Ezgo 2006 ST 4X4, Service & Parts Manual

Page 1: ...19 17 18 13 6 5 9 15 16 7 8 10 4 3 11 1 INCLUDES ITEMS 3 16 GASOLINE POWERED UTILITY VEHICLE ISSUED DATE MAY 2006 REVISED DATE JULY 2008 SERVICE PARTS MANUAL 605271 ...

Page 2: ......

Page 3: ...ld and the infor mation contained in this manual is subject to change without notice E Z GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual CUSTOMER SERVICE DEPARTMENT IN USA PHONE 1 800 241 5855 FAX 1 800 448 8124 OUTSIDE USA PHONE 001 706 798 4311 FAX 001 706 771 4609 E Z GO DIVISIO...

Page 4: ...ve factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies ...

Page 5: ...BODY REAR C 7 ROPS AND CAB C 9 BRAKES D 1 BRAKES PARK E 1 DIRECTION AND DRIVE SELECTOR F 1 DRIVETRAIN FRONT G 1 DRIVETRAIN MID G 7 DRIVETRAIN REAR G 11 DRIVETRAIN TRANSMISSION G 17 ELECTRICAL H 1 EXHAUST J 1 FRONT SUSPENSION K 1 FUEL SYSTEM L 1 HITCH M 1 REAR SUSPENSION N 1 SEATING P 1 STEERING Q 1 TRUCK BED R 1 WHEELS TIRES S 1 SPECIALTY PRODUCTS APPENDIX A 1 OPTIONS ACCESSORIES APPENDIX B 1 ...

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

Page 7: ...llustration required Introduction of some revisions varies due to supply of components therefore it is possible that various combinations of components may be found that are not directly reflected by each illustration Consult the illustration that best suits your situation Locate the serial number plate see BODY located in the Illustrated Parts Breakdown section of this manual for its location and...

Page 8: ...ng it with the pictorial representation on the illustrated page Should an asterisk appear in the part number column on the parts list page read upwards until a part number is found The part number is the lowest assembly sold by Service Parts The asterisk indicates that the part depicted is not available for purchase NOTE Descriptions are indented under the assembly that they are used on That assem...

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

Page 10: ... 11 Ref Acl 19 24 14 12 33 32 34 35 37 30 29 36 28 Part of Frame 27 Includes Items 28 36 31 Includes Items 32 35 8 6 3 4 7 5 49 42 18 19 20 41 53 54 55 56 52 2 1 21 38 45 46 Part of Carburetor 60 62 61 70 59 63 64 65 66 69 ACCELERATOR ...

Page 11: ...CREW 1 2 13 X 3 1 2 1 4 00643 G3 WASHER 1 2 1 5 73995 G01 BUSHING 2 6 73993 G01 INNER PIVOT TUBE 1 7 800700 LOCK NUT 1 2 13 1 8 73813 G01 EXTENSION SPRING 1 9 10 11 73699 G01 ACCELERATOR CABLE 1 12 10386 G3 CLEVIS PIN 5 16 X 13 16 LG 1 13 10387 G3 COTTER PIN 3 32 X 3 4 LG 1 14 12064 G3 PUSH NUT 3 16 2 15 16 17 18 73720 G01 ACCELERATOR AND GOVERNOR CABLE BRACKET 1 19 311391 SCREW 3 8 16 X 4 2 20 00...

Page 12: ... 32 25274 G1 GOVERNOR ROD 1 33 23578 G1 COMPRESSION SPRING 1 34 23859 G1 GOVERNOR ADJUSTER 11 35 00526 G4 NUT 10 32 1 36 14390 G4 LOCK NUT 1 4 20 1 37 00491 G4 SETSCREW 1 4 20 X 1 2 LG 2 38 25738 G01 SPRING 1 39 40 41 73571 G01 GOVERNOR CABLE AND CHOKE BRACKET 1 42 73875 G01 BOLT M8 1 25 X 20MM LG 2 43 44 45 73722 G01 BALL STUD 1 46 00734 G5 LOCK NUT 10 32 1 47 48 49 73862 G01 EXTENSION SPRING 1 5...

Page 13: ...ividual part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page A 4 Service Parts Manual ACCLERATOR 61 00415 G2 BOLT 1 4 20 X 1 1 4 LG 1 62 00559 G7 WASHER 1 4 1 63 75677 G01 BUSHING 1 64 23726 G7 SPACER 9 16 1 65 23577 G1 TORSION SPRING 1 66 14390 G4 LOCK NUT 1 4 20 1 67 68 69 73745 G01 BALL STUD 1 70 00734 G2 LOCK NUT 1 4 28 1 ...

Page 14: ...Page B 1 Service Parts Manual AIR FILTER Ref Air 19 20 13 30 14 15 16 17 9 10 11 27 7 28 See DRIVETRAIN MID Section 1 Includes Items 2 5 8 6 4 Front of Vehicle 3 5 19 23 2 24 25 AIR FILTER ...

Page 15: ... CLEANER O RING 1 5 AIR CLEANER LATCH 2 6 72987 G01 AIR CLEANER ELEMENT 1 7 01055 G01 SCREW M8 1 25 X 30MM LG 2 8 450411 LOCK WASHER M8 2 9 73713 G01 AIR FILTER BRACKET 1 10 73876 G01 BOLT M6 1 00 x 12MM LG 1 11 73875 G01 BOLT M8 1 25 x 20MM LG 1 12 13 73695 G01 AIR INTAKE PLENUM TO CARBURETOR SEAL 1 14 73694 G01 AIR INTAKE PLENUM 1 15 73711 G01 SPACER 2 16 16469 G1 WASHER 1 4 2 17 73715 G01 BOLT ...

