Bad Boy OFF ROAD AMBUSH iS, Service & Parts Manual

Page 1: ...640770 AB REVISED JUL Y 2017 ISSUED OCTOBER 2014 SERVICE PARTS MANUAL...

Page 2: ......

Page 3: ...by 2006 42 EC TO CONTACT US Textron Specialized Vehicles Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 NORTH AMERICA Technical Assistance Warranty PHONE 1 800 774 3946 FAX 1 800 448 8124...

Page 4: ...icle to maintain a full charge on the batteries provided the charger is plugged into an active electrical source If power to the electrical source is disconnected or interrupted the battery charger wi...

Page 5: ...BODY C 1 BRAKES D 1 CLUTCH E 1 DIRECTION SELECTOR F 1 DIFFERENTIAL LOCK G 1 ELECTRICAL SYSTEM H 1 ENGINE J 1 ENGINE MUFFLER K 1 FRONT AXLE L 1 FRONT SUSPENSION AND STEERING M 1 FUEL SYSTEM N 1 MOTOR...

Page 6: ...NOTES Notes Page iv 640770 Service Parts Manual...

Page 7: ...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 t...

Page 8: ...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 th...

Page 9: ...t 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 wit...

Page 10: ...Service Parts Manual ACCELERATOR Page A 1 640770 Service Parts Manual 1 6 5 9 8 7 16 21 23 23 18 17 19 14 20 10 2 3 4 11 12 13 ACCELERATOR PEDAL ASSEMBLY includes items 2 14 1...

Page 11: ...TARY POSITION SENSOR 1 4 600543 TORX BOLT M4 75 X 12MM LG 2 5 612889 PEDAL SWITCH 1 6 620030 SOCKET HEAD CAP SCREW M5 8 X 10MM LG 2 7 600683 COILED SPRING PIN 4MM X 26MM 1 8 638177 ACCELERATOR PIVOT S...

Page 12: ...A 3 640770 Service Parts Manual 2 4 3 15 17 18 24 Front of Vehicle GOVERNOR BRACKET ASSEMBLY includes items 6 13 5 GOVERNOR ASSEMBLY includes items 2 21 1 12 10 11 13 16 9 7 7 6 8 Front of Vehicle Eng...

Page 13: ...1 3 638954 GOVERNOR LEVER WELDMENT 1 4 72732G01 BALL JOINT 1 5 22751G2 GOVERNOR BRACKET ASSEMBLY INCLUDES ITEMS 6 13 1 6 22754G1 BUSHING FLIP LOCK 25 1 7 25661G01 CUP WASHER 84 2 8 25274G1 GOVERNOR RO...

Page 14: ...Service Parts Manual Notes ACCELERATOR Page A 5 640770 Service Parts Manual...

Page 15: ...Service Parts Manual Notes ACCELERATOR Page A 6 Service Parts Manual 640770 Service Parts Manual...

Page 16: ...vice Parts Manual BATTERY SYSTEM Page B 1 640770 Service Parts Manual B A 25 3 1 22 13 15 14 1 24 17 28 29 29 27 26 34 35 33 32 4 9 5 6 6 8 6 6 7 7 10 7 8 9 20 17 17 17 21 B D C A C D 23 31 2 36 38 16...

Page 17: ...8G6 LOCK NUT 5 16 18 6 8 00438G8 HEX HEAD BOLT 5 16 18 X 1 LG 4 9 00715G2 FLANGED HEX HEAD BOLT 5 16 18 X 875 LG 4 10 70200G01 TRUSS HEAD MACHINE SCREW 3 8 16 X 1 LG 2 11 12 13 633190 BATTERY HOLD DOW...

Page 18: ...ates 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 00426G8 HEX HEAD BOLT 5...

Page 19: ...Service Parts Manual Notes BATTERY SYSTEM Page B 4 Service Parts Manual 640770 Service Parts Manual...

Page 20: ...Service Parts Manual BATTERY SYSTEM Page B 5 640770 Service Parts Manual 1 2 2 3 3 9 14 10 11 12 To Controller To Solenoid 15 6...

Page 21: ...individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 634715 WIRE 2 AWG 71 LG 2 2 634718 WIRE 2 AWG 10 LG 2 3 634717 WIRE 2...

Page 22: ...Service Parts Manual Notes BATTERY SYSTEM Page B 7 640770 Service Parts Manual...

Page 23: ...Service Parts Manual Notes BATTERY SYSTEM Page B 8 Service Parts Manual 640770 Service Parts Manual...

Page 24: ...F 1 33 5 Front of Vehicle 6 11 12 8 9 4 6 14 5 6 18 24 INSTRUMENT PANEL ASSEMBLY includes items 15 17 15 17 16 32 17 12 9 22 6 6 6 A A 35 34 19 26 21 29 A A 638040 MIN 150 cm www badboybuggies com 30...

