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Shuttle6e Parts

This electric vehicle service parts manual provides information for servicing electric utility vehicles, including the Shuttle 2, Shuttle 4, and Shuttle 6 models, starting in 2012. It contains sections on major vehicle systems and components with illustrated parts breakdowns and lists. The manual is intended to help technicians and mechanics identify replacement parts.

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0% found this document useful (0 votes)

517 views

Shuttle6e Parts

Uploaded by

Bill

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Electric Powered Vehicle

Service Parts Manual

624956

ISSUED NOVEMBER 2011 REVISED APRIL 2014

SERVICE PARTS MANUAL

ELECTRIC POWERED UTILITY VEHICLE

SHUTTLE 2

SHUTTLE 4

SHUTTLE 6

STARTING MODEL YEAR 2012

DISCLAIMER: The E-Z-GO Division of Textron Inc. (E-Z-GO) reserves the right to incorporate engineering and design changes to products in this Manual,
without obligation to include these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically E-Z-GO, and therefore is subject to change without notice.
E-Z-GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE-
QUENTIAL DAMAGES RESULTING FROM THE USE OF THE INFORMATION AND MATERIALS IN THIS MANUAL.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: 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: 001-706-798-4311, FAX: 001-706-771-4609
E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906-3852

Service Parts Manual Page i

GENERAL INFORMATION

To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
Distributor, authorized Branch or the Warranty Department with vehicle serial number and
manufacturer code.

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

Overfilling of batteries may void the warranty.

BATTERY PROLONGED STORAGE

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

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

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

Page ii Service Parts Manual

TABLE OF CONTENTS

SECTION Page No.

HOW TO USE THE SERVICE PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

ACCELERATOR PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1

BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1

BODY - HAULER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1

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

BRAKES - FRONT DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1

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

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

FRONT SUSPENSION - STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 5

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

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

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

SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 1

WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1

WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1

Service Parts Manual Page iii

NOTES

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 and accessories.

USE OF THE MANUAL

To use this manual, consult the GENERAL INDEX to locate the information or illustration required.

Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of
components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your
situation and then contact the Service Parts Department. It is important that the serial number of your vehicle and its
model number be supplied to Service Parts when ordering any replacement components.

Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its loca-
tion) and note the complete number shown on the plate.

Service Parts Manual Page v

HOW TO USE THE SERVICE PARTS MANUAL

Title Title

106
*See Body Section for
decal information
Front of Vehicle 102,104 107

79
103
105

83,88
81,86
84,89 101
100
99 74
82,87
98 - 66, 69 -
Items 63
62 - IncludesItems 71 - 74
70 - IncludesItems 82 - 84
81 - IncludesItems 87 - 89
86 - IncludesItems 95, 96114
94 94 - Includes Items 112 -121
111 - IncludesItems 119 -131
118 - IncludesItems 127 -
96 126 - Includes
95
64 74
91 63 70
65
92 69 120
62
71 123
66
67
116

113
73
72

118
121

119
122

111

112 131
130
115 114
127 126

128 129

Left hand illustration page

(continued on right hand page Parts list (continued on
if required) rear of page if required)

1. WHEN THE PART NUMBER IS NOT KNOWN

• Determine the function and application of the part required. Turn to the General Index and select the most
appropriate title.
• Turn to the page number indicated and locate the desired part on the illustration.
• From the illustration, obtain the item number assigned to the desired part. Refer to the accompanying
description for specific information regarding the part.

2. IF YOU KNOW THE PART NUMBER

• Locate the part number or description in the appropriate column on the parts list page.
NOTE: It is suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on
the illustrated page.

Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is
found. The part number is the lowest assembly sold by Service Parts and the asterisk (*) indicates that the part depicted
is not available for purchase.

NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.

To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.

Page vi Service Parts Manual

HOW TO USE THE SERVICE PARTS MANUAL

3. COLOR CODE FOR BODY COMPONENTS

The last two digits of the part number for the body part will denote the color code, locate the part number for the cowl,
rear body, seat pod, side panel or seat wrap then locate your color in the list below, replace the last ** or XX with the two
digit color code.

CODE # DESCRIPTION CODE # DESCRIPTION

01 NO PAINT 53 MOSSY OAK NEW BREAK UP - DIPPED
02 SPECIAL COLOR 54 MOSSY OAK OBSESSION - DIPPED
05 JACOBSEN ORANGE 55 REALTREE ADVANTAGE MAX 4 - DIPPED
06 LIGHT GOLD PEARL 56 REALTREE HARDWOOD BROWN - DIPPED
07 SILVER PEARL METALIC 57 REALTREE AP HOT PINK - DIPPED
11 BLACK 58 BLACK / SILVER MARBLE - DIPPED
12 EMERALD GREEN PEARL 59 RED / SILVER MARBLE - DIPPED
13 CLOUD GRAY 60 HOT PINK / SILVER MARBLE - DIPPED
14 VIPER BLUE METALLIC 61 REALTREE AP
19 PATRIOT BLUE PEARL 62 REALTREE MAX 4
20 INFERNO RED METALLIC 63 MOSSY OAK BREAKUP
23 ADVANTAGE CLASSIC CAMO 64 MOSSY OAK TREESTAND
24 NATURAL 65 REALTREE APG
25 VIVID NEW HOLLAND BLUE 66 REALTREE MAX 1
26 STEEL BLUE PEARL 67 REALTREE AP PINK
27 BRIGHT SILVER METALLIC 68 REALTREE AP - DIPPED
29 PRIMER ONLY 69 MONSTER GREEN
30 HD ADVANTAGE CAMO 74 BARLEY GOLD
31 METALLIC CHARCOAL 75 OASIS GREEN
32 LIGHT ALMOND PEARL 76 JAVA BROWN
33 TIMBERLINE GREEN
34 DEEP MOLTEN RED
35 SAFETY YELLOW
36 IVORY
37 FOREST GREEN
38 BRIGHT WHITE
39 FLAME RED
40 BLACK
41 ELECTRIC BLUE
42 PLATINUM
43 BURGUNDY
44 ALMOND
45 BLACK
46 FLAME RED
47 BURLINGTON GREEN
48 BLACK
49 FLAME RED
50 RECON GREEN
51 SUNBURST ORANGE
52 BRITISH RACING GREEN

Service Parts Manual Page vii

ACCELERATOR

1 PEDAL BOX ASSEMBLY Includes Items 2 - 37

12 19
11 18
13 22
9
14 2
15
17

4
2
3
8
6
7

39
23

To Direction
24 Selector
Harness

Page A-1 Service Parts Manual

ACCELERATOR

29
26 ACCELERATOR PEDAL ASSEMBLY Includes Items 27 - 30
40
30

37
36
32
35

Service Parts Manual Page A-2

ACCELERATOR
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 73333G07 PEDAL BOX ASSEMBLY
(INCLUDES ITEMS 2 - 37).............................................................................. 1
2 25853G01 PEDAL BOX AND COVER (SEAL AND BEARING) ................................. 1
3 25854G01 INDUCTIVE THROTTLE SENSOR........................................................... 1
4 00983G01 SELF THREADING NUT, 3/16"................................................................. 2
5
6 25857G01 PLUNGER SLEEVE.................................................................................. 1
7 28443G01 PLUNGER................................................................................................. 1
8 28444G01 PLUNGER CAM........................................................................................ 1
9 73332G01 ACCELERATOR ROD .............................................................................. 1
10
11 00532G4 LOCK NUT, 5/16 - 24 ................................................................................ 1
12 10385G4 YOKE (ADJUSTABLE).............................................................................. 1
13 17677G2 SPRING RETAINER, 3/8" ......................................................................... 1
14 73046G01 COMPRESSION SPRING ........................................................................ 1
15 17979G1 ACCELERATOR ROD BUSHING ............................................................. 1
16
17 17677G1 SPRING RETAINER, 1/2" ......................................................................... 1
18 25861G02 MICRO SWITCH ...................................................................................... 1
19 01050G01 SCREW, #4 - 20 X 5/8" LG ....................................................................... 2
20 25879G06 WIRING HARNESS (PEDAL BOX ASSEMBLY) ...................................... 1
21
22 00684G6 SCREW, #8 - 32 X 3/4" LG ....................................................................... 2
23 70116G02 ACCELERATOR PEDAL BRACKET......................................................... 1
24 01051G01 SCREW, #8 - 16 X 1/2" LG ....................................................................... 4
25
26 25799G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 27 - 30)......... 1
27 70125G04 ACCELERATOR PEDAL ....................................................................... 1
28
29 27512G01 ACCELERATOR PEDAL PAD.......................................................... 1
30 16409G1 OVAL RIVET 3/16" X 7/16" LG ........................................................ 6
31

Page A-3 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

32 17838G1 BUSHING ................................................................................................. 3

33 74432G01 PEDAL PIVOT PIN ................................................................................... 1
34 12064G6 PUSHNUT, 9/32" I.D................................................................................. 1
35 10386G3 CLEVIS PIN, 5/16" X 13/16" LG ............................................................... 1
36 17255G1 TEFLON WASHER, 5/16" ........................................................................ 1
37 10387G3 COTTER PIN, 3/32" X 3/4" LG ................................................................. 1
38
39 00715G2 BOLT, 5/16 - 18 X 13/16" LG. .......................................................................... 4
40 70135G01 PEDAL PIVOT COVER................................................................................... 1

Service Parts Manual Page A-4

ACCELERATOR

Notes:

Page A-5 Service Parts Manual

ACCELERATOR

Notes:

Service Parts Manual Page A-6

BATTERY CHARGER

1 DELTA-Q BATTERY CHARGER Includes Item 2 - 3

6 DELTA-Q BATTERY CHARGER Includes Item 7, 12 -13

9 DELTA-Q BATTERY CHARGER Includes Item 10, 12 -13

12
1

2
7
10

Page B-1 Service Parts Manual

BATTERY CHARGER
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 603869 48V DELTA-Q BATTERY CHARGER WITH 10’ DC CORD

(INCLUDES ITEMS 2 - 3) ............................................................................ 1
2 600463G02 48V DC CABLE ASSEMBLY .................................................................... 1
3 600462G01 AC POWER CORD (NOT SHOWN)......................................................... 1
4
5
6 600341G03 48V DELTA-Q BATTERY CHARGER WITH 10’ DC CORD
(INCLUDES ITEMS 7, 12 - 13) .................................................................... 1
7 600463G02 48V DC CABLE ASSEMBLY, 10’.............................................................. 1
8
9 600341G04 48V DELTA-Q BATTERY CHARGER WITH 18’ DC CORD
(INCLUDES ITEMS 10, 12 - 13) .................................................................. 1
10 600463G04 48V DC CABLE ASSEMBLY, 18’.............................................................. 1
11
12 600340G02 48V DELTA-Q BATTERY CHARGER ....................................................... 1
13 600462G01 AC CORD (NOT SHOWN) ....................................................................... 1

Service Parts Manual Page B-2

BATTERY CHARGER

Notes:

Page B-3 Service Parts Manual

BATTERY CHARGER

Notes:

Service Parts Manual Page B-4

BODY

9 14

15 10

P
19
12 R P
P
N
F 60178
1

13
F

18
25%
< 14°
25%
< 14°

1
8

49 48

50
49
6

51 52 4
47

ASHTRAY

25
24

36 35

26
34

27
37
29
38 30

Page C-1 Service Parts Manual

BODY
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 71151G01 INSTRUMENT PANEL ASSEMBLY ............................................................... 1

2
3 16816G2 RATCHET FASTENER, 1/4" X 3/4" LG........................................................... 4
4 637534 UPPER FLOORPAN ....................................................................................... 1
5
6 14601G11 RIVET (ALUMINUM), 3/16" X 9/16" LG ......................................................... 16
7
8 601781 OPERATOR INSTRUCTION DECAL.............................................................. 1
9 613036GXX COWL ............................................................................................................. 1
10 71055G01 RIVET, 3/16" X 1" LG ...................................................................................... 7
11 617643 GRILL COVER ................................................................................................ 1
12 71055G01 RIVET, 3/16’ X 1" LG....................................................................................... 6
13 614378 FENDER FLARE (DRIVER SIDE) .................................................................. 1
14 613274 FENDER FLARE (PASSENGER SIDE).......................................................... 1
15 71597G01 SELF-THREADING NUT, 3/16" X 19/32 ......................................................... 2
16
17
18 71115G01 VINYL TRIM .................................................................................................... 2
19 71055G01 RIVET, 3/16" X 1" LG ...................................................................................... 10
20
21
22
23
24 27731G01 ASHTRAY ....................................................................................................... 1
25 27736G01 GASKET.......................................................................................................... 1
26 75108G02 BRACKET ....................................................................................................... 1
27 00100G4 SELF TAPPING SCREW, #10 - 16 X 1/2" LG................................................. 4
28 619135 CUSHMAN COWL DECAL ............................................................................. 1
29 617620 BRUSHGUARD............................................................................................... 1
30 00440G2 HEX HEAD BOLT, 5/16" - 18 X 2 1/4" LG ....................................................... 2
31

