Textron E-Z-GO RXV Shuttle 2+2, Service & Parts Manual

Page 1: ...ISSUED MAY 2019 RXV Shuttle 2 2 Service Parts Manual 689390 B REVISEDAUGUST 2019 ...

Page 2: ......

Page 3: ...gn changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by TSV and therefore is subject to change without notice TSV DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE QUENTIAL DAMAGES resulting from the use of the informat...

Page 4: ...tates 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 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 BATTERY DISP...

Page 5: ...FILTER B 1 BODY C 1 BRAKES D 1 CLUTCH E 1 DIRECTION SELECTOR F 1 ELECTRICAL SYSTEM G 1 ENGINE AND MUFFLER H 1 ENGINE MOUNTING J 1 FRAME K 1 FRONT SUSPENSION AND STEERING L 1 FUEL SYSTEM M 1 REAR AXLE N 1 REAR SUSPENSION P 1 SEATING R 1 STARTER GENERATOR S 1 WEATHER PROTECTION T 1 WHEELS AND TIRES U 1 DECALS AND LABELS V 1 ...

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

Page 7: ...HE MANUAL To use this manual consult the TABLE OF CONTENTS 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 De...

Page 8: ...ber 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 r...

Page 9: ...your color in the list below replace the last or XX with the two digit color code CODE DESCRIPTION 02 SPECIAL COLOR 11 BLACK 19 PATRIOT BLUE PEARL 20 INFERNO RED METALLIC 26 STEEL BLUE PEARL 31 METALLIC CHARCOAL 36 IVORY 37 FOREST GREEN 38 BRIGHT WHITE 39 FLAME RED 41 ELECTRIC BLUE 42 PLATINUM 43 BURGUNDY 44 ALMOND 51 SUNBURST ORANGE 52 BRITISH RACING GREEN 74 BARLEY GOLD 75 OASIS GREEN 76 JAVA BR...

Page 10: ...Page A 1 689390 Service Parts Manual ACCELERATOR 2 3 15 16 6 8 4 14 9 10 11 17 5 4 7 1 Accelerator Pedal Assembly includes items 2 17 Front of Vehicle 12 ...

Page 11: ...rvice Parts Manual ACCELERATOR 1 653202 Accelerator Pedal Assembly Includes Items 2 17 1 2 Pedal Bracket 1 3 Pedal 1 4 Flanged Bushing 16mm x 12mm 2 5 Pivot Shaft 16mm 1 6 600683 Spirol Pin Heavy Duty 4mm x 26mm 1 7 Torsion Spring 4 5mm Dia 1 8 604097 Rebound Bumper 1 9 603808 Ball Bearing 1 10 600702 Bell crank Arm 1 11 604475 Ball Stud 6mm Dia 1 12 668945 Linkage Rod Saddle Clip Assembly 1 13 14...

Page 12: ...age A 3 689390 Service Parts Manual ACCELERATOR Front of Vehicle 1 5 7 6 4 15 11 18 12 20 19 23 13 22 24 Rear Axle Engine Front of Vehicle 16 26 To Direction Selector Shifter Cable To Accelerator Bracket ...

Page 13: ... Head Shoulder Bolt M8 1 25 x 20mm Lg 1 6 649803 Pan Head Torx Screw M6 2 65 x 25mm Lg 3 7 614393 Pedal Insert 1 8 9 10 11 606005 Governor Bracket Lower 1 12 606284 Governor Link Rod 1 13 660005 Governor Guard Bracket 1 14 15 606083 Governor Bracket Upper 1 16 632936 Governor Cable Direction Selector Bracket 1 17 18 606283 Governor Lever Bushing 1 19 606421 Flanged Hex Head Bolt M6 1 x 30mm Lg Gra...

Page 14: ...Page A 5 689390 Service Parts Manual Notes ACCELERATOR ...

Page 15: ...Page A 6 689390 Service Parts Manual Notes ACCELERATOR ...

Page 16: ...Page B 1 689390 Service Parts Manual AIR FILTER 6 5 4 3 2 9 16 10 1 7 Front of Vehicle Canister Bracket Air Cleaner Assembly includes items 2 7 11 12 1 13 14 ...

Page 17: ...s Manual AIR FILTER 1 688989 Air Cleaner Assembly Includes Items 2 7 1 2 28462G01 Dust Ejector Valve 1 3 72604G01 Air Cleaner Clip 2 4 691746 Air Cleaner Cover 1 5 28463G01 Air Filter 1 6 689988 Air Cleaner Housing 1 7 689987 Air Cleaner Seal 1 8 9 601910 Air Filter Hose 14 Lg 1 10 11391G7 Hose Clamp 1 56 1 11 606261 Flanged Hex Head Bolt M8 1 25 x 20mm Lg Grade 8 8 2 12 606272 Lock Washer 8mm 2 1...

Page 18: ...Page B 3 689390 Service Parts Manual Notes AIR FILTER ...

Page 19: ...Page B 4 689390 Service Parts Manual Notes AIR FILTER ...

Page 20: ...89390 Service Parts Manual Page C 1 BODY 1 4 12 10 27 28 5 21 20 11 17 6 18 19 7 8 5 Instrument Panel includes item 6 7 Access Cover Assembly IP includes item 8 Front of Vehicle 29 30 Instrument Panel 23 ...

Page 21: ...7 602388 Access Cover Assembly IP Includes Item 8 1 8 602100 U clip 3 9 10 649803 Pan Head Torx Screw M6 2 65 x 25mm Lg 4 11 70200G01 Truss Head Torx Bolt 3 8 16 x 3 4 Lg 2 12 16816G2 Ratchet Rivet 25 x 887 3 13 14 15 16 17 608864 Instrument Panel Trim Opening For Key Switch SOC and Light Switch 1 18 602572 Pan Head Taptite Bolt M10 1 5 x 25mm Lg Grade 8 8 4 19 604066 Flat Washer M10 4 20 600241 B...