Page 25: ...1055G01 RIVET 3 16 X 1 LG 29 7 8 617643 COWL GRILL COVER 1 9 71597G01 SELF THREADING NUT 5MM X 10MM X 15MM 2 10 11 633268GXX ACCESS COVER See COLOR CODE in HOW TO USE Section of Manual 1 12 617533 PUS...

Page 26: ...information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual BODY FRONT Page C 3 640770 Service Parts Manual 31 32 655620G01 SIDE COWL DECAL DRIVER SIDE FOR VEHICLES MANUFACTURED FROM 19 S...

Page 27: ...Service Parts Manual Notes BODY Page C 4 Service Parts Manual 640770 Service Parts Manual...

Page 28: ...Service Parts Manual BODY MID Page C 5 640770 Service Parts Manual Front of Vehicle Front of Vehicle 10 5 3 1 4 6 11 9 2 8 7 11 16 8 4 14 16 15 16 A 7 8 9 10 A 11...

Page 29: ...ce Parts Manual 640770 Service Parts Manual 1 632254 FLOOR MAT DIAMOND PLATE 1 2 618886 ROCKER PANEL DRIVER SIDE 1 3 618885 ROCKER PANEL PASSENGER SIDE 1 4 71440G03 PANEL BRACE DRIVER SIDE 1 5 71440G0...

Page 30: ...Service Parts Manual BODY MID Page C 7 640770 Service Parts Manual 3 1 2 4 5 6 6 7 8 11 Front of Vehicle 16 15 14 Front of Vehicle 20 9 9 10 10 17 18 19...

Page 31: ...In HOW TO USE Section 1 3 10570G10 RIVET SS 156 X 55 8 4 10570G12 RIVET 257 X 556 4 5 16469G1 FENDER WASHER 1 4 4 6 71055G01 RIVET 3 16 4 7 642136 SEAT RETENTION BRACKET 2 8 638668 SEAT RETENTION GROM...

Page 32: ...Parts Manual BODY REAR Page C 9 640770 Service Parts Manual 1 2 6 13 11 12 Front of Vehicle Front of Vehicle Body Trim for 2 Passenger Vehicle 21 19 20 22 23 Rear Fender Flare Driver Side 3 4 5 17 15...

Page 33: ...5 REAR FENDER FLARE 2 PASSENGER PASSENGER SIDE 1 3 00414G6 HEX HEAD BOLT 1 4 20 X 1 2 LG 4 4 00642G7 FLAT WASHER 5 16 8 5 14390G4 LOCK NUT 1 4 20 4 6 16816G2 RATCHET RIVET 25 X 887 8 7 8 9 10 11 63569...

Page 34: ...Service Parts Manual BODY REAR Page C 11 640770 Service Parts Manual Body Trim for 4 Passenger Vehicle 6 3 5 2 Front of Vehicle 8 16 17 10 9 9 1 7...

Page 35: ...nual BODY REAR Page C 12 Service Parts Manual 640770 Service Parts Manual 1 635690 SEAT FILLER PANEL DRIVER SIDE 1 2 635691 SEAT FILLER PANEL PASSENGER SIDE 1 3 10570G10 RIVET 5 32 X 9 16 LG 8 4 5 633...

Page 36: ...Service Parts Manual Notes BODY Page C 13 640770 Service Parts Manual...

Page 37: ...Service Parts Manual Notes BODY Page C 14 Service Parts Manual 640770 Service Parts Manual...

Page 38: ...D 1 640770 Service Parts Manual Front of Vehicle 6 1 Front of Vehicle 10 9 Caliper 14 19 20 2 4 Front of Vehicle 5 8 11 12 13 14 15 16 17 18 9 9 9 3 16 7 23 DISC BRAKE ASSEMBLY includes items 24 30 2...

Page 39: ...X 1 LG 4 6 601476 FLANGED LOCK NUT M6 1 2 7 640478 PEDAL GRIP 1 8 613292 BANJO BOLT M10 1 25 X 20MM LG 2 9 613293 CRUSH WASHER M10 12 10 616459 BANJO BOLT M10 1 X 20MM LG 4 11 626613 FRONT BRAKE LINE...

Page 40: ...Service Parts Manual BRAKES Page D 3 640770 Service Parts Manual 4 3 8 1 10 10 9 Front of Vehicle 2 PARK BRAKE LEVER WITH CABLES includes items 3 4 4 6...

Page 41: ...itional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual BRAKES Page D 4 Service Parts Manual 640770 Service Parts Manual 1 627940 PARK BRAKE BOOT 1 2 640186 PARK BRAKE LEVER WI...