Service Parts Manual Page C-2

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

32
33
34 00440G6 HEX HEAD BOLT, 5/16" - 18 X 2 3/4" LG........................................................ 2
35 75048G04 SPACER, 1"..................................................................................................... 2
36 75048G01 SPACER, 1/2".................................................................................................. 2
37 00559G8 FLAT WASHER, 5/16" ..................................................................................... 4
38 00565G8 LOCK WASHER, 5/16".................................................................................... 4
39
40
41
42
43
44
45
46 613273 FRONT FASCIA .............................................................................................. 1
47 70725G02 FRONT SHIELD BRACE................................................................................. 2
48 16469G1 FENDER WASHER, 9/32" I.D. X 1 1/4" O.D. ................................................. 2
49 01038G01 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG............................................................. 4
50 15058G1 RIVET (ALUMINUM), 3/16" X 4/9" LG............................................................. 2
51 618653 FASCIA BRACKET.......................................................................................... 1
52 00414G6 HEX HEAD BOLT, 1/4" - 20 X 3/4" LG............................................................. 2
53 14390G4 HEX NUT, 1/4" - 20.......................................................................................... 2
54
55
56
57
58
59
60
61
62

Page C-3 Service Parts Manual

BODY

Notes:

Service Parts Manual Page C-4

BODY

67
68
71

72
64
66
76 75
78
63 74
77

89 73

93
85

88
90
84
83
90

Page C-5 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

63 70451G01 LOWER FLOORPAN ...................................................................................... 1

64 70452G01 ACCESS COVER............................................................................................ 1
65 70823G01 REAR FLOORPAN.......................................................................................... 1
66 10570G10 RIVET (SS), 5/32" X 9/16" LG......................................................................... 5
67 70668G02 FLOORMAT WITH HORN HOLE (SHUTTLE 4 & 6)....................................... 1
68 70663G04 FLOOR MAT WITH HORN HOLE (SHUTTLE 2 ONLY) ................................. 1
69
70
71 605694 SEAT FRAME WELDMENT............................................................................ 1
72 70441G01 SEAT FRAME ................................................................................................. 1
73 70046G02 BATTERY RACK............................................................................................. 1
74 00715G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG ...................................................... 4
75 00438G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG .......................................................... 2
76 00559G8 FLAT WASHER, 5/16"..................................................................................... 2
77 11098G6 LOCK NUT, 5/16" - 18..................................................................................... 2
78 70200G01 TORX TRUSS HEAD SCREW, 3/8" - 16 X 3/4" LG........................................ 2
79
80
81
82
83 618889 ROCKER PANEL (DRIVER SIDE) (SHUTTLE 4 AND 6 ONLY) ..................... 1
84 618888 ROCKER PANEL (PASSENGER SIDE) (SHUTTLE 4 AND 6 ONLY) ............ 1
85 00789G2 PHILLIPS TRUSS HEAD SCREW #10 - 24 X 1.25 ........................................ 2
86 14390G10 LOCK NUT, #10 - 24 ....................................................................................... 2
87 16705G1 TRUSS HEAD PHILIPS SCREW (SS), 1/4" - 20 X 1" LG............................... 6
88 14390G4 LOCK NUT, 1/4" - 20....................................................................................... 6
89 00660G5 FLAT WASHER, #10 ....................................................................................... 2
90 23726G4 SPACER, 5/16" ............................................................................................... 8
91
92 15058G6 RIVET (ALUMINUM), 3/16" X 15/16" LG ........................................................ 2
93 00559G7 FLAT WASHER, .577" (SHUTTLE 2) .............................................................. 4

Service Parts Manual Page C-6

BODY

110

111

109
108

107
114
118
105

117
112

113 115
116

120
106
96
119 122 121
94
96 123
95

98 100

100 103
102

101

Page C-7 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

94 629688G02 BATTERY TRAY (PASSENGER SIDE)........................................................... 1

95 629688G01 BATTERY TRAY (DRIVER SIDE) ................................................................... 1
96 00715G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG ...................................................... 8
97
98 635054G02 FENDER (PASSENGER SIDE) ...................................................................... 1
99 635054G01 FENDER (DRIVER SIDE) ............................................................................... 1
100 16816G2 RATCHET FASTENER ................................................................................... 8
101 14601G17 RIVET, 3/16" X 9/16" LG ................................................................................. 2
102 74892G01 FENDER (DRIVER SIDE) (SHUTTLE 2) ........................................................ 1
103 74892G02 FENDER (PASSENGER SIDE) (SHUTTLE 2)................................................ 1
104
105 71331G0XX REAR BODY WITH LNR and WITH LIGHT
(See COLOR CODE in HOW TO USE SECTION) ......................................... 1
106 71554G01 J-TYPE NUT RETAINER, 1/4" - 20 ................................................................. 2
107 71609G01 HINGE PLATE................................................................................................. 2
108 10570G11 RIVET (SS), 3/16" X 3/4" LG........................................................................... 4
109 71316G01 PLUG .............................................................................................................. 1
110 71320G01 ACCESS PANEL............................................................................................. 1
111 01107G01 PAN HEAD TORX SCREW, #8 X 5/8" LG ...................................................... 5
112 71364G02 ‘J’ CLIP, #8 ...................................................................................................... 1
113 10570G12 RIVET (ALUMINUM), 1/4" X 9/16" LG ............................................................ 4
114 10570G10 RIVET (SS), 5/32" X 9/16" LG......................................................................... 6
115 16816G1 RATCHET FASTENER, 1/4" X 3/4" LG........................................................... 20
116 18436G1 PLASTIC DRIVE RIVET, 1/4" X 9/16" LG ....................................................... 2
117 73173G02 COVER PLATE ............................................................................................... 1
118 71055G01 RIVET (ALUMINUM), 3/16" X 1" LG ............................................................... 4
119 71102G03 HEX HEAD BOLT, 1/4" - 20 X 11/16" LG ........................................................ 2
120 71451G02 REAR BUMPER.............................................................................................. 1
121 71102G01 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG ........................................................ 4
122 00571G2 FLAT WASHER, 5/16"..................................................................................... 4
123 71455G01 BUMPER PLUG .............................................................................................. 4

Service Parts Manual Page C-8

BODY

124 FOOT REST ASSEMBLY includes items 125 & 126

145
144

131
182

139 128

140
136
135

134
140
141
127

125 126

Page C-9 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

124 70361G02 FOOT REST ASSEMBLY (INCLUDES ITEMS 125 & 126) ............................ 1
125 70633G01 FOOT REST ............................................................................................. 1
126 70362G01 FLOORMAT .............................................................................................. 1
127 19853G1 END CAP ........................................................................................................ 2
128 74129G01 REFLECTOR .................................................................................................. 1
129
130
131 608537 REAR SEAT FACING WARNING LABEL ...................................................... 1
132
133
134 00769G2 CARRIAGE BOLT, 3/8" - 16 X 1 1/4" LG......................................................... 2
135 00560G1 FLAT WASHER, 3/8"....................................................................................... 2
136 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 2
137
138
139 00427G6 HEX HEAD BOLT, 3/8" - 16 X 1 3/4" LG ......................................................... 2
140 00560G1 FLAT WASHER, 3/8"....................................................................................... 4
141 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 2
142
143
144 70113G01 ADJUSTABLE BUMPER................................................................................. 4
145 11027G1 LOCK NUT, 5/16" - 18..................................................................................... 6
146
147
148
149
150
151
152
153
154

Service Parts Manual Page C-10

BODY

165

169

170

171
168

171
156 155
172
157
161

179 161

180
162

175

176

Page C-11 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

155 4126G01 VERTICAL FRAME SUPPORT (PASSENGER SIDE).................................... 1

156 74126G02 VERTICAL FRAME SUPPORT (DRIVER SIDE) ............................................ 1
157 00427G4 HEX HEAD BOLT, 3/8" - 16 X 1 1/2" LG (SHUTTLE 4) .................................. 2
158
159
160
161 00560G1 FLAT WASHER, 3/8"....................................................................................... 4
162 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 2
163
164
165 74111G01 SEAT BACK SUPPORT (SHUTTLE) .............................................................. 2
166
167
168 70364G01 SPACER, 8.45" X 2" (SHUTTLE 6)................................................................. 2
169 00427G02 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG ......................................................... 4
170 00426G8 HEX HEAD BOLT, 3/8" - 16 X 1" LG ............................................................... 2
171 00560G1 FLAT WASHER, 3/8"....................................................................................... 4
172 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 2
173
174
175 74890G01 VALANCE PANEL ........................................................................................... 1
176 16816G2 RATCHET FASTENER, 1/4" X 3/4" LG........................................................... 2
177
178
179 619146 CUSHMAN - LABEL (SHUTTLE 4)................................................................. 1
180 619148 CUSHMAN - LABEL (SHUTTLE 6)................................................................. 1
181
182
183
184
185

Service Parts Manual Page C-12

BODY

200
201
202

203

194

193
196
198
192
197
203

191
207 195
190

150

213

187
188
186

188 210
212
209
208

Page C-13 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

186 72914G01 HOLD DOWN BRACKET................................................................................ 1

187 70113G01 ADJUSTABLE BUMPER................................................................................. 2
188 11027G1 LOCK NUT, 5/16" - 18..................................................................................... 4
189
190 74080G01 CARGO DECK (SHUTTLE 4) ......................................................................... 1
191 23052G1 NOISE SUPPRESSOR ................................................................................... 1
192 74082G01 STEEL DECK.................................................................................................. 1
193 74097G01 CARGO BED MAT .......................................................................................... 1
194 16705G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG.......................... 8
195 14390G4 LOCK NUT, 1/4" - 20....................................................................................... 8
196 608984 DOUBLE SIDED TAPE ................................................................................... 40"
197 72913G01 LATCH............................................................................................................. 1
198 00100G6 SELF TAPPING SCREW, #10 - 16 X 3/4" LG................................................. 3
199
200 34280G02 FRONT/REAR CARGO RACK........................................................................ 2
201 34280G01 SIDE CARGO RACK....................................................................................... 2
202 74079G01 TAILGATE RETAINER BRACKET .................................................................. 2
203 00666G6 TAPPING SCREW, #10 - 12 X 3/4" LG........................................................... 10
204
205
206
207 17838G1 NYLON BUSHING, .5" .................................................................................... 4
208 00440G4 HEX HEAD BOLT, 5/16" - 18 X 2 1/2" LG ....................................................... 2
209 00559G8 FLAT WASHER, 5/16"..................................................................................... 2
210 11098G6 LOCK NUT, 5/16" - 18..................................................................................... 2
211
212 74099G01 BED LATCH, WARNING LABEL (SHUTTLE 4) .............................................. 1
213 74095G01 LOAD BED, WARNING LABEL (SHUTTLE 4)................................................ 1
214
215
216

Service Parts Manual Page C-14

BODY

224
223
230

226

222
225

Front of Vehicle
255 256
254 257

259
231
235 228

249 237
236
238
248
233
220 250
251

227
239 228

265 267
218 240
217
242 241

264
266
242

271
243

270

Page C-15 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

217 619094 ROCKER PANEL (DRIVER SIDE) (SHUTTLE 2) .......................................... 1

218 619095 ROCKER PANEL (PASSENGER SIDE) (SHUTTLE 2) .................................. 1
219
220 70135G01 PEDAL PIVOT COVER................................................................................... 1
221
222 72966G01 CARGO DECK (SHUTTLE 2) ......................................................................... 2
223 33121G01 HINGE............................................................................................................. 2
224 16705G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG.......................... 8
225 16705G9 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1 1/4" LG....................... 2
226 00559G7 FLAT WASHER, 1/4"....................................................................................... 4
227 00559G7 FLAT WASHER, 1/4"....................................................................................... 2
228 00654G2 LOCK NUT, 1/4" - 20....................................................................................... 4
229
230 00753G5 TRUSS HEAD PHILLIPS SCREW, 1/4" - 20 X 2" LG ..................................... 2
231 16469G1 FENDER WASHER, 1/4" ................................................................................ 2
232
233 72956G01 BED FRAME ................................................................................................... 1
234
235 01075G01 HEX HEAD BOLT, 3/8" - 16 X 2 3/4" LG ......................................................... 2
236 00571G3 FLAT WASHER, 3/8"....................................................................................... 2
237 00439G6 HEX HEAD BOLT, 5/16" - 18 X 1 3/4" LG ....................................................... 4
238 00559G8 FLAT WASHER, 5/16"..................................................................................... 8
239 11098G6 LOCK NUT, 5/16" - 18..................................................................................... 4
240 72982G01 BRACKET ....................................................................................................... 2
241 00438G6 HEX HEAD BOLT, 5/16" - 18 X 3/4" LG .......................................................... 2
242 00559G8 FLAT WASHER, 5/16"..................................................................................... 2
243 11098G6 LOCK NUT, 5/16" - 18..................................................................................... 2
244
245
246
247

Service Parts Manual Page C-16

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

248 72983G01 BED MOUNT BRACKET ................................................................................. 2
249 16705G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG .......................... 4
250 00559G7 FLAT WASHER, 1/4" ....................................................................................... 4
251 00654G2 LOCK NUT, 1/4" - 20 ....................................................................................... 4
252
253
254 72967G01 BULKHEAD ..................................................................................................... 1
255 16705G3 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 3/4" LG .......................... 6
256 00559G7 FLAT WASHER, 1/4" ....................................................................................... 6
257 00654G2 LOCK NUT, 1/4" - 20 ....................................................................................... 6
258
259 22524G1 FOAM TAPE .................................................................................................... 40"
260
261
262
263
264 74892G01 FENDER (DRIVER SIDE) ............................................................................... 1
265 74892G02 FENDER (PASSENGER SIDE) ....................................................................... 1
266 74892G03 FENDER WITH TAILLIGHT (DRIVER SIDE) .................................................. 1
267 74892G04 FENDER WITH TAILLIGHT (PASSENGER SIDE).......................................... 1
268
269
270 74890G01 REAR PANEL .................................................................................................. 1
271 16816G2 RATCHET TYPE FASTENER, 1/4” X 57/64” ................................................... 4
272
273
274
275
276
277
278