Page 22: ...689390 Service Parts Manual Page C 3 BODY Front of Vehicle Front of Vehicle 1 2 4 6 7 5 3 2 12 22 17 21 18 13 10 11 Cup Holder Assembly includes item 12 13 19 20 ...

Page 23: ...ck Nut M10 1 5 2 4 641628 Bumper Attachment Bracket 1 5 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 4 6 646348 Thread Forming Screw 1 4 20 x 1 Lg 1 7 646345 Flat Washer 1 4 1 8 9 10 603725 Ashtray 1 11 644117 Cup Holder Assembly Includes Items 12 13 1 12 640706 Center Console 1 13 71364G02 J type Speed Nut 8 4 14 15 16 17 638348G01 Center Compartment 1 18 638348G02 Center Compartment ...

Page 24: ...689390 Service Parts Manual Page C 5 BODY 1 12 13 15 16 5 8 10 10 9 10 7 6 3 4 4 10 ...

Page 25: ...ice Parts Manual 1 600225 Floorboard 1 2 3 16816G2 Ratchet Rivet 25 x 887 5 4 16816G1 Ratchet Rivet 25 x 680 2 5 604066 Flat Washer M10 2 6 601257 Upper Rocker Panel Driver Side 1 7 600253 Lower Rocker Panel Driver Side 1 8 601258 Upper Rocker Panel Passenger Side 1 9 600257 Lower Rocker Panel Passenger Side 1 10 649804 Button Head Torx Screw M8 3 5 x 30mm Lg 5 11 12 603707 Floormat Horn Attachmen...

Page 26: ...689390 Service Parts Manual Page C 7 BODY 2 16 24 21 17 18 3 14 19 19 22 23 15 11 13 13 12 1 Rear Body Assembly with Lights includes items 2 3 5 6 7 8 ...

Page 27: ...ear Reflex Reflector Red Driver Side 1 6 625244 Rear Reflex Reflector Red Passenger Side 1 7 608993 Side Reflector Red Driver Side 1 8 608996 Side Reflector Red Passenger Side 1 9 10 11 650443 Access Cover 1 12 602409 Barrel Clip M6 1 4 13 601326 Button Head Torx Bolt M6 1 x 20mm Lg Grade 8 8 4 14 601621 Rear Splash Guard Driver Side 1 15 601622 Rear Splash Guard Passenger Side 1 16 601921 Front S...

Page 28: ...689390 Service Parts Manual Page C 9 BODY MESSAGE HOLDER 1 2 Canopy Shown For Reference Only Front of Vehicle Foot Rest 6 5 8 4 7 Two Bag 4 Caddy Attachment Kit includes items 5 8 ...

Page 29: ...consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 10 BODY 689390 Service Parts Manual 1 609308 Message Holder Single 1 2 617613 Message Holder Double 1 3 4 75183G01 Two Bag 4 Caddy Attachment Kit Includes Items 5 8 1 5 75188G01 Bag Attachment Assembly 1 6 22238G2 Knob 3 8 16 x 1 1 2 Lg 1 7 17255G1 Flat Washer Plastic 1 8 620184 Support Bra...

Page 30: ...Page C 11 Notes BODY 689390 Service Parts Manual ...

Page 31: ...Page C 12 Notes BODY 689390 Service Parts Manual ...

Page 32: ...e Parts Manual BRAKES Front of Vehicle 2 7 7 7 16 18 20 23 34 35 15 4 3 7 5 8 12 38 19 21 33 22 19 22 9 10 13 11 11 20 39 40 14 26 27 28 29 30 24 36 25 17 22 37 11 13 24 32 31 24 6 1 Brake Pedal Assembly includes items 2 40 ...

Page 33: ...g 1 6 Torsion Spring 4 5mm Dia 1 7 Flanged Bushing 16mm x 12mm 4 8 Bush Sleeve Split 8mm x 12mm 1 9 604459 Cable Pull Clip 1 10 604458 Equalizer 1 11 601835 E ring 8mm 4 12 601895 Clevis Pin 8mm x 27mm 1 13 601894 Clevis Pin 8mm x 21 5mm 2 14 Flanged Bushing 16mm x 12mm 1 15 Ball Stud 6mm Dia 1 16 Multi Latch Cam 1 17 604097 Rebound Bumper 2 18 609226 Bracket 1 19 Button Head Torx Bolt M6 1 x 20mm...

Page 34: ...al part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY BRAKES 32 626156 Park Brake Pad 1 33 Solid Pin 4mm x 57mm 1 34 610471 Brake Pedal Cover 1 35 610635 Park Brake Pedal Cover 1 36 Latch Ratchet 2 37 613231 Flanged Hex Head Bolt M6 1 x 20mm Lg Grade 8 8 2 38 Pivot Shaft 1 39 626146 Brake Cable Arm 1 40 606265 Flanged Hex Head Bolt ...

Page 35: ...Page D 4 689390 Service Parts Manual Notes BRAKES ...

Page 36: ...Page D 5 689390 Service Parts Manual BRAKES 1 2 11 4 5 3 12 6 7 Front of Vehicle 10 9 ...

Page 37: ... 689390 Service Parts Manual BRAKES 1 611373 Brake Cable Driver Side 1 2 612519 Brake Cable Passenger Side 1 3 605254 Socket Head Bolt M8 1 25 x 90mm Lg 4 4 10386G3 Clevis Pin 5 16 x 940 1 5 10387G3 Cotter Pin 094 x 3 4 Lg 1 6 605688 Brake Pedal Cover 1 7 600543 Button Head Torx Bolt M4 75 x 12mm Lg 2 8 17618G1 Nylon Clamp 8 Lg Not Illustrated 1 9 601327 Lock Washer Split 6mm 2 10 800425 Hex Head ...