Page 42: ...Service Parts Manual Notes BRAKES Page D 5 640770 Service Parts Manual...

Page 43: ...Service Parts Manual Notes BRAKES Page D 6 Service Parts Manual 640770 Service Parts Manual...

Page 44: ...Service Parts Manual CLUTCH Page E 1 640770 Service Parts Manual 13 19 9 14 16 15 7 5 17 20 6 16 10 1 8 18 3 4 2 SECONDARY CLUTCH ASSEMBLY includes items 3 4 21 11 12...

Page 45: ...UDES ITEMS 3 4 1 3 632613 SECONDARY CLUTCH 1 4 633212 THRUST WASHER 1 53 X 1 83 X 06 1 5 636512 CLUTCH FRONT COVER 1 6 00566G2 LOCK WASHER SPRING TYPE 7 16 1 7 629496 HEX HEAD BOLT 5 16 18 X 4 50 LG 1...

Page 46: ...Service Parts Manual Notes CLUTCH Page E 3 640770 Service Parts Manual...

Page 47: ...Service Parts Manual Notes CLUTCH Page E 4 Service Parts Manual 640770 Service Parts Manual...

Page 48: ...ervice Parts Manual 16 21 1 18 4 3 9 14 15 12 11 11 10 10 8 2 21 ELECTRIC DIRECTION SELECTOR SHIFT ASSEMBLY includes items 9 15 21 27 29 A 18 18 19 28 20 25 26 21 21 19 A 19 13 NEUTRAL BRACKET WITH BU...

Page 49: ...TOR ASSEMBLY INCLUDES ITEMS 9 15 1 9 633258 DIRECTION SELECTOR CLEVIS ROD WELDMENT 1 10 25727G01 CUP WASHER 68 O D X 26 I D 4 11 636045 COMPRESSION SPRING 2 12 00734G5 LOCK NUT 10 32 1 13 633009 NEUTR...

Page 50: ...Service Parts Manual Notes DIRECTION SELECTOR Page F 3 640770 Service Parts Manual...

Page 51: ...Service Parts Manual Notes DIRECTION SELECTOR Page F 4 Service Parts Manual 640770 Service Parts Manual...

Page 52: ...Service Parts Manual DIFFERENTIAL LOCK Page G 1 640770 Service Parts Manual 1 2 3 Front Cable Details 3 Rear Cable Details 2 5 6 7 7 9 10 11 12 13 13 4 8 9 Differential Lock Pod 8 15...

Page 53: ...Manual 640770 Service Parts Manual 1 632886 DIFFERENTIAL LOCK POD 1 2 633163 REAR DIFFERENTIAL LOCK CABLE 1 3 633164 FRONT DIFFERENTIAL LOCK CABLE 1 4 75697G01 DIFFERENTIAL LOCK TRIM PLATE 2 5 71055G0...

Page 54: ...Service Parts Manual Notes DIFFERENTIAL LOCK Page G 3 640770 Service Parts Manual...

Page 55: ...Service Parts Manual Notes DIFFERENTIAL LOCK Page G 4 Service Parts Manual 640770 Service Parts Manual...

Page 56: ...Service Parts Manual ELECTRICAL SYSTEM Page H 1 640770 Service Parts Manual 16 5 19 8 3 12 7 13 14 6 11 17 18 9 1 FUSE BOX 4 12...

Page 57: ...ice Parts Manual 1 644891 MAIN HARNESS 1 2 3 632866 TERMINAL STUD BRACKET 1 4 637110 GAS POWERTRAIN HARNESS 1 5 632683 DC DC CONVERTER 48V 30A 1 6 633235G01 JUNCTION BLOCK STUD BLACK 5 16 1 7 633235G0...

Page 58: ...Service Parts Manual ELECTRICAL SYSTEM Page H 3 640770 Service Parts Manual 5 4 1 3 2 2 3 4 10 7 8 6 9 CONTROLLER BRACKET FUSE BLOCK...

Page 59: ...information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual ELECTRICAL SYSTEM Page H 4 Service Parts Manual 640770 Service Parts Manual 1 632676 POWER ELECTRONICS BRACKET 1 2 00661G8 HEX H...

Page 60: ...Service Parts Manual ELECTRICAL SYSTEM Page H 5 640770 Service Parts Manual 4 12 7 9 8 11 11 10 W W V V U U CONTROLLER MOTOR To Battery ve Terminal 5 2 1 To Battery ve Terminal 3 3 6...

Page 61: ...DESCRIPTION QTY Service Parts Manual ELECTRICAL SYSTEM Page H 6 Service Parts Manual 640770 Service Parts Manual 1 632556 CONTROLLER 48V 1 2 00415G2 HEX HEAD BOLT 1 4 20 X 1 1 4 LG 4 3 01110G01 FLAT W...