Page C-17 Service Parts Manual

BODY

Notes:

Service Parts Manual Page C-18

BODY

280

311 313
312
305 314
306

297 318

322

319
307 320
308
321

303
304
298
299
300

SHUTTLE 2

285

286
289

287

288
282
293 281

292

291
279

Page C-19 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

279 619144 CUSHMAN - LABEL (SHUTTLE 2)................................................................. 1

280 605694 SEAT FRAME ................................................................................................. 1
281 602037G01 SIDE PANEL (DRIVER SIDE)......................................................................... 1
282 602029G02 SIDE PANEL (PASSENGER SIDE) ................................................................ 1
283
284
285 10570G11 RIVET (SS), 3/16" X 3/4" LG........................................................................... 4
286 71609G01 SEAT HINGE................................................................................................... 2
287 600034G01 SEAT WRAP PANEL....................................................................................... 1
288 10570G10 RIVET (SS), 5/32" X 9/16" LG......................................................................... 5
289 10570G10 RIVET (SS), 5/32" X 9/16" LG......................................................................... 2
290
291 10570G10 RIVET (SS), 5/32" X 9/16" LG......................................................................... 4
292 10570G12 RIVET, 1/4" X 9/16" LG ................................................................................... 2
293 16469G01 FENDER WASHER, 1/4" ................................................................................ 4
294
295
296
297 609588 SEAT FRAME WELDMENT............................................................................ 1
298 00438G8 HEX HEAD BOLT, 5/16" - 18 x 1"LG............................................................... 2
299 00559G8 FLAT WASHER, 5/16"..................................................................................... 2
300 11098G6 LOCK NUT, 5/16" - 18..................................................................................... 2
301
302
303 00715G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG ...................................................... 4
304 70200G01 TORX TRUSS SCREW, 3/8" - 16 X 3/4" LG................................................... 2
305 624486 SEAT BACK BRACKET .................................................................................. 2
306 00427G8 HEX HEAD BOLT, 3/8" - 16 X 1" LG ............................................................... 4
307 00560G1 FLAT WASHER, 3/8"....................................................................................... 4
308 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 4
309

Service Parts Manual Page C-20

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

310
311 70441G01 SEAT FRAME .................................................................................................. 1
312 70046G02 BATTERY RACK WELDMENT........................................................................ 1
313 00715G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG....................................................... 4
314 00438G8 HEX HEAD BOLT, 5/16" - 18 x 1" LG .............................................................. 2
315
316
317
318 00559G8 FLAT WASHER, 5/16" ..................................................................................... 2
319 11098G6 LOCK NUT, 5/16" - 18 ..................................................................................... 2
320 00715G2 HEX HEAD BOLT, 5/16" - 18 X 13/16" LG....................................................... 2
321 11098G6 LOCK NUT, 5/16" - 18 ..................................................................................... 2
322 70200G01 TRUSS HEAD TORX SCREW, 3/8" - 16 X 3/4" LG ........................................ 2

Page C-21 Service Parts Manual

BODY

Notes:

Service Parts Manual Page C-22

BODY

VEHICLES MANUFACTURED FROM MARCH 2014

328

323

327
Taillight

330
325

Page C-23 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

323 625272G0XX REAR BODY (WITH LIGHTS)

(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
324
325 624374 BAGWELL LINER
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
326
327 633917 RIVET (FOR VEHICLES MANUFACTURED FROM MARCH 2014) .............. 2
328 16816G2 RATCHET RIVET, .25" X .887"
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 2
329
330 619752G0XX REAR BODY
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1

Service Parts Manual Page C-24

BODY

Notes:

Page C-25 Service Parts Manual

BODY

Notes:

Service Parts Manual Page C-26

BRAKES

1 BRAKE PEDAL ASSEMBLY includes items 2 - 10

115 COMPENSATOR ASSEMBLY includes items 116 - 125

9 10

8
4
1
3
2
6

5
50
40
43 49 12
41 48
31 30
42
39

35 24
46
36 38

37 13 Part of Frame
45 14
16
15
25 30

35
37 36 28
Accelerator 26 28
38 Pedal
31

116
119
122

120 123
121
119

125

122
117
124

Page D-1 Service Parts Manual

BRAKES

59
59

55
62
57
57
63
68
65

74
71 67
74
73 77
61

WHT 69 66
BLK 73 72 64
76
76 78 75
75
70
74

74
53 BRAKE PEADAL ASSEMBLY includes items 54 - 80
53

79
79 54

Brake Pedal (Vehicle With Brake Lights)

Service Parts Manual Page D-2

BRAKES

82 BRAKE ASSEMBLY (DRIVER SIDE) includes items 84 - 92

83 BRAKE ASSEMBLY (PASSENGER SIDE) includes itmes 84 - 89, 93

100 BRAKE DRUM ASSEMBLY includes items 101 -102

110
111
92 86
93

88
89
89 97

101
98

96
96
85
85

107

TOP PULL

ADJUSTER ASSEMBLY
102
105
106
108
106

Page D-3 Service Parts Manual

BRAKES

BOTTOM PULL

97
97
84
90
88
TENSION PIN 101

107

86
92
93 87
98
85 87
87

105 106
98
102 108
106

ADJUSTER ASSEMBLY

98
82 BRAKE ASSEMBLY includes items 84 - 92

83 BRAKE ASSEMBLY includes itmes 84 - 89, 93

100 BRAKE DRUM ASSEMBLY includes items 101, 102

Service Parts Manual Page D-4

BRAKES
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 70612G02 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS)
(INCLUDES ITEMS 2 - 10).............................................................................. 1
2 70681G01 TORSION SPRING ................................................................................... 2
3 70682G01 PIVOT PIN ................................................................................................ 1
4 01071G01 PUSHNUT, 5/16"....................................................................................... 2
5 70259G02 BRAKE PEDAL ......................................................................................... 1
6 70611G01 PARK BRAKE PEDAL............................................................................... 1
7
8 70257G01 SERVICE BRAKE PAD ............................................................................. 1
9 70256G01 PARK BRAKE PEDAL PAD ...................................................................... 1
10 16409-G1 OVAL RIVET, 3/16" X 7/16" LG................................................................. 9
11
12 70582G01 SHOULDER BOLT, 3/8 - 16 X 4" LG (STAINLESS STEEL) ............................ 1
13 70581G01 FLANGED BUSHING ...................................................................................... 2
14 70676G01 TORSION SPRING ......................................................................................... 1
15 00643G1 FLAT WASHER, 3/8" ....................................................................................... 1
16 11098G5 LOCK NUT, 3/8 - 16......................................................................................... 1
17
18 01038G01 SWAGEFORM SCREW, 1/4 - 20 (NOT ILLUSTRATED) ................................ 1
19
20
21 12416G2 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED) ................................. 3
22
23
24 28083G01 BRAKE COMPENSATOR BUMPER ............................................................... 2
25 624695 BRAKE CABLE (DRIVER SIDE) ..................................................................... 1
26 624696 BRAKE CABLE (PASSENGER SIDE)............................................................. 1
27
28 01111G01 RETAINING RING, 13/32" (STAINLESS STEEL) ............................................ 4
29

Page D-5 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

30 10386G3 CLEVIS PIN, 5/16" X 13/16" LG....................................................................... 3

31 10387G3 COTTER PIN, 3/32" X 3/4" LG......................................................................... 3
32 14443G2 CLEVIS PIN, 5/16" X 5/8" LG........................................................................... 2
33
34 70601G01 KICK-OFF LINK ............................................................................................... 1
35 17838G1 NYLON BUSHING ........................................................................................... 2
36 20835G1 TEFLON WASHER, 3/8" .................................................................................. 2
37 00559G8 FLAT WASHER, 5/16"...................................................................................... 2
38 10387G3 COTTER PIN, 3/32" X 3/4" LG......................................................................... 2
39 70098G01 KICK-OFF CAM PIVOT.................................................................................... 1
40 10097G6 FLANGED BEARING ....................................................................................... 2
41 70587G01 KICK-OFF CAM ............................................................................................... 1
42 71215G01 SETSCREW, 1/4 - 20 X 1/2" LG ...................................................................... 2
43 14134G4 SPACER........................................................................................................... 1
44
45 70113G01 ADJUSTABLE BUMPER.................................................................................. 1
46 11027G1 LOCK NUT, 5/16 - 18 ....................................................................................... 1
47
48 70080G02 CATCH BRACKET ........................................................................................... 1
49 00414G6 BOLT, 1/4 - 20 X 3/4" LG.................................................................................. 2
50 14390G4 LOCK NUT, 1/4 - 20 (STAINLESS STEEL)...................................................... 2
51
52
53 70690G02 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS)
(INCLUDES ITEMS 54 - 80) ............................................................................ 1
54 70686G02 BRAKE PEDAL.......................................................................................... 1
55 70611G01 PARK BRAKE PEDAL ............................................................................... 1
56
57 70257G01 SERVICE BRAKE PAD.............................................................................. 1
58 70256G01 PARK BRAKE PAD.................................................................................... 1

Service Parts Manual Page D-6

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

59 16409G1 OVAL RIVET, 3/16" x 7/16" LG ........................................................... 9
60
61 70258G03 SERVICE BRAKE PEDAL PLATE ............................................................ 1
62 70682G01 PIVOT PIN ................................................................................................ 1
63 70681G01 TORSION SPRING ................................................................................... 2
64 01071G01 PUSHNUT, 5/16"....................................................................................... 1
65 00737G8 SCREW, #10 - 24 X 7/8" LG ..................................................................... 4
66 00739G1 RUBBER NUT, #10 - 24 ............................................................................ 2
67 74535G01 BRAKE PEDAL STANDOFF ..................................................................... 2
68 27137G01 CONICAL SPRING ................................................................................... 2
69 14390G10 LOCK NUT, #10 - 24 ................................................................................. 2
70 10606G8 MICRO SWITCH ....................................................................................... 1
71 00645G2 BOLT, # 6 - 32 X 1 1/4" LG........................................................................ 2
72 00559G5 FLAT WASHER, #10 ................................................................................. 2
73 00559G3 FLAT WASHER, # 6 .................................................................................. 4
74 00565G3 LOCK WASHER, # 6................................................................................. 2
75 00525G5 NUT, # 6 - 32 ............................................................................................. 2
76 13514G1 SCREW AND LOCK WASHER, # 6.......................................................... 2
77 00642G8 FLAT WASHER # 4 - 5/16......................................................................... 2
78 14628G1 FASTON TAB ............................................................................................ 2
79 24605G1 WIRE HARNESS (BRAKE LIGHT) ........................................................... 1
80 17618G1 WIRE TIE .................................................................................................. 3
81
82 612211 BRAKE ASSEMBLY (DRIVER SIDE) (INCLUDES ITEMS 84 - 92) ................ 1
83 612189 BRAKE ASSEMBLY (PASSENGER SIDE) (INCLUDES ITEMS 84 - 91, 93).. 1
84 612411 BRAKE SHOE, L ...................................................................................... 2
85 612412 BRAKE SHOE, T....................................................................................... 2
86 612413 DUST COVER........................................................................................... 1
87 612415 BRAKE SPRING ....................................................................................... 1
88 612414 BRAKE SPRING ....................................................................................... 1

Page D-7 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

89 612416 SHOE CLAMP ........................................................................................... 2

90
91
92 612418 GEAR ADJUSTER .................................................................................... 1
93 612417 GEAR ADJUSTER .................................................................................... 1
94
95
96 17083G2 BOLT, 5/16 - 24 X 1" LG................................................................................... 8
97 15126G1 LOCK NUT, 5/16 - 24 ....................................................................................... 8
98 21809G1 FLAT WASHER, 13/16" ................................................................................... 2
99
100 21807G1 BRAKE DRUM ASSEMBLY (INCLUDES ITEMS 101 - 102) ........................... 2
101 20947G1 BRAKE DRUM........................................................................................... 1
102 19862G1 LUG BOLT, 1/2 - 20 X 1 3/16" LG.............................................................. 4
103
104
105 21830G1 FLAT WASHER, 1 3/8" O.D. X 21/32".............................................................. 2
106 613172 CASTELLETED NUT, 5/8 - 18 ........................................................................ 2
107 10387G1 COTTER PIN, 1/8" X 1 1/2" LG........................................................................ 2
108 74175G01 SPINDLE CAP
109
110 608200 BRAKE CABLE BRACKET (PASSENGER SIDE) ........................................... 1
111 608201 BRAKE CABLE BRACKET (DRIVER SIDE).................................................... 1
112
113
114
115 612558 COMPENSATOR ASSEMBLY (INCLUDES ITEMS 116 - 126)........................ 1
116 00532G4 HEX NUT................................................................................................... 2
117 629486 HEX NUT, 5/16 - 24 ................................................................................... 1
118 28082G01 EQUALIZER BRACKET ............................................................................ 1
119 15121G1 FLAT WASHER - 5/16 ............................................................................... 2