Page 38: ...l BRAKES TOP PULL Front of Vehicle 26 25 10 18 17 1 2 16 Brake Assembly Driver Side includes items 3 9 Brake Assembly Passenger Side includes items 3 8 10 Brake Drum Assembly includes items 17 18 22 5 21 24 3 8 7 6 9 Tension Pin 14 13 4 ...

Page 39: ... Shoe Leading 1 4 612412 Brake Shoe Trailing 1 5 612413 Dust Cover 1 6 612415 Brake Spring Top 1 7 612414 Brake Spring Bottom 1 8 612416 Shoe Clamp 2 9 612418 Gear Adjuster Driver Side 1 10 612417 Gear Adjuster Passenger Side 1 11 12 13 17083G2 Hex Head Bolt 5 16 24 x 1 Lg Grade 8 4 14 15126G1 Lock Nut 5 16 24 4 15 16 21807G2 Brake Drum Assembly Includes Items 17 18 1 17 20947G1 Brake Drum 1 18 19...

Page 40: ...Page D 9 689390 Service Parts Manual Notes BRAKES ...

Page 41: ...Page D 10 689390 Service Parts Manual Notes BRAKES ...

Page 42: ...2 13 21 19 22 24 15 16 30 17 18 14 7 10 31 8 Front of Vehicle 1 Primary Team Clutch GC includes items 2 11 12 Secondary Team Clutch GC includes items 13 19 27 Primary Team Clutch TRK includes items 2 4 and 6 11 28 29 Secondary Team Clutch TRK includes items 13 15 and 17 19 30 ...

Page 43: ...n Not Illustrated 1 10 619332 Hex Washer Head Bolt 1 4 20 x 3 4 Lg 7 11 644306 Torque Button Plug Not Illustrated 6 12 644300 Secondary Team Clutch GC Includes items 13 19 1 13 Secondary Stationary Clutch 1 14 Moveable Secondary Clutch 1 15 619327 Inner Retainer Spring 1 16 644304 Compression Spring 1 17 619329 Outer Spring Retainer 1 18 619330 Retainer Ring 1 19 619331 Thrust Washer 1 530 x 1 830...

Page 44: ...Page E 3 689390 Service Parts Manual Notes CLUTCH ...

Page 45: ...Page E 4 689390 Service Parts Manual Notes CLUTCH ...

Page 46: ... Front of Vehicle Direction Selector Assembly Seat Support Assembly 49 48 5 12 11 10 37 17 20 21 14 19 13 32 34 30 31 31 30 30 30 33 29 46 45 18 44 43 36 5 3 2 6 4 9 8 Governor Cable Bracket Front of Vehicle 1 Direction Selector Assembly includes items 2 34 ...

Page 47: ...ection Selector Bracket 1 3 608150 Direction Selector Shaft 1 4 603700 Direction Selector Cam 1 5 14390G1 Lock Nut 3 8 24 1 6 25664G2 Bushing 1 2 x 750 Lg 1 7 8 72724G01 Neutral Lock Pin 1 9 72733G01 Compression Spring 1 10 72729G01 Neutral Lock Latch 1 11 00734G2 Lock Nut 1 4 28 1 12 28574G01 Extension Spring 1 13 72732G01 Ball Stud 10 32 1 14 00734G5 Lock Nut 10 32 1 15 16 17 72736G01 Micro Swit...

Page 48: ...ion ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY DIRECTION SELECTOR 32 632891 Pivot Bracket 1 33 00734G5 Lock Nut 10 32 1 34 22754G4 Bushing Flip Lok 250 1 35 36 601326 Button Head Torx Bolt M6 1 x 20mm Lg Grade 8 8 2 37 450452 Hex Nut M6 1 2 38 39 40 41 42 43 71205G01 Direction Selector Handle 1 44 01037G02 Pan Head Phillips Screw 10 32 x 1 2 Lg 1 45 606421 Flanged Hex Head Bolt M6 1 x 30mm Lg Grade 8 ...

Page 49: ...Page F 4 689390 Service Parts Manual Notes DIRECTION SELECTOR ...

Page 50: ...6 11 17 18 Taillight Assembly Driver Side includes items 21 24 26 19 Taillight Assembly Passenger Side includes items 22 26 2 Headlight Assembly Passenger Side includes items 8 9 11 17 8 14 14 17 6 9 15 16 12 13 11 5 28 27 26 21 22 24 25 Taillight Installation Headlight Installation Front of Vehicle Front of Vehicle ...

Page 51: ...ver Side 1 7 8 607437 Headlight Gasket Passenger Side 1 9 607435 Headlight Passenger Side 1 10 11 74004G01 Headlight Bulb 1 12 676687 Front Turn Signal Bulb 1 13 607487 Wiring Harness Turn Signal Lamp 1 14 607434 Headlight Clip 4 15 608328 Button Head Torx Screw Plastite M3 1 3 x 14mm Lg 1 16 608322 Headlight Retainer 1 17 615459 Anti Rotation Collar 1 18 648672G01 Taillight Assembly Driver Side I...

Page 52: ...Page G 3 689390 Service Parts Manual ELECTRICAL Front of Vehicle 4 5 1 3 2 13 Main Harness Front of Vehicle Front of Vehicle 15 10 11 9 12 ...

Page 53: ...EM PART NO 1 2 3 4 5 DESCRIPTION QTY Page G 4 689390 Service Parts Manual ELECTRICAL 1 611284 Keyswitch 1 2 609696 Keyswitch and Key Set Unique 1 3 611282 Key Set Common 1 4 612314 Fuel Meter 1 5 604019 Headlight Switch 1 6 7 8 9 643145 Battery Tie Down 1 10 637484 Battery 12V 1 11 638433 Battery Heavy Duty 12V 1 12 649804 Button Head Torx Screw M8 3 50 x 30mm Lg 2 13 602572 Pan Head Taptite Bolt ...