Page 62: ...ervice Parts Manual 2 PASSENGER Rear Fender 2 1 3 4 6 8 5 9 6 9 4 PASSENGER 3 10 11 13 12 Inside of Cowl Front of Vehicle To Main Harness 3 Pin LED HEADLIGHT ASSEMBLY PASSENGER SIDE includes item 12 1...

Page 63: ...ce Parts Manual 640770 Service Parts Manual 1 614497 HEADLIGHT ASSEMBLY PASSENGER SIDE 1 2 614501 HEADLIGHT ASSEMBLY DRIVER SIDE 1 3 71597G01 SELF THREADING NUT 5MM X 10MM X 15MM 8 4 71781G02 VINYL TA...

Page 64: ...Service Parts Manual ELECTRICAL SYSTEM Page H 9 640770 Service Parts Manual 1 2 F E 1 2 F E 2 2 3 4 5 5 6 7 8 12 13 14 11 Front of Vehicle Dash Panel 10 12V 10Amp MAX 15 18 20 16 17...

Page 65: ...al 1 2 631656 FUEL AND SOC METER 2 3 627035 PLUG PANEL 1 4 628931 2 POSITION SWITCH 1 5 626658 3 POSITION SWITCH 2 6 609692 KEY SET AND KEY SWITCH 1 7 626659 2 POSITION SWITCH 1 8 638063G02 CONTROL CO...

Page 66: ...Service Parts Manual Notes ELECTRICAL SYSTEM Page H 11 640770 Service Parts Manual...

Page 67: ...Service Parts Manual Notes ELECTRICAL SYSTEM Page H 12 Service Parts Manual 640770 Service Parts Manual...

Page 68: ...Service Parts Manual ENGINE Page J 1 640770 Service Parts Manual 18 30 3 31 SUBARU ENGINE EH722 includes items 2 18 1 2 5 7 6 25 26 27 4 28 25 24 27 23 Front of Vehicle 26...

Page 69: ...637254 IGNITION COIL NOT ILLUSTRATED 2 10 635762 MAIN BEARING COVER GASKET NOT ILLUSTRATED 1 11 635763 CYLINDER HEAD GASKET 1 NOT ILLUSTRATED 1 12 635764 CYLINDER HEAD GASKET 2 NOT ILLUSTRATED 1 13 6...

Page 70: ...Service Parts Manual ENGINE Page J 3 640770 Service Parts Manual Front of Vehicle 1 13 12 9 10 7 6 15 16 16 2 25 32 6 11 7 6 34 20 21 6 5 4 25 26 36 11 8 38 16 23 37 3 26 24 29 39...

Page 71: ...15 TUBE PLUG PLASTIC 1 5 O D 2 5 00428G8 HEX HEAD BOLT 3 8 16 X 2 1 4 LG 4 6 00560G1 FLAT WASHER 3 8 14 7 11098G5 LOCK NUT 3 8 16 6 8 645169G2 FAST SPRING TRIM 1 9 12262G1 FLANGED LOCK NUT 3 8 16 2 10...

Page 72: ...INE Page J 5 640770 Service Parts Manual 32 00463G4 HEX HEAD BOLT 7 16 14 X 1 5 LG 2 33 34 634762 TUBING PLUG 1 5 X 2 2 35 36 635176 RIB NECK BOLT 3 8 16 X 1 3 4 LG 4 37 12262G1 FLANGED LOCK NUT 3 8 1...

Page 73: ...Service Parts Manual Notes ENGINE Page J 6 Service Parts Manual 640770 Service Parts Manual...

Page 74: ...Service Parts Manual ENGINE MUFFLER Page K 1 640770 Service Parts Manual Front of Vehicle 9 7 8 10 2 4 3 14 13 14 8 10 8 10 1 7 15 13 7...

Page 75: ...T NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual ENGINE MUFFLER Page K 2 Service Parts Manual 640770 Service Parts Manual 1 637546 EXHAUST MANIFOLD 1 2 632218 28 HP SUBARU MUFFLER 1 3 632666 MUFFLE...

Page 76: ...Service Parts Manual Notes ENGINE MUFFLER Page K 3 640770 Service Parts Manual...

Page 77: ...Service Parts Manual Notes ENGINE MUFFLER Page K 4 Service Parts Manual 640770 Service Parts Manual...

Page 78: ...Service Parts Manual FRONT AXLE Page L 1 640770 Service Parts Manual 12 1 INDEPENDENT DIFFERENTIAL includes items 2 3 13 Part of Frame 4 4 11 10 9 3 Front of Vehicle Motor 1 2 16 15...

Page 79: ...al part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 631489G02 INDEPENDENT DIFFERENTIAL INCLUDES ITEMS 2 3 1 2 OIL FILL PLUG 1 3 OI...

