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1. SERVICE PARTS MANUAL Industrial 640 605510 Electric Three Wheeled vehicles ISSUED JULY 2006 REVISED SEPTEMBER 2009 SERVICE PARTS MANUAL ELECTRIC THREE WHEEL UTILITY VEHICLES INDUSTRIAL 640 STARTING MODEL YEAR 2007 E Z GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold 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 DIVISION OF TEXTRON INC P O BOX 388 AUGUSTA GEORGIA USA 30906 3852 Service Parts Manual Page i NOTES To obtain a copy of the limited warranty applicable to the vehicle call or write a local Distributor authorized Branch or the Warranty Department with vehicle serial number and manufacturer code The use of non Original Equipment Manufacturer OEM parts may void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in o
2. 00556 G3 LOCK WASHER 00533 G1 NUT 1 2 13 22288 G1 TAILLIGHT ASSEMBLY 00513 G4 SCREW 8 18 X 1 1 2 LG 00180 G6 SCREW 10 24 X 3 4 LG 00739 G1 WELL NUT 10 24 21759 G1 LIGHT BULB 32985 G01 WIRE HARNESS LIGHTS 20058 1 WIRE TIE ADHESIVE BASE 17618 G1 WIRE TIE 33021 G01 WIRE HARNESS LIFT OUT BATTERIES 17902 G1 TAB ADAPTOR 33208 G02 16 GA WIRE WHITE 6 33208 G01 16 GA WIRE BLACK 6 33212 G01 STROBE LIGHT KIT INCLUDES ITEMS 52 65 25617 G01 STROBE LIGHT ASSEMBLY 00156 G4 SCREW 10 32 X 1 2 LG 00594 G5 LOCK WASHER 10 00672 G4 NUT 10 32 STAINLESS STEEL 33201 G01 STROBE MOUNTING BRACKET 00753 G7 SCREW 1 4 20 X 2 1 2 LG STAINLESS STEEL 00660 G7 WASHER 1 4 STAINLESS STEEL 00654 G2 LOCK NUT 1 4 20 STAINLESS STEEL 17902 G1 TAB ADAPTER Page F 5 Service Parts Manual ELECTRICAL SYSTEM When ordering parts please specify the model and serial number of 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 23 4 5 DESCRIPTION 25615 01 25616 01 22594 G1 17618 G1 33203 G01 33587 G01 33636 G02 17902 G1 25978 G62 28178 G01 609067 33586 G01 33633 G01 28178 G01 32860 G1 25978 G91 35111G01 00661 G8 14390 G4 20948 G1 14601 G8 32660 1 32660 2 32662 1 32590 1 32561 1 16 WIRE RED 41 16 GA WIRE GRAY 83 FUSE
3. Turn to the page number indicated and locate the part description in the parts list Read the full accompanying description for specific information regarding the part that was not shown in the index From the parts list obtain the item number assigned to it and confirm that the part selected is correct by verifying it with the pictorial representation on the illustrated page 2 IF YOU KNOW THE PART NUMBER Turn to the page number indicated and locate the part number in the parts list Refer to the accompanying description for specific information regarding the part From the parts list obtain the item number assigned to it and confirm that the part selected is correct by verifying 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 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 repair of the vehicle a Technician s Repair and Service Manual is available from the Service Parts Department Page vi Service Parts Manual ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PART