Page 16: ...e Parts Manual Ref Bod 19 1 1 8 14 58 43 44 45 Part of Item 7 7 3 70 72 73 74 71 63 5 17 18 2 56 59 19 57 46 47 52 51 10 38 31 32 33 Mounts To Frame Mounts To Frame 34 39 4 27 28 5 4 64 65 66 20 22 9 78 21 BODY FRONT ...

Page 17: ...3586 G01 COWL FRAME 1 3 73583 G01 FRONT COWL BRACKET 1 4 00565 G5 LOCK WASHER 10 12 5 73640 G01 SCREW 10 16 X 3 4 12 6 7 73639 G01 HOOD LATCH 2 8 00379 G4 SCREW 10 24 X 1 2 LG 4 9 14390 G10 LOCK NUT 10 24 4 10 14601 G9 RIVET 3 16 X 9 16 LG STAINLESS STEEL 4 11 12 13 14 74813 G01 LABEL EZGO 1 15 16 17 73496 G01 COWL LATCH 1 18 73653 G01 SCREW TORX 3 8 16 X 1 1 8 LG 1 19 00771 G4 NYLON WASHER 1 2 1 ...

Page 18: ...ER SIDE 1 32 73585 G02 COWL SUPPORT BRACKET PASSENGER SIDE 1 33 13437 G3 LOCK SCREW 5 16 18 X 1 LG 4 34 800697 LOCK NUT 5 16 18 4 35 36 37 38 70113 G01 ADJUSTABLE BUMPER 2 39 11027 G1 LOCK NUT 5 16 18 4 40 41 42 43 72842 G01 INSTRUMENT PANEL 1 44 73638 G01 CUP HOLDER 2 45 73726 G01 HAND RADIO HOLDER 1 46 73653 G01 SCREW TORX 3 8 16 X 1 1 8 LG 4 47 11098 G5 LOCK NUT 3 8 16 4 48 49 50 51 73597 G01 I...

Page 19: ...itional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 4 Service Parts Manual BODY FRONT 61 62 63 74973 G01 BRUSH GUARD 1 64 00463 G4 BOLT 7 16 14 X 1 1 2 LG 6 65 00643 G3 WASHER 1 2 12 66 00734 G1 LOCK NUT 7 16 14 6 67 68 69 70 74978 G01 BRUSH GUARD SIDE DRIVER SIDE 1 71 74978 G02 BRUSH GUARD SIDE PASSENGER SIDE 1 72 13437 G4 LOCK SCREW 3 8 16 X 1 LG 8 73 00571 G2 WASHER 5 16 8 74 1109...

Page 20: ...Page C 5 Service Parts Manual Ref Bod 19 2 8 4 2 10 9 3 24 25 15 18 Mounts To Items 31 32 In BODY FRONT Mounts To Frame 1 29 22 23 14 17 16 5 BODY MID ...

Page 21: ...RX 1 4 20 X 1 LG STAINLESS STEEL 2 3 00642 G8 WASHER 5 16 2 4 800706 LOCK NUT 1 4 20 2 5 35643 G01 HOLE PLUG 2 6 7 8 72940 G01 FRONT VALANCE 1 9 73653 G01 BOLT 3 8 16 X 1 1 8 4 10 11098 G5 LOCK NUT 3 8 16 4 11 12 13 14 73833 G01 FLOORPAN 1 15 14382 G4 NOISE SUPPRESSION STRIP 6 6 16 14382 G7 NOISE SUPPRESSION STRIP 2 2 17 600610 SCREW TORX 1 4 20 X 1 LG STAINLESS STEEL 11 18 800706 LOCK NUT 1 4 20 ...

Page 22: ...Page C 7 Service Parts Manual Ref Bod 19 3 3 2 19 1 18 10 9 4 13 14 11 12 21 20 5 29 30 26 27 28 Attaches To Frame 25 SEE SEATING SECTION FOR CROSSMEMBER BODY REAR ...

Page 23: ...RETAINER NUT J TYPE 1 4 20 9 5 600610 SCREW TORX 1 4 20 X 1 LG STAINLESS STEEL 9 6 7 8 9 600417 G01 REAR FENDER DRIVER SIDE 1 10 600417 G02 REAR FENDER PASSENGER SIDE 1 11 13437 G9 LOCK SCREW 1 4 20 X 3 4 LG 4 12 16469 G1 WASHER 1 4 4 13 800706 LOCK NUT 1 4 20 4 14 16816 G2 RATCHET FASTENER 1 4 X 3 4 LG 4 15 16 17 18 73819 G01 SEAT PANEL DRIVER SIDE 1 19 73818 G01 SEAT PANEL PASSENGER SIDE 1 20 60...

Page 24: ...Damage to any component of the ROPS will require replacement of entire unit Roof Windshield Support Rear Support Rear Window Rear Panel Cowl Windshield Passenger Side Door Major Cab Components Shown Item 2 Item 1 Includes All ROPS Components Item 2 Includes All Cab Components Driver Side Door ROPS AND CAB ...

Page 25: ...4 5 DESCRIPTION QTY Page C 10 Service Parts Manual ROPS AND CAB 1 600895 ROPS UNIT INCLUDES ALL ITEMS IN GRAY AND REQUIRED HARDWARE 1 2 600917 CAB REQUIRES INSTALLATION OF ROPS UNIT INCLUDES ALL MAJOR ITEMS SHOWN WINDSHIELD WIPER MOTOR ALL WEATHER STRIPPING AND MOUNTING HARDWARE 1 INDIVIDUAL REPLACEMENT PARTS OF ROPS ARE NOT AVAILABLE IN CASE OF DAMAGE ENTIRE UNIT MUST BE REPLACED CAB COMPONENTS C...

Page 26: ... 52 Includes Items 53 63 66 Includes Items 60 63 67 Includes Items 56 59 55 60 61 56 62 58 57 53 25 34 33 37 36 44 45 1 14 17 10 11 20 63 54 24 38 9 Mounts To Frame Mounts To Frame Mounts To Frame 8 4 18 21 19 5 2 3 35 47 46 48 29 28 30 74 59 To Passenger Side Caliper BRAKES ...

