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E-Z-GO Cushman, Service & Parts Manual

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Appendix A-2

SPECIALTY PRODUCTS

Service Parts Manual

SPECIAL TOOLS

PART NO.

HIGH RESISTANCE SPARK PLUG WIRE SET............................................................................................... 26733-G02
CLUTCH PULLER (DRIVE) ................................................................................................................................ 19779-G2
FLYWHEEL PULLER........................................................................................................................................ 27111-G01
CURRENT INDICATOR...................................................................................................................................... 16489-G2
DIGITAL MULTI-METER .................................................................................................................................. 27481-G01
SLIDE HAMMER (AXLE/HUB REMOVAL)......................................................................................................... 15947-G1
SLIDE HAMMER (AXLE REMOVAL ONLY)....................................................................................................... 18753-G1
COMPRESSION TESTER................................................................................................................................ 72524-G01
FEELER GAUGE .............................................................................................................................................. 72525-G01
TACHOMETER................................................................................................................................................. 72526-G01

ENGINE OIL

PART NO.

4 CYCLE ENGINE OIL, 5 GALLON (19 LITER) ............................................................................................... 25730-G03
4 CYCLE ENGINE OIL, 12 QUART CASE ....................................................................................................... 25730-G04
4 CYCLE ENGINE OIL, 1 QUART BOTTLE (950 ML) ..................................................................................... 25730-G06

TOUCH UP PAINT

PART NO.

PEN 3 OUNCE (89 ML) - HUNTER GREEN .................................................................................................... 28432-G02
PEN 3 OUNCE (89 ML) - CHAMPAGNE BEIGE.............................................................................................. 28432-G01
PEN 3 OUNCE (89 ML) - WHITE ..................................................................................................................... 28432-G05
PEN 3 OUNCE (89 ML) - INDUSTRIAL YELLOW............................................................................................ 28432-G03
PEN 3 OUNCE (89 ML) - ORANGE ................................................................................................................. 28432-G04
PEN 3 OUNCE (89 ML) - STEEL BLUE PEARL .............................................................................................. 28432-G24
PEN 3 OUNCE (89 ML) - OLIVE GREEN.......................................................................................................... 28432-G**
PEN 3 OUNCE (89 ML) - CAMOUFLAGE PAINT (THREE PENS).................................................................. 75831-G01
AEROSOL 12 OUNCE (360 ML) - HUNTER GREEN ...................................................................................... 28140-G09
AEROSOL 12 OUNCE (360 ML) - CHAMPAGNE BEIGE................................................................................ 28140-G15
AEROSOL 12 OUNCE (360 ML) - WHITE ....................................................................................................... 28140-G03
AEROSOL 12 OUNCE (360 ML) - INDUSTRIAL YELLOW.............................................................................. 28140-G14
AEROSOL 12 OUNCE (360 ML) - ORANGE ................................................................................................... 28140-G13
AEROSOL 12 OUNCE (360 ML) - STEEL BLUE PEARL ................................................................................. 28140-G**
AEROSOL 12 OUNCE (360 ML) - OLIVE GREEN............................................................................................ 28140-G**

Summary of Contents for Cushman

Page 1: ...17 18 13 6 5 9 15 16 7 8 10 4 3 11 1 INCLUDES ITEMS 3 16 A Textron Company GASOLINE POWERED PERSONNEL CARRIERS AND GOLF CAR ISSUED DATE SEPTEMBER 2005 REVISED DATE JULY 2008 SERVICE PARTS MANUAL 6010...

Page 2: ......

Page 3: ...iously The information contained in this Manual may be revised periodically by the E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABLITY FOR ERRORS I...

Page 4: ...s 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...

Page 5: ...BODY C 1 BRAKES MECHANICAL D 1 BRAKES FRONT DISC E 1 CARBURETOR AND CHOKE F 1 CLUTCH G 1 DIRECTION SELECTOR H 1 ELECTRICAL SYSTEM J 1 ENGINE AND MUFFLER K 1 ENGINE MOUNTING L 1 FRONT SUSPENSION STEERI...

Page 6: ...Page iv TABLE OF CONTENTS Service Parts Manual Notes...

Page 7: ...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...

Page 8: ...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 a...

Page 9: ...Page vii Service Parts Manual ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN...

Page 10: ...14 15 24 25 26 27 28 23 29 4 16 5 23 19 21 20 22 Part of Accelerator Cable 18 36 3 1 Includes Items 3 39 41 49 2 Includes Items 3 37 40 49 TG5 7 8 31 32 33 35 34 50 Part of Frame 43 47 48 31 46 45 51...

Page 11: ...s Items 86 96 106 Includes Items 107 119 61 104 102 101 80 A C B 88 Includes Items 89 96 94 93 91 91 90 90 92 89 95 96 B 55 54 57 58 53 66 Includes Items 67 74 70 74 73 72 69 71 67 68 A 111 Includes I...