4. 1 2 20 X 1 3 16 LG 50908 G1 BEARING AND RACE 19471 G1 GREASE SEAL 11655 G2 AXLE SPACER 00667 G8 JAM NUT 3 4 16 STAINLESS STEEL 00571 G8 WASHER 3 4 oo N BB ND A O o N A N 30878 1 SPLASH SHIELD 14269 G1 RIVET 3 16 X 1 2 LG N N c N 71948 G01 STEERING WHEEL 14390 G2 LOCK NUT 5 8 18 75910 G01 CLIP BOARD 33175 G CONTROL PANEL COVER 34507 G01 HOLE PLUG 00102 G6 SCREW 8 18 X 3 4 LG 00559 G4 WASHER 8 m N N N N N OD Page H 3 Service Parts Manual FRONT FORK AND STEERING When ordering parts please specify the model and serial number of 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 12 345 DESCRIPTION 31 31922 G1 UPPER FIXED HUB ASSEMBLY INCLUDES ITEMS 34 40 30866 G1 UPPER HUB FIXED 10389 G3 GREASE FITTING STRAIGHT 30154 G1 BUSHING 00731 G1 SPRING WASHER 30156 G1 THRUST WASHER 3 4 71897 G01 SPROCKET AND SHAFT UPPER 00271 G8 BOLT 5 16 18 X 2 LG 00565 G8 LOCK WASHER 5 16 00532 G3 NUT 5 16 18 31921 G1 HUB ASSEMBLY LOWER SLIDING INCLUDES ITEMS 47 49 30869 G1 HUB LOWER SLIDING 18456 G1 GREASE FITTING 90 30154 G1 BUSHING 00571 G8 WASHER 3 4 30156 G1 THRUST WASHER 3 4 10387 G9 COTTER PIN 1 8 X 1 1 4 LG 30861 G1 SPROCKET AND SHAFT
5. 33738 G02 BODY PANEL RH SIDE IF EQUIPPED WITH PORTABLE CHARGER 33739 G01 BODY PANEL LH SIDE 00414 G6 BOLT 1 4 20 X LG 16705 G4 SCREW 1 4 20 X 1 2 LG STAINLESS STEEL LIAC LEE va A OO 33750 G01 FRONT TRAY 11027 G2 LOCK NUT 1 4 20 Lk Sq oS oz 32574 G1 CHARGER MOUNT DOOR ASSEMBLY D 16705 2 SCREW 1 4 20 X 5 8 LG STAINLESS STEEL 14390 G4 LOCK NUT 1 4 20 22524 G1 FOAM TAPE CUT TO 1 LG 22280 G1 TRIM BLACK CUT TO 3 1 2 LG N N N N gt a N 33291 G01 LADDER KIT 4 STEP 33291 G02 LADDER KIT 6 STEP INCLUDES ITEMS 28 32 32556 G1 COUNTER WEIGHT 00659 G2 BOLT 1 2 13 X 2 1 4 LG STAINLESS STEEL 00679 G3 WASHER 1 2 STAINLESS STEEL N 3 Service Parts Manual BODY When ordering parts please specify the model and serial number of 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 12 3 4 5 DESCRIPTION 31 00891 G4 30931 G1 30917 G2 00126 G6 00288 G8 00566 G2 00532 G7 71037 G02 23093 G1 10570 G9 35432 G01 31127 G1 27493 G01 34359 G01 25775 G01 31158 G2 32980 G04 30817 G1 00427 G4 00560 G1 11098 G5 LOCK NUT 1 2 13 BACKREST FRAME CUSHION BACKREST SCREW 12 11 X 3 4 LG BOLT 7 16 14 X 1