Page 27: ...R INCLUDES ITEM 3 2 3 72935 G01 BRAKE PADS SET OF 4 1 4 73972 G01 BOLT 3 8 24 x 1 LG 4 5 00878 G1 LOCK WASHER 3 8 4 6 7 8 73791 G01 FRONT BRAKE LINE 1 9 00414 G8 BOLT 1 4 20 X 2 LG 1 10 00559 G7 WASHER 1 4 1 11 14390 G4 LOCK NUT 1 4 20 1 12 13 14 73864 G02 CLAMP 3 4 10 15 16 17 73800 G01 REAR BRAKE LINE 1 18 00414 G8 BOLT 1 4 20 X 1 LG 1 19 00559 G7 WASHER 1 4 1 20 14390 G4 LOCK NUT 1 4 20 1 21 11...

Page 28: ...95 G01 BUSHING 2 36 73993 G01 INNER PIVOT TUBE 1 37 311398 SCREW 1 2 13 X 3 1 2 LG 1 38 800700 LOCK NUT 1 2 13 1 39 40 41 42 43 44 10385 G10 CLEVIS YOKE ADJUSTABLE 1 45 00544 G2 JAM NUT 1 4 28 1 46 73545 G01 BUSHING 1 47 10386 G4 CLEVIS PIN 3 8 X 15 16 1 48 00798 G1 COTTER PIN 1 16 X 1 LG 1 49 50 51 72819 G01 BRAKE ASSEMBLY DRIVER SIDE INCLUDES ITEMS 53 63 1 52 72819 G02 BRAKE ASSEMBLY PASSENGER S...

Page 29: ...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 D 4 Service Parts Manual BRAKES 61 WASHER 2 62 BOLT 1 4 28 X 1 2 LG 2 63 DUST COVER 1 64 65 66 75826 G01 ADJUSTER KIT INCLUDES ITEMS 60 63 1 67 75827 G01 HARDWARE KIT INCLUDES ITEMS 56 59 1 68 69 70 71 72 73 74 72818 G01 BRAKE DRUM 2 ...

Page 30: ...e Parts Manual BRAKES PARK 60 Ref Brp 19 47 51 16 49 49 2 3 5 4 1 7 41 42 8 12 13 14 Pulley 15 20 21 22 26 34 25 34 27 28 29 30 38 Includes Items 39 41 Mounts To Frame Mounts To Frame 39 43 40 48 50 55 56 BRAKES PARK ...

Page 31: ...LEVIS PIN 3 8 X 1 1 8 LG 1 5 75791 G02 COTTER PIN 15 32 X 2 13 16 LG 1 6 7 13437 G3 LOCK SCREW 5 16 18 X 1 LG 2 8 800697 LOCK NUT 5 16 18 2 9 10 11 12 600054 G01 PULLEY MOUNT BRACKET DRIVER SIDE 1 13 600053 G01 PULLEY MOUNT BRACKET PASSENGER SIDE 1 14 75789 G01 PULLEY 2 DIA 1 15 00439 G4 BOLT 5 16 18 X 1 1 2 LG 1 16 800697 LOCK NUT 5 16 18 1 17 18 19 20 28082 G01 EQUALIZER BRACKET 1 21 00963 G01 S...

Page 32: ... BRAKES PARK 31 32 33 34 73864 G02 CLAMP 3 4 2 35 36 37 38 600052 G01 SENSOR ASSEMBLY INCLUDES ITEMS 39 41 1 39 73826 G01 PROXIMITY SENSOR SWITCH 1 40 600051 G01 SENSOR BRACKET 1 41 10570 G3 RIVET 1 8 X 17 32 LG ALUMINUM 2 42 13437 G3 LOCK SCREW 5 16 18 X 1 LG 2 43 800697 LOCK NUT 5 16 18 2 44 45 46 47 73676 G01 PARK BRAKE FRAME 1 48 00438 G6 BOLT 5 16 18 X 3 4 LG 5 49 800697 LOCK NUT 5 16 18 5 50...

Page 33: ...Page E 4 Service Parts Manual BRAKES PARK Notes ...

Page 34: ...Parts Manual DIRECTION AND DRIVE SELECTOR 16 Ref Dsl 19 1 Includes Items 2 22 2 10 7 5 12 11 23 24 19 18 13 29 21 8 9 4 15 Levers On Transfer Case 33 32 42 41 28 27 22 14 37 6 17 16 17 3 20 DIRECTION AND DRIVE SELECTOR ...

Page 35: ...HOULDER BOLT 1 4 20 1 7 14390 G4 LOCK NUT 1 4 20 1 8 73745 G01 BALL STUD 1 9 00734 G2 LOCK NUT 1 4 28 1 10 73741 G01 TWO FOUR WHEEL DRIVE SELECTOR HANDLE INCL ITEMS 11 15 1 11 72733 G01 COMPRESSION SPRING 3 8 X 5 8 LG 1 12 73746 G01 DETENT PIN 1 13 00734 G5 LOCK NUT 10 32 1 14 73745 G01 BALL STUD 1 15 00734 G2 LOCK NUT 1 4 28 1 16 75937 G01 PIVOT SHAFT 2 17 14390 G1 LOCK NUT 3 8 24 2 18 601568 TWO...

Page 36: ...the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY DIRECTION AND DRIVE SELECTOR 31 32 73745 G01 BALL STUD 2 33 00734 G2 LOCK NUT 1 4 28 2 34 35 36 37 73988 G01 KNOB 2 38 39 40 41 17618 G1 WIRE TIE 1 42 73864 G02 CLAMP 3 4 2 ...

Page 37: ...Page F 4 Service Parts Manual DIRECTION AND DRIVE SELECTOR Notes ...