Page 12: ...3 4 LG STAINLESS STEEL 2 7 25861 G01 MICRO SWITCH 1 8 01050 G01 SCREW 4 20 X 5 8 LG 2 9 10 72066 G01 CONTROL ARM 1 11 23860 G1 BEARING 2 12 24621 G1 NYLON WASHER 5 16 2 13 12064 G1 PUSH NUT 5 16 1 14...

Page 13: ...T ILLUSTRATED A R 38 39 72201 G02 WIRE HARNESS PEDAL BOX 1 40 72201 G03 WIRE HARNESS PEDAL BOX TG5 1 41 17313 G1 FLEX LOOM BULK AR 42 17618 G1 WIRE TIE 2 43 72402 G01 ACCELERATOR CABLE 1 44 00559 G8 W...

Page 14: ...23860 G1 BEARING 2 69 24621 G1 NYLON WASHER 5 16 2 70 25768 G01 PIVOT ROD 1 71 12064 G1 PUSH NUT 5 16 1 72 24479 G1 BALL JOINT BALL 2 73 00565 G5 LOCK WASHER 10 2 74 00526 G4 NUT 10 32 2 75 72197 G01...

Page 15: ...OCK WASHER 5 16 2 100 101 25737 G03 GOVERNOR LINKAGE ROD INCLUDES ITEMS 102 104 1 102 23722 G1 ADJUSTING ROD 1 103 24465 G1 BALL JOINT SOCKET 2 104 00526 G4 NUT 10 32 2 105 106 25690 G01 GOVERNOR BELL...

Page 16: ...tes consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 121 25738 G01 SPRING 1 122 25286 G1 SAFETY SEAL 3 8 1 123 12064 G3 PUSH NUT 3 16 1 124 125 256...

Page 17: ...Page A 8 Service Parts Manual ACCELERATOR...

Page 18: ...Page B 1 Service Parts Manual 13 12 14 1 11 Ignition Coil Bracket 2 5 20 Carburetor 21 6 9 7 4 26 16 18 17 7 8 Ref Air 8 AIR CLEANER...

Page 19: ...AIR BOX GASKET 2 2 26728 G01 CHOKE BRACKET 1 3 4 23726 G6 SPACER 7 16 4 5 72178 G02 HOUSING 1 6 00664 G7 LOCK WASHER 1 4 STAINLESS STEEL 2 7 13632 G1 NUT M6 X 1 4 8 72529 G01 BAFFLE 1 9 72514 G01 STU...

Page 20: ...Page C 1 Service Parts Manual 40 39 32 34 4 2 3 31 1 32 7 8 5 35 33 23 27 1 Includes Items 2 5 14 15 11 12 16 18 21 22 20 19 9 Ref Bod 8 1 BODY...

Page 21: ...Page C 2 Service Parts Manual 29 37 38 25 95 87 88 94 93 26 27 28 36 89 90 91 92 96 96 42 43 Ref Bod 8 2 BODY...

Page 22: ...Page C 3 Service Parts Manual 66 67 68 71 57 64 63 47 48 58 61 59 60 49 62 50 51 81 83 78 79 84 82 80 52 53 56 46 44 45 46 85 77 74 75 76 73 TG5 70 56 69 55 54 TG5 Ref Bod 8 3 BODY...

Page 23: ...Page C 4 Service Parts Manual 98 108 109 107 110 111 101 104 105 100 104 102 103 112 111 99 119 120 116 117 115 Ref Bod 8 4 BODY...

Page 24: ...Page C 5 Service Parts Manual 138 139 121 122 146 123 123 144 143 142 125 126 128 129 130 131 132 127 133 136 137 139 141 Ref Bod 8 5 BODY...

Page 25: ...Page C 6 Service Parts Manual 158 159 160 162 163 168 171 172 169 156 154 153 174 155 163 164 151 Includes Items 152 155 Ref Bod 8 6 158 BODY...

Page 26: ...of Vehicle 15 200 204 207 205 221 220 SHUTTLE 2 176 216 218 219 217 185 186 187 184 182 183 181 189 179 180 178 177 224 199 198 195 197 196 206 201 210 211 212 209 235 213 208 232 227 229 231 223 222...

Page 27: ...Page C 8 Service Parts Manual 238 239 241 240 248 261 262 263 249 250 251 265 266 252 253 254 255 256 257 258 242 243 245 246 247 244 SHUTTLE 2 BODY...

Page 28: ...6 5 71158 G01 INSTRUMENT PANEL INSERT 4 CUP HOLDER 1 6 7 35962 G01 LABEL SAFETY 1 8 35964 G01 LABEL SAFETY EC 1 9 74443 G01 LABEL ANTI ROLLBACK 1 10 11 71413 G01 SPLASH PANEL 1 12 16816 G2 RATCHET FA...

Page 29: ...7 G02 E Z GO NAMEPLATE GOLD 1 40 71597 G01 NUT SELF THREADING 2 41 42 70440 G03 SEAT FRAME 1 43 00715 G2 BOLT 5 16 18 X 4 5 LG 2 44 600496 BATTERY TRAY 1 45 70244 G03 SPLASH PAN 1 46 00715 G2 BOLT 5 1...

