Textron EZGO EXPRESS S4, Service & Parts Manual

Page 1: ...ISSUED JUNE 2019 Express S4 72V Service Parts Manual 699361 B REVISED SEPTEMBER 2019...

Page 2: ......

Page 3: ...nges 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 subjec...

Page 4: ...ates 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 d...

Page 5: ...SERVICE PARTS MANUAL V ACCELERATOR A 1 BATTERY CHARGER B 1 BODY C 1 BRAKES D 1 ELECTRICAL E 1 ELECTRONIC SPEED CONTROL F 1 FRONT SUSPENSION AND STEERING G 1 MOTOR H 1 REAR AXLE J 1 REAR SUSPENSION K 1...

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

Page 7: ...E 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...

Page 8: ...er 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 assemb...

Page 9: ...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 35 SAFETY YELLOW 36 IVOR...

Page 10: ...22 24 20 15 14 26 25 36 2 3 4 32 34 33 10 9 11 21 19 18 17 16 4 5 7 6 8 RED GRN To harness from direction selector Part of Frame WHT 1 Pedal Box Assembly includes items 2 34 27 Accelerator Pedal Assem...

Page 11: ...2 6 25861G01 Micro Switch 1 7 01050G01 Pan Head Torx Screw 4 20 x 5 8 Lg 2 8 28444G01 Accelerator Rod Cam 1 9 25854G01 Inductive Throttle Sensor 1 10 00983G01 Self Threading Nut 38 2 11 602484 Plunger...

Page 12: ...vailable as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY ACCELERATOR 699361 Service Parts Manual 32 25879G08 Pedal...

Page 13: ...Page A 4 Notes ACCELERATOR 699361 Service Parts Manual...

Page 14: ...Page B 1 699361 Service Parts Manual BATTERY CHARGER 1 2 3...

Page 15: ...t Indicates 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 B 2 699361 Serv...

Page 16: ...Page B 3 699361 Service Parts Manual Notes BATTERY CHARGER...

Page 17: ...Page B 4 699361 Service Parts Manual Notes BATTERY CHARGER...

Page 18: ...Page C 1 699361 Service Parts Manual BODY 5 4 3 2 7 6 1 19 20 12 14 15 21 17 18 13 16 10 11 9 8 Front of Vehicle Front of Vehicle...

Page 19: ...4 75048G04 Spacer 328 x 75 x 1 Lg 2 5 75048G02 Spacer 328 x 75 x 1 31 Lg 2 6 00559G8 Flat Washer Narrow 5 16 4 7 00565G8 Lock Washer 5 16 4 8 70452G01 Access Cover 1 9 14601G11 Rivet Aluminum 3 16 x...

Page 20: ...rvice Parts Manual BODY 7 Instrument Panel Assembly includes items 8 16 8 Instrument Panel Assembly with Ball Deflector includes items 9 13 17 18 19 22 15 12 13 21 23 22 10 11 9 14 16 4 3 6 5 4 2 1 23...

Page 21: ...Driver Side 1 6 613274 Fender Flare Passenger Side 1 7 662328 Instrument Panel Assembly Includes Items 8 16 1 8 71917G01 Instrument Panel Assembly with Ball Deflector Includes Items 9 13 1 9 00614G3...

Page 22: ...Page C 5 699361 Service Parts Manual BODY 6 7 8 9 2 25 13 29 27 28 12 14 21 20 1 5 25 23 24 Front of Vehicle Front of Vehicle 15 22 10...

Page 23: ...her 5 16 2 8 11098G6 Lock Nut 5 16 18 2 9 00715G2 Hex Washer Head Bolt 5 16 18 x 8 Lg 2 10 70200G01 Truss Head Torx Screw 3 8 16 x 3 4 Lg 2 11 12 658946 Fender Liner Passenger Side 1 13 658949 Fender...

Page 24: ...Page C 7 699361 Service Parts Manual BODY 1 2 6 7 7 8 10 9 3 Front of Vehicle Rear Bumper Installation 16 14 15 14 17 13 19 Front of Vehicle 4 22 20 21 23 Front of Vehicle...