Page 54: ...Page G 5 689390 Service Parts Manual ELECTRICAL 2 3 10 11 9 6 13 4 14 12 18 19 17 16 8 15 9 9 8 8 7 1 Solenoid Harness assembly includes items 2 22 21 22 5 ...

Page 55: ...ket 1 4 603390 Solenoid Cover 1 5 663593 Relay 12V 1 6 27739G01 Voltage Regulator 1 7 16816G1 Ratchet Rivet 25 x 680 1 8 601326 Button Head Torx Bolt M6 1 x 20mm Lg Grade 8 8 3 9 601476 Lock Nut M6 1 4 10 602053 Lock Nut M4 7 3 11 600543 Button Head Torx Bolt M4 75 x 12mm Lg Grade 8 8 3 12 645209 6 GA Wire Assembly B Sol 1 13 602063 Button Head Torx Bolt M6 1 x 40mm Lg 1 14 603874 6 AWG Wire Assem...

Page 56: ...olumn without Steering wheel 3 2 1 6 5 Hose clamp Turn Signal Switch includes item 2 1 Seat Support Front of Vehicle Hour Meter 8 11 Direction Selector Mounting Bolts 9 10 Front of Vehicle Horn Assembly Installation Momentary Switch Installation 16 12 17 15 Front of Vehicle 13 ...

Page 57: ...Turn Signal Switch Includes Item 2 1 2 604367 Flasher Unit 1 3 20965G3 Steering Column Cover 1 4 19344G1 Vinyl Tape 40mm Not Illustrated 1 5 6 16816G5 Ratchet Rivet 187 x 550 2 7 31539G1 Nylon Clamp 15 5 Lg Not Illustrated 1 8 617074 Hour Meter 1 9 659101 Malfunction Indicator Light 1 10 659085 Fuse Bracket For Vehicles without Hour Meter 11 11 662631 Fuse Bracket For Vehicles with Hour Meter 11 1...

Page 58: ...Page G 9 689390 Service Parts Manual ELECTRICAL Front of Vehicle 17 16 1 3 7 5 6 Front of Vehicle 8 USB Port Housing Assembly includes item 9 10 14 Front of Vehicle From USB Port 9 10 11 13 ...

Page 59: ...TION QTY Page G 10 689390 Service Parts Manual ELECTRICAL 1 645208 Accessory Harness 1 2 01072G01 Cable Clip Not Illustrated 3 3 17618G1 Nylon Clamp 8 Lg 3 4 5 71078G01 12V Power Outlet 1 6 600543 Button Head Torx Screw M4 75 x 12mm Lg Grade 8 8 2 7 602053 Lock Nut M4 7 2 8 639384 USB Port Housing Assembly Includes Items 9 10 1 9 Housing 1 10 Lid 1 11 638233 USB Electronics 1 12 13 17618G1 Nylon C...

Page 60: ...5 7 11 Speaker Assembly Mounting Passenger Side includes items 6 11 Bluetooth Speakers Assembly includes items 13 18 Bluetooth Speaker Parent includes items 14 16 Front of Vehicle Negative Harness Positive Harness Part of Body Front of Vehicle A 1 5 17 7 8 11 9 14 16 14 15 10 3 4 12 13 6 2 13 0000 18 A ...

Page 61: ...embly Mounting Driver Side Includes Items 5 7 11 1 4 697231 Speaker Assembly Mounting Passenger Side Includes Items 6 11 1 5 690335G01 Speaker Bracket Driver Side 1 6 690335G02 Speaker Bracket Passenger Side 1 7 620634 End Cap 1 8 600527 Button Head Torx Bolt M10 1 5 x 60 mm Lg 1 9 600525 Lock Nut M10 1 5 1 10 648473 Front Mirror Mount Strut 1 11 603823 Flat Washer 1 12 692171 Bluetooth Speakers A...

Page 62: ...Page G 13 689390 Service Parts Manual Notes ELECTRICAL ...

Page 63: ...Page G 14 689390 Service Parts Manual Notes ELECTRICAL ...

Page 64: ...Page H 1 689390 Service Parts Manual ENGINE AND MUFFLER 3 1 6 2 4 5 Gas Engine 13HP includes items 2 5 10 12 11 15 13 14 14 9 16 12 11 16 17 ...

Page 65: ...Service Parts Manual ENGINE AND MUFFLER 1 658237 Gas Engine 13HP Includes Items 2 5 1 2 607454 Oil Filter 1 3 607462 Spark Plug 1 4 603557 Oil Drain Plug 3 5 603562 O ring 16mm 3 6 606390 Dip Stick 1 7 8 9 674854 Muffler 1 10 657450 Exhaust Pipe 1 11 606272 Lock Washer 8mm 4 12 606267 Hex Jam Nut M8 x 1 25 4 13 606279 Flanged Hex Nut M10 1 25 1 14 606256 Flanged Hex Head Bolt M10 1 25 x 25mm Lg Gr...

Page 66: ...Page H 3 689390 Service Parts Manual Notes ENGINE AND MUFFLER ...

Page 67: ...Page H 4 689390 Service Parts Manual Notes ENGINE AND MUFFLER ...

Page 68: ...Page J 1 689390 Service Parts Manual ENGINE MOUNTING 10 11 1 14 2 4 4 5 6 12 13 9 Engine Front of Vehicle 15 Frame 8 Front Mount Bracket Assembly includes items 9 13 ...

Page 69: ...NGINE MOUNTING 1 630776 Engine Pan 1 2 606259 Flanged Hex Head Bolt M10 1 25 x 45mm Lg Grade 8 8 4 3 4 606256 Flanged Hex Head Bolt M10 1 25 x 25mm Lg Grade 8 8 4 5 603823 Flat Washer M10 x 22mm x 2 5mm 4 6 606279 Flanged Hex Nut M10 1 25 4 7 8 662794 Front Mount Bracket Assembly Includes Items 9 13 1 9 625345 Front Mount Bracket 1 10 605757 Rubber Bumper 2 11 00974G01 Hex Nut M10 1 5 2 12 608654 ...