Service Parts Manual Page D-8

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

120 17979G1 ACCELERATOR ROD BUSHING ............................................................. 1
121 23061G2 TUBE......................................................................................................... 1
122 23463G1 COMPRESSION SPRING ........................................................................ 1
123 27330G01 BRAKE YOKE ........................................................................................... 1
124 11098G9 HEX LOCK NUT, 5/16 - 24........................................................................ 1
125 612557 COMPENSATOR LINK ROD .................................................................... 1

Page D-9 Service Parts Manual

BRAKES

Notes:

Service Parts Manual Page D-10

BRAKES - FRONT DISC

140 141
10
11
142
139
8 132

135
4
3
134
2
133
43 6
137
38 5
136
35 41
36 12
42 27
37 26
34

30 40 22
31 39
27
Part of Frame
32 16 13
14
15 23 26
32

35 29

31 28
27 Accelerator 24 25
Pedal 27

120
123
126

124 127
125
123

129
122
121
128

119 COMPENSATOR ASSEMBLY includes items 120 - 129

132 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS) includes items 133 - 142

Page D - 11 Service Parts Manual

BRAKES - FRONT DISC

44 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS) includes items 45 - 70

67
48
46 58

55
53

61 57
51
63 56
54
WHT
BLK 59 62

63 65
68
64
60
66

BRAKE PEDAL
45 (VEHICLE WITH BRAKE LIGHTS)

Service Parts Manual Page D - 12

BRAKES - FRONT DISC

76
74

72
72

73
73
77

100 75
75

78 SPINDLE ASSEMBLY (DRIVER SIDE) includes items 79 - 91

96
92 SPINDLE ASSEMBLY (PASSENGER SIDE) includes items 81 - 91, 93, 94

86
86

79 92
94
80

91 85
83
84
82
88
90
87 84
83

89
98

Disc Hub
99

81
Brake Line Assembly 116
93 Caliper
115
93

Page D - 13 Service Parts Manual

101 FRONT DISC BRAKE ACTUATOR ASSEMBLY includes items 102 - 113

4 106

107

Front of Vehicle 103

3
104
102 106 2

1
109
7
112 8
108

Service Parts Manual

106

113

111 110

104

BRAKE ACTUATOR ASSEMBLY

105
6
BRAKES - FRONT DISC

Page D - 14
BRAKES - FRONT DISC
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 17838G1 NYLON BUSHING........................................................................................... 2
2 10387G3 COTTER PIN, 3/32" X 3/4".............................................................................. 2
3 10386G3 CLEVIS PIN, 5/16" X 1"................................................................................... 4
4 612704 ACTUATOR COVER ....................................................................................... 1
5 01038G01 SWAGEFORM SCREW WITH DOGPOINT, 1/4" - 20 X 3/4" LG .................... 3
6 00414G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG............................................................. 2
7 14390G4 LOCKNUT, 1/4" - 20 ........................................................................................ 2
8 608943 ACTUATOR LINKAGE..................................................................................... 1
9 00771G5 FLAT WASHER, 3/8" (NOT ILLUSTRATED) ................................................... 1
10 21504G1 BRAKE FLUID (NOT ILLUSTRATED) ............................................................. A/R
11
12 70582G01 SHOULDER BOLT, 3/8" - 16 X 4" LG .............................................................. 1
13 70581G01 ACETAL BUSHING ......................................................................................... 2
14 70676G01 TORSION SPRING ......................................................................................... 1
15 00643G1 FLAT WASHER, 3/8" ....................................................................................... 1
16 11098G5 LOCK NUT, 3/8" - 16 ....................................................................................... 1
17
18
19 12416G2 NYLON WEDGE LOCK CLAMP (NOT ILLUSTRATED) ................................. 3
20
21
22 28083G01 BRAKE COMPENSATOR BUMPER ............................................................... 2
23 624695 BRAKE CABLE (DRIVER SIDE), 65.06" LG ................................................... 1
24 624696 BRAKE CABLE (PASSENGER SIDE), 74.81" LG........................................... 1
25 01111G01 RETAINING RING (SS) ................................................................................... 4
26 10386G3 CLEVIS PIN, 5/16" X 1"................................................................................... 4
27 10387G3 COTTER PIN, 3/32" X 3/4".............................................................................. 3
28
29 70601G01 KICK-OFF LINK............................................................................................... 1
30 17838G1 NYLON BUSHING........................................................................................... 2
31 20835G1 NYLON WASHER, 3/8" ................................................................................... 2

Page D - 15 Service Parts Manual

BRAKES - FRONT DISC
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

32 00559G8 FLAT WASHER, 5/16"..................................................................................... 2

33
34 70098G01 KICK-OFF CAM PIVOT................................................................................... 1
35 10097G6 FLANGED BEARING ...................................................................................... 2
36 70587G01 KICK-OFF CAM .............................................................................................. 1
37 71215G01 SETSCREW WITH PATCH LOCK, 1/4" - 20 X 1/2" LG .................................. 2
38 14134G4 SPACER, 1 1/4" LG ........................................................................................ 1
39 70113G01 ADJUSTABLE BUMPER................................................................................. 1
40 11027G1 LOCK NUT, 5/16" - 18..................................................................................... 1
41 70080G02 CATCH BRACKET .......................................................................................... 1
42 00414G6 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG ............................................................ 2
43 14390G4 LOCK NUT, 1/4" - 20....................................................................................... 2
44 74874G01 BRAKE PEDAL ASSEMBLY (WITH BRAKE LIGHTS)
(INCLUDES ITEMS 45 - 70) ........................................................................... 1
45 74870G01 BRAKE PEDAL......................................................................................... 1
46 607395 PARK BRAKE PEDAL .............................................................................. 1
47 00642G8 FLAT WASHER, 5/16" .............................................................................. 1
48 70257G01 SERVICE BRAKE PAD............................................................................. 1
49 70256G01 PARK BRAKE PAD................................................................................... 1
50 16409G1 OVAL RIVET, 3/16" X 15/32" LG .............................................................. 9
51 70258G03 BRAKE PEDAL PLATE ............................................................................ 1
52 70682G01 PIVOT PIN................................................................................................ 1
53 70681G01 TORSION SPRING................................................................................... 2
54 01071G01 PUSHNUT, 5/16" ...................................................................................... 2
55 00737G8 PHILLIPS FLAT HEAD MACHINE SCREW, #10 - 24 X 1" LG................. 4
56 00739G1 RUBBER NUT, #10 - 24 ........................................................................... 2
57 74535G01 BRAKE PEDAL STANDOFF..................................................................... 2
58 27137G01 CONICAL SPRING................................................................................... 2
59 14390G10 LOCK NUT, #10 - 24................................................................................. 2
60 10606G8 LIMIT SWITCH (3 POLE) ......................................................................... 1
61 00645G2 PHILLIPS PAN HEAD MACHINE SCREW, #6 - 32 X 1 1/4" LG .............. 2

Service Parts Manual Page D - 16

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

62 00559G5 FLAT WASHER, #10 ................................................................................. 2
63 00559G3 FLAT WASHER, #6 ................................................................................... 4
64 00565G3 LOCK WASHER, #6.................................................................................. 2
65 00525G5 HEX NUT, #6 - 32...................................................................................... 2
66 13514G1 PHILLIPS PAN HEAD MACHINE SCREW, #6 - 32 X 7/32" LG................ 2
67 20835G1 TEFLON WASHER, 3/8" ........................................................................... 2
68 14628G1 FASTON TAB ............................................................................................ 2
69 24605G1 WIRE HARNESS (BRAKE LIGHT) ........................................................... 1
70 17618G1 WIRE TIE .................................................................................................. 3
71 74731G02 SPRING PLATE (PASSENGER SIDE)............................................................ 1
72 74731G01 SPRING PLATE (DRIVER SIDE) .................................................................... 1
73 74730G01 FOUR LINK ROD ............................................................................................ 2
74 606279 FLANGED HEX NUT, M10 - 1.25 .................................................................... 4
75 630766 BRAKE LINE ................................................................................................... 1
76 01038G01 SWAGEFORM SCREW WITH DOGPOINT, 1/4" - 20 X 1/2" LG .................... 1
77 74875G01 WIRE RETAINER ............................................................................................ 2
78 602281 SPINDLE ASSEMBLY (DRIVER SIDE)
(INCLUDES ITEMS 79 - 91)............................................................................ 1
79 602176 DISC BRAKE SPINDLE (DRIVER SIDE).................................................. 1
80 633918G02 CALIPER (DRIVER SIDE) ........................................................................ 1
81 12093G1 SLOTTED NUT, 1" - 14 ............................................................................. 1
82 74864G01 DRIVE FLANGE STUD, 1.5" LG............................................................... 4
83 11750G2 ROLLER BEARING................................................................................... 2
84 51141G1 BEARING RACE ....................................................................................... 2
85 630672 DISC BRAKE HUB.................................................................................... 1
86 70648G01 FLANGED BEARING ................................................................................ 1
87 00566G1 LOCK WASHER, 3/8" ............................................................................... 2
88 00426G6 HEX HEAD BOLT, 3/8" - 16 X 1" LG ......................................................... 2
89 70749G01 BEARING .................................................................................................. 1
90 00798G8 COTTER PIN 5/32" X 1 3/4" ..................................................................... 1
91 25146G1 GREASE SEAL ......................................................................................... 1

Page D - 17 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

92 602288 SPINDLE ASSEMBLY (PASSENGER SIDE)

(INCLUDES ITEMS 81 - 91, 93, 94) ............................................................... 1
93 602158 DISC BRAKE SPINDLE (PASSENGER SIDE)......................................... 1
94 633918G01 CALIPER (PASSENGER SIDE) ............................................................... 1
95
96 70745G01 KINGPIN TUBE............................................................................................... 2
97 70754G01 THRUST WASHER (SS), 0.995" I.D. X 1.38" O.D.......................................... 2
98 00560G3 FLAT WASHER, 1/2"....................................................................................... 4
99 14390G6 LOCKNUT, 1/2" - 13........................................................................................ 2
100 00407G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG .............................................................. 2
101 608706 FRONT DISC BRAKE ACTUATOR ASSEMBLY
(INCLUDES ITEMS 102 - 113)....................................................................... 1
102 612706 MASTER CYLINDER WELDMENT .......................................................... 1
103 11098G5 PLASTIC LOCK NUT, 3/8" - 16 ................................................................ 1
104 00679G1 FLAT WASHER (SS), 3/8" ........................................................................ 1
105 74711G01 ACTUATOR PIVOT BOLT, 3/8" - 16 X 4 1/2" LG...................................... 1
106 70581G02 ACETAL BUSHING................................................................................... 4
107 608122 WELDMENT BRACKET, UPPER BRAKE ................................................ 1
108 608118 WELDMENT BRAKCET, LOWER BRAKE ............................................... 1
109 887364 MASTER CYLINDER ............................................................................... 1
110 00439G1 HEX HEAD BOLT, 5/16" - 18 x 1 1/8" LG ................................................ 2
111 11098G6 LOCK NUT, 5/16" - 18 .............................................................................. 2
112 10386G3 CLEVIS PIN, 5/16" X 1" ............................................................................ 1
113 10387G3 COTTER PIN, 3/32" X 3/4" ....................................................................... 1
114
115 613293 CRUSH WASHER, M10.................................................................................. 4
116 616459 BANJO BOLT, M10 - 1" X 20" LG ....................................................................... 2
117
118
119 612558 COMPENSATOR ASSEMBLY (INCLUDES 120 - 129) .................................. 1
120 00532G4 HEX NUT, 1/4" - 20................................................................................... 2
121 629486 HEX NUT, 5/16" - 24................................................................................. 1

Service Parts Manual Page D - 18

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

122 28082G01 EQUALIZER BRACKET............................................................................ 1
123 15121G1 FLAT WASHER, 5/16"............................................................................... 2
124 17979G1 ACCELERATOR ROD BUSHING ............................................................. 1
125 23061G2 TUBE......................................................................................................... 1
126 23463G1 COMPRESSION SPRING ........................................................................ 1
127 27330G01 BRAKE YOKE ........................................................................................... 1
128 11098G9 HEX LOCK NUT, 5/16" - 24 ...................................................................... 1
129 612557 COMPENSATOR LINK ROD .................................................................... 1
130
131
132 74723G01 BRAKE PEDAL ASSEMBLY (WITHOUT BRAKE LIGHTS)
(INCLUDES ITEMS 133 - 142)........................................................................ 1
133 70681G01 TORSION SPRING ................................................................................... 2
134 70682G01 PIVOT PIN ................................................................................................ 1
135 01071G01 PUSHNUT, 5/16"....................................................................................... 1
136 74721G01 BRAKE PEDAL ......................................................................................... 1
137 607395 PARK BRAKE PEDAL............................................................................... 1
138
139 70257G01 SERVICE BRAKE PAD ............................................................................. 1
140 70256G01 PARK BRAKE PEDAL PAD ...................................................................... 1
141 16409G1 OVAL RIVET, 3/16" X 15/32" LG............................................................... 9
142 20835G1 TEFLON WASHER, 3/8" ........................................................................... 2

Page D - 19 Service Parts Manual

BRAKES - FRONT DISC

Notes:

Service Parts Manual Page D - 20

Page F-1
5

7
1 CHARGER HARNESS Includes Items 2 - 11
6
3 CHARGER HARNESS RECEPTACLE Includes Items 4 - 11 12 11 10 2

24
26

31 8
32 4
33
ELECTRICAL SYSTEM

23 30

Service Parts Manual

31
A2
F2 25
28
A1
F1

21
20 15 27
20

19
ELECTRICAL SYSTEM

RED GRN/BLK

59
60 54
53
42 55
56

57
OFF ON

61 41

45
58
46
43
47
48

Service Parts Manual Page F-2

ELECTRICAL SYSTEM

50 49

52
BLU/WHT
ORN/WHT

RED
GRN

FLOOR MOUNTED HORN BUTTON

90 87
Floorboard 89

HOR

N
87
86
88

Front of Vehicle

YEL
BLK

Page F-3 Service Parts Manual

ELECTRICAL SYSTEM

HEAD LIGHT
&
TURN SIGNAL

66
68

66 80

71 80 70

67
69

Rear 79 TURN SIGNAL KIT Includes items 80 - 85

TAILLIGHT Fender

75 85
74

82
83

Service Parts Manual Page F-4

ELECTRICAL SYSTEM

HOUR METER

Hour Meter
94

95
97

93 HOUR METER Includes Items 94 - 98

Passenger Side
Seat Support Front of Vehicle

98
Electrical
Components
Cover

Note:
Hold lower nut when
Seat
(+) (-)
tightening top nut.
Support
Solenoid

DC TO DC 36
CONVERTER KIT 101

38 100
39

35
For Models before 02 October 2013
For Models after 02 October 2013

34 DC TO DC CONVERTOR KIT Includes Items 35 - 40, 100 & 101

Page F-5 Service Parts Manual

ELECTRICAL SYSTEM

Rear Fender
TAILLIGHT

87
102

WHT to BLU/WHT from Harness - Both Sides

BLK to BLK from Harness - Both Sides
RED to BRN from Harness - Both Sides (without Turn Signals)
RED to WHT from Harness - Driver Side (with Turn Signals)
RED to YEL from Harness - Passenger Side (with Turn Signals)

105

103

104

108 109

107

106

Service Parts Manual Page F-6

ELECTRICAL SYSTEM
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 73311G03 CHARGER HARNESS / RECEPTACLE (INCLUDES ITEMS 2 - 11) .............. 1
2 602822 CHARGER HARNESS.............................................................................. 1
3 73051G30 CHARGER HARNESS RECEPTACLE (INCLUDES ITEMS 4 - 11) ......... 1
4 73051G22 RECEPTACLE BOTTOM........................................................................ 1
5 73051G21 RECEPTACLE COVER .......................................................................... 1
6 73051G08 BINDING HEAD BRASS SCREW, #10 - 32 X 1/2" LG........................... 2
7 73051G09 PHILLIPS HEAD SCREW, #6 - 32 X 1 3/4" LG ...................................... 3
8 73051G10 LOCK NUT, #6 - 32................................................................................. 3
9 25978G25 RED JUMPER WIRE, 18 GA.................................................................. 1
10 73051G23 FEMALE CONTACT ............................................................................... 1
11 73051G24 FEMALE CONTACT, INSULATED.......................................................... 1
12 71055G01 RIVET, 3/16" X 1" LG....................................................................................... 4
13
14
15 73349G01 POWER HARNESS......................................................................................... 1
16
17
18 00993G01 LOCK WASHER, 5/16".................................................................................... 4
19 28418G01 HEX NUT, 5/16" - 18........................................................................................ 4
20 27327G0* CLAMP ............................................................................................................ 1
21 10570G11 RIVET (SS), 3/16" X 3/4" LG .......................................................................... 1
22
23 XXXXXG** 6 VOLT BATTERY ........................................................................................... 8
24 612867 BATTERY RETAINER ..................................................................................... 1
25 01101G01 HOLD DOWN BOLT ........................................................................................ 2
26 11027G1 LOCK NUT, 5/16" - 18 ..................................................................................... 6
27 70386G01 HOLD DOWN BOLT ........................................................................................ 4
28 70387G01 BATTERY RETAINER ..................................................................................... 2
29
30 25971G18 4 GA WIRE (BLK 6")........................................................................................ 4
31 25971G16 4 GA WIRE (BLK 19")...................................................................................... 1

Page F-7 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

32 25971G13 4 GA WIRE (BLK 10 1/2") ............................................................................... 2

33 00702G2 HEX NUT, 5/16" - 18 ....................................................................................... 16
34 605988 DC TO DC CONVERTER KIT (INCLUDES ITEMS 35 - 40, 100 & 101) ........ 1
35 632185 DC TO DC CONVERTER
(FOR MODELS AFTER 02 OCTOBER 2013) .......................................... 1
36 626315 BRACKET................................................................................................. 1
37 606018 DC TO DC WIRING HARNESS................................................................ 1
38 632372 PHILIPS PAN HEAD SCREW, #10 - 24 X 1/2" LG
(FOR MODELS AFTER 02 OCTOBER 2013) .......................................... 4
39 16816G5 CHRISTMAS TREE RIVET, .187" X 0.55" LG .......................................... 1
40 00715G2 HEX HEAD BOLT, 5/16" - 18 X .80" LG (NOT ILLUSTRATED) ............... 2
41 18602G1 IGNITION SWITCH ......................................................................................... 1
42 00568G6 LOCK WASHER, 3/4" ..................................................................................... 1
43 17137G1 FACE NUT ...................................................................................................... 1
44 17955G1 IGNITION SWITCH (WITHOUT LIGHTS, NON-STANDARD KEY) ................ 1
45 18027G1 IGNITION SWITCH (WITHOUT LIGHTS, INDIVIDUALLY KEYED) ............... 1
46 33639G01 IGNITION SWITCH (WITH LIGHTS, STANDARD KEY)................................. 1
47 33639G02 IGNITION SWITCH (WITH LIGHTS, NON-STANDARD KEY) ....................... 1
48 33639G03 IGNITION SWITCH (WITH LIGHTS, INDIVIDUALLY KEYED)....................... 1
49 22674G1 FUSE BLOCK ................................................................................................. 1
50 01041G01 RIVET, 5/32" X 3/8" LG ................................................................................... 2
51 18392G1 FUSE, 15 AMP................................................................................................ 3
52 619156 WIRE HARNESS (ACCESSORY) .................................................................. 1
53 73030G06 CONSOLE INSERT PLATE ............................................................................ 1
54 74320G01 LABEL, DIRECTION SELECTOR AND STATE OF CHARGE METER .......... 1
55 74322G01 LABEL, LIGHTS, DIRECTION SELECTOR & STATE OF CHARGE METER 1
56 74323G01 DIRECTION SELECTOR SWITCH................................................................. 1
57 33636G05 STATE OF CHARGE METER (VERTICAL) .................................................... 1
58 33623G02 RIVET, 3/16" X 3/8" LG ................................................................................... 2
59 609067 SOC FUSE HARNESS ................................................................................... 1
60 73334G01 HARNESS (CONTROL).................................................................................. 1
61 25978G74 18 GA WIRE (RED 6") .................................................................................... 1

Service Parts Manual Page F-8

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

62 73290G02 BUZZER .......................................................................................................... 1
63 01041G01 RIVET, 5/32" X 3/4" LG.................................................................................... 2
64 32860G1 HORN .............................................................................................................. 1
65
66 614497 HEADLIGHT W/O TURN SIGNAL (PASSENGER SIDE)................................ 1
67 614501 HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) ........................................ 1
68 618556 LED HEADLIGHT W/O TURN SIGNAL (PASSENGER SIDE)........................ 1
69 618555 LED HEADLIGHT W/O TURN SIGNAL (DRIVER SIDE) ................................ 1
70 71597G01 SELF THREADING NUT, 5 X 10X 15MM........................................................ 8
71 71781G02 VINYL TAPE .................................................................................................... 2
72
73
74 618257 WIRE HARNESS (ACCESSORY), 48V DC, SWB .......................................... 1
75 618260 JUMPER PLUG, TAIL LIGHT .................................................................... 1
76
77 32739G2 TAIL LIGHT...................................................................................................... 1
78
79 622712 TURN SIGNAL KIT (INCLUDES ITEMS 80 - 85) ............................................ 1
80 619102 TURN SIGNAL BULB................................................................................ 1
81 611810 TURN SIGNAL SWITCH ASSEMBLY....................................................... 1
82 32307G3 FLEX LOOM, 3/8" X 8" LG........................................................................ 1
83 17618G1 WIRE TIE .................................................................................................. 2
84 20965G3 STEERING COLUMN COVER ................................................................. 1
85 21640G01 FLASHER UNIT ........................................................................................ 1
86 17318G1 HORN SWITCH............................................................................................... 1
87 17318G2 HORN SWITCH CAP AND NUT ..................................................................... 2
88 27068G01 HORN SWITCH BOOT.................................................................................... 1
89 608397 HORN SWITCH LABEL................................................................................... 1
90 01041G01 RIVET, 5/32" X 3/4" LG.................................................................................... 2
91
92

Page F-9 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

93 75113G06 HOUR METER KIT (INCLUDES ITEMS 94 - 98)............................................ 1

94 74665G02 HOUR METER ........................................................................................ 1
95 74716G01 HOUR METER BRACKET ....................................................................... 1
96 74696G01 RETAINER CLIP....................................................................................... 1
97 10570G11 RIVET, 3/16" X .70.................................................................................... 2
98 75117G04 WIRE HARNESS (HOUR METER) .......................................................... 1
99
100 604884 DC TO DC CONVERTER
(FOR MODELS BEFORE 02 OCTOBER 2013) ....................................... 1
101 00379G4 PHILLIPS PAN HEAD SCREW, #10 - 24 X 1/2" LG
(FOR MODELS BEFORE 02 OCTOBER 2013) ....................................... 6
102 22288G1 TAIL LIGHT ASSEMBLY COMPLETE ............................................................ 2
103 625251 BEZEL, TAILLIGHT (DRIVER SIDE)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
104 625252 BEZEL, TAILLIGHT (PASSENGER SIDE)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
105 71364G02 "J" TYPE NUT, #8
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 8
106 00513G4 PAN HEAD PHILLIPS SCREW, #8 X 1.5" LG
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 4
107 22288G1 TAILLIGHT ASSEMBLY
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 2
108 71425G01 TAPPING SCREW, #8 - 18 X .75" LG
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 8
109 14601G11 RIVET, 3/16" X 9/16"
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 2

Service Parts Manual Page F-10

ELECTRICAL SYSTEM

Notes:

Page F-11 Service Parts Manual

ELECTRICAL SYSTEM

Notes:

Service Parts Manual Page F-12

ELECTRONIC SPEED CONTROL

1 ELECTRONIC SPEED CONTROL ASSEMBLY Includes Items 2 - 16, 31 - 37

Walkaway #10 Black

33 Relay From Motor F2 PURPLE
36 34 (Power Harness) From Walkaway Fuse
Walkaway To Solenoid (+)
Fuse 23 21

24 22 14 16 #4 Black
35 From Motor A1
(Power Harness)
#4 Black
From Motor A2
(Power Harness)
#18 Yellow
From J1 Pin 5
(Control Harness)
F2 37 #18 Blue
From J1 Pin 17
B+ (Control Harness)
J3
10
9 12
J2 M- 8
7
4
6
J1
#18 Red
2 B- From Tow
Switch and
Reverse Buzzer
(Control Harness)
F1
#10 White
From Charger
Receptacle

Speed Sensor 26
Harness
25 #4 Black
From Charger Power Harness
18 Charger Receptacle (Charger Harness) #4 Black
Harness From Battery (-)
#18 Red/White (Power Harness
Red FromWalkaway From Tow Switch #4 Black
Relay (Control Harness) From Motor A1
19 To Solenoid (-) To Ignition Interlock (Power Harness)
(Charger Receptacle)

29 Code Fault Code

1-1
1-2
HW FAILSAFE
THROTTLE FAULT 1
Symptoms
Vehicle will not run
Vehicle will not run
Corrective Action
Check motor wiring, replace controller
Check pedal box adjustment, connections,
replace ITS
1-3 SPEED SENSOR FAULT Vehicle runs slowly Check speed sensor connection, and wiring,
replace sensor if required
1-4 HPD Vehicle will not run Release and reapply pedal.
Check pedal box, linkage, switch and key switch
1-5 MOTOR STALL Vehicle stopped Remove mechanical blockage
2-1 LOW BATTERY VOLTAGE Vehicle performance reduced Charge batteries, replace bad batteries
2-2 OVERVOLTAGE Regen performance reduced Check that battery voltage is less than 60 VDC
WARNI Vehicle performance reduced Allow controller to cool
Always
select 'TOW TOWING
NG 2-3
2-4
THERMAL CUTBACK
MAIN DRIVER ON Vehicle runs slowly Solenoid driver defective, replace controller
/ MAIN
TENANCE' 2-5 VDD FAULT Vehicle will not run Replace controller
position
before 3-1 MAIN DRIVER OFF Solenoid does not close Replace controller

27 28
RUN towing.
l
3-2 MAIN WELDED Vehicle runs slowly Verify solenoid welded, replace solenoid
TOW
MAINTENA 3-3 PRECHARGE FAULT Vehicle will not run Check for additional electronics attached to
Possibility MAINT NCE
Before of elect ENA B+, replace controller
and batte NCE
remo rical arc
turn switc ving/conn 3-4 FIELD MISSING Solenoid closes, vehicle will Check wiring.
h to 'TOW ecting batte ry explosion.