Page 80: ...Service Parts Manual Notes FRONT AXLE Page L 3 640770 Service Parts Manual...

Page 81: ...Service Parts Manual Notes FRONT AXLE Page L 4 Service Parts Manual 640770 Service Parts Manual...

Page 82: ...e Parts Manual FRONT SUSPENSION AND STEERING Page M 1 640770 Service Parts Manual STEERING RACK WITH SPACER includes items 25 26 8 28 26 20 24 10 10 13 26 19 17 17 23 25 8 7 16 14 27 28 15 21 4 1 9 2...

Page 83: ...ENT 1 5 637745 CONTROL ARM BUSHING 51 I D X 84 O D 8 6 7 00463G11 HEX HEAD BOLT 7 16 14 X 1 1 2 LG 6 8 11027G5 FLANGED LOCK NUT 3 8 16 8 9 00429G4 HEX HEAD BOLT 3 8 16 X 3 5 LG 4 10 306982 FLAT WASHER...

Page 84: ...cludes items 3 23 STRUT BEARING ASSEMBLY DRIVER SIDE includes items 25 27 STRUT BEARING ASSEMBLY PASSENGER SIDE includes items 26 28 FRONT STRUT ASSEMBLY PASSENGER SIDE includes items 3 22 24 Part of...

Page 85: ...3792G02 HUB 1 7 616053 HUB WASHER 52MM 1 8 616060 STRUT WASHER 52MM 1 9 645047 STRUT BALL JOINT 1 10 616073 STRUT BUMP STOPS 1 11 638129 BRAKE CALIPER 1 12 616451 BRAKE CALIPER MOUNT BRACKET 1 13 6165...

Page 86: ...sult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual FRONT SUSPENSION AND STEERING Page M 5 640770 Service Parts Manual 29 30 31 32 6...

Page 87: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page M 6 Service Parts Manual 640770 Service Parts Manual...

Page 88: ...RONT SUSPENSION AND STEERING Page M 7 640770 Service Parts Manual 9 6 6 8 6 7 2 STEERING COLUMN ASSEMBLY includes items 5 9 4 11 10 3 1 12 13 5 9 6 6 8 6 7 2 STEERING COLUMN ASSEMBLY includes items 5...

Page 89: ...anual 640770 Service Parts Manual 1 639439 STEERING WHEEL COVER 1 2 601709 LOCK NUT M16 2 1 3 639437 STEERING WHEEL 1 4 600333 STEERING COLUMN ASSEMBLY INCLUDES ITEMS 5 9 1 5 608117 COLUMN SUB ASSEMBL...

Page 90: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page M 9 640770 Service Parts Manual...

Page 91: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page M 10 Service Parts Manual 640770 Service Parts Manual...

Page 92: ...Service Parts Manual FUEL SYSTEM Page N 1 640770 Service Parts Manual Front of Vehicle 7 8 9 13 14 18 1 3 6 10 CARB FUEL TANK ASSEMBLY WITH SWITCH includes items 4 14 11 4 EARLY PRODUCTION VEHICLES...

Page 93: ...part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 645035 CARB FUEL TANK ASSEMBLY WITH SWITCH INCLUDES ITEMS 4 14 1 2 3 4 633024G03...

Page 94: ...3 640770 Service Parts Manual Front of Vehicle Fuel Filter To Engine To Fuel Pump Part of Frame 3 7 1 4 4 6 9 8 2 15 26 16 16 14 1 7 5 27 15 15 4 4 15 4 9 11 10 1 7 3 20 19 23 24 25 22 Fuel Pump 12 4...

Page 95: ...BOLT 5 16 18 X 1 LG 3 4 18292G1 TUBING CLAMP 7 5 70483G01 SPACER 5 16 18 X 66 LG 1 6 FUEL HOSE 1 7 00559G8 FLAT WASHER 5 16 8 8 611181 FUEL SHUT OFF VALVE 1 9 615350 FUEL HOSE 2 2 10 606071 CARBON CAN...

Page 96: ...L SYSTEM Page N 5 640770 Service Parts Manual To Fuel Pump Fuel Pump LATE PRODUCTION VEHICLES 1 2 5 3 10 12 12 24 25 29 25 30 26 27 27 28 23 12 12 13 15 13 11 21 20 14 19 4 6 20 7 16 18 17 8 7 8 7 8 9...

Page 97: ...G4 LOCK NUT 1 4 20 1 7 11098G6 LOCK NUT 5 16 18 5 8 00559G8 FLAT WASHER 5 16 8 9 615346 HOSE REDUCER 1 4 I D X 3 16 O D 1 10 27184G01 FUEL TUBE 1 11 633623 FUEL HOSE 1 2 I D X 34 LG 1 12 18292G1 TUBIN...