Page 38: ...Page G 1 Service Parts Manual 1 8 12 11 33 17 15 16 20 22 21 23 26 25 24 30 11 4 6 5 7 9 8 7 DRIVETRAIN FRONT ...

Page 39: ...ludes items 35 36 39 includes items 40 43 45 includes items 46 48 52 includes items 53 55 58 includes items 59 60 62 includes items 63 67 68 includes items 69 70 35 37 38 38 72 46 48 47 69 70 40 41 43 42 44 49 73 73 73 51 56 50 49 71 53 54 60 59 61 74 63 64 65 66 67 55 57 36 67 ...

Page 40: ...SHAFT 2 5 602951 BOOT KIT INNER 1 6 602952 BOOT KIT OUTER 1 7 00426 G8 BOLT 3 8 16 X 1 LG 10 8 00566 G1 WASHER LOCK 3 8 10 9 00560 G1 WASHER 3 8 4 10 11 13437 G4 LOCK SCREW 3 8 16 X 1 LG 10 12 800698 LOCK NUT 3 8 16 10 13 14 15 73948 G01 FRONT DRIVE SHAFT 1 16 00565 G8 LOCK WASHER 5 16 2 17 72687 G01 BOLT PATCHLOCK 5 16 24 X 1 1 2 LG 2 18 19 20 600047 G01 SOLENOID 1 21 600117 G01 SCREW WASHER 1 4 ...

Page 41: ...UDES ITEMS 35 36 1 35 PLUG 3 8 16 1 36 WASHER 1 37 602789 SCREW 3 8 16 X 1 1 4 LG 8 38 602778 SCREW 5 16 18 X 1 1 2 LG 13 39 602787 DIFFERENTIAL LOCK LEVER KIT INCLUDES ITEMS 40 43 1 40 LOCK NUT 5 16 24 1 41 BELLCRANK 1 42 WELDMENT 1 43 SEAL 1 44 602808 WASHER 1 45 602788 DIFFERENTIAL CASE KIT UPPER INCLUDES ITEMS 46 48 1 46 DIFFERENTIAL CASE 1 47 PIN 1 48 TUBE 1 49 602837 RETAINING RING EXTERNAL ...

Page 42: ...er Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY DRIVETRAIN FRONT 61 602831 DOG ENGAGEMENT 1 62 602805 DIFFERENTIAL PINION AND GEAR SET INCLUDES ITEMS 63 67 1 63 PINION 2 64 DIFFERENTIAL PIN 1 65 GEAR OUTPUT SHAFT 1 66 GEAR OUTPUT SHAFT DIFFERENTIAL 1 67 RETAINING RING 2 68 602779 BELLOW KIT INCLUDES ITEMS 69 70 1 69 VENT 1 70 SPRING CLIP 1 71 602806 COLLAR 1...

Page 43: ...Page G 6 Service Parts Manual DRIVETRAIN FRONT Notes ...

Page 44: ...Page G 7 Service Parts Manual DRIVETRAIN MID Ref Dtm 19 2 1 41 8 3 2 4 5 27 29 28 38 39 40 42 31 Includes items 32 37 32 34 35 36 37 33 DRIVETRAIN MID ...

Page 45: ...Page G 8 Service Parts Manual DRIVETRAIN MID 14 18 19 15 16 24 25 26 17 11 Includes items 12 26 20 12 13 21 22 23 ...

Page 46: ... 4 00565 G7 LOCK WASHER 1 4 3 5 00414 G6 BOLT 1 4 20 X 3 4 LG 3 6 7 8 73965 G01 DRIVE BELT 1 9 10 11 73841 G01 DRIVE CLUTCH ASSEMBLY INCLUDES ITEMS 12 26 1 12 602877 SCREW 312 X 1 3 4 LG 2 13 602879 LOCK NUT 1 4 20 2 14 603009 SHIM AR 15 603011 COMPRESSION SPRING 1 16 603013 LOCK WASHER 1 4 4 17 603014 SCREW 1 4 20 X 1 1 4 LG 4 18 603003 BEARING 1 19 603004 BEARING 1 20 603005 WEIGHT CLUTCH 2 21 6...

Page 47: ...ation ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page G 10 Service Parts Manual DRIVETRAIN MID 31 73842 G01 DRIVEN CLUTCH ASSEMBLY INCLUDES ITEMS 32 37 1 32 602881 WASHER THRUST 1 33 602883 SPRING RETAINER INNER 1 34 602884 COMPRESSION SPRING 1 35 602885 SPRING RETAINER OUTER 1 36 602886 RETAINER RING 1 37 602887 BEARING 2 38 25756 G1 RETAINING WASHER 1 39 00565 G8 LOCK WASHER 5 16 1 40 548958 SCREW 5...

Page 48: ...Page G 11 Service Parts Manual DRIVETRAIN REAR 3 2 1 6 7 9 8 10 12 Ref Dtr 19 20 11 21 16 18 17 DRIVETRAIN REAR ...

Page 49: ...4 23 45 54 43 34 44 46 39 64 62 59 53 58 48 49 33 57 32 28 27 66 67 36 37 30 38 41 31 52 20 Includes items 21 67 22 Includes items 23 24 29 Includes items 30 33 35 Includes items 36 38 40 Includes items 41 43 47 Includes items 48 49 51 Includes items 52 54 65 Includes items 66 67 ...

Page 50: ...0117 G01 SCREW WASHER 1 4 28 X 5 8 LG 2 8 00544 G2 JAM NUT 1 4 28 2 9 00565 G7 LOCK WASHER 1 4 1 10 600046 G01 DIFFERENTIAL LOCK LINKAGE 1 11 73962 G01 SHOULDER BOLT 10 24 1 12 14390 G10 LOCK NUT 10 24 1 13 14 15 16 73399 G01 REAR DIFFERENTIAL GUARD 1 17 73653 G01 BOLT 3 8 16 X 1 1 8 LG 4 18 800698 LOCK NUT 3 8 16 4 19 20 73840 G01 REAR AXLE INCLUDES ITEMS 21 67 1 21 72759 G01 LUG BOLT 1 2 20 REAR...

