813 . . . . . . . . . . . . . Electrical System

Service Parts Manual Appendix B-3

Notes:


Appendix B-4 Service Parts Manual

E-Z-GO Division Of Textron, Inc.,

1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852

TO CONTACT US

North America:

Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124

Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175

International:

Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609

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

SERVICE PARTS MANUAL 602907

SERVICE PARTS MANUAL

ELECTRIC POWERED FLEET GOLF CARS &

PERSONAL VEHICLES

ISSUED DATE SEPTEMBER 2005 REVISED DATE JULY 2008

SERVICE PARTS MANUAL

ELECTRIC POWERED FLEET GOLF

CARS & PERSONAL VEHICLES

NOTES

ILLUSTRATED PARTS BREAKDOWN

SPECIALTY PRODUCTS

SPECIALTY PRODUCTS

SPECIALTY PRODUCTS

OPTIONS/ACCESSORIES

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