Page 30: ...UPPRESSOR DRIVER SIDE SIDE 1 69 72548 G01 FENDER NOISE SUPPRESSOR 2 70 72551 G01 FENDER NOISE SUPPRESSOR DRIVER SIDE FRONT 1 71 22744 G1 BAGWELL NOISE SUPPRESSOR 1 72 73 71578 G01 BUMPER TG5 1 74 0057...

Page 31: ...L 6 96 15058 G6 RIVET 3 16 X 15 16 LG ALUMINUM 4 97 98 74149 G01 VALANCE PANEL 1 99 16816 G2 RATCHET FASTENER 1 4 X 3 4 LG 4 100 74126 G01 VERTICAL FRAME SUPPORT PASSENGER SIDE 1 101 74126 G02 VERTICA...

Page 32: ...ARGO DECK 1 126 23052 G1 NOISE SUPPRESSOR 1 127 608984 TAPE DOUBLE SIDED 40 128 74082 G01 STEEL DECK 1 129 74097 G01 CARGO BED MAT 1 130 16705 G3 SCREW 1 4 20 X 3 4 LG STAINLESS STEEL 8 131 14390 G4 L...

Page 33: ...G01 WARNING LABEL 1 154 70362 G01 FLOOR MAT 1 155 70633 G01 FOOT REST 1 156 19853 G1 END PLUG 2 157 158 00769 G2 CARRIAGE BOLT 3 8 16 X 1 1 4 LG 2 159 00560 G1 WASHER 3 8 2 160 11098 G5 LOCK NUT 3 8 1...

Page 34: ...1 4 20 4 186 600035 G01 ROCKER PANEL DRIVER SIDE 1 187 600035 G02 ROCKER PANEL PASSENGER SIDE 1 188 00789 G2 SCREW 10 24 X 1 1 4 LG 4 189 23726 G2 SPACER 1 4 4 190 00660 G5 WASHER 10 4 191 11098 G7 L...

Page 35: ...EEL 4 218 00559 G7 WASHER 1 4 4 219 00654 G2 LOCK NUT 1 4 20 4 220 72967 G01 BULKHEAD 1 221 16705 G3 SCREW 1 4 20 X 3 4 LG STAINLESS STEEL 4 222 00559 G7 WASHER 1 4 4 223 00654 G2 LOCK NUT 1 4 20 4 22...

Page 36: ...16 LG STAINLESS STEEL 2 245 10570 G10 RIVET 5 32 X 9 16 LG STAINLESS STEEL 4 246 10570 G12 RIVET 1 4 X 9 16 LG 2 247 23726 G2 WASHER 1 4 4 248 600038 G01 SEAT FRAME WELDMENT 1 249 00438 G8 BOLT 5 16...

Page 37: ...Page C 18 Service Parts Manual BODY...

Page 38: ...t of Frame 2 3 4 19 20 5 6 7 8 9 10 1 12 13 14 15 16 18 23 24 32 30 31 28 28 31 46 45 34 35 38 39 35 42 41 50 43 48 40 49 Accelerator Pedal 36 36 37 38 37 18 Includes Items 19 20 22 Includes Items 23...

Page 39: ...Parts Manual 68 67 57 66 71 73 75 70 62 55 73 54 65 64 63 61 74 80 79 BRAKE PEDAL VEHICLE WITH BRAKE LIGHTS 56 WHT BLK 69 72 53 Includes Items 54 80 56 Includes Items 57 59 59 58 76 78 Ref Brm 8 2 BR...

Page 40: ...02 101 98 90 85 88 87 96 94 95 91 92 93 89 97 110 111 82 Includes Items 84 92 94 95 83 Includes Items 84 91 93 95 84 Includes Items 85 86 Includes Items 87 91 92 Includes Items 94 95 93 Includes Items...

Page 41: ...0611 G02 PARK BRAKE PEDAL 1 7 70274 G01 BRAKE PARK BRAKE PEDAL PAD KIT INCLUDES ITEMS 8 10 1 8 SERVICE BRAKE PAD 1 9 PARK BRAKE PEDAL PAD 1 10 15766 G1 OVAL RIVET 3 16 X 7 16 LG 9 11 12 70582 G01 SHOU...

Page 42: ...YLON BUSHING 2 36 20835 G1 TEFLON WASHER 3 8 2 37 00559 G8 WASHER 5 16 2 38 10387 G3 COTTER PIN 3 32 X 3 4 LG 2 39 70098 G01 KICK OFF CAM PIVOT 1 40 10097 G6 FLANGED BEARING 2 41 70587 G01 KICK OFF CA...