Page 70: ...Page J 3 689390 Service Parts Manual Notes ENGINE MOUNTING ...

Page 71: ...Page J 4 689390 Service Parts Manual Notes ENGINE MOUNTING ...

Page 72: ...Page K 1 689390 Service Parts Manual FRAME 5 12 11 3 8 9 9 7 4 1 Front of Vehicle ...

Page 73: ...5 DESCRIPTION QTY Page K 2 689390 Service Parts Manual FRAME 1 657280G05 Frame Weldment P coat 1 2 3 614597 Instrument Panel Support Weldment 1 4 602572 Pan Head Taptite Bolt M10 1 5 x 25mm Lg Grade 8 8 2 5 600525 Flanged Lock Nut M10 1 5 2 6 7 600218 Seat Support Bracket Driver Side 1 8 613187 Seat Support Bracket Passenger Side 1 9 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 3 10 11...

Page 74: ...Page K 3 689390 Service Parts Manual Notes FRAME ...

Page 75: ...Page K 4 689390 Service Parts Manual Notes FRAME ...

Page 76: ... 23 22 24 19 20 6 8 12 15 13 14 34 36 37 42 43 36 45 46 48 49 48 49 34 39 40 39 33 14 26 17 9 29 28 2 Shock Absorber Driver Side includes items 6 9 11 26 32 Control Arm Assembly includes items 33 34 1 Shock Absorber Passenger Side includes items 5 8 11 26 11 Hub Assembly includes items 12 15 ...

Page 77: ...indle Passenger Side 1 6 663345 Spindle Driver Side 1 7 8 655529 Strut Passenger Side 1 9 655526 Strut Driver Side 1 10 11 609603 Hub Assembly Includes Items 12 15 1 12 602340 Hub 1 13 602342 Bearing Spacer 28mm O D x 22mm I D x 46 7mm Lg 1 14 602341 Ball Bearing 47mm O D x 20mm I D x 14mm 2 15 19862G1 Wheel Bolt 1 2 20 x 1 218 Lg 4 16 17 12091G2 Spindle Cap 1 18 632925 Flanged Bushing 1 19 632926...

Page 78: ...RONT SUSPENSION AND STEERING 32 608089 Control Arm Assembly Includes Items 33 34 1 33 608090 Control Arm 1 34 608086 Mounting Sleeve Rubber 2 35 36 601340 Control Arm Bushing 2 37 602085 Control Arm Carrier Tube 2 38 39 602415 Flanged Hex Head Bolt M10 1 5 x 80mm Lg 2 40 600525 Lock Nut M10 1 5 2 41 42 601754 Flanged Hex Head Bolt M10 1 5 x 100mm Lg 1 43 600525 Lock Nut M10 1 5 1 44 45 618329 Stee...

Page 79: ...Page L 4 689390 Service Parts Manual Notes FRONT SUSPENSION AND STEERING ...

Page 80: ...Page L 5 689390 Service Parts Manual FRONT SUSPENSION AND STEERING 1 5 4 7 6 9 8 7 8 12 11 2 Steering Column Assembly includes items 5 9 ...

Page 81: ...ion ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page L 6 689390 Service Parts Manual FRONT SUSPENSION AND STEERING 1 602980 Steering Wheel 1 2 601709 Lock Nut M6 2 1 3 4 600333 Steering Column Assembly Includes Items 5 9 1 5 608117 Steering Column 1 6 608114 Steering Yoke 1 7 608653 Socket Head Bolt M10 1 5 x 35mm Lg 2 8 608654 Lock Washer 10 5mm 2 9 608655 Hex Nut M10 1 5 1 10 11 602572 Pan Head Tapti...

Page 82: ...Page L 7 689390 Service Parts Manual Notes FRONT SUSPENSION AND STEERING ...

Page 83: ...Page L 8 689390 Service Parts Manual Notes FRONT SUSPENSION AND STEERING ...

Page 84: ...Page M 1 689390 Service Parts Manual FUEL SYSTEM Frame Engine 7 9 8 11 13 14 6 7 12 10 10 13 1 Fuel Tank ...

Page 85: ...TEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page M 2 689390 Service Parts Manual FUEL SYSTEM 1 666351 Fuel Hose 1 2 3 4 5 6 27184G05 Fuel Tube 25 I D x 5 O D x 42 Lg 1 7 18292G1 Tubing Clamp 1 8 664747 Tubing Clamp 2 9 602409 Barrel Clip M6 1 2 10 606264 Flanged Hex Head Bolt M6 1 x 20mm Lg Grade 8 8 2 11 603818 Barrel Clip M10 1 5 1 12 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 1 13 60406...

Page 86: ...Page M 3 689390 Service Parts Manual FUEL SYSTEM Fuel Tank with Sender Unit includes items 2 8 Front of Vehicle 1 3 4 2 5 8 7 6 ...

Page 87: ...lt Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page M 4 689390 Service Parts Manual FUEL SYSTEM 1 646833 Fuel Tank with Sender Unit Includes Items 2 8 1 2 646358 Fuel Pickup with Sender Assembly 1 3 646284 Fuel Tank 1 4 646837 Fuel Pump Lid 1 5 646838 Mason Jar Seal 1 6 647810 Rollover Valve Grommet 1 7 647809 Rollover Valve 1 8 670898 Fuel Tank Ca...

Page 88: ...Page M 5 689390 Service Parts Manual FUEL SYSTEM Front of Vehicle 1 2 6 7 6 3 Carbon Canister Assembly includes items 5 7 4 5 ...