6. LOWER 00271 G8 BOLT 5 16 18 X 2 LG 00743 G1 SCREW 5 16 18 X 3 1 2 LG 00565 G8 LOCK WASHER 5 16 00532 G3 NUT 5 16 18 00565G8 LOCK WASHER 5 16 Service Parts Manual FRONT FORK AND STEERING When ordering parts please specify the model and serial number of 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 12 345 DESCRIPTION 61 30870 G1 CHAIN ROLLER 30871 G1 MASTER LINK 30420 G1 VERTICAL LINK ASSEMBLY INCLUDES ITEMS 66 78 30873 G1 VERTICAL LINK 27205 G02 TIE ROD END RH THREAD INCLUDES ITEMS 68 71 50641 G1 RUBBER BOOT 50209 G2 CASTELLATED NUT 7 16 20 10387 G1 COTTER PIN 1 8 X 1 1 2 LG 10389 G3 GREASE FITTING STRAIGHT 27205 G01 TIE ROD END LH THREAD INCLUDES ITEMS 73 76 50641 G1 RUBBER BOOT 50209 G2 CASTELLATED NUT 7 16 20 10387 G1 COTTER PIN 1 8 X 1 1 2 LG 10389 G3 GREASE FITTING STRAIGHT 18434 G3 JAM NUT 9 16 18 LEFT HAND THREADS 18434 G4 JAM NUT 9 16 18 RIGHT HAND THREADS 30874 G1 BELLCRANK 30772 G2 PIVOT SHAFT 8 70581 G01 BUSHING 10387 G9 COTTER PIN 1 8 X 1 1 4 LG 30419 G1 HORIZONTAL LINKAGE ASSEMBLY INCLUDES ITEMS 72 77 89 95 30872 G1 HORIZONTAL LINK 27205 G02 TIE ROD END RH THREAD INCLUDES ITEMS 91 94 Page H 5 Service Parts Manual FRONT FORK AND STEERING When ordering parts please specify the model and se
7. product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 23 4 5 DESCRIPTION 00441 G8 11098 G6 10386 G3 10387 G2 30177 G1 10386 G3 10387 G2 Page A 3 BOLT 5 16 18 X 4 LG LOCK NUT 5 16 18 STAINLESS STEEL CLEVIS PIN 5 16 X 13 16 LG COTTER PIN 3 32 X 1 LG EXTENSION SPRING CLEVIS PIN 5 16 X 13 16 LG COTTER PIN 3 32 X 1 LG Service Parts Manual ACCELERATOR Service Parts Manual Page A 4 BATTERY CHARGER PORTABLE Ref Bel 16 Page B 1 Service Parts Manual BATTERY CHARGER PORTABLE When ordering parts please specify the model and serial number of 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 12 345 DESCRIPTION 1 602712 BATTERY CHARGER LESTER 24 VOLT PORTABLE For service or replacement parts contact Lester Electrical 625 West A Street Lincoln NE 68522 Phone USA 001 402 477 8988 FAX 001 402 474 1769 Always provide the following information when requesting information or ordering replacement parts Model Number Serial Number stamped into housing Service Parts Manual Page B 2 BATTERY CHARGER BOARD Ref Bcl 16 Page B 3 Service Parts Manual BATTERY CHARGER BOA
8. CT US North America Technical Assistance amp Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET E Z GO 1 888 438 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 50 9001 150 14001 ey This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
9. HOLDER WIRE TIE 16 GA WIRE GRAY 48 STATE OF CHARGE METER ASSEMBLY INCLUDES ITEMS 68 71 STATE OF CHARGE METER 24 VOLT TAB ADAPTER 18 GA WIRE RED 12 MOUNTING PLATE SOC FUSE HARNESS HOUR METER ASSEMBLY INCLUDES ITEMS 74 75 HOUR METER 18 60 VDC MOUNTING PLATE HORN ASSEMBLY 18 GA WIRE ORANGE 12 18 GA WIRE YELLOW RED 12 BOLT 1 4 20 X 1 LG STAINLESS STEEL LOCK NUT 1 4 20 HORN SWITCH RIVET 3 16 X 7 16 LG ALUMINUM LIFT OUT BATTERY ASSEMBLY RIGHT LIFT OUT BATTERY ASSEMBLY LEFT CHARGER CONNECTOR LIFT OUT BATTERY RH CHARGER CONNECTOR LIFT OUT BATTERY LH BATTERY CONNECTOR BRACKET Service Parts Manual ELECTRICAL SYSTEM When ordering parts