Page 43: ...X 7 8 LG 4 66 00739 G1 RUBBER NUT 10 24 2 67 74535 G01 BRAKE PEDAL STANDOFF 2 68 27137 G01 CONICAL SPRING 2 69 14390 G10 LOCK NUT 10 24 2 70 10606 G8 MICRO SWITCH 1 71 00957 G1 BOLT 6 32 X 1 1 4 LG 2...

Page 44: ...SIDE INCLUDES ITEMS 94 95 1 93 72582 G02 BRAKE ADJUSTER KIT PASSENGER SIDE INCL ITEMS 94 95 1 94 ADJUSTER 1 95 TEFLON WASHER 2 96 17083 G2 BOLT 5 16 24 X 1 LG 8 97 15126 G1 LOCK NUT 5 16 24 8 98 21809...

Page 45: ...Page D 8 Service Parts Manual BRAKES MECHANICAL...

Page 46: ...21 1 Part of Frame 2 3 4 19 20 5 6 7 8 9 11 10 1 12 13 14 15 16 18 23 24 25 32 30 31 26 28 28 31 46 45 34 35 38 39 35 42 41 50 43 48 40 49 Accelerator Pedal 36 37 18 Includes Items 19 20 22 Includes I...

Page 47: ...arts Manual 68 67 57 66 71 73 75 62 55 73 54 65 64 63 61 74 80 79 BRAKE PEDAL VEHICLE WITH BRAKE LIGHTS 56 WHT BLK 69 72 53 Includes Items 54 80 56 Includes Items 57 59 77 59 58 Ref Brh 21 2 70 76 78...

Page 48: ...nual Ref Brh 21 3 86 84 88 83 82 85 87 95 96 103 102 97 95 93 101 94 91 105 113 96 111 110 109 92 107 98 111 112 99 100 90 Includes Items 91 103 105 Includes Items 93 103 106 107 108 Includes Items 94...

Page 49: ...ce Parts Manual Ref Brh 21 4 116 118 127 128 129 136 120 119 120 130 141 140 142 138 139 138 120 136 135 135 122 133 132 121 123 125 126 115 Includes 116 133 FRONT DISC BRAKE ACTUATOR ASSEMBLY 140 BRA...

Page 50: ...1 7 70274 G01 BRAKE PARK BRAKE PEDAL PAD KIT INCLUDES ITEMS 8 10 1 8 SERVICE BRAKE PAD 1 9 PARK BRAKE PEDAL PAD 1 10 16409 G1 OVAL RIVET 3 16 X 15 32 LG 9 11 20835 G1 WASHER TEFLON 3 8 2 12 70582 G01...

Page 51: ...8 G1 NYLON BUSHING 2 36 20835 G1 TEFLON WASHER 3 8 2 37 00559 G8 WASHER 5 16 2 38 10387 G3 COTTER PIN 3 32 X 3 4 LG 2 39 70098 G01 KICK OFF CAM PIVOT 1 40 10097 G6 FLANGED BEARING 2 41 70587 G01 KICK...

Page 52: ...0 24 X 1 LG 4 66 00739 G1 RUBBER NUT 10 24 2 67 74535 G01 BRAKE PEDAL STANDOFF 2 68 27137 G01 CONICAL SPRING 2 69 14390 G10 LOCK NUT 10 24 2 70 10606 G8 MICRO SWITCH 1 71 00957 G1 SCREW 6 32 X 1 1 4 L...

Page 53: ...OLLER BEARING 2 96 51141 G1 BEARING RACE 2 97 749951 G01 DISC BRAKE HUB 1 98 70648G01 FLANGED BEARING 1 99 00566G1 WASHER 3 8 2 100 00426 G8 BOLT 3 8 16 X 1 2 101 70749 G01 BEARING 1 102 00798 G8 COTT...

Page 54: ...00439 G1 SCREW CAP HEX HD 5 16 18 X 1 1 18 LG 2 124 125 11098 G06 LOCKNUT 5 16 18 2 126 887364 CYLINDER 1 127 608661 MASTER CYLINDER MOUNT WELDMENT 1 128 11098 G5 LOCKNUT 3 8 16 1 129 00679 G1 WASHER...

Page 55: ...Page E 10 Service Parts Manual BRAKES FRONT DISC...

Page 56: ...Page F 1 Service Parts Manual 32 31 31 5 16 17 18 19 20 21 22 23 27 28 23 25 26 25 24 6 4 9 10 11 1 Includes Items 2 28 8 13 12 14 3 29 7 15 2 CARBURETOR AND CHOKE...

Page 57: ...Page F 2 Service Parts Manual CARBURETOR AND CHOKE 40 See AIR CLEANER Section 37 36 38 39 34 Ref Cac 2 2...

Page 58: ...2 1 4 26649 G05 PILOT JET 46 1 5 26841 G01 PLUG 1 6 72306 G01 GASKET 1 7 72578 G01 NEEDLE VALVE 1 8 26648 G01 FLOAT 1 9 26840 G01 FLOAT PIN 1 10 26843 G01 FLOAT BOWL GASKET 1 11 26844 G01 FLOAT CHAMBE...