Page 89: ... consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page M 6 689390 Service Parts Manual FUEL SYSTEM 1 659882 Canister Bracket 1 2 606310 Canister Mounting Bracket 1 3 00106G6 Pan Head Phillips Screw 12 24 x 3 4 Lg 2 4 662808 Carbon Canister Assembly Includes Items 5 7 1 5 606071 Carbon Canister 1 6 606963 Hose Clamp 3 16 I D 2 7 692912 Hose 3 16 ...

Page 90: ...Page M 7 689390 Service Parts Manual Notes FUEL SYSTEM ...

Page 91: ...Page M 8 689390 Service Parts Manual Notes FUEL SYSTEM ...

Page 92: ... 41 37 40 39 30 29 27 45 28 27 33 32 19 62 23 18 67 50 21 61 A A 4 DETAIL A Rear Axle 11 47 1 includes items 3 63 1 Axle Case L Complete includes items 4 13 24 Axle Case R Complete includes items 13 19 23 Differential Case includes items 34 47 49 and 50 3 18 46 Axle Shaft R Complete includes item 56 55 Differential Assembly includes items 46 48 and 52 63 Axle Shaft L Complete includes item 56 54 ...

Page 93: ... 7 8 639698 Governor Gear Shaft 1 9 639707 Governor Shaft 1 10 639736 Flat Washer 6mm 2 11 607911 Oil Seal 6 x 10 x 2 5mm 1 12 607913 Retaining Ring E5 1 13 639738 Oil Seal 24 x 40 x 9mm 2 14 26818G01 Steel Ball 1 15 26819G01 Spring 1 16 26831G01 Gasket 10 1 17 26820G01 Flanged Hex Head Bolt M10 1 25 x 12mm Lg 1 18 639865 Axle Case R Complete Includes Items 13 19 23 1 19 639746 Select Shaft 1 20 6...

Page 94: ...42 670697 Center Shaft 1 43 639774 Clutch Pin 1 44 670696 Gear 61 1 45 639797 Spacer 20 x 2mm 2 46 639872 Differential Case Includes Items 34 47 49 and 50 1 47 639800 Differential Pair Gear 1 48 26808G01 Hex Head Bolt M10 1 25 x 26mm Lg 6 49 28723G01 Differential Shaft 1 50 28697G01 Spring Pin 4 x 40L 1 51 639801 Ball Bearing 6007 1 52 640739 Gear 60 Complete Includes Item 51 1 53 607938 Castle Nu...

Page 95: ...Page N 4 689390 Service Parts Manual Notes REAR AXLE ...

Page 96: ...Page P 1 689390 Service Parts Manual REAR SUSPENSION 1 8 10 9 3 3 4 6 4 4 6 11 12 14 15 13 12 13 12 13 12 14 16 16 13 4 5 5 7 2 2 Front of Vehicle 7 ...

Page 97: ...04494 Heavy Duty Leaf Spring 1 2 614974 Flanged Hex Nut M10 1 5 3 3 652245 Shackle Plate 2 4 624030 Flanged Bushing 4 5 601754 Flanged Hex Head Bolt M10 1 5 x 100mm Lg 3 6 620161 Split Spacer Steel 3 7 620160 Flanged Bushing Urethane 2 8 625658 Shock Mount Plate Passenger Side 1 9 625657 Shock Mount Plate Driver Side 1 10 626422 Axle Support Bracket 1 11 76418G01 Shock Absorber 2 12 10435G1 Shock ...

Page 98: ...Page P 3 689390 Service Parts Manual Notes REAR SUSPENSION ...

Page 99: ...Page P 4 689390 Service Parts Manual Notes REAR SUSPENSION ...

Page 100: ...689390 Service Parts Manual Page R 1 SEATING 11 12 1 Seat Bottom Assembly includes items 2 12 14 Seat Back Assembly includes items 15 17 15 16 2 7 7 8 10 5 12 8 3 4 Front of Vehicle 17 ...

Page 101: ...l and Foam Seat Bottom 1 644819G02 Stone Beige 644819G01 Oyster 644819G06 Black 644819G04 Gray 3 644351 Wooden Base Assembly 1 4 602551 Cover Plate 1 5 16816G2 Ratchet Rivet 25 x 887 4 6 7 71610G01 Seat Hinge 1 8 00720G08 Flat Head Phillips Tapping Screw 12 14 x 1 Lg 3 9 10 617645 Hip Restraint Driver Side 1 11 617644 Hip Restraint Passenger Side 1 12 615417 Button Head Torx Bolt M10 1 5 x 25mm Lg...

Page 102: ...y includes items 2 4 13 Seat Bottom Assembly Fixed includes items 14 16 20 Floorboard Assembly Fixed Seat includes items 21 23 2 3 4 14 37 36 15 16 39 21 18 9 36 6 7 6 7 34 33 18 23 27 26 28 31 26 27 28 11 10 10 11 22 21 Seat support Seat support 30 Front of Vehicle ...

Page 103: ...eige 644820G01 Oyster 644820G06 Black 644820G04 Gray 3 605529 Cover Plastic 1 4 644268 Base Assembly 1 5 6 606286 Rear Seat Support Bracket 1 7 600530 Button Head Torx Bolt M10 1 5 x 25mm Lg Grade 8 8 2 8 9 604473 Seat Support 1 10 603800 Flanged Hex Head Bolt M10 1 5 x 50mm Lg Grade 8 8 4 11 600525 Flanged Lock Nut M10 1 5 4 12 13 Seat Bottom Assembly Fixed Includes Items 14 16 1 608010 Oyster 60...

Page 104: ...1 2 22 638346G01 Footrest Weldment 1 23 640653 Grip Tape 1 24 25 26 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 4 27 602415 Flanged Hex Head Bolt M10 1 5 x 80mm Lg 2 28 600525 Lock Nut M10 1 5 2 29 30 603800 Flanged Hex Head Bolt M10 1 5 x 50mm Lg Grade 8 8 2 31 603818 Barrel Clip M10 1 5 2 32 33 604723 Arm Rest Driver Side 1 34 604725 Arm Rest Passenger Side 1 35 36 600530 Button Hea...