please specify the model and serial number of 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 12 345 DESCRIPTION QTY 91 00438 G6 BOLT 5 16 18 X 3 4 LG 92 00565 G8 LOCK WASHER 5 16 93 00532 G3 NUT 5 16 18 94 00415 G4 BOLT 1 4 20 X 1 1 2 LG 95 00554 G7 WASHER 1 4 96 14390 G4 NUT 1 4 20 Page F 7 Service Parts Manual ELECTRICAL SYSTEM Service Parts Manual Page F 8 ELECTRONIC SPEED CONTROL Item 1 Includes Items 2 31 Service Parts Manual Page G 1 ELECTRONIC SPEED CONTROL When ordering parts please specify the model and seri
10. LG LOCK WASHER 7 16 NUT 7 16 14 NAMEPLATE E Z GO INCLUDES ITEM 43 DOUBLE SIDED TAPE CUT TO LENGTH SERIAL NUMBER PLATE RIVET 1 8 X 11 32 LG ALUMINUM LABEL INDUSTRIAL LABEL DIRECTION SELECTOR LABEL CHARGER OPERATION INSTRUCTIONS LABEL SAFETY OPERATION INSTRUCTIONS LABEL CHARGER WARNING SIDE RAILS PINTLE HITCH KIT INCLUDES ITEMS 58 61 PINTLE HITCH BOLT 3 8 16 X 1 1 2 LG WASHER 3 8 LOCK NUT 3 8 16 Service Parts Manual BODY When ordering parts please specify the model and serial number of 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 12 3 4 5 DESCRIPTION 61 33732 G04 33731 G01 00427 G6 00560 G1 11098 G5 Page C 5 E HITCH KIT INCLUDES ITEMS 65 68 E HITCH BOLT 3 8 16 X 1 3 4 LG WASHER 3 8 LOCK NUT 3 8 16 Service Parts Manual Service Parts Manual Page C 6 BRAKES 1 Includes Items 4 6 26 2 Includes Items 5 26 23 Includes Items 24 25 Ref Brk 16 Page D 1 Service Parts Manual BRAKES When ordering parts please specify the model and serial number of 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 2345 DESCRIPTION 20938 61 BRAKE ASSEMBLY L H INCLUDES I
11. RD When ordering parts please specify the model and serial number of 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 12 345 DESCRIPTION 1 602707 BATTERY CHARGER ASSEMBLY LESTER 24 VOLT For service or replacement parts contact Lester Electrical 625 West A Street Lincoln NE 68522 Phone USA 001 402 477 8988 FAX 001 402 474 1769 Always provide the following information when requesting information or ordering replacement parts Model Number Serial Number stamped into housing Service Parts Manual Page 4 See FRONT FORK and STEERING Section Item 27 Includes Items 28 32 Ref Bod 16 1 Page C 1 Service Parts Manual BODY I o E lt n D S E HITCH Ref Bod 16 2 Page C 2 Service Parts Manual BODY When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION 35700 G01 LOAD DECK 31051 G1 GALVANIZED STEEL LOAD DECK 31051 G2 STAINLESS STEEL LOAD DECK 00753 G3 SCREW 1 4 20 X 1 1 2 LG STAINLESS STEEL 00559 G8 WASHER 5 16 33738 G01 BODY PANEL RH SIDE IF EQUIPPED WITH ONBOARD CHARGER