Page 59: ...Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page F 4 Service Parts Manual CARBURETOR AND CHOKE 30 31 26726 G01 CARBURETOR MOUNT GASKET 2 32 72883 G01 CARBURETO...

Page 60: ...Page G 1 Service Parts Manual 15 11 13 20 1 7 9 10 8 14 17 3 4 5 18 19 12 Ref Clt 8 CLUTCH...

Page 61: ...26952 G01 DRIVE CLUTCH 1 2 3 00473 G9 BOLT 7 16 20 X 6 1 2 LG 1 4 00566 G2 LOCK WASHER 7 16 1 5 25757 G1 PILOT WASHER 1 6 7 26301 G DRIVEN CLUTCH ASSEMBLY INCLUDES ITEMS 8 15 1 8 MOVABLE SHEAVE INCLUD...

Page 62: ...Page H 1 Service Parts Manual 11 21 12 22 13 23 2 27 25 26 30 31 6 39 19 20 10 8 18 9 5 37 28 29 41 17 16 15 34 33 35 36 34 1 IncludesItems2 27 44 40 42 4 3 43 DIRECTION SELECTOR...

Page 63: ...CAM 1 6 14390 G1 LOCK NUT 3 8 24 1 7 8 10606 G1 MICRO SWITCH 1 9 27151 G01 MICRO SWITCH SPACER 1 10 00645 G2 SCREW 6 32 X 1 1 4 LG 2 11 00559 G3 WASHER 6 2 12 00565 G3 LOCK WASHER 6 2 13 00525 G5 NUT...

Page 64: ...rvice Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 31 10387 G8 COTTER PIN 1 16 X 3 4 LG 2 32 33 72619 G01 PIVOT ARM 1 34 25727 G01 CUP WASHER 1 4 4 35 27764 G01 SPRING...

Page 65: ...Page H 4 Service Parts Manual DIRECTION SELECTOR Notes...

Page 66: ...s Manual 32 GRN 37 See Starter Generator Section 42 F 2 A2 A1 F1 43 47 DF 13 14 67 23 18 19 21 20 25 26 24 44 30 29 See BODY Section 1 2 33 40 35 1 Includes Item 2 Front of Vehicle Ref Ele 2 1 31 6 7...

Page 67: ...Page J 2 Service Parts Manual To F2 On Starter Generator BLACK 48 67 53 71 52 51 47 Includes Items 48 72 RED 53 49 69 57 58 Ref Ele 2 2 50 70 64 63 62 72 56 ELECTRICAL SYSTEM...

Page 68: ...Page J 3 Service Parts Manual Front of Vehicle FUSE BLOCK HORN BUTTON GRN 77 78 76 HOR N Floorboard 88 86 87 90 89 87 HORN Seatwrap Support BLK YEL 83 82 84 81 Ref Ele 8 3 ELECTRICAL SYSTEM...

Page 69: ...e 101 102 102 103 103 110 Rear Fender WHT to BLK from Harness Both Sides BLK to BLU WHT from Harness Both Sides RED to WHT from Harness Driver Side RED to YEL from Harness Passenger Side RED TO BRN fr...

Page 70: ...l TURN SIGNAL 118 114 115 116 120 128 152 ON OFF FUEL F E 131 136 145 132 133 137 138 146 147 139 127 140 126 121 122 123 124 125 141 149 142 150 FUEL GAUGE LOW OIL PRESSURE LIGHT AND KEY SWITCH 113 R...

Page 71: ...J 6 Service Parts Manual HOUR METER 155 Includes Items 156 160 Ref Ele 8 6 Electrical Components Cover Front of Vehicle Seat Support Solenoid Black Yellow Hour Meter 159 160 156 157 158 ELECTRICAL SY...

Page 72: ...R ASSEMBLY M5 X 0 8 X 10 MM LG 2 3 4 5 6 72866 G01 IGNITION COIL ASSEMBLY INCLUDES SPARK PLUG WIRES 1 7 FLAT WASHER 2 8 LOCK WASHER 2 9 72871 SCREW 2 10 11 12 13 25887 G01 6 GA WIRE BLACK 6 F1 A2 1 14...

Page 73: ...26676 G01 FLANGED BOLT M6 X 1 X 23 MM LG 1 34 35 25972 G85 6 GA WIRE BLACK 23 F2 SOL 1 36 37 74937 G02 WIRE HARNESS CONTROL 1 38 39 40 17618 G1 WIRE TIE AR 41 42 73049 G01 COVER 1 43 16469 G1 WASHER...

Page 74: ...NUT 10 32 2 65 66 67 25978 G56 18 GA WIRE BLACK 5 3 4 1 68 69 22585 G3 IN LINE FUSE HOLDER 1 70 00565 G8 LOCK WASHER 5 16 2 71 00544 G4 JAM NUT 5 16 24 2 72 25972 G33 6 GA WIRE BLACK 24 B SOL 1 73 74...