Page 51: ...ASE UPPER INCLUDES ITEMS 36 38 1 36 TUBE 1 37 DIFFERENTIAL CASE 1 38 PIN 1 39 602809 BALL BEARING 1 40 602780 GEAR AND PINION KIT INCLUDES ITEMS 41 43 1 41 GEAR 1 42 BALL BEARING 1 43 PINION 1 44 602810 BEARING 1 45 602830 RETAINING RING EXTERNAL 1 46 602811 DIFFERENTIAL CASE LOWER 1 47 602786 DIFFERENTIAL LOCK HOUSING KIT INCLUDES ITEMS 48 49 1 48 HOUSING 1 49 BALL BEARING 1 50 602831 DOG ENGAGEM...

Page 52: ... product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY DRIVETRAIN REAR 61 602836 SHIM 1 62 602837 RETAINING RING 1 63 602838 BRAKE DRUM 1 64 602839 SHIM 1 65 602779 BELLOW SERVICE KIT INCLUDES ITEMS 66 67 1 66 VENT 1 67 SPRING CLIP 1 ...

Page 53: ...Page G 16 Service Parts Manual DRIVETRAIN REAR Notes ...

Page 54: ...anual DRIVETRAIN TRANSMISSION Ref Dtm 19 1 6 2 7 8 9 31 15 16 17 21 25 26 23 24 22 27 Front of Vehicle 1 13 Item 10 11 Installed If Required Engine Model GX610K1 VDF R280 RCD View From Underneath Vehicle DRIVETRAIN TRANSMISSION ...

Page 55: ... 85 41 34 33 98 97 101 100 61 60 59 62 66 38 69 34 33 99 99 40 31 Includes items 32 105 32 Includes items 33 34 36 Includes items 37 39 43 Includes items 44 46 51 Includes items 52 54 58 Includes items 59 62 63 Includes items 64 68 71 Includes items 72 73 75 Includes items 76 77 79 Includes items 80 82 83 Includes items 84 87 92 Includes items 93 94 96 Includes items 97 98 102 Includes items 103 1...

Page 56: ... SPARK PLUG NGK 2 3 4 5 6 73680 G01 ENGINE HONDA 18 HP MODEL GX610K1 VDF2 R280 RCD 1 7 311392 BOLT 7 16 14 X 2 LG 4 8 00922 G3 WASHER 7 16 8 9 00734 G1 LOCK NUT 7 16 14 4 10 72971 G01 HIGH ALTITUDE KIT 5 8 000 FT AR 11 72971 G02 HIGH ALTITUDE KIT 8 10 00 FT AR 12 13 72686 G01 INDICATOR SWITCH 1 14 15 311391 BOLT 3 8 16 X 4 LG 2 16 00560 G1 WASHER 3 8 4 17 11098 G5 LOCK NUT 3 8 16 2 18 19 20 21 738...

Page 57: ... 33 34 1 33 PLUG 1 2 20 2 34 WASHER NYLON 2 35 602850 SCREW 1 4 20 6 36 602848 GOVERNOR LINKAGE KIT INCLUDES ITEMS 37 39 1 37 SCREW 2 38 GOVERNOR ARM 1 39 FORK GOVERNOR 1 40 602840 SCREW 5 16 18 X 1 1 2 LG 11 41 NUT 5 16 24 1 42 602856 WASHER 1 43 602972 FRONT OUTPUT COVER KIT INCLUDES ITEMS 44 46 1 44 DOWEL PIN 1 45 COVER 1 46 SEAL 1 47 602857 WASHER 2 48 602858 BALL BEARING 1 49 602859 NEEDLE BE...

Page 58: ... GEAR CASE KIT INCLUDES ITEMS 64 68 1 64 DOWEL PIN 2 65 GEAR CASE FRONT 1 66 TUBE VENT 1 67 SEAL 1 68 SEAL 1 69 602864 GEAR CASE REAR 1 70 602831 DOG ENGAGEMENT 2 71 602845 GEAR KIT INCLUDES ITEMS 72 73 1 72 GEAR 1 73 OUTPUT GEAR 1 74 602865 SHIFTER 1 75 602844 SPROCKET KIT INCLUDES ITEMS 76 77 1 76 SPROCKET 18 TEETH 1 77 SPROCKET 38 TEETH 1 78 602855 COLLAR 2 79 602842 INPUT SHAFT AND GEAR KIT IN...

Page 59: ... ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page G 22 Service Parts Manual DRIVETRAIN TRANSMISSION 91 602869 FRONT OUTPUT SHAFT 1 92 602847 GOVERNOR KIT INCLUDES ITEMS 93 94 1 93 FLY WEIGHT 1 94 GOVERNOR SPOOL 1 95 602870 CHAIN 1 96 602851 SPPED SENSOR PLUG KIT INCLUDES ITEMS 97 98 1 97 SCREW 1 4 20 1 98 PLUG 1 99 602871 SEAL 2 100 602872 BELLCRANK FNR 1 101 602873 LOCK NUT 3 8 24 1 102 602849 FNR GUI...

Page 60: ...Page H 1 Service Parts Manual ELECTRICAL HEADLIGHT 8 2 3 15 1 12 13 7 6 15 FUSE BLOCK 30 20 26 25 28 21 22 23 29 27 ELECTRICAL ...