30
To disab
le
/MAINTEN ries or
elect not run Replace power harness and motor if required.
ANCE'
position electrical syste position. rical componen
and m place ts 3-5 FIELD OVERCURRENT Vehicle will not run Field windings or power harness shorted.
After recon remove batte switch
in 'TOW
necti ry wire. /MAINTEN Verify, replace motor if necessary.
before
selecting ng batteries, ANCE'
'RUN' posit allow a minim 4-1 CURRENT SENSE FAULT Vehicle will not run Replace controller
ion um of 30
seconds 4-3 M- FAULT Vehicle will not run Check M- wiring and repair, replace controller
4-4 AUX CONT DNC Vehicle will not run Replace controller
4-5 WELDED AUX CONT Vehicle runs slowly Replace controller
73340G01 5-1 EEPROM FAILSAFE Vehicle will not run Replace controller
5-2 MAIN COIL OPEN Vehicle will not run Check coil connections/wiring.
Replace solenoid if necessary
5-3 MAIN CONT DNC Vehicle will not run Check all solenoid wiring.
Replace solenoid if necessary
5-5 MISSING CONTACTOR Vehicle stops Check all solenoid wiring.
Replace solenoid if necessary

Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close),
HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor),
M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault)

DIAGNOSTIC FAULT CODES

The LED will flash a diagnostic fault code when a fault is detected
Some faults may only be detected by operating the vehicle with the rear of the
vehicle raised and supported on safety stands
Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery
compartment) to the 'TOW/MAINTENANCE' position before performing any repairs
or maintenance to the vehicle
Select 'RUN' before returning the vehicle to service
P/N 73398-G01

Page G-1 Service Parts Manual

ELECTRONIC SPEED CONTROL
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 73348G04 ELECTRONIC SPEED CONTROL ASSEMBLY

(INCLUDES ITEMS 2 - 16, 31 - 37) ................................................................ 1
2 73351G01 CONTROLLER MOUNT........................................................................... 1
3
4 611173 ELECTRONIC SPEED CONTROLLER.................................................... 1
5
6 73231G01 48 VOLT SOLENOID (INCLUDES ITEMS 7 - 10) .................................... 1
7 * LOCK WASHER, #10............................................................................. 2
8 * NUT, #10 - 32 ......................................................................................... 2
9 * LOCK WASHER, 5/16" .......................................................................... 2
10 * JAM NUT, 5/16 - 24................................................................................ 2
11
12 73446G01 FASTON TAB............................................................................................ 4
13
14 11027G2 LOCK NUT, 1/4 - 20.................................................................................. 6
15
16 25971G17 4 GA WIRE (BLK 9")................................................................................. 1
17
18 73053G01 DOUBLE TUBE CLAMP ................................................................................. 1
19 11027G2 LOCK NUT, 1/4 - 20 ........................................................................................ 4
20 73523G01 CONTROLLER COVER.................................................................................. 1
21 73296G01 BOLT, 8MM X 16MM LG ................................................................................. 3
22 00993G01 LOCK WASHER, 5/16" ................................................................................... 3
23 73346G01 BOLT, 6MM X 1 X 12MM LG........................................................................... 2
24 00993-G02 LOCK WASHER, 1/4" ..................................................................................... 2
25 73334G01 CONTROL HARNESS .................................................................................... 1
26 25971G06 4 GA WIRE (BLK 59 1/2") (SOL - BATTERY +) .............................................. 1
27 74878G01 TOW-MAINTENANCE SWITCH (SHUTTLE 4/6) ........................................... 1
28 73347G03 TOW-MAINTENANCE SWITCH (SHUTTLE 2) .............................................. 1
29 71055G01 RIVET, 5/32" X 3/4" LG ................................................................................... 2
30 73398G01 DIAGNOSTIC LABEL (FAULT CODE)............................................................ 1

Service Parts Manual Page G-2

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

31 615551 ELECTRONIC SPEED CONTROLLER SVC KIT (Includes 4, 32-37)............. 1
32 17618G1 NYLON WIRE TIE..................................................................................... 1
33 608931 WALKAWAY RELAY HARNESS ASSEMBLY (includes 34) ..................... 1
34 604110 RELAY .................................................................................................... 1
35 16816G5 RIVET, 0.18 X 0.55.................................................................................... 1
36 16816G2 RIVET, 0.25 X 0.88.................................................................................... 1
37 73499G01 FUSE COVER........................................................................................... 1

Page G-3 Service Parts Manual

ELECTRONIC SPEED CONTROL

Notes:

Service Parts Manual Page G-4

FRONT SUSPENSION / STEERING

*Truck
Models 29
Only
31*
Front of Vehicle Part of
30* Frame
24
33

38
25 32

34
26
96
2
1

11 39
37
Part of
Frame
25
13
39
23 28
7
10 35
36
5
39 *NOTE: Tie Rod Not 38
6
4 LUG 8 Shown for
Clarity
6
9
3 12 3 SPINDLE AND HUB ASSEMBLY includes items 4 -10
19
7 WHEEL HUB ASSEMBLY WITH RACES includes item 8

12 SPINDLE AND HUB ASSEMBLY includes items 5 - 10, 13

20
14 SPINDLE AND HUB ASSEMBLY includes items 16 - 21
21
16 18 WHEEL HUB ASSEMBLY WITH RACES includes item 19
17
5 LUG 22 SPINDLE AND HUB ASSEMBLY includes items 16 - 21

17 18
22
14

Page H-1 Service Parts Manual

FRONT SUSPENSION / STEERING

88
Front of Vehicle 85 83

87 61
84

66
62 68
64 81
69 80
65
63 79
78

52
72 77

73 76
44
60 43
70 45
48
40
71 50
46 49
56
58 47
59

95 57
53
51

55
54
93
94

90 89

92
91
40 RACK AND PINION UNIT includes items 41 - 52

62 STEERING COLUMN KIT includes items 63 - 65

66 STEERING COLUMN KIT includes items 67 - 69

74 STEERING COLUMN KIT includes items 61, 63 - 65, 75 - 81

89 TIE ROD ASSEMBLY includes items 90 - 94

Service Parts Manual Page H-2

FRONT SUSPENSION / STEERING
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 602513 FRONT AXLE .................................................................................................. 1
2 602327 FRONT AXLE WITH FRONT DISC BRAKES ................................................. 1
3 70942G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (PASSENGER SIDE)
(INCLUDES ITEMS 4 - 10).............................................................................. 1
4 70942G04 SPINDLE ASSEMBLY (PASSENGER SIDE)............................................ 1
5 25146G1 GREASE SEAL ......................................................................................... 1
6 50892G1 ROLLER BEARING AND RACE ASSEMBLY........................................... 2
7 70589G01 WHEEL HUB ASSEMBLY WITH RACES, 4 LUG (INCLUDES ITEM 8) .. 1
8 19862G1 LUG BOLT, 1/2 - 20 X 1 3/16" LG........................................................... 4
9 12093G1 CASTELLATED NUT, 1" - 14 .................................................................... 1
10 00798G8 COTTER PIN, 5/32" X 1 3/4" LG............................................................... 1
11 12091G2 SPINDLE CAP................................................................................................. 2
12 70673G03 SPINDLE AND HUB ASSEMBLY, 4 LUG (DRIVER SIDE)
(INCLUDES ITEMS 5 - 10, 13)........................................................................ 1
13 70673G04 SPINDLE ASSEMBLY (DRIVER SIDE) .................................................... 1
14 602288 SPINDLE AND HUB ASSEMBLY WITH FRONT DISC BRAKES
(PASSENGER SIDE)(INCLUDES ITEMS 16 - 21) .......................................... 1
15
16 12092G1 GREASE SEAL ......................................................................................... 1
17 50892G1 ROLLER BEARING AND RACE ASSEMBLY........................................... 2
18 74673G01 WHEEL HUB ASSEMBLY WITH RACES, (INCLUDES ITEM 19)............ 1
19 30143G1 LUG BOLT, 1/2" - 20 X 1 7/32" LG.......................................................... 5
20 12093G1 CASTELLATED NUT, 1" - 14 .................................................................... 1
21 00798G8 COTTER PIN, 5/32" X 1 3/4" LG............................................................... 1
22 602281 SPINDLE AND HUB ASSEMBLY, WITH FRONT DISC BRAKES
(DRIVER SIDE)(INCLUDES ITEMS 15 - 20) .................................................. 1
23
24 00407G6 HEX HEAD BOLT, 1/2" - 13 X 6" LG................................................................ 2
25 00560G3 FLAT WASHER, 1/2" ....................................................................................... 4
26 70745G01 KING PIN TUBE .............................................................................................. 2
27 70754G01 THRUST WASHER (SS), 1" ........................................................................... 2
28 14390G6 LOCK NUT, 1/2" - 13 ....................................................................................... 2
29 76419G01 SHOCK ABSORBER....................................................................................... 2

Page H-3 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

30 70509G01 SHOCK ABSORBER BOOT ........................................................................... 2

31 31539G1 WIRE TIE ........................................................................................................ 4
32 10435G1 SHOCK ABSORBER WASHER...................................................................... 8
33 10194G1 RUBBER BUSHING........................................................................................ 8
34 00532G6 HEX NUT, 3/8" - 24 ......................................................................................... 4
35
36 70664G03 LEAF SPRING (HEAVY DUTY) (SEE PART NUMBER ON SPRING)............ 2
37 70163G03 SPRING PLATE .............................................................................................. 4
38 00734G1 LOCK NUT, 7/16" - 14..................................................................................... 11
39 00463G11 HEX HEAD BOLT, 7/16" - 14 X 1 3/4" LG ....................................................... 11
40 70964G01 RACK AND PINION UNIT (COMPLETE) (INCLUDES ITEMS 41 - 52).......... 1
41 70965G01 STEERING RACK COVER & BEARING .................................................. 1
42 * STEERING BOX INSTALLATION TAG .................................................... 1
43 70694G01 RACK EXTENSION.................................................................................. 1
44 * JAM NUT, 1/2" - 20 ................................................................................... 1
45 70961G01 RACK BOOT ............................................................................................ 1
46 12416G2 WIRE TIE.................................................................................................. 1
47 11391G8 CLAMP, 1 13/16" - 2 3/8" .......................................................................... 1
48 70638G01 PINION SEAL ........................................................................................... 1
49 70695G01 TIE ROD END - OUTER........................................................................... 1
50 * GROMMET - TIE ROD END .................................................................... 1
51 * CASTELLATED NUT, 7/16 - 20 ................................................................ 1
52 10389G3 GREASE FITTING, STRAIGHT................................................................ 1
53 10387G2 COTTER PIN, 3/32" X 1" LG.................................................................. ......... 1
54 00464G8 HEX HEAD BOLT, 7/16" - 14 X 2 3/4" LG ....................................................... 2
55 01068G01 HEX HEAD BOLT, 7/16" - 14 X 3 1/2" LG ....................................................... 1
56 70667G02 SPACER, 1.21" LG ......................................................................................... 2
57 70667G04 SPACER (SHORT), 0.69" LG.......................................................................... 1
58 00532G7 HEX NUT, 7/16" - 14 ....................................................................................... 1
59 00560G2 FLAT WASHER, 7/16"..................................................................................... 7
60 00734G1 LOCK NUT, 7/16" - 14..................................................................................... 3

Service Parts Manual Page H-4

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

61 70607G01 STEERING SHAFT ................................................................................... 1
62 70758G06 STEERING COLUMN KIT (INCLUDES ITEMS 63 - 65) ................................. 1
63 70610G03 STEERING COLUMN ............................................................................... 1
64 28569G01 STEERING COLUMN BUSHING.............................................................. 1
65 01022G01 HEX WASHER HEAD SCREW, #6 - 20 X 5/16" LG ................................. 1
66 70758G08 STEERING COLUMN KIT (HORN) (INCLUDES ITEMS 67 - 69) ................... 1
67 70610G04 STEERING COLUMN ............................................................................... 1
68 28569G01 STEERING COLUMN BUSHING.............................................................. 1
69 01022G01 HEX WASHER HEAD SCREW, #6 - 20 X 5/16" LG ................................. 1
70 01006G01 HEX WASHER HEAD BOLT, 3/8" - 16 X 1 1/4" LG ......................................... 4
71 00879G1 LOCK WASHER, 3/8"...................................................................................... 4
72 70997G01 COVER............................................................................................................ 1
73 71055G01 RIVET, 3/16" X 1" LG (ALUMINUM) ................................................................ 1
74 70758G05 STEERING COLUMN KIT (INCLUDES ITEMS 61, 63 - 65, 75 - 81) .............. 1
75 70580G01 INTERMEDIATE SHAFT (INCLUDES ITEMS 75, 76) .............................. 1
76 01055G01 HEX HEAD BOLT, M8 X 1.25 - 6G............................................................ 1
77 00565G8 LOCK WASHER, 5/16" ............................................................................. 1
78 70751G01 RETAINING RING (INTERNAL)................................................................ 1
79 70888G01 RETAINING RING (EXTERNAL) .............................................................. 1
80 15112G1 BALL BEARING ........................................................................................ 1
81 70887G01 WAVE WASHER ....................................................................................... 1
82
83 618086 CUSHMAN STEERING WHEEL DECAL ........................................................ 1
84 71147G01 STEERING WHEEL COVER........................................................................... 1
85 602979 STEERING WHEEL ........................................................................................ 1
86 607925 CLIPBOARD.................................................................................................... 1
87 71949G01 HUB COVER ................................................................................................... 1
88 14390G2 LOCK NUT, 5/8" - 18 ....................................................................................... 1
89 70876G02 TIE ROD ASSEMBLY (INCLUDES ITEMS 90 - 94) ........................................ 1
90 70897G02 THREADED ROD (24" LG) ....................................................................... 1
91 70902G01 TIE ROD END (LEFT HAND THREADS) ................................................. 1