Page 25: ...10570G10 Rivet SS 5 32 x 9 16 Lg 5 3 10570G12 Rivet Aluminum 257 x 556 Lg 4 4 633917 Rivet Plastic 2 5 6 71320G01 Access Panel 1 7 01107G01 Pan Head Torx Screw SS 8 x 63 Lg 5 8 16816G2 Ratchet Rivet 2...

Page 26: ...Page C 9 699361 Service Parts Manual BODY FLOOR MOUNT GUN HOLDER 1 2 6 6 4 5 7 Front of Vehicle Front of Vehicle...

Page 27: ...dividual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 10 699361 Service Parts Manual BODY 1 74365G01 Gun Holder Floor Mou...

Page 28: ...Page C 11 699361 Service Parts Manual Notes BODY...

Page 29: ...Page C 12 699361 Service Parts Manual Notes BODY...

Page 30: ...699361 Service Parts Manual Page D 1 BRAKES 28 19 21 3 10 11 12 24 26 18 21 22 23 17 20 25 14 9 13 5 6 7 16 15 27 2 WHITE BLACK 1 Brake Pedal Assembly with Brake Lights includes items 2 28...

Page 31: ...7 16409G1 Oval Rivet 3 8 x 15 32 Lg 9 8 9 652820 Service Brake Pedal Plate 1 10 70682G01 Pivot Pin 1 11 70681G01 Torsion Spring 408 Dia x 93 Lg 2 12 658825 Push Nut 5 16 2 13 00737G8 Flat Head Phillip...

Page 32: ...3 BRAKES Part of Frame Accelerator Pedal 1 12 21 29 30 13 47 48 2 15 17 17 27 28 18 19 18 19 16 16 20 24 25 26 31 3 4 5 49 11 36 37 40 43 41 42 40 44 46 39 38 45 Compensator Assembly includes items 3...

Page 33: ...Hex Washer Head Bolt 1 4 20 x 7 Lg Not Illustrated 1 7 12416G2 Nylon Wedge Lock Clamp Not Illustrated 3 8 9 10 11 01111G01 Retaining Ring SS Dia 8 4 12 10386G3 Clevis Pin 438 x 938 Lg 1 13 10387G3 Cot...

Page 34: ...levis Pin 438 x 938 Lg 1 33 10387G3 Cotter Pin 094 x 75 Lg 1 34 35 36 654663 Compensator Assembly Includes Items 37 49 1 37 00532G4 Hex Nut 1 4 20 1 38 629486 Spherical Hex Nut 5 16 24 1 39 28082G01 E...

Page 35: ...Page D 6 Notes BRAKES 699361 Service Parts Manual...

Page 36: ...S Front of Vehicle 4 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 23 3 8...

Page 37: ...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 Passen...

Page 38: ...Page D 9 Notes BRAKES 699361 Service Parts Manual...

Page 39: ...Page D 10 Notes BRAKES 699361 Service Parts Manual...

Page 40: ...Page E 1 699361 Service Parts Manual ELECTRICAL Note FRAME SHOWN PARTIALLY 3 4 1 9...

Page 41: ...omer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page E 2 699361 Service Parts Manual ELECTRICAL 1 687518 Main Harness 1 2 3 20965G3 Steering Column Cover 1 4...

Page 42: ...Page E 3 699361 Service Parts Manual ELECTRICAL 23 11 1 2 2 1 10 3 4 11 7 7 1 6 6 6 21 19 18 15 17 13 6 6 7 7 7 Front of Vehicle 2 28 29 25 26...

Page 43: ...n Bolt 2 4 11027G1 Flanged Lock Nut 5 16 18 2 5 6 70386G01 Battery Tie Down Bolt 5 16 18 x 2 Lg 6 7 11027G1 Flanged Lock Nut 5 16 18 6 8 9 10 658565 Battery Hold Down 1 11 631988 Battery Hold Down 2 1...

