Ezgo EXPRESS L6 2012 Technician'S Repair And Service Manual Download

Page: 34 / 202

Page C-6

Repair and Service Manual

BODY

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

rocker panel is removed, be sure to locate the three spac-
ers (30) under each rocker panel for reuse when rocker
panel are reinstalled.

Remove the rivet (11) in the rocker panel (28).

Replace the rocker panel in reverse order of disassem-
bly.

Align the replacement rocker panel with spacers in place
and install hardware.

Front Seat Pod Replacement

Tool List

Qty.

Wrench, 7/16” .............................................................. 2
Wrench, 1/2” ................................................................ 2
Wrench, 9/16” .............................................................. 2
Phillips Screwdriver ..................................................... 1
Drill .............................................................................. 1
Drill Bit, 3/16” ............................................................... 1
Drill Bit, 5/16” ............................................................... 1
Rivet Gun..................................................................... 1

To reduce the danger of battery explosion, dis-
connect the negative (-) battery cable before
proceeding.

To gain access to the inside of the seat pod (18), lift the
front seat bottom vertically from its positioning pins (Ref.
Fig. 3). Remove the hardware attaching the seat back
supports and remove the supports from pod.

Remove the handle and knob (22) from the direction
selector shaft (23).

Remove the two bolts securing the direction selector to
the bracket and remove the direction selector. See
DIRECTION SELECTOR for more information.

Disconnect the four-pin connector from the Speed control
at connection near the floor.

Remove the hardware (26) securing the seat pod to the
floor and remove the pod.

Installation of new seat pod is the reverse order of disas-
sembly using new rivets.

Rear Body Replacement

Tool List

Qty.

Electric/air drill ............................................................ 1
Drill bit, 7/32” ............................................................... 1
Socket, 3/8” ................................................................. 1
Socket, 1/2” ................................................................. 1

Socket, 9/16”, deepwell, 3/8” drive ..............................1
Ratchet, 3/8” drive .......................................................1
Wrench, 3/8” ................................................................1
Wrench, 1/2” ................................................................1
Wrench, 9/16” ..............................................................1
Rivet gun......................................................................1
Phillips screwdriver ......................................................1
Pry Bar .........................................................................1

To prevent possible injury or death from bat-
tery explosion.

The battery should always be removed
before any servicing that will generate
sparks.

It is important to use a sharp drill bit when
removing the rivets on the side of the vehi-
cle. Extreme care must be used when drill-
ing out the rivets located in the front of the
body and the bottom side of the body.
Excessive pressure could result in the drill
bit being forced through the body panel and
penetrating the battery. As extra protection,
it is recommended that a protective piece of
sheet metal be placed between the battery
and the rivet. Use of a drill depth stop will
provide additional protection.

Prior to removing the rear body, the foot rest or cargo bed, as
applicable, must be removed. See the applicable paragraphs
for instructions for replacement of those items.

To avoid damage to the plastic body component, remove or
install seat support brackets by sliding to the open end of the
molded channel. Do not force the seat support brackets into or
out of the channels from above.

Remove the rear rocker panel ends as described above.

Remove the rear seat from the rear body (32) (Ref. Fig.
3).

Remove the hardware (35) attaching rear option (cargo
bed or rear facing seat) to the seat back supports (36).

Remove the screws (37) that secure seat back support to
the vehicle frame. Remove the hardware (38) that
secures the seat back support to the frame support (39).
Remove each seat back support and spacer (40) from
rear body. Repeat procedure on other seat back support.

NOTICE