Page H-5 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

92 01069G01 JAM NUT, M12 X 1.25 - 05 (LEFT HAND THREADS) ............................. 1

93 70902G02 TIE ROD END (RIGHT HAND THREADS) .............................................. 1
94 01069G02 JAM NUT, M12 X 1.25 - 05 (RIGHT HAND THREADS) ........................... 1
95 00734G1 LOCK NUT, 7/16" - 14..................................................................................... 2
96 10044G01 VINYL CAP ..................................................................................................... 4

Service Parts Manual Page H-6

FRONT SUSPENSION / STEERING

Notes:

Page H-7 Service Parts Manual

FRONT SUSPENSION / STEERING

Notes:

Service Parts Manual Page H-8

MOTOR

1 MOTOR Includes Items 2 - 12

6
4

8 7

14
10 13 12
2

11
15

Page J-1 Service Parts Manual

MOTOR
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 73291G04 MOTOR (SEPARATELY EXCITED) (INCLUDES ITEMS 2-12) ..................... 1

2 73120G36 ARMATURE.............................................................................................. 1
3 73120G38 BRUSH SPRING ...................................................................................... 8
4 73120G39 BRUSH ..................................................................................................... 8
5 73120G40 BRUSH BOX ............................................................................................ 1
6 73120G41 BRUSH REPLACEMENT KIT (INCLUDES HARDWARE) ....................... 1
7 73120G07 BEARING ................................................................................................. 1
8 73120G06 SNAP RING.............................................................................................. 1
9 73120G43 HEADBAND.............................................................................................. 1
10 73120G37 FRAME AND FIELD COIL (INCLUDES HARDWARE) ............................ 1
11 73120G42 COVER COMMUTATOR END.................................................................. 1
12 73277G01 RETAINING RING .................................................................................... 1
13 01037G02 SCREW, #10 - 32 X 1/2" LG ........................................................................... 1
14 73328G01 MAGNET......................................................................................................... 2
15 73327G02 SPEED SENSOR............................................................................................ 1

Service Parts Manual Page J-2

MOTOR

Notes:

Page J-3 Service Parts Manual

MOTOR

Notes:

Service Parts Manual Page J-4

REAR AXLE

1 REAR AXLE ASSEMBLY Includes Items 2 - 7

NOTE: Apply a light coat of moly grease to

male spline before assembly. Reference 12
13
part number 15. 14

4
3
5

Page K-1 Service Parts Manual

REAR AXLE
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 74612G01 REAR AXLE ASSEMBLY 14.76:1 (INCLUDES ITEMS 2 - 7) ......................... 1

2 617609 AXLE SHAFT (PASSENGER SIDE)......................................................... 1
3 617608 AXLE SHAFT (DRIVER SIDE) ................................................................. 1
4 * DIFFERENTIAL COVER .......................................................................... 1
5 601081 FILL PLUG WITH 'O' RING ...................................................................... 1
6 15558G1 BOLT, 5/16 - 18 X 3/4" LG ........................................................................ 10
7 73050G01 VENT ........................................................................................................ 1
8
9 72763-G02 SCUFF GUARD .............................................................................................. 1
10
11 24261G1 SPLINE BUMPER ........................................................................................... 1
12 00797G2 BOLT, 1/4 - 20 X 1 1/4" LG.............................................................................. 3
13 00664G7 LOCK WASHER, 1/4" (STAINLESS STEEL) .................................................. 3
14 01110G01 WASHER, 1/4" (STAINLESS STEEL) ............................................................. 3
15 12719G1 ANTI-SIEZE. ................................................................................................... AR

Service Parts Manual Page K-2

REAR AXLE

Notes:

Page K-3 Service Parts Manual

REAR AXLE

Notes:

Service Parts Manual Page K-4

REAR SUSPENSION

17 1

2
11
3 12
13
6
14
9

3
2
7
20

Page L-1 Service Parts Manual

REAR SUSPENSION
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 76418G01 SHOCK ABSORBER ...................................................................................... 2

2 10435G1 SHOCK ABSORBER WASHER...................................................................... 8
3 10194G1 RUBBER SHOCK ABSORBER BUSHING ..................................................... 8
4 00532G6 HEX NUT, 3/8" - 24 ......................................................................................... 4
5
6 74207G03 LEAF SPRING (HEAVY DUTY) ...................................................................... 2
7 72618G01 “U” BOLT, 3/8" - 16 X 2" X 2 1/2" LG............................................................... 4
8 00560G1 FLAT WASHER, 3/8"....................................................................................... 8
9 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 8
10
11 70289G02 SPLIT STEEL SPACER .................................................................................. 4
12 624030 FLANGED BUSHING...................................................................................... 12
13 70290G02 SHACKLE PLATE ........................................................................................... 4
14 00665G9 HEX HEAD BOLT, 3/8" - 16 X 3 1/2" LG (STAINLESS STEEL)...................... 4
15 11098G5 LOCK NUT, 3/8" - 16....................................................................................... 4
16
17 14158G1 SHOULDER BOLT, 3/8" - 16 X 3 1/4" LG........................................................ 2
18 12262G1 LOCK NUT, 3/8" - 16....................................................................................... 2
19
20 10044G01 VINYL CAP ..................................................................................................... 2

Service Parts Manual Page L-2

REAR SUSPENSION

Notes:

Page L-3 Service Parts Manual

REAR SUSPENSION

Notes:

Service Parts Manual Page L-4

SEATING

1 SEAT BACK ASSEMBLY includes items 3 - 6, 8 & 9

17
117 SEAT BACK ASSEMBLY includes items 3 - 6, 8, 118 & 119

115 FLIP FLOP SEAT BOTTOM ASSEMBLY includes items 57 - 60, 116

119 8
9
5
3
12 4
6
Front of Vehicle 18
14

118
13
57 12
59
58 11
57
68

60
56

52
55
116

21 SEAT BOTTOM ASSEMBLY includes items 22 - 33

120 SEAT BOTTOM ASSEMBLY includes items 22 - 27, 32, 107 - 109, 112, 121
Front of Vehicle

52
121
26

30
27
29 109
108

Front of Vehicle
107
28

44
23
53
32 46
22
31
33 24
112

Page M-1 Service Parts Manual

SEATING

80 HANDRAIL KIT, FLIP FLOP SEAT includes items 81 - 86

87 HANDRAIL KIT, FLIP FLOP SEAT includes items 82- 86 & 88

113
MAX
250 lbs.
110 kg
74 64
126 61 83 MAX
4 in.
10 cm MAX
14o / 25%

73 62

76
610631

69 124
72 88
72
81

75
72
69 83
70
78 125
72
122
65 69 82
69
72

123 84

85
74
77
63 85
114 84
72 86
65 74
85

Top of Vehicle

77
72 69
67 66 77
74
72

Service Parts Manual Page M-2

SEATING

SHUTTLE 4 and 6

91 SEAT BOTTOM ASSEMBLY includes items 92 - 96

34
91

93 35

40
41 36

94 37
95
96
49
48
38
50
39
43
Floormat 42
44
44
34
45

51
47

Page M-3 Service Parts Manual

SEATING
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 3 - 6, 8 & 9) ............................ 1

71751G01 WHITE
71751G02 GRAY
71751G03 OYSTER
71751G04 TAN
71751G06 BROWN
71751G07 BLACK
606828 RED/BLACK
604908 WHITE/BLUE
604907 WHITE/RED
2
3 * FLAT STAPLE........................................................................................... 95
4 71752G01 PLASTIC SEAT BACK COVER ................................................................ 1
5 76414G01 SEAT BACK (WOOD)............................................................................... 1
6 01107G01 PAN HEAD TORX SCREW, #8 X 5/8" LG ................................................ 4
7 607535 PAN HEAD TORX SCREW, #8 X .88" LG ...................................................... 4
8 71754G01 FOAM PADDING (SEAT BACK)............................................................... 1
9 *** VINYL SEAT BACK COVER..................................................................... 1
71753G01 WHITE
71753G02 GRAY
71753G03 OYSTER
71753G04 TAN
71513G06 BROWN
71513G07 BLACK
604912G0304 RED/BLACK
604916G0102 WHITE/BLUE
604916G0103 WHITE/RED
604916G0304 RED/BLACK
10
11 00661G8 HEX HEAD BOLT, 1/4" - 20 X 1/2" LG ............................................................ 4
12 00664G7 LOCK WASHER, .255" X .263"....................................................................... 4

Service Parts Manual Page M-4

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

13 615730 SEAT BACK SUPPORT .................................................................................. 1
14 71204G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG ........................ 8
15
16
17 *** SEAT BACK ASSEMBLY................................................................................. 1
71274G03 TAN
71274G04 GRAY
71274G05 OYSTER
71274G06 SPECIAL
18 605056 HEX HEAD BOLT, 1/4" - 20 X 1" LG................................................................ 4
19
20
21 *** SEAT BOTTOM ASSEMBLY
(INCLUDES ITEMS 22 - 33)............................................................................ 1
71611G01 WHITE
71611G03 GRAY
71611G05 OYSTER
71611G07 TAN
71611G09 SPECIAL
71611G16 BROWN
71611G17 BLACK
71611G35 RED ON BLACK
604902 WHITE WITH RED
604906 WHITE WITH BLUE
22 17074G1 RUBBER PAD ........................................................................................... 2
23 * FLAT STAPLE ........................................................................................... 110
24 * FLAT STAPLE ........................................................................................... 36
25 71012G01 VINYL TRIM (SEAT BOTTOM) ................................................................. 1
26 *** VINYL SEAT BOTTOM COVER ............................................................... 1
71602G01 WHITE
71602G02 GREY
71602G03 OYSTER

Page M-5 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

71602G04 TAN
71602G05 SPECIAL
71602G06 BLACK
71602G07 BROWN
604912G0103 WHITE ON RED
604912G0102 WHITE/BLUE
27 71603G02 FOAM PADDING (SEAT BOTTOM) ......................................................... 1
28 76411G01 SEAT BOTTOM (WOOD) ......................................................................... 1
29 71702G01 HIP RESTRAINT (DRIVER SIDE) ............................................................ 1
30 710701G01 HIP RESTRAINT (PASSENGER SIDE) ................................................... 1
31 71204G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG ................. 8
32 71610G01 SEAT HINGE ............................................................................................ 2
33 00720G08 FLAT HEAD PHILLIPS SCREW, #12 -14 X 1" LG .................................. 6
34 71632G01 HAND GRIP WELDMENT............................................................................... 1
35 71204G02 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 2" LG........................... 4
36 626576 SEAT BACK SUPPORT WELDMENT ........................................................... 2
37 32805G6 TRIM (BLACK) ................................................................................................ 1
38 70836G0** SEAT POD ...................................................................................................... 1
39 27731G01 ASHTRAY ....................................................................................................... 1
40 15717G5 ACORN NUT, 3/8" - 16.................................................................................... 2
41 23726G4 SPACER, 5/16" ............................................................................................... 2
42 00427G8 HEX HEAD BOLT, 3/8" - 16 X 2" LG ............................................................... 2
43 00439G8 HEX HEAD BOLT, 5/16" - 18 X 2" LG ............................................................. 3
44 00675G1 FLAT WASHER (SS), 3/8" .............................................................................. 5
45 71883G01 RUBBER WASHER, 5/8" ................................................................................ 3
46 23726G9 SPACER, 3/4" ................................................................................................. 3
47 11098G6 LOCK NUT (SS), 5/16" - 18 ............................................................................ 3
48 00976G06 TRUSS HEAD PHILLIPS SCREW (SS), 5/16" - 18 X 3/4" LG........................ 2
49 01110G01 FLAT WASHER (SS), 1/4" .............................................................................. 2
50 11098G6 LOCK NUT (SS), 1/4" - 20 .............................................................................. 2
51 71599G01 VENT PLUG.................................................................................................... 4