Page 44: ...of Vehicle To Battery Positive Front of Vehicle Battery Installation Fuse Block Installation Fender Liner 2 2 1 1 Front of Vehicle Instrument Panel 16 25 24 20 21 18 22 15 23 19 12 14 Charger Recepta...

Page 45: ...Battery Wire 15 Lg 3 2 634270G01 4 AWG Battery Wire 6 Lg 2 3 16816G2 Ratchet Rivet 25 x 887 1 4 5 634270G02 4 AWG Battery Wire 9 Lg 1 6 7 32860G01 Horn 1 8 9 613271 Reverse Buzzer 1 10 01041G01 Rivet...

Page 46: ...ont of Vehicle Light Assembly To Bezel 35 Taillight Assembly Driver Side includes items 31 33 35 29 LED Headlight Assembly Driver Side includes item 17 15 LED Headlight Assembly Passenger Side include...

Page 47: ...1 13 608290 Self Tapping Screw 10 16 x 780 Lg 3 14 71597G01 Self Threading Nut 5mm x 10mm x 15mm 4 15 659008 LED Headlight Assembly Passenger Side Includes Item 17 1 16 659009 LED Headlight Assembly...

Page 48: ...duct Indicates 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 ELECTRICAL 32 625...

Page 49: ...Page E 10 699361 Service Parts Manual Notes ELECTRICAL...

Page 50: ...Page F 1 699361 Service Parts Manual ELECTRONIC SPEED CONTROL Front of Vehicle 2 10 11 4 8 5 9 3 6 7 1 6 3 Battery Tray Electronic Speed Control Assembly includes items 2 8...

Page 51: ...ION QTY Page F 2 699361 Service Parts Manual ELECTRONIC SPEED CONTROL 1 689763 Electronic Speed Control Assembly Includes Items 2 8 1 2 672599G011 Controller 1234SE AC 350A 1 3 73876G01 Flanged Hex He...

Page 52: ...Page F 3 699361 Service Parts Manual Notes ELECTRONIC SPEED CONTROL...

Page 53: ...Page F 4 699361 Service Parts Manual Notes ELECTRONIC SPEED CONTROL...

Page 54: ...Tie Rod Not Shown for Clarity Part of Frame Part of Frame 2 13 14 2 13 20 Spindle and Hub Assembly Passenger Side includes items 3 12 Spindle and Hub Assembly Driver Side includes items 4 12 14 21 25...

Page 55: ...bly 2 6 74332G01 Wheel Hub 1 7 36038G01 Drive Flange Stud 4 8 12093G1 Castle Nut 1 14 1 9 00798G8 Cotter Pin 5 32 x 1 3 4 Lg 1 10 632925 Flanged Bushing 1 11 632926 Bushing Sleeve 1 12 51141G1 Race Be...

Page 56: ...al FRONT SUSPENSION AND STEERING Front of Vehicle 19 5 Steering Column Assembly includes items 6 16 19 Tie Rod Assembly includes items 20 24 32 6 9 3 3 3 4 15 14 12 29 28 13 17 8 7 27 38 39 40 23 24 2...

Page 57: ...ering Column Bushing 1 9 70580G01 Intermediate Shaft 1 10 01055G01 Hex Head Bolt M8 1 25 x 1 18 Lg Grade 5 1 11 00565G8 Lock Washer 5 16 1 12 70751G01 Retaining Ring Internal 1 13 70888G01 Retaining R...

Page 58: ...hat 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 FRONT SUSPENSION AND STEERING 32 71147G01 Ste...

Page 59: ...Page G 6 699361 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 60: ...G 7 699361 Service Parts Manual FRONT SUSPENSION AND STEERING Rack and Pinion Unit includes items 2 23 1 Tie Rod End Outer includes items 24 25 23 16 15 14 13 12 5 6 7 8 9 19 2 20 11 4 18 10 21 17 24...

Page 61: ...2 20 1 5 70750G01 Retaining Ring External 1 6 15112G1 Ball Bearing 1 7 70603G01 Pinion 1 8 70751G01 Retaining Ring Internal 1 9 70638G01 Seal Pinion 1 10 70604G01 Steering Rack 1 11 Set Screw 10 32 x...