Page 105: ...Page R 6 Notes SEATING 689390 Service Parts Manual ...

Page 106: ... 27 61 62 33 34 35 1 Seat Back Assembly includes items 2 4 9 Seat Bottom Assembly Flip includes items 10 20 10 Seat Bottom Assembly includes items 11 14 23 Floorboard Assembly Flip Seat includes items 24 29 37 Deck Bed Assembly includes items 38 41 Front of Vehicle Front of Vehicle 68 Front of Vehicle Front of Vehicle 66 67 Bagwell Closeout Assembly includes items 65 67 ...

Page 107: ... Beige 644820G01 Oyster 644820G06 Black 644820G04 Gray 5 6 600530 Button Head Torx Bolt M10 1 5 x 25mm Lg Grade 8 8 4 7 603823 Flat Washer M10 x 22mm x 2 5mm 4 8 9 Seat Bottom Assembly Flip Includes Items 10 20 1 615193 Stone Beige 615194 Oyster 615137 Black 670860 Gray 10 Seat Bottom Assembly Includes Items 11 14 1 615192 Stone Beige 75197G03 Oyster 75197G07 Black 75197G02 Gray 11 Vinyl Cover 1 6...

Page 108: ...10 27 19853G1 Tube Cap 1 x 1 2 28 614973 Oval Reflector Red 4 29 608290 Self Tapping Screw 10 16 x 3 4 Lg 2 30 31 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg 4 32 33 604473 Seat Support 1 34 601414 Flanged Hex Head Bolt M10 1 5 x 65mm Lg Grade 8 8 4 35 600525 Lock Nut M10 1 5 4 36 37 615138 Deck Bed Assembly Includes Items 38 41 1 38 620878 Middle Lifted Deck Bed 1 39 75250G01 Seat Hinge Passen...

Page 109: ...ual 51 52 602415 Flanged Hex Head Bolt M10 1 5 x 80mm Lg 2 53 600525 Lock Nut M10 1 5 2 54 55 73876G01 Flanged Hex Head Bolt M6 1 x 12mm Lg Grade 8 8 2 56 601476 Lock Nut M6 1 2 57 58 600530 Button Head Torx Bolt M10 1 5 x 25mm Lg Grade 8 8 2 59 603818 Barrel Clip M10 1 5 2 60 61 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 2 62 600525 Lock Nut M10 1 5 2 63 64 643973 Bagwell Closeout A...

Page 110: ...anual Page R 11 SEATING 12 Seatbelt Installation Hardware Kit includes items 13 17 3 Seatbelt Structure Hardware Kit includes items 4 6 4 5 1 8 15 16 16 15 17 6 17 14 17 16 15 10 14 14 13 17 13 17 16 Sash Guide Sash Guide 9 ...

Page 111: ...atbelt Weldment 1 2 3 612126 Seatbelt Structure Hardware Kit Includes Items 4 6 1 4 602415 Flanged Hex Head Bolt M10 1 5 x 80mm Lg 4 5 600525 Flanged Lock Nut M10 1 5 4 6 604066 Flat Washer Steel M10 4 7 8 609031 Seat Belt Buckle 9 Lg 2 9 661524 Seat Belt Buckle 6 Lg 2 10 649131 Seat Belt Retractor Assembly 4 11 12 612127 Seatbelt Installation Hardware Kit Includes Items 13 17 1 13 605686 Cap Viny...

Page 112: ...Page R 13 Notes SEATING 689390 Service Parts Manual ...

Page 113: ...Page R 14 Notes SEATING 689390 Service Parts Manual ...

Page 114: ...Page S 1 689390 Service Parts Manual STARTER AND GENERATOR 9 10 11 12 13 14 15 16 18 7 8 6 5 4 3 2 1 Starter Generator includes items 2 17 17 Headband Kit includes item 18 ...

Page 115: ...ual STARTER AND GENERATOR 1 660379 Starter Generator Includes Items 2 17 1 2 612029 Hex Nut 1 3 612030 Lock Washer 1 4 625716 Pulley 2 5 O D 1 5 654715 Drive End Head 1 6 612033 Bearing 1 7 612034 Retaining Ring 1 8 612035 Woodruff Key 1 9 612036 Armature Assembly 1 10 654716 Frame And Field Assembly 1 11 612038 Brush Lead And Terminal Package 1 12 654717 Brush Box Assembly 1 13 656659 Brush Sprin...

Page 116: ...Page S 3 689390 Service Parts Manual STARTER AND GENERATOR 1 7 2 7 8 13 10 12 2 7 9 5 Front of Vehicle ...

Page 117: ...RT NO 1 2 3 4 5 DESCRIPTION QTY Page S 4 689390 Service Parts Manual STARTER AND GENERATOR 1 631972 Starter Generator Support Bracket 1 2 606235 Flanged Hex Head Bolt M10 1 25 x 20mm Lg 2 3 4 5 606261 Flanged Hex Head Bolt M8 1 25 x 20mm Lg Grade 8 8 2 6 7 606256 Flanged Hex Head Bolt M10 1 25 x 25mm Lg Grade 8 8 3 8 606255 Hex Jam Nut M10 1 25 1 9 606274 Flanged Hex Nut M10 1 25 1 10 630587 Start...

Page 118: ...Page S 5 689390 Service Parts Manual Notes STARTER AND GENERATOR ...

Page 119: ...Page S 6 689390 Service Parts Manual Notes STARTER AND GENERATOR ...

Page 120: ...PROTECTION 3 11 9 3 16 15 27 28 11 4 14 4 6 3 21 5 10 12 7 13 6 5 5 6 1 Sun Top Kit Stone Beige includes items 3 18 2 Sun Top Kit Oyster includes items 4 18 21 8 Sun Top Hardware Kit includes items 9 16 18 Sun Top Hardware Kit includes items 19 20 ...