Page 61: ...LAR INCLUDES ITEM 2 2 2 00906 G6 SCREW 10 16 X 1 LG 2 3 74337 G01 JUMPER WIRE HEADLIGHT 2 4 5 6 20574 G4 LENS AMBER 2 7 00645 G5 SCREW 6 32 X 5 8 LG 4 8 14390 G9 LOCK NUT 6 32 4 9 10 11 12 20058 G1 WIRE TIE ADHESIVE BASE 2 13 17618 G1 WIRE TIE 2 14 15 31539 G1 WIRE TIE 2 16 17 18 19 20 35211 G02 FUSE BLOCK 12 POSITION 1 21 00379 G2 SCREW 10 24 X 1 1 4 LG 2 22 00559 G5 WASHER 10 2 23 14390 G10 LOCK...

Page 62: ...Page H 3 Service Parts Manual ELECTRICAL SWITCHES AND GAUGE CLUSTER 19 1 6 7 10 9 3 8 23 24 26 27 28 29 ...

Page 63: ...rvice Parts Manual ELECTRICAL 1 73660 G01 GAUGE PLATE 1 2 3 71055 G01 RIVET 3 16 X 1 LG ALUMINUM 4 4 5 6 600807 GAUGE CLUSTER 1 7 73829 G01 LIGHT SWITCH AR 8 73877 G01 SWITCH HOLE PLUG AR 9 73830 G01 BED DUMP SWITCH SEE POWER DUMP SECTION 1 10 73892 G01 SWITCH HOLE PLUG AR 11 12 13 14 15 16 17 18 19 73829 G02 ROCKER SWITCH 2 20 21 22 23 71078 G01 POWER OUTLET 1 24 71045 G01 RIVET 5 32 X 3 4 LG 2 2...

Page 64: ...Page H 5 Service Parts Manual ELECTRICAL Ref Ele 19 3 1 11 6 12 13 14 7 10 18 19 20 2 3 4 16 30 22 27 23 24 25 28 29 5 UNDER COWL Wire From Positive Battery Post ...

Page 65: ... 16 18 SILICON BRONZE 2 5 35493 G01 LABEL BATTERY DISPOSAL CE 1 6 74957 G01 BATTERY TRAY 1 7 00438 G8 BOLT 5 16 18 X 1 LG 3 8 9 10 800697 LOCK NUT 5 16 18 3 11 74958 G01 BATTERY RETAINER 1 12 00438 G8 BOLT 5 16 18 X 1 LG 2 13 00642 G8 WASHER 5 16 2 14 11098 G6 LOCK NUT 5 16 18 2 15 16 25972 G144 6 GA WIRE BLACK 94 B SOL 1 17 18 25972 G145 6 GA WIRE BLACK 20 B GRD 1 19 00438 G8 BOLT 5 16 18 X 1 LG ...

Page 66: ...3 6 23 20 21 24 12 22 25 26 10 11 9 17 18 30 29 28 27 19 15 14 PASSENGER SIDE OF E NGINE All Items Are Not Shown But Are Item 3 Qty 19 DRIVER SI DE FRONT OF VEHICLE Oil Pressure Switch Mounted On Passenger Side Of Engine Front Of Vehicle Existing Engine Parts ...

Page 67: ...6 12914 G1 FASTON MALE TERMINAL 10 X 1 4 1 7 8 9 73561 G01 ALTERNATOR BELT 1 10 893633 ALTERNATOR 1 11 73557 G01 ALTERNATOR MOUNTING SHAFT 1 12 800698 LOCK NUT 3 8 16 2 13 14 00438 G8 BOLT 5 16 18 X 1 LG 1 15 00571 G2 WASHER 5 16 1 16 17 73556 G01 ALTERNATOR BRACKET 1 18 00426 G8 BOLT 3 8 16 X 1 LG 4 19 800698 LOCK NUT 3 8 16 4 20 73558 G01 PTO SHAFT 1 21 01120 G01 WASHER M8 3 22 01119 G01 BOLT M8...

Page 68: ...Page H 9 Service Parts Manual ELECTRICAL 12 14 11 6 13 4 2 8 1 9 6 7 10 5 3 Fuse Bracket ...

Page 69: ... Page H 10 Service Parts Manual ELECTRICAL 1 600399 G01 BRAKE LIGHT HARNESS 1 2 600398 G01 TAIL LIGHT MOUNTING BRACKET 1 3 600401 G01 ADAPTER 1 4 32739 G3 TAILLIGHT WITH SEALED CONNECTORS 1 5 21510 G1 BRAKE LIGHT SWITCH 1 6 11845 G7 INSULATED CABLE CLAMP 1 2 1 7 00414 G6 BOLT 1 4 20 X 3 4 LG 2 8 14390 G4 LOCK NUT 1 4 20 2 9 31539 G1 WIRE TIE 8 10 600479 WASHER M8 PRESSURE SEALING 1 11 35212 G01 FU...

Page 70: ...Page J 1 Service Parts Manual EXHAUST 8 Ref Exh 20 3 6 7 19 9 14 13 12 5 15 4 2 3 3 23 21 22 Cross Member Item 1 Includes Items 2 5 EXHAUST ...

Page 71: ...arts Manual EXHAUST 1 73579 G01 MUFFLER ASSEMBLY INCLUDES ITEMS 2 5 1 2 73575 G01 MUFFLER 1 3 73544 G01 SPRING 8 4 73578 G01 MOUNTING BRACKET INCLUDES ITEM 5 1 5 BUSHING 2 6 73628 G01 EXHAUST PIPE 1 7 73627 G01 EXHAUST MANIFOLD 1 8 73860 G01 GASKET 2 9 94050 08000 NUT 4 10 11 12 311398 BOLT 1 2 13 X 3 1 2 LG 1 13 00643 G3 WASHER 1 2 1 14 73993 G01 INNER PIVOT TUBE 1 15 800700 LOCK NUT 1 2 13 1 16 ...

Page 72: ...Page K 1 Service Parts Manual FRONT SUSPENSION 12 Ref Fsp 19 1 6 9 7 8 24 25 18 15 13 14 16 19 20 10 To Steering Tie Rod End 21 3 4 29 28 27 23 5 2 FRONT SUSPENSION ...