Page 98: ...Service Parts Manual FUEL SYSTEM Page N 7 640770 Service Parts Manual 8 1 FUEL TANK ASSEMBLY WITH SENDER UNIT includes items 2 9 Front of Vehicle 2 3 4 5 6 9 7 LATE PRODUCTION VEHICLES...

Page 99: ...ailable as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 656141 FUEL TANK ASSEMBLY WITH SENDER UNIT INCLUDES ITEM...

Page 100: ...Service Parts Manual Notes FUEL SYSTEM Page N 9 640770 Service Parts Manual...

Page 101: ...Service Parts Manual Notes FUEL SYSTEM Page N 10 Service Parts Manual 640770 Service Parts Manual...

Page 102: ...Service Parts Manual MOTOR Page P 1 640770 Service Parts Manual 3 4 5 1 8 9 7 2 SPEED SENSOR KIT includes items 8 9...

Page 103: ...mponent 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 615557 MOTOR 72V 1 2 629597 MOTOR...

Page 104: ...Service Parts Manual Notes MOTOR Page P 3 640770 Service Parts Manual...

Page 105: ...Service Parts Manual Notes MOTOR Page P 4 Service Parts Manual 640770 Service Parts Manual...

Page 106: ...Parts Manual OPERATOR PROTECTION SYSTEM Page Q 1 640770 Service Parts Manual Front of Vehicle 5 7 6 1 8 7 27 24 4 23 20 21 12 30 28 11 13 2 22 15 14 29 25 5 16 Part of Frame 19 Part of frame 23 31 20...

Page 107: ...023 FRONT CROSSBAR TUBE 1 6 00427G2 HEX HEAD BOLT 3 8 16 X 1 1 4 LG 4 7 00571G2 FLAT WASHER 5 16 8 8 11098G5 LOCK NUT 3 8 16 4 9 10 11 00439G2 HEX HEAD BOLT 5 16 18 X 1 1 4 LG 2 12 00571G2 FLAT WASHER...

Page 108: ...l OPS Bottom Ref only Front of Vehicle 2 9 8 25 5 4 6 22 22 24 14 23 24 12 ACCESSORIES OPS KIT includes items 11 18 OPS ACCESSORY HARDWARE KIT includes items 22 28 10 21 OPS UPPER HARDWARE KIT include...

Page 109: ...SIDE 1 6 629081 FRONT CONNECTOR PASSENGER SIDE 1 7 629328 OPS UPPER HARDWARE KIT INCLUDES ITEMS 8 9 1 8 630642 HEX HEAD BOLT 3 8 16 X 2 1 2 LG 16 9 630643 LOCK NUT 3 8 16 16 10 640436 OPS ACCESSORIES...

Page 110: ...Service Parts Manual Notes OPERATOR PROTECTION SYSTEM Page Q 5 640770 Service Parts Manual...

Page 111: ...Service Parts Manual Notes OPERATOR PROTECTION SYSTEM Page Q 6 Service Parts Manual 640770 Service Parts Manual...

Page 112: ...Service Parts Manual REAR AXLE Page R 1 640770 Service Parts Manual 1 MANUAL INDEPENDENT DIFFERENTIAL includes items 2 4 Part of Frame Front of Vehicle 1 4 6 8 7 6...

Page 113: ...at 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 631810 MANUAL INDEPENDENT DIFFERENTIAL INCLU...

Page 114: ...Parts Manual 8 32 18 19 16 17 9 37 37 10 15 15 14 36 40 41 42 43 44 45 28 30 3 29 22 24 56 55 25 57 23 26 49 50 51 48 52 58 27 33 21 20 35 7 5 38 39 46 47 53 54 62 13 59 8 60 16 19 15 15 18 6 34 2 61...

Page 115: ...MBLY 1 3 638278 RIGHT AXLE HOUSING 1 4 638279 DETENT KIT 1 5 638280 OIL SEAL 1 6 638281 SHIFT ACTUATOR 1 7 638282 SHIFT ROD ASSEMBLY 1 8 638283 OIL SEAL 2 9 638284 OIL SEAL 1 10 638285 TUBE ASSEMBLY 1...

Page 116: ...ER 2 38 638310 THRUST WASHER 1 39 638311 THRUST WASHER 1 40 638312 FORWARD GEAR ASSEMBLY 1 41 638313 CLUTCH GEAR 1 42 638314 INTERMEDIATE SHAFT 1 43 638315 REVERSE GEAR ASSEMBLY 1 44 638316 PINION GEA...

Page 117: ...Service Parts Manual Notes REAR AXLE Page R 6 Service Parts Manual 640770 Service Parts Manual...