12. RIPTION 17421 G1 KEY SWITCH INCLUDES ITEMS 2 4 P PAL NUT 17137 G1 FACE NUT 3 4 20 17063 G1 IGNITION KEY 30533 G1 ON OFF PLATE 31114 G2 CABLE RETAINER 00852 G1 RIVET 3 16 X 7 16 LG 17618 G1 WIRE TIE 20058 G1 WIRE TIE ADHESIVE BASE o N ODO OC A WO PD 11845 G3 INSULATED CABLE CLAMP 3 4 00852 1 RIVET 3 16 X 7 16 LG 00993 G01 LOCK WASHER 5 16 SILICON BRONZE 00565 G8 WASHER 5 16 SILICON BRONZE 31387 G1 BATTERY HOLD DOWN 30429 G2 BATTERY HOLD DOWN ROD 5 16 18 00642 G8 WASHER 5 16 00532 G3 NUT 5 16 18 00702 G2 NUT 5 16 18 32626 G1 CONTROL HARNESS 18392 G1 FUSE 15 AMP 32615 G1 POWER HARNESS ON BOARD CHARGER 31178 G1 6 GA WIRE BLACK 18 1 4 31178 G2 6 GA WIRE BLACK 8 3 4 32642 G1 POWER HARNESS PORTABLE CHARGER m m N N N mw c c SI GI RK N SI ODO m 32684 G1 10 GA WIRE BLACK 18 1 2 eo Service Parts Manual Page F 4 ELECTRICAL SYSTEM When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION 32984 G02 LIGHT KIT INCLUDES ITEMS 33 45 32984 G03 LIGHT KIT W LIFT OUT BATTERIES INCLUDES ITEMS 33 50 18431 G1 LIGHT SWITCH ASSEMBLY 30394 G1 HEAD LIGHT ASSEMBLY
13. S BREAKDOWN Service Parts Manual Page vii ACCELERATOR Front Of Vehicle To Electronic Speed Control To Brake Lever Ref Acl 16 Page A 1 Service Parts Manual ACCELERATOR When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION 32277 61 PEDAL 21531 92 ABRASIVE STRIP 70581 G01 BUSHING 00771 G2 NYLON WASHER 1 2 30772 G4 PIVOT SHAFT 1 2 DIA X 17 LG 10387 G2 COTTER PIN 3 32 X 1 LG 32279 G1 CONTROL ARM 70581 G01 BUSHING 30772 G3 PIVOT SHAFT 1 2 DIA X 16 LG 10387 G9 COTTER PIN 1 8 X 1 1 4 LG oo _ lx c N o 30783 G1 CONTROL LINK 14443 G3 CLEVIS PIN 5 16 X 1 LG 10387 G2 COTTER PIN 3 32 X 1 LG Sk E ok 30182 1 CLEVIS 00272 G4 BOLT 5 16 18 X 2 1 2 LG 11098 G6 LOCK NUT 5 16 18 STAINLESS STEEL 10386 G3 CLEVIS PIN 5 16 X 13 16 LG 10387 G2 COTTER PIN 3 32 X 1 LG 14443 G3 CLEVIS PIN 5 16 X 7 8 LG 30779 G1 BRAKE EQUALIZER 35428 G01 EXTENSION SPRING 31855 G1 SPRING LINK N N N N N A N 30182 1 CLEVIS Service Parts Manual Page A 2 ACCELERATOR When ordering parts please specify the model and serial number of the
14. T 1 4 20 X 1 LG STAINLESS STEEL 11027 G2 LOCK NUT 1 4 20 32618 G1 LINKAGE SHIELD 32619 G1 SPEED CONTROL COVER 00709 G1 U NUT 1 4 20 00565 G5 LOCK WASHER 10 00526 G4 NUT 10 32 00565 G8 LOCK WASHER 5 16 00532 G3 JAM NUT 5 16 24 23726 G1 WASHER 1 4 STAINLESS STEEL 11027 G2 LOCK NUT 1 4 20 25949 G01 VARISTOR MOV 25972 G83 6 GA WIRE BLACK 9 25977 G85 16 GA WIRE BLUE 23 Page G 3 Service Parts Manual ELECTRONIC SPEED CONTROL Service Parts Manual Page G 4 FRONT FORK AND STEERING 9 Includes Item 10 Ref Fss 16 1 Page H 1 Service Parts Manual FRONT FORK AND STEERING Ref Fss 16 2 Service Parts Manual 33 Includes Items 34 46 Includes Items 47 65 Includes Items 66 67 Includes Items 68 72 Includes Items 73 88 Includes Items 72 90 Includes Items 91 Page H 2 FRONT FORK AND STEERING When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION S 30905 G1 FRONT FORK 30146 G1 DUST CAP 10387 G5 COTTER PIN 3 32 X 1 1 4 LG 00536 G8 CASTELLATED NUT 3 4 16 00571 G8 WASHER 3 4 50892 G1 BEARNG AND RACE ASSEMBLY COMPLETE 12092 G1 GREASE SEAL 10223 G7 FRONT AXLE 19888 G1 HUB INCLUDES ITEM 10 19862 G1 LUG BOLT