Page 62: ...Page G 9 699361 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 63: ...Page G 10 699361 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 64: ...Page H 1 699631 Service Parts Manual MOTOR 7 10 2 11 12 Front of Vehicle Part of Motor 1 Rear Axle 6 14 5 6 5 Front of Vehicle 17 18 19 20...

Page 65: ...ge H 2 699631 Service Parts Manual MOTOR 1 681071 Motor 72V 1 2 601327 Lock Washer 6mm 6 3 4 5 00915G1 Bonded Seal Washer 1 4 I D 3 6 616716 Hex Head Bolt M6 1 x 16mm Lg 3 7 605741 Hex Head Bolt M6 1...

Page 66: ...Page H 3 699631 Service Parts Manual Notes MOTOR...

Page 67: ...Page H 4 699631 Service Parts Manual Notes MOTOR...

Page 68: ...LE 24 12 13 10 23 11 17 21 29 20 7 31 8 30 22 19 36 18 36 9 33 4 25 9 14 7 29 32 19 36 18 36 36 35 34 28 35 36 17 Front of Vehicle 2 Rear Axle 16 99 1 includes items 4 42 1 Rear Axle with Limited Slip...

Page 69: ...ntial Assembly 1 5 614059 Limited Slip Differential with CC Clutch 1 6 7 15118G1 Hex Head Bolt 3 8 16 x 2 125 Lg 4 8 15558G1 Hex Head Bolt 5 16 18 x 75 Lg 10 9 17473G1 Bearing Assembly 2 10 23519G2 Ba...

Page 70: ...lt Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY REAR AXLE 32 620349 Intermediate Gear Assembly 1 33 620350 Drive Gear 1 34 620355 Ball Bearing 1 35 620...

Page 71: ...Page J 4 699631 Service Parts Manual Notes REAR AXLE...

Page 72: ...699361 Service Parts Manual Page K 1 REAR SUSPENSION 4 3 3 2 2 1 12 13 12 16 12 12 13 17 15 10 9 8 7 11 9 3 2 4 5 2 3 18 19 6 Front of Vehicle 20...

Page 73: ...sher I D 406 x O D 1 25 4 3 10194G1 Rubber Bushing 4 4 00532G6 Hex Nut 3 8 24 2 5 10044G01 Vinyl Cap 1 6 667990 Leaf Spring 2 7 624030 Flanged Bushing 2 8 652708G03 Lift Bracket 1 9 00560G1 Flat Washe...

Page 74: ...Page K 3 Notes REAR SUSPENSION 699361 Service Parts Manual...

Page 75: ...Page K 4 Notes REAR SUSPENSION 699361 Service Parts Manual...

Page 76: ...1 35 34 33 36 36 37 38 Seat Back Assembly includes items 2 9 1 Seat Back Assembly includes items 5 9 4 Seat Bottom Assembly includes items 17 26 16 Flip Seat Bottom Assembly includes items 31 38 30 Se...

Page 77: ...te Yellow 632818G14 Gray Black 632818G15 Oyster Garnet 2 634178 Support Weldment 1 3 71204G01 Hex Washer Head Bolt with Patch Lock 1 4 20 x 875 Lg 4 4 Seat Back Assembly Includes Items 5 9 2 71751G02...

Page 78: ...106 Black 629269G0107 Brown 629269G0109 White Blue 629269G0110 Red Black 629269G0111 White Red 629269G0112 White Black 629269G0113 White Yellow 629269G0114 Gray Black 629269G0115 Oyster Garnet 17 0072...

Page 79: ...8058G07 Brown 628058G09 White Blue 628058G10 Red Black 628058G11 White Red 628058G12 White Black 628058G13 White Yellow 628058G14 Gray Black 628058G15 Oyster Garnet 31 634190 Deck Board Assembly 1 32...

Page 80: ...er of the product Indicates 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 SEAT...

Page 81: ...Page L 6 699361 Service Parts Manual Notes SEATING...