Page 75: ...98 74001 G01 HEADLIGHT AND TURN SIGNAL LIGHT 1 99 00114 G6 SCREW 1 4 14 X 3 4 LG 4 100 101 74004 G01 HEADLIGHT BULB AR 102 74005 G01 MARKER LIGHT BULB AR 103 74006 G01 TURN SIGNAL BULB AR 104 105 7437...

Page 76: ...G1 KEY SET 1 128 73041 G01 WIRE HARNESS KEY SWITCH 1 129 130 131 73030 G01 PLATE KEY SWITCH ONLY 1 132 71145 G01 LABEL KEY SWITCH ONLY WITHOUT HEADLIGHTS 1 133 71181 G01 LABEL KEY SWITCH ONLY WITH HE...

Page 77: ...sult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page J 12 Service Parts Manual 151 152 33623 G02 DRIVE RIVET 3 16 X 3 8 LG 2 153 154 155 75114 G02 HO...

Page 78: ...e K 1 Service Parts Manual 14 12 9 15 See ELECTRICAL Section See CARBURETOR AND CHOKE Section 11 16 24 17 18 2 23 13 Part of Rear Engine Mount 29 27 28 Ref Emf 2 25 26 6 4 5 3 19 20 7 ENGINE AND MUFFL...

Page 79: ...IMING BELT COVER GROMMET 1 6 26678 G01 BOLT M6 X 1 X 12 MM LG 3 7 72538 G01 DIP STICK 0 DEGREES 1 8 9 72869 G01 IGNITION COIL BRACKET 350cc 1 10 11 72867 G01 SPARK PLUG NGK BPR5ES RESISTOR 350cc 2 12...

Page 80: ...Page L 1 Service Parts Manual O I L 21 22 29 40 39 2 28 23 1 11 20 21 9 10 25 24 21 8 Part of Frame 14 16 15 13 12 19 38 34 35 3 4 5 30 31 Ref Emt 8 ENGINE MOUNTING...

Page 81: ...G3 WASHER 7 16 4 6 7 8 00428 G6 BOLT 3 8 16 X 2 3 4 LG 2 9 72016 G01 SPACER 2 10 70269 G02 CROSSMEMBER BRACE 1 11 72044 G01 MOUNT BRACKET 1 12 00643 G1 WASHER 3 8 2 13 11098 G5 LOCK NUT 3 8 16 2 14 0...

Page 82: ...available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 31 00922 G3 WASHER 7 16 4 32 33 34 00439 G2 BOLT 5 16...

Page 83: ...Page L 4 Service Parts Manual ENGINE MOUNTING...

Page 84: ...rame 45 126 43 44 34 4 15 19 30 53 53 40 41 42 Part of Frame Front of Vehicle 8 6 6 5 10 9 21 22 7 20 25 50 23 4 LUG 5 LUG 35 Truck Models Only 3 IncludesItems4 10 7 IncludesItem 8 14 IncludesItems5 1...

Page 85: ...86 84 89 109 113 115 79 92 93 116 114 56 Includes Items 57 69 65 Includes Items 66 69 81 Includes Items 82 84 86 Includes Items 87 89 100 Includes Items 101 102 119 Includes Items 120 124 120 121 122...

Page 86: ...EARING AND RACE ASSEMBLY 2 7 70895 G01 WHEEL HUB ASSEMBLY WITH RACES 4 LUG INCLUDES ITEM 8 1 8 19862 G1 LUG BOLT 1 2 20 X 1 3 16 LG 4 9 12093 G1 CASTELLATED NUT 1 14 1 10 00798 G8 COTTER PIN 5 32 X 1...

Page 87: ...LT 1 2 13 X 6 LG 2 34 00560 G3 WASHER 1 2 4 35 70745 G01 KING PIN TUBE 2 36 70754 G01 THRUST WASHER 1 STAINLESS STEEL 2 37 14390 G6 LOCK NUT 1 2 13 2 38 39 40 76419 G01 SHOCK ABSORBER 2 41 70509 G01 S...

Page 88: ...ON SEAL 1 65 70695 G01 RACK BALL JOINT INCLUDES ITEMS 66 69 1 66 50641 G1 RUBBER BOOT 1 67 50209 G2 CASTELLATED NUT 7 16 20 1 68 10387 G2 COTTER PIN 3 32 X 1 LG 1 69 10389 G3 GREASE FITTING STRAIGHT 1...

Page 89: ...6 X 1 1 4 LG 4 93 00879 G1 LOCK WASHER 3 8 4 94 95 96 70997 G01 COVER 1 97 71055 G01 RIVET 3 16 X 1 LG ALUMINUM 1 98 99 100 70580 G01 INTERMEDIATE SHAFT INCLUDES ITEMS 101 102 1 101 01055 G01 BOLT M8...

Page 90: ...Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 118 119 70876 G02 TIE ROD ASSEMBLY INCLUDES ITEMS 120 124 1 120 70897 G02 THREADED ROD 24 LG 1 121 70902 G01 TIE RO...