Service Parts Manual Page M-6

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

52 71204G01 MACHINE SCREW WITH PATCH LOCK, 1/4" - 20 X 7/8" LG ........................ 12
53 74140G01 VINYL TRIM FRONT ....................................................................................... 1
54
55 *** FLIP FLOP SEAT BOTTOM ............................................................................ 1
617902 GRAY
617903 TAN
617905 BROWN
617907 WHITE/RED
617906 WHITE/BLUE
617908 RED/BLACK
617911 BLACK
56 617137 DECK BOARD ASSEMBLY............................................................................. 1
57 16705G1 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1" LG....................... 5
58 617402 SEAT STRAP ............................................................................................ 1
59 00559G7 FLAT WASHER, 1/4"................................................................................. 1
60 634190 DECK BOARD ASSEMBLY
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).................... 1
61 634180 SEAT FRAME WELDMENT
(FOR VEHICLES MANUFACTURED FROM MARCH 2014) .......................... 1
62 615712 SEAT FRAME WELDMENT ............................................................................ 1
63 615714 FOOTREST WELDMENT ............................................................................... 1
64 615729 ARMREST, REAR SEAT ................................................................................. 2
65 615713 SEAT FRAME SUPPORT................................................................................ 2
66 615728 FOOTREST BRACKET (PASSENGER SIDE) ................................................ 1
67 615727 FOOTREST BRACKET (DRIVER SIDE)......................................................... 1
68 01006G01 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG.......................................................... 4
69 00427G4 HEX HEAD BOLT, 3/8" - 16 X 1 1/2" LG.......................................................... 16
70 00429G2 HEX HEAD BOLT, 3/8" - 16 X 3 1/4" LG.......................................................... 2
71 16705G9 TRUSS HEAD PHILLIPS SCREW (SS), 1/4" - 20 X 1 1/4" LG ....................... 4
72 614221 FLAT WASHER, 3/8" ....................................................................................... 24
73 01110G01 FLAT WASHER, 1/4" ....................................................................................... 4
74 11098G5 LOCK NUT, 3/8" - 16 ....................................................................................... 10

Page M-7 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

75 11027G5 LOCK NUT, 3/8" - 16....................................................................................... 4

76 14390G4 LOCK NUT, 1/4" - 20....................................................................................... 4
77 19853G1 SQUARE CAP TUBE, 1"................................................................................. 2
78 00427G2 HEX HEAD BOLT, 3/8" - 49 X 1.25" LG
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).............................. 4
79
80 617901 HANDRAIL KIT, FLIP FLOP SEAT (INCLUDES ITEMS 81 - 86).................... 1
81 615721 FOOTREST HANDLE WELDMENT......................................................... 1
82 19859G1 SQUARE CAP TUBE, 3/4" ....................................................................... 2
83 610631 DECAL...................................................................................................... 1
84 00427G8 HEX HEAD BOLT, 3/8" - 16 X 2" LG......................................................... 4
85 614221 FLAT WASHER, 3/8" ................................................................................ 8
86 11098G5 LOCK NUT, 3/8" - 16 ................................................................................ 4
87 634184 HANDRAIL KIT, FLIP FLOP SEAT (INCLUDES ITEMS 82 - 86 & 88)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
88 631485 FOOTREST HANDLE WELDMENT............................................................. 1
89
90 71751G** SEAT BACK ASSEMBLY ................................................................................ 1
91 71888G** SEAT BOTTOM (INCLUDES ITEMS 92 - 96) (SHUTTLE 4 & 6).................... 1
92 71701G01 HIP RESTRAINT (PASSENGER SIDE) ................................................... 1
93 71702G01 HIP RESTRAINT (DRIVER SIDE) ............................................................ 1
94 01110G01 FLAT WASHER (SS), 1/4" ........................................................................ 8
95 00664G7 LOCK WASHER (SS), 1/4"....................................................................... 8
96 00415G2 HEX HEAD BOLT, 1/4" - 20 X 1 1/4" LG................................................... 8
97
98
99
100
101
102
103
104

Service Parts Manual Page M-8

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

105 15717-G5 ACORN NUT, 3/8" - 16 .................................................................................... 2
106 23726-G4 SPACER, 5/16"................................................................................................ 2
107 629301 SEAT BOTTOM (WOOD)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).................... 1
108 617644 HIP RESTRAINT (DRIVER SIDE)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).................... 1
109 617645 HIP RESTRAINT (PASSENGER SIDE)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).................... 1
110
111
112 600530 HEX HEAD BOLT, M10 - 1.5 X 24MM LG
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).................... 8
113 634175 REAR SEAT ARM REST
(FOR VEHICLES MANUFACTURED FROM MARCH 2014) .......................... 2
114 634179 FOOTREST WELDMENT
(FOR VEHICLES MANUFACTURED FROM MARCH 2014) .......................... 1
115 *** FLIP FLOP SEAT BOTTOM ASSEMBLY
(FOR VEHILCES MANUFACTURED FROM MARCH 2014)
(INCLUDES ITEMS 57 - 60, 116) .................................................................... 1

628058G01 OYSTER
628058G03 TAN
628058G04 GRAY
628058G06 BLACK
628058G07 BROWN
628058G09 WHITE/BLUE
628058G10 RED/BLACK
628058G11 WHITE/RED
628058G12 WHITE/BLACK
628058G13 WHITE/YELLOW
628058G14 GRAY/BLACK
628058G15 OYSTER/GARNET
116 *** FLIP FLOP VINYL SEAT BOTTOM COVER ............................................ 1
617892 GRAY
617893 BROWN
615646 OYSTER
615647 TAN
611125 WHITE/BLUE
611126 WHITE/RED
615648 BLACK
611127 WHITE/YELLOW
611137 GRAY/BLACK
611130 WHITE/BLACK

Page M-9 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

611135 RED/BLACK
611136 OYSTER/RUBY
117 *** SEAT BACK ASSEMBLY (INCLUDES ITEMS 3 - 6, 8, 118 &119)
(FOR VEHICELS MANUFACTURED FROM MARCH 2014).......................... 1
620794 WHITE/YELLOW
620796 GRAY/BLACK
615838 WHITE/BLACK
615837 OYSTER/GARNET
118 634178 SEAT BACK SUPPORT ........................................................................... 1
119 *** VINYL SEAT BACK COVER..................................................................... 1
604916G0704 GRAY/BLACK
604916G0108 WHITE/YELLOW
604916G0304 RED/BLACK
604916G0104 WHITE/BLACK
604916G0506 OYSTER/GARNET
120 *** SEAT BOTTOM ASSEMBLY
(INCLUDES ITEMS 22 - 27, 32, 107 - 109, 112, 121)
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
620798 WHITE/YELLOW
620801 GRAY/BLACK
121 *** VINYL SEAT BOTTOM COVER ............................................................... 1
604912G0108 WHITE/YELLOW
604912G0704 GRAY/BLACK
604912G0304 RED/BLACK
604912G0104 WHITE/BLACK
604912G0506 OYSTER/GARNET
122 634174 SEAT FRAME SUPPORT
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
123 00427G6 HEX HEAD BOLT, 3/8" - 16 X 1 1/4" LG
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 1
124 00427G2 HEX HEAD BOLT, 3/8" - 16 X 1 1/4"
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 16
125 00428G8 HEX HEAD BOLT, 3/8" - 16 X 2 1/4" LG
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 2
126 00559G7 FLAT WASHER, 1/4"
(FOR VEHICLES MANUFACTURED FROM MARCH 2014).......................... 4

Service Parts Manual Page M-10

SEATING

Notes:

Page M-11 Service Parts Manual

SEATING

Notes:

Service Parts Manual Page M-12

WEATHER PROTECTION

9 18 23 21
8
7
5 6
25
25

Front Of
Vehicle
27 22
21
19
Rear of Vehicle 28
5

(Driver Side
Shown)

17
A 21
D
13
A 19 21
C

B C

19 21
Sun 15
21
Top Front
Strut
Front of Vehicle

14
4
1 SUN TOP KIT BLACK includes items 4 - 6, 7, 10 - 25

2 SUN TOP KIT WHITE includes items 4 - 6, 8, 10 - 25 20

3 SUN TOP KIT BEIGE includes items 4 - 6, 9, 10 - 25 12

11
10 SUN TOP HARDWARE KIT includes items 11 - 25

29 SUN TOP KIT WHITE includes items 4, 8,10 - 28

30 SUN TOP KIT BLACK includes items 4, 7,10 - 28

31 SUN TOP KIT BEIGE includes items 4, 9,10 - 28

Page N-1 Service Parts Manual

WEATHER PROTECTION

WINDSHIELD

40 39
Front Top
Strut
38

Setscrew

REAR VIEW MIRROR

37 REAR VIEW MIRROR KIT includes items 38 - 40

WINDSHIELD

Service Parts Manual Page N-2

WEATHER PROTECTION
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 610266 SUN TOP KIT BLACK (INCLUDES ITEMS 4 - 6, 7, 10 - 25) .......................... 1
2 610268 SUN TOP KIT, WHITE (INCLUDES ITEMS 4 - 6, 8, 10 - 25) .......................... 1
3 610267 SUN TOP KIT, BEIGE (INCLUDES ITEMS 4 - 6, 9 - 25) ................................ 1
4 610260 FRONT SUPPORT ................................................................................... 1
5 602743 REAR SUPPORT (DRIVER SIDE) ........................................................... 1
6 602741 REAR SUPPORT (PASSENGER SIDE) ................................................... 1
7 610263 SUN TOP, BLACK..................................................................................... 1
8 610265 SUN TOP, WHITE ..................................................................................... 1
9 610264 SUN TOP, BEIGE...................................................................................... 1
10 610259 SUN TOP HARDWARE KIT (INCLUDES ITEMS 11 - 25) ....................... 1
11 00440G2 HEX HEAD BOLT, 5/16" - 18 X 2 1/4" LG........................................... 2
12 00565G8 LOCK WASHER, 5/16" ....................................................................... 4
13 00771G5 NYLON WASHER, 3/8" ...................................................................... 4
14 75048G01 SPACER, 1/2"..................................................................................... 2
15 18716G1 ALUMINIUM SPACER, 3" LG............................................................. 2
16 00674G8 HEX HEAD BOLT (SS), 3/8" - 16 X 5" LG .......................................... 2
17 00665G5 HEX HEAD BOLT (SS), 3/8" - 16 X 1 3/4" LG .................................... 4
18 00665G6 HEX HEAD BOLT (SS), 3/8" - 16 X 2" LG .......................................... 2
19 00891G5 LOCK NUT, 3/8" - 16 .......................................................................... 10
20 00559G8 FLAT WASHER 5/16", BLACK ........................................................... 4
21 00653G1 FLAT WASHER (SS), 5/8" .................................................................. 20
22 24647G1 SPACER, 1/4" THICK ......................................................................... 2
23 00665G3 HEX HEAD BOLT, 3/8" - 16 X 2 1/2" LG............................................. 4
24 00879G1 LOCK WASHER, 3/8" ......................................................................... 4
25 19853G1 END CAP, 1"....................................................................................... 2
26
27 611701 REAR SUPPORT (SHUTTLE 2) ............................................................... 2
28 611700 CROSS REAR SUPPORT (SHUTTLE 2) ................................................. 1
29 611702 SUN TOP KIT, WHITE (INCLUDES ITEMS 4, 8, 10 - 28) ............................... 1
30 611707 SUN TOP KIT, BLACK (INCLUDES ITEMS 4, 7, 10 - 28) ............................... 1
31 611706 SUN TOP KIT, BEIGE (INCLUDES ITEMS 4, 9, 10 - 28)................................ 1

Page N-3 Service Parts Manual

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

32
33 611099 WINDSHIELD KIT .......................................................................................... 1
34 615662 SASH, 26"................................................................................................. 2
35 611100 WINDSHIELD KIT ........................................................................................... 1
36 615661 SASH, 12"................................................................................................. 2
37 19528G2 REAR VIEW MIRROR KIT (INCLUDES ITEMS 38 - 40) ............................... 1
38 19496G1 REAR VIEW MIRROR .............................................................................. 1
39 19502G2 SUPPORT BRACKET .............................................................................. 1
40 19527G1 HEX HEAD BOLT (SS), # 8 - 32 X 5/8" LG .............................................. 1

Service Parts Manual Page N-4

WEATHER PROTECTION

Notes:

Page N-5 Service Parts Manual

WEATHER PROTECTION

Notes:

Service Parts Manual Page N-6

WHEELS AND TIRES

1 TIRE AND WHEEL ASSEMBLY Includes Items 2 - 4

7 TIRE AND WHEEL ASSEMBLY Includes Items 8 - 10

8 2

10 4

13 5
(Style of tire may differ from tire shown)

Page P-1 Service Parts Manual

WHEELS AND TIRES
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.

ITEM PART NO. 1 2 3 4 5 DESCRIPTION QTY.

1 28842G01 TIRE AND WHEEL ASSEMBLY

(INCLUDES ITEMS 2, 3, 4)............................................................................. 4
2 28764G01 TIRE, 18 X 8.50 - 8 LINKS® ..................................................................... 1
3 28759G01 WHEEL RIM ............................................................................................. 1
4 11657G2 VALVE STEM............................................................................................ 1
5 14723G1 LUG NUT, 1/2 - 20........................................................................................... 16
6
7 612772 TIRE AND WHEEL ASSEMBLY
(INCLUDES ITEMS 2, 3, 4)............................................................................. 4
8 612771 TIRE, 18 X 8.50 - 8 LINKS® ..................................................................... 1
9 612770 WHEEL RIM ............................................................................................. 1
10 11657G2 VALVE STEM............................................................................................ 1
11
12 611321 HUB CAP SILVER........................................................................................... 4
13 615617 HUB CAP GOLD ............................................................................................. 4

Service Parts Manual Page P-2

WHEELS AND TIRES

Notes:

Page P-3 Service Parts Manual

E-Z-GO Division of Textron Inc.,
1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA

Service Parts Manuals, as well as Repair and Service Manuals

are available from a local Distributor, an authorized Branch,
Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.

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

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