Page 73: ...AL BALL 2 5 73612 G01 BALL SEAT 2 6 73613 G01 STRUT 2 7 73623 G01 KNUCKLE DRIVER SIDE 1 8 73623 G02 KNUCKLE PASSENGER SIDE 1 9 00427 G8 BOLT 3 8 16 X 2 LG 4 10 11098 G4 LOCK NUT 3 8 16 4 11 12 73786 G01 BALL JOINT 2 13 00664 G8 LOCK WASHER 5 16 STAINLESS STEEL 6 14 01055 G01 BOLT M8 1 25 X 30MM LG 6 15 73814 G01 CASTLE NUT 2 16 00798 G1 COTTER PIN 1 16 X 1 LG 2 17 18 600423 G01 CONTROL ARM 2 19 70...

Page 74: ...Page L 1 Service Parts Manual FUEL SYSTEM 3 2 1 4 19 17 30 29 18 7 14 6 23 18 10 11 9 25 24 22 26 5 FUEL SYSTEM ...

Page 75: ...CK NUT 3 8 16 3 4 74759 G01 FUEL TANK ASSEMBLY 1 5 20048 G6 FUEL LEVEL SENDER INCLUDES ITEM 6 1 6 20048 G3 SCREW 10 32 x 3 4 LG 5 7 73773 G01 FUEL TANK MOUNTING STRAP 1 8 9 00439 G1 BOLT 5 16 18 X 1 1 8 LG 1 10 00565 G8 LOCK WASHER 5 16 1 11 00642 G8 WASHER 5 16 1 12 13 14 73815 G01 FUEL CAP 1 15 16 17 17470 G1 TUBING 1 4 I D X 1 2 O D BULK AR 18 18292 G1 CLAMP 2 19 11845 G3 INSULATED CABLE CLAMP ...

Page 76: ...Page M 1 Service Parts Manual HITCH Ref Hit 19 5 4 2 3 6 7 1 INCLUDES ITEMS 2 7 HITCH ...

Page 77: ...an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page M 2 Service Parts Manual HITCH 1 74989 G01 REAR HITCH KIT INCLUDES ITEMS 2 7 1 2 74987 G01 REAR HITCH 1 3 74988 G01 BACKING PLATE 2 4 00403 G4 BOLT 1 2 13 X 1 1 2 LG 4 5 00643 G3 WASHER 1 2 8 6 14390 G6 LOCK NUT 1 2 13 4 7 74991 G01 LABEL HITCH CAPACITY 1 ...

Page 78: ...Page N 1 Service Parts Manual REAR SUSPENSION 26 25 24 19 12 10 Ref Rsp 19 1 3 5 6 4 18 20 14 13 13 13 11 2 REAR SUSPENSION ...

Page 79: ...USPENSION 1 73802 G01 LEAF SPRING 265 500 LB 2 2 73896 G01 SHOCK MOUNTING BRACKET 2 3 600282 G01 LEAF SPRING PLATE 2 4 73900 G01 U BOLT 3 8 16 4 5 00560 G1 WASHER 3 8 8 6 11098 G5 LOCK NUT 3 8 16 8 7 8 9 10 73898 G01 LEAF SPRING SHACKLE 4 11 70291 G01 FLANGED BUSHING 12 12 316913 SCREW 1 2 13 X 4 LG 6 13 00643 G3 WASHER 1 2 8 14 14390 G6 LOCK NUT 1 2 13 6 15 16 17 18 73805 G01 SHOCK ABSORBER 2 19 ...

Page 80: ...Page P 1 Service Parts Manual SEATING Ref Sea 19 49 1 2 4 5 26 30 50 9 3 10 11 15 48 19 20 28 29 43 44 39 21 22 27 34 35 SEATING ...

Page 81: ...T BOTTOM FRAME 1 3 34197 G02 HINGE 2 4 00664 G7 LOCK WASHER 1 4 STAINLESS STEEL 8 5 600610 SCREW 1 4 20 X 1 LG STAINLESS STEEL 8 6 7 8 9 35914 G01 HOUSING HALF HINGE 2 10 71204 G01 BOLT 1 4 20 X 7 8 LG 8 11 800706 LOCK NUT 1 4 20 8 12 13 14 15 35928 G01 HINGE PIN 2 16 17 18 19 73652 G SEAT BACK 1 20 73651 G01 SEAT BACK COVER PLATE 1 21 00664 G7 LOCK WASHER 1 4 STAINLESS STEEL 4 22 600610 SCREW TOR...

Page 82: ... part G Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY SEATING 31 32 33 34 00664 G7 LOCK WASHER 1 4 STAINLESS STEEL 4 35 600610 SCREW TORX 1 4 20 X 1 LG STAINLESS STEEL 4 36 37 38 39 73563 G01 BRACE 1 40 41 42 43 70113 G01 ADJUSTABLE BUMPER 2 44 800697 LOCK NUT 5 16 18 4 45 46 47 48 600268 G01 SEAT FRAME 1 49 00426 G6 BOLT 3 8 16 X 3...

Page 83: ...Page P 4 Service Parts Manual SEATING Notes ...

Page 84: ...Page Q 1 Service Parts Manual STEERING Ref Str 19 3 8 14 21 22 12 17 18 27 24 28 29 11 7 13 14 13 13 4 6 5 1 Includes Items 2 8 19 20 30 2 To Knuckle In FRONT SUSPENSION Section STEERING ...

Page 85: ...ER SIDE 1 4 73814 G02 NUT CASTLE M12 X 1 25 2 5 00679 G3 WASHER 1 2 STAINLESS STEEL 2 6 00798 G1 COTTER PIN 1 16 X 1 LG 2 7 BOOT DRIVER SIDE 1 8 BOOT PASSENGER SIDE 1 9 10 11 00441 G8 BOLT 5 16 18 X 4 LG 2 12 13437 G3 LOCK SCREW 5 16 18 X 1 LG 2 13 00660 G8 WASHER 5 16 STAINLESS STEEL 6 14 11098 G6 LOCK NUT 5 16 18 4 15 16 17 73807 G01 STEERING COLUMN 1 18 00426 G8 BOLT 3 8 16 X 1 LG 2 19 00879 G1...