Page 91: ...Page M 8 Service Parts Manual FRONT SUSPENSION STEERING...

Page 92: ...Page N 1 Service Parts Manual Front of Vehicle 19 1 9 2 20 29 10 3 4 13 11 21 19 20 18 12 14 11 Part of Frame 7 6 5 Ref Fsy 8 25 25 28 25 24 26 To Carburetor To Crankcase Pulse Fitting 22 FUEL SYSTEM...

Page 93: ...G01 SCREW 6 32 X 1 2 LG 2 5 20048 G2 FUEL LEVEL SENDER ELEC FUEL GAUGE INCLUDES ITEMS 6 7 1 6 GASKET 1 7 72232 G01 SCREW 10 32 x 3 4 LG 5 8 9 605521 FUEL TANK FOR VEHICLES WITHOUT GAUGE 1 10 11 00438...

Page 94: ...rts Manual Front of Vehicle 7 6 5 2 4 3 14 12 29 13 1 9 25 To Crankcase Pulse Fitting 18 28 To Carburetor 25 25 24 26 19 21 20 22 14 12 11 Part of Frame CALIFORNIA EMISSION REQUIREMENT FUELSYSTEM CALI...

Page 95: ...6 32 X 1 2 LG 2 5 20048 G2 FUEL LEVEL SENDER ELEC FUEL GAUGE INCLUDES ITEMS 6 7 1 6 GASKET 1 7 72232 G01 SCREW 10 32 x 3 4 LG 5 8 9 605521 FUEL TANK FOR VEHICLES WITHOUT GAUGE 1 10 11 00438 G8 BOLT 5...

Page 96: ...Page P 1 Service Parts Manual 21 1 16 5 6 25 20 23 22 13 18 9 14 15 12 O I L 29 19 30 1 Includes Items 3 27 10 27 11 3 4 7 7 7 8 8 8 Ref Rxm 8 REAR AXLE...

Page 97: ...LG 1 6 72052 G01 FLANGED BOLT M8 X 1 25 X 130 MM LG 1 7 26826 G01 LOCK WASHER M8 14 8 26827 G01 NUT M8 X 1 25 MM 14 9 26768 G01 OIL CHECK PLUG 1 10 26769 G01 GASKET 8 MM 1 11 26770 G01 OIL DRAIN PLUG...

Page 98: ...Page Q 1 Service Parts Manual 5 21 20 10 14 15 17 18 19 16 20 20 7 21 21 22 20 21 1 8 2 22 9 13 6 11 3 4 Ref Rsm 8 REAR SUSPENSION...

Page 99: ...T BUSHING 2 4 72037 G01 ISOMOUNT CAP 2 5 72618 G01 U BOLT 3 8 16 X 2 X 2 1 2 LG 4 6 00560 G1 WASHER 3 8 8 7 11098 G5 LOCK NUT 3 8 16 8 8 74207 G03 HEAVY DUTY LEAF SPRING TG5 ONLY 1 9 70291 G01 FLANGED...

Page 100: ...R 1 Service Parts Manual SEATING 30 Floormat 11 22 4 3 17 18 19 20 21 26 27 10 5 31 28 29 24 23 6 8 7 TG5 10 Includes Items 11 14 SHUTTLE 3 Includes Items 4 8 1 27 25 34 32 33 12 13 14 25 34 27 Ref Se...

Page 101: ...Page R 2 Service Parts Manual 37 73 50 51 49 45 46 47 48 38 39 See Body Section SHUTTLE 44 IncludesItems45 51 TG5 54 IncludesItems55 58 61 44 77 53 55 56 57 58 42 38 39 41 37 73 Ref Sea 8 2 SEATING...

Page 102: ...Page R 3 Service Parts Manual 71 81 80 79 70 69 78 64 67 65 72 68 76 74 75 63 Includes Items 64 76 66 Includes Items 67 72 SHUTTLE 6 Ref Sea 8 3 SEATING...

Page 103: ...7 00664 G7 LOCKWASHER 1 4 STAINLESS STEEL 8 8 00415 G2 BOLT 1 4 20 X 1 1 4 LG 8 9 10 71875 G SEAT BOTTOM INCLUDES ITEMS 11 14 TG5 1 11 71877 G01 HIP RESTRAINT PASSENGER SIDE 1 12 71877 G02 HIP RESTRAI...

Page 104: ...20 X 1 LG STAINLESS STEEL 4 39 00664 G7 LOCK WASHER 1 4 STAINLESS STEEL 4 40 41 74137 G01 SEAT BACK SUPPORT TG5 2 42 01006 G02 BOLT 3 8 16 X 1 1 4 LG TG5 4 43 44 71611 G SEAT BOTTOM INCLUDES ITEMS 45...