Page 82: ...EATING 31 1 42 43 2 8 9 10 11 16 41 20 19 19 19 21 19 35 36 36 36 37 35 17 25 26 28 28 28 28 29 29 27 18 32 33 11 12 3 4 3 Rear Flip Seat Handrail Kit includes items 32 37 Flip Seat Bottom Assembly Fr...

Page 83: ...asher 3 8 2 4 11098G5 Lock Nut 3 8 16 1 5 6 7 8 634179 Footrest Weldment 1 9 19853G1 Square Tube Cap 1 1 10 00427G6 Hex Head Bolt 3 8 16 x 1 25 Lg Grade 5 1 11 614221 Flat Washer 3 8 2 12 11098G5 Lock...

Page 84: ...Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY SEATING 31 634184 Rear Flip Seat Handrail Kit Includes Items 32 37 1 32 634185 Footrest Handle Weldment 1 33 19859G...

Page 85: ...Page L 10 699361 Service Parts Manual Notes SEATING...

Page 86: ...27 25 26 28 29 22 17 15 15 Driver Side Shown D B A C 1 32 Sun Top Kit Tan includes items 3 29 36 35 DETAIL D REAR Passenger Side Shown Front of Vehicle 2 33 36 11 7 6 3 8 4 5 47 10 23 21 14 16 22 20 2...

Page 87: ...er Side 1 5 602741 Rear Strut Passenger Side 1 6 19853G1 End Cap 1 Sq 1 7 24647G1 Spacer 1 4 1 8 00891G5 Lock Nut 3 8 16 2 9 10 00665G6 Hex Head Bolt SS 3 8 16 x 2 Lg 1 11 00665G3 Hex Head Bolt SS 3 8...

Page 88: ...icates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY WEATHER PROTECTION 32 603119 Sun Top Kit White 80 Lg Includes Items 3 29 33 1 33 27604G01 S...

Page 89: ...Page M 4 699361 Service Parts Manual Notes WEATHER PROTECTION...

Page 90: ...22 23 24 25 26 27 28 29 30 Full Windshield Kit includes items 2 7 1 Strut Rubber Latch Front of Vehicle Windshield Retainer 5 4 14 6 3 Split Windshield Kit Clear includes items 12 13 11 Hardware Kit i...

Page 91: ...d 1 10 11 71966G05 Split Windshield Kit Clear Includes Items 12 13 1 12 630012 Split Windshield Clear 1 13 71956G05 Hardware Kit Includes Items 3 6 14 1 14 615661 Sash 12 Lg 2 15 71966G06 Split Windsh...

Page 92: ...Page M 7 699361 Service Parts Manual Notes WEATHER PROTECTION...

Page 93: ...Page M 8 699361 Service Parts Manual Notes WEATHER PROTECTION...

Page 94: ...Number Wheel design may vary by Part Number Wheel and Tire Assembly Kenda includes items 2 4 4 19 3 1 Wheel and Tire Assembly Kenda includes items 7 9 6 Wheel and Tire Assembly Left Side includes ite...

Page 95: ...a Includes Items 2 4 1 2 652986 Tire 20 x 8 10 1 3 643934 Wheel 10 x 6 1 4 643948 Valve Stem 1 5 6 652392 Wheel and Tire Assembly Kenda Includes Items 7 9 1 7 652992 Tire 205 65 1 8 643934 Wheel 10 x...

Page 96: ...Page N 3 699361 Service Parts Manual Notes WHEELS AND TIRES...

Page 97: ...Page N 4 699361 Service Parts Manual Notes WHEELS AND TIRES...

Page 98: ...on wet or loose terrain and when backing up Avoid sudden stops Drive slowly when turning Drive straight up and down slopes Do not coast use brake when going down a slope Never leave children unattend...

Page 99: ...Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page P 2 699361 Service Parts Manual DECALS AND LABELS 1 619206 E Z GO Cowl Decal 1 2 6...

Page 100: ...Page P 3 699361 Service Parts Manual Notes DECALS AND LABELS...

Page 101: ...Page P 4 699361 Service Parts Manual Notes DECALS AND LABELS...

Page 102: ...ecialized 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 loc...