Page 118: ...3 9 20 5 11 17 10 21 22 16 7 18 23 6 12 36 4 24 37 REAR STRUT ASSEMBLY DRIVER SIDE includes items 3 23 25 1 REAR STRUT ASSEMBLY PASSENGER SIDE includes items 3 22 24 26 2 35 19 STRUT BEARING ASSEMBLY...

Page 119: ...3792G02 HUB ASSEMBLY 1 7 616053 STRUT WASHER 52MM 1 8 9 645047 STRUT BALL JOINT 1 10 616073 STRUT BUMP STOP 1 11 634936G01 SPRING SPACER 1 13 1 12 616451 CALIPER MOUNT BRACKET 1 13 616596 SOCKET HEAD...

Page 120: ...t Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual REAR SUSPENSION Page S 3 640770 Service Parts Manual 30 31 625748 NYLOCK NUT 1 2 13...

Page 121: ...Service Parts Manual Notes REAR SUSPENSION Page S 4 Service Parts Manual 640770 Service Parts Manual...

Page 122: ...Service Parts Manual REAR SUSPENSION Page S 5 640770 Service Parts Manual 1 2 4 6 8 11 11 13 5 7 Front of Vehicle 3 TIE ROD ASSEMBLY includes items 4 8 POA of STRUT A A 17 18 19 15 14 16...

Page 123: ...STEERING ROD MOUNTING BRACKET 1 2 13437G3 FLANGED HEX HEAD BOLT 5 16 18 X 1 LG 4 3 633535 TIE ROD ASSEMBLY INCLUDES ITEMS 4 8 2 4 632114 THREADED TIE ROD 1 5 70902G01 TIE ROD END DRIVER SIDE 1 6 70902...

Page 124: ...Service Parts Manual REAR SUSPENSION Page S 7 640770 Service Parts Manual 10 9 1 3 2 4 6 8 7 Front of Vehicle 5...

Page 125: ...n ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual REAR SUSPENSION Page S 8 Service Parts Manual 640770 Service Parts Manual 1 633473 SWAY BAR 1 2 633953 SWAY BAR BUSHING 75 DIA 2 3 632380...

Page 126: ...Service Parts Manual Notes REAR SUSPENSION Page S 9 640770 Service Parts Manual...

Page 127: ...Service Parts Manual Notes REAR SUSPENSION Page S 10 Service Parts Manual 640770 Service Parts Manual...

Page 128: ...BOTTOM BLACK includes items 3 4 Front of Vehicle Front of Vehicle 2 SEAT BOTTOM ASSEMBLY BLACK includes items 2 9 1 SEAT BACK ASSEMBLY BLACK includes items 13 18 12 SEAT BACK BLACK includes items 14...

Page 129: ...EAT BOTTOM 1 5 6 639904 RETENTION PIN 2 7 638701G01 SEAT LOCATOR TAB DRIVER SIDE 1 8 638701G02 SEAT LOCATOR TAB PASSENGER SIDE 1 9 16705G1 TRUSS HEAD PHILLIPS SCREW SS 1 4 20 X 1 LG 4 10 11 12 640781G...

Page 130: ...vice Parts Manual FLIP SEAT BOTTOM ASSEMBLY includes items 3 4 2 FLIP SEAT BOTTOM ASSEMBLY BLACK includes items 2 8 1 BACKREST ASSEMBLY BLACK includes items 17 21 Seat Backrest Assembly 16 3 4 6 22 7...

Page 131: ...2 621036 FLIP SEAT BOTTOM ASSEMBLY INCLUDES ITEMS 3 4 1 3 617400 SEAT BOTTOM PLYWOOD 1 4 617401 SEAT BOTTOM FOAM 1 5 6 615648 SEAT BOTTOM VINYL 1 7 627157 DECK BOARD ASSEMBLY 1 8 16705G1 TRUSS HEAD P...

Page 132: ...Service Parts Manual SEATING Page T 5 640770 Service Parts Manual Upper OPS Front of Vehicle Lower OPS 5 1 7 6 8 4 3 3 9...

Page 133: ...nsult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual SEATING Page T 6 Service Parts Manual 640770 Service Parts Manual 1 649134 SEAT...

Page 134: ...Service Parts Manual SEATING Page T 7 640770 Service Parts Manual 1 3 5 6 6 7 12 24 25 8 2 10 16 22 17 18 19 Front of vehicle Front of vehicle 26 20 10 9 15 21 19 23 17 A A 14 12 12 11 13 4 2...

Page 135: ...630643 LOCK NUT 3 8 16 4 6 11098G5 LOCK NUT 3 8 16 8 7 642863 SEAT FRAME BRACKET 2 8 00427G2 HEX HEAD BOLT 3 8 16 X 1 25 LG 2 9 633131 CLOSE OUT PANEL 1 10 606264 FLANGED HEX HEAD BOLT M6 1 X 20MM LG...