Page 86: ...Page R 1 Service Parts Manual TRUCK BED A DETAIL A DETAIL B B 9 4 8 6 7 14 2 1 Includes items 2 10 10 5 3 TRUCK BED ...

Page 87: ...Page R 2 Service Parts Manual TRUCK BED 30 20 19 24 26 19 19 19 32 20 33 25 23 31 29 18 18 ...

Page 88: ...Page R 3 Service Parts Manual Page R 3 Service Parts Manual TRUCK BED A B C B C A 36 37 39 40 41 41 38 42 40 35 Includes Items 36 42 ...

Page 89: ...49 INCLUDES ITEMS 2 10 1 2 602021 PLASTIC BED 49 1 3 602026 LATCH PIN 2 4 602027 PLATE LATCH 2 5 602022 TAILGATE 1 6 73455 G01 TAILGATE CABLE 2 7 73454 G01 PIVOT TAILGATE 2 8 73449 G02 CHANNEL EXTRUSION 1 9 74384 G01 SCREW 1 4 20 8 10 73460 G01 SHOULDER BOLT 2 11 12 13 14 74821 G04 LABEL BED LOAD WARNING 1 15 16 17 18 73903 G01 BUSHING 2 19 21683 G1 COTTER PIN 15 32 X 2 13 16 LG 4 20 73904 G01 CLE...

Page 90: ...er Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY TRUCK BED 31 01118 G01 SCREW 1 4 20 6 32 70113 G01 ADJUSTABLE RUBBER BUMPER 2 33 11027 G1 LOCK NUT 5 16 18 2 34 35 73940 G01 BED LATCH ASSEMBLY INCLUDES ITEMS 36 42 1 36 73905 G02 BED LATCH 1 37 71538 G01 LATCH TORSION SPRING 1 38 71099 G02 KEEPER PLATE 2 39 71477 G02 RETAINER BRACKET 1 40 00414 G5 BOLT 1 4 20 ...

Page 91: ...Page R 6 Service Parts Manual TRUCK BED Notes ...

Page 92: ...Page R 7 Service Parts Manual Page R 7 Service Parts Manual POWER DUMP 9 8 3 6 4 7 17 4 5 2 16 10 23 25 24 18 17 15 1 Includes Items 2 25 14 11 12 Service Parts Manual ...

Page 93: ...OWER DUMP KIT INCLUDES ITEMS 2 25 1 2 602315 TRUCK BED FRAME 1 3 00415 G4 BOLT 1 4 20 X 1 1 2 LG 4 4 00565 G7 LOCK WASHER 1 4 8 5 16469 G7 FENDER WASHER 1 4 4 6 00414 G7 BOLT 1 4 20 X 7 8 LG 4 7 00642 G7 WASHER 1 4 4 8 602310 BRACE 1 9 602356 U BOLT 1 4 20 2 10 14390 G4 LOCK NUT 1 4 20 4 11 602357 U BOLT 3 8 16 1 12 11098 G5 LOCK NUT 3 8 16 2 13 14 27613 G01 SPACER 2 15 602353 ACTUATOR 1 16 14443 ...

Page 94: ...Page S 1 Service Parts Manual WHEELS TIRES 1 Includes Items 2 3 4 7 Includes Items 2 3 4 13 Includes Items 14 3 4 Ref Whl 19 Rotation 10 2 3 4 14 10 3 4 WHEELS TIRES ...

Page 95: ...nt for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page S 2 Service Parts Manual WHEELS TIRES 1 72941 G02 TIRE AND WHEEL ASSEMBLY DRIVER SIDE INCLUDES ITEMS 2 4 2 2 TIRE AT489 25 X 11 12 1 3 WHEEL 10 X 6 1 4 VALVE STEM 1 5 6 7 72941 G03 TIRE AND WHEEL ASSY PASSENGER SIDE INCLUDES ITEMS 2 4 2 8 9 10 14723 G1 LUG NUT 1 2 20 16 11 12 13 72994 G02 TIRE AND WHEEL ASSEMBLY INCLUDES ITE...

Page 96: ...Page S 3 Service Parts Manual WHEELS TIRES Notes ...

Page 97: ...Appendix A 1 Service Parts Manual SPECIALTY PRODUCTS SPECIALTY PRODUCTS ...

Page 98: ...PLEXUS CLEANER 7 OUNCE 210 ML FOR WINDSHIELDS 28433 G01 PLEXUS CLEANER 13 OUNCE 380 ML FOR WINDSHIELDS 28433 G02 BATTERY PROTECTOR 14 OUNCE 410 ML SPRAY 75500 G01 CARBURETOR CHOKE CLEANER 15 OUNCE 440 ML SPRAY 75501 G01 WHITE LITHIUM 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 PURPO...

Page 99: ...Appendix B 1 Service Parts Manual OPTIONS ACCESSORIES OPTIONS ACCESSORIES ...

Page 100: ...82 G01 Body SIDE BRUSH GUARD KIT 74983 G01 Body REAR HITCH KIT 74989 G01 Hitch WINCH KIT 74259 G05 HIGH ALTITUDE CONVERSION KIT 5 8K FT 72971 G01 HIGH ALTITUDE CONVERSION KIT 8 10K FT 72971 G02 TURF TIRE AND WHEEL ASSEMBLY 600872 Wheels And Tires FRONT DIFFERENTIAL GUARD 72844 G01 Drivetrain Front REAR DIFFERENTIAL GUARD 72899 G01 Drivetrain Rear ...

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Page 102: ...hnical 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 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 ...