Page 121: ...t Driver Side 1 6 604424 Rear Strut Passenger Side 1 7 603800 Flanged Hex Head Bolt M10 1 5 x 50mm Lg Grade 8 8 2 8 610468 Sun Top Hardware Kit Includes Items 9 16 1 9 601414 Flanged Hex Head Bolt M10 1 5 x 65mm Lg Grade 8 8 4 10 602415 Flanged Hex Head Bolt M10 1 5 x 80mm Lg Grade 12 9 4 11 600525 Flanged Lock Nut M10 1 5 8 12 602770 Strut Grommet Driver Side 1 13 602992 Strut Grommet Passenger S...

Page 122: ...Page T 3 689390 Service Parts Manual WEATHER PROTECTION Instrument Panel 1 2 3 14 13 8 9 10 11 12 Front of Vehicle REAR VIEW MIRROR ...

Page 123: ... for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page T 4 689390 Service Parts Manual WEATHER PROTECTION 1 648473 Strut 1 2 602770 Strut Grommet Driver Side 1 3 602992 Strut Grommet Passenger Side 1 4 5 6 7 8 600527 Button Head Torx Bolt M10 1 5 x 6mm Lg Grade 8 8 1 9 600525 Lock Nut M10 1 5 1 10 648528 Mirror Bracket 1 11 Hex Head Bolt 1 4 20 x 5 8 Lg 1 12 Lock Washer 1 4 1 13 7...

Page 124: ...5 689390 Service Parts Manual WEATHER PROTECTION 5 8 6 3 12 10 11 4 1 Split Windshield Kit includes items 2 9 2 Split Windshield Assembly includes items 3 6 9 Split Windshield Hardware Kit includes items 10 12 ...

Page 125: ...TY Page T 6 689390 Service Parts Manual WEATHER PROTECTION 1 606584 Split Windshield Kit Includes Items 2 9 1 2 606623 Split Windshield Assembly Includes Items 3 6 1 3 603738 Split Windshield 1 4 603201 Lower Windshield Latch 2 5 603198 Upper Windshield Latch 2 6 604115 Windshield Isolator 2 7 8 613136 Windshield Attachment Sash 2 9 668122 Split Windshield Hardware Kit Includes Items 10 12 1 10 60...

Page 126: ...Page T 7 689390 Service Parts Manual Notes WEATHER PROTECTION ...

Page 127: ...Page T 8 689390 Service Parts Manual Notes WEATHER PROTECTION ...

Page 128: ...4 14 19 1 Wheel and Tire Assembly Machine Alloy includes items 2 4 11 Wheel and Tire Assembly Hole N One includes items 12 14 16 Wheel and Tire Assembly USA Trail includes items 17 19 5 6 9 Tire design may vary by Part Number 21 22 Wheel cover design may vary by Part Number ...

Page 129: ...ly Machine Alloy Includes Items 2 4 1 2 647040 Wheel 10 1 3 647044 Tire Kenda 205 50 10 1 4 604915 Valve Stem Chrome 1 5 605310 Lug Nut Chrome 4 6 652122 Wheel Cap Chrome 1 7 8 74175G01 Dust Cap 1 9 14723G1 Lug Nut 1 2 20 4 10 11 612772 Wheel and Tire Assembly Hole N One Includes Items 12 14 1 12 612770 Wheel 8 1 13 612771 Tire Kenda 1 14 11657G2 Valve Stem 1 15 16 28842G01 Wheel and Tire Assembly...

Page 130: ...Page U 3 689390 Service Parts Manual Notes WHEELS AND TIRES ...

Page 131: ...Page U 4 689390 Service Parts Manual Notes WHEELS AND TIRES ...

Page 132: ... Do not operate vehicle until all occupants are properly seated with their backs against the seat and feet flat on the floor Do not leave children unattended or allow them to play on a parked vehicle SAFETY INSTRUCTIONS 1 Cup Holder Cowl Rear Body 3 608528 Failure to follow these instructions can result in SERIOUS INJURY or DEATH Except where PERMITTED BY LAW NEVER drive on public roads Drivers mu...

Page 133: ...cates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page V 2 DECALS AND LABELS 689390 Service Parts Manual 1 619206 E Z GO Cowl Decal 1 2 608528 Warning Label Instrument Panel 1 3 690342 Shuttle 2 2 EFI Decal 1 4 664789 Warning Label Steering Wheel 1 5 608527 Governor Warning Label 1 6 685698 MADE IN USA Decal 1 7 647213 Anti Rollback Label 1...

Page 134: ...n A V O I D s t a n d i n g i n f r o n t o f o r b e h i n d v e h i c l e O N L Y 2 o c c u p a n t s p e r s e a t A l w a y s r e m a i n P R O P E R L Y S E A T E D a n d H O L D I N G O N 6 0 8 5 3 7 1 Footrest Weldment MAX 4 in 10 cm MAX 14o 25 MAX 250 lbs 110 kg 610631 2 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY AVOID FALLS from the vehicle and other SERIOUS...

Page 135: ...dicates 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 Page V 4 DECALS AND LABELS 689390 Service Parts Manual 1 608537 Rear Facing Seat Warning Label 1 2 610631 Clays Bed Label 1 3 611362 Rear Facing Seat Label 1 ...

Page 136: ...Page V 5 Notes DECALS AND LABELS 689390 Service Parts Manual ...

Page 137: ...Page V 6 Notes DECALS AND LABELS 689390 Service Parts Manual ...

Page 138: ...pecialized Vehicles Technical Publications Department Textron Specialized Vehicles Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Owner s Guides and Repair Manuals are available from a local Distributor an authorized Branch Parts Accessories Department or at www shop txtsv com shop ezgo CONTACT INFORMATION ...