Page 136: ...Service Parts Manual SEATING Page T 9 640770 Service Parts Manual 2 13 11 11 3 1 12 4 5 13 7 16 8 9 4 10 14 6 1 Front of Vehicle Front of Vehicle...

Page 137: ...rts Manual 640770 Service Parts Manual 1 14390G4 LOCK NUT 1 4 20 8 2 609854 SEAT BELT LATCH BUCKLE 6 2 3 609787 REAR SEAT BELT BRACKET 1 4 16705G9 TRUSS HEAD PHILLIPS SCREW SS 1 4 20 X 1 25 LG 8 5 627...

Page 138: ...Service Parts Manual Notes SEATING Page T 11 640770 Service Parts Manual...

Page 139: ...Service Parts Manual Notes SEATING Page T 12 Service Parts Manual 640770 Service Parts Manual...

Page 140: ...3 12 Front of Vehicle PLASTIC BED ASSEMBLY MANUAL LIFT includes items 2 27 1 34 Front of Vehicle B A 3 7 4 44 45 6 11 12 9 C D 20 40 39 35 36 25 27 37 38 PLASTIC BED LATCH includes items 35 43 B A C B...

Page 141: ...73460G01 SHOULDER BOLT 1 4 20 X 3 4 LG 2 6 73455G01 TAILGATE CABLE 2 7 73450G01 ANGLE 1 8 16705G2 PAN HEAD SCREW SS 1 4 20 X 5 8 LG 4 9 73449G01 EXTRUSION CHANNEL 1 10 71541G01 TAILGATE CABLE SPACER...

Page 142: ...LATCH INCLUDES ITEMS 35 43 1 35 633698 BED LATCH 1 36 652440G03 RETAINER BRACKET 1 37 01118G01 HEX HEAD BOLT 1 4 20 X 77 LG 4 38 652442G03 LATCH PLATE 2 39 71538G01 BED LATCH TORSION SPRING 1 40 71704...

Page 143: ...Service Parts Manual Notes TRUCKBED Page U 4 Service Parts Manual 640770 Service Parts Manual...

Page 144: ...s Manual Front of Vehicle A C C B A Front of Vehicle 25 2 24 19 21 22 WINDSHIELD KIT FULL includes items 2 14 1 WINDSHIELD KIT SPLIT includes items 19 38 18 28 23 30 30 B Vehicle shown for reference o...

Page 145: ...Parts Manual 1 627079 WINDSHIELD KIT FULL INCLUDES ITEMS 2 14 1 2 WINDSHIELD 1 3 AWNING MOLDING ALUMINUM 1 4 TEXTILE SKIRT PLACEHOLDER 1 5 PLASTIC CLAMP 4 6 HEX NUT 6 7 FLAT WASHER 12 8 HEX HEAD BOLT...

Page 146: ...t 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 Service Parts Manual WEATHER PROTECTION Pa...

Page 147: ...Service Parts Manual Notes WEATHER PROTECTION Page V 4 Service Parts Manual 640770 Service Parts Manual...

Page 148: ...arts Manual WEATHER PROTECTION Page V 5 640770 Service Parts Manual B A A B BAD BOY TOP KIT includes items 2 3 1 CANOPY TOP HARDWARE KIT includes items 4 9 3 Vehicle shown for reference only 7 8 7 4 2...

Page 149: ...t for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual WEATHER PROTECTION Page V 6 Service Parts Manual 640770 Service Parts Manual 1 628584 BAD BOY TOP KIT 43 LG INC...

Page 150: ...Service Parts Manual Notes WEATHER PROTECTION Page V 7 640770 Service Parts Manual...

Page 151: ...Service Parts Manual Notes WEATHER PROTECTION Page V 8 Service Parts Manual 640770 Service Parts Manual...

Page 152: ...ms 7 8 5 WHEEL AND TIRE ASSEMBLY REAR DRIVER SIDE includes items 7 8 6 23 24 WHEEL AND TIRE ASSEMBLY FRONT PASSENGER SIDE includes items 15 16 13 WHEEL AND TIRE ASSEMBLY FRONT DRIVER SIDE includes ite...

Page 153: ...25 X 8 12 1 5 639549 WHEEL AND TIRE ASSEMBLY REAR PASSENGER SIDE INCLUDES ITEMS 7 8 1 6 639551 WHEEL AND TIRE ASSEMBLY REAR DRIVER SIDE INCLUDES ITEMS 7 8 1 7 631041 WHEEL STEEL 12 X 7 1 8 639541 TIR...

Page 154: ...Service Parts Manual Notes WHEELS AND TIRES Page W 3 640770 Service Parts Manual...

Page 155: ......

Page 156: ...38 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Br...