Page 105: ...RACKET 2 65 71751 G SEAT BACK 1 66 74139 G SEAT BOTTOM INCLUDES ITEMS 67 72 1 67 71701 G01 HIP RESTRAINT PASSENGER SIDE 1 68 71702 G01 HIP RESTRAINT DRIVER SIDE 1 69 00661 G8 BOLT 1 4 20 X 1 LG STAINL...

Page 106: ...es Items 3 5 9 Includes Items 10 13 17 Includes Items 18 23 25 Includes Items 26 28 32 Includes Items 33 37 40 Includes Items 41 43 17 32 2 30 3 27 37 18 36 19 28 38 39 42 22 21 41 8 14 4 5 31 10 11 1...

Page 107: ...1 G01 REAR BALL BEARING 1 4 26872 G01 FRONT BALL BEARING 1 5 26873 G01 BEARING HOLDER 1 6 7 8 26875 G01 FIELD COIL 1 9 26876 G01 INSULATING BRUSH ASSEMBLY F INCLUDES ITEMS 10 13 2 10 NUT 2 11 LOCK WAS...

Page 108: ...EW ASSEMBLY INCLUDES ITEMS 33 37 1 33 NUT 1 34 LOCK WASHER 1 35 SCREW 3 36 SCREW 4 37 SCREW 2 38 26887 G01 BRUSH 1 COVER 3 39 26888 G01 BRUSH 2 COVER 1 40 26889 G01 BOLT AND WASHER ASSEMBLY INCLUDES I...

Page 109: ...Page S 4 Service Parts Manual STARTER GENERATOR...

Page 110: ...le Windshield Retainer FOLD DOWN WINDSHIELD 1 Includes Items 2 7 16 15 Strut 13 17 14 12 Front of Vehicle REAR WINDSHIELD 15 11 Includes Items 12 17 24 23 23 Strut 21 25 22 20 Front of Vehicle FULL WI...

Page 111: ...nt of Vehicle 29 41 42 39 40 Inside 43 49 Front Passenger Side Shown Front of Vehicle 44 48 36 30 31 34 34 33 Driver Side Shown 35 SUN TOP SHUTTLES A C B E 45 45 32 46 Rear Strut 37 28 Rear of Vehicle...

Page 112: ...2 55 54 Driver Side Shown Front Of Vehicle 58 56 55 59 61 60 63 62 64 65 68 67 Front Of Vehicle 66 66 69 67 68 Driver Side Rear Shown Front Of Vehicle SUN TOP TE5 TG5 A D C B A D B 51 Includes Items 5...

Page 113: ...GWHN12 LOCK NUT 1 4 20 STAINLESS STEEL 2 8 9 10 11 75535 G01 WINDSHIELD KIT REAR INCLUDES ITEMS 12 17 1 12 EIRWFB3 REAR WINDSHIELD 1 13 EGWHC14 SASH 1 X 15 9 16 LG 2 14 EGWHS14 SCREW 1 4 20 X 2 LG STA...

Page 114: ...LG 4 38 00441 G2 BOLT 5 16 18 X 3 1 4 LG 2 39 00879 G1 WASHER 3 8 4 40 75048 G01 SPACER 1 2 2 41 00905 G8 LOCK WASHER 5 16 4 42 00440 G2 BOLT 5 16 18 X 2 1 4 LG 4 43 75240 G01 HANDLE 5 44 00163 G2 SC...

Page 115: ...nal information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page T 6 Service Parts Manual 61 00905 G8 LOCK WASHER 5 16 4 62 75048 G01 SPACER 1 2 2 63 00879 G1 LOCK WASHER 3 8 4 64 74374 G01 SUN TOP 1 65 00...

Page 116: ...Page U 1 Service Parts Manual 3 1 Includes Items 2 3 4 Style of tire may differ from tire shown 2 5 4 WHEELS AND TIRES...

Page 117: ...ailable as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page U 2 Service Parts Manual 1 28757 G01 TIRE AND WHEEL...

Page 118: ......

Page 119: ...Appendix A 1 Service Parts Manual SPECIALTY PRODUCTS SPECIALTY PRODUCTS...

Page 120: ...QUART BOTTLE 950 ML 25730 G06 TOUCH UP PAINT PART NO PEN 3 OUNCE 89 ML HUNTER GREEN 28432 G02 PEN 3 OUNCE 89 ML CHAMPAGNE BEIGE 28432 G01 PEN 3 OUNCE 89 ML WHITE 28432 G05 PEN 3 OUNCE 89 ML INDUSTRIAL...

Page 121: ...GREASE 14 OUNCE 410 ML SPRAY 75502 G01 PENETRANT LUBRICANT 15 OUNCE 440 ML SPRAY 75503 G01 MULTI PURPOSE CLEANER DEGREASER 14 OUNCE 410 ML SPRAY 75504 G01 MULTI PURPOSE HAND CLEANER 32 OUNCE 950 ML L...

Page 122: ...Appendix A 4 SPECIALTY PRODUCTS Service Parts Manual...

Page 123: ......

Page 124: ...nical Communications Department E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance Warranty Phone 1 800 774 3946 FA...

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