15. TEMS 4 6 26 20938 62 BRAKE ASSEMBLY INCLUDES ITEMS 5 26 22519 G1 BACKING PEATE EH 2 nt ana nina uen 22518 1 BACKING PLATES RE ait tit etd 22516 G1 ADJUSTER ASSEMBLY INCLUDES ITEMS 7 9 22520 G1 ADJUSTER BODY INCLUDES ITEMS 8 9 17287 G1 ADJUSTER BOLT 17289 G1 PISTON ANCHOR 00664 G7 LOCK WASHER 1 4 STAINLESS STEEL 13632 G1 NUT 6MM 17294 G1 ADJUSTING BOLT CAP o oo A 22512 1 ACTUATING LEVER 22513 G1 LEVER PIN 22514 G1 U CLIP 22515 G1 SLIDING BLOCK 22511 1 DUST COVER 17292 G1 TENSION PIN 17291 G1 SPRING CLAMP 23398 G1 BRAKE SHOE SET INCLUDES ITEMS 24 25 23355 G1 BRAKE SHOE LEADING 23355 G2 BRAKE SHOE TRAILING 17290 G1 BRAKE SPRING 17083 G1 BOLT 5 16 24 X 3 4 LG 15126 G1 LOCK NUT 5 16 24 Service Parts Manual Page D 2 BRAKES When ordering parts please specify the model and serial number of 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 12345 DESCRIPTION QTY 31 19186 G2 BRAKE DRUM AND HUB ASSEMBLY 32 33 15485 G1 WASHER 13 16 34 15487 G1 WASHER 1 3 8 O D X 21 32 35 612928 CASTELLATED NUT 5 8 18 36 10387 G1 COTTER PIN 1 8 X 1 1 2 LG Page D 3 Service Parts Manual BRAKES Service Parts Manual Page D 4 DIRECTION SELECTOR Item 1 Includes Items 2 25 Item 2 Includes Ite
16. al number of 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 2 3 4 5 DESCRIPTION m 32568 G1 SPEED CONTROLLER ASSEMBLY INCLUDES ITEMS 2 31 32558 G1 SPEED CONTROL BRACKET 32636 G1 POTENTIOMETER SUPPORT 24002 G1 FOUR PIN CONNECTOR FEMALE 32630 G1 16 GA WIRE WHITE RED 22 3 4 20468 G3 HEAVY DUTY SOLENOID 24 VOLT 20972 G1 SPEED CONTROLLER 00414 G6 BOLT 1 4 20 X 3 4 LG ON DO N 11027 G2 LOCK NUT 1 4 20 23726 G1 SPACER 1 4 _ n n n 32632 G1 16 GA WIRE BLUE 18 3 4 32684 G1 10 GA WIRE BLACK 18 1 2 25972 G83 6 GA WIRE BLACK 6 3 4 32627 G1 16 GA WIRE BLACK 18 32631 G1 16 GA WIRE RED WHITE 8 1 2 32620 G1 ANGLE SHIELD RH 32620 G2 ANGLE SHIELD LH N N N N N N fF 2 O a A N O N Q 00414 G7 BOLT 1 4 20 X 7 8 LG 00414 G4 BOLT 1 4 20 X 1 2 LG 00438 G6 BOLT 5 16 18 X 5 8 LG 11027 G1 LOCK NUT 5 16 18 21764 G1 RESISTOR N Service Parts Manual ELECTRONIC SPEED CONTROL When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION 30353 G1 DIODE 3 AMP 00661 G8 BOL
17. ms 3 6 Ref Dsl 16 Page E 1 Service Parts Manual DIRECTION SELECTOR When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION m 32042 G2 14651 G1 24940 G1 00565 G7 LOCK WASHER 1 4 STAINLESS STEEL 00414 G6 NUT 1 4 20 8 BOARD AND CONTACT 12835 G1 19470 G1 00560 G1 14390 G1 20757 G1 o R N _ n n N 00645 G6 SCREW 6 32 X 1 3 4 LG 12806 G1 SPACER 00565 G3 LOCK WASHER 6 00525 G5 NUT 6 32 10606 G2 MICRO SWITCH HEAVY DUTY 13514 G1 SCREW 6 32 X 7 32 LG 14628 G1 FASTON TAB 5 16 X 5 16 00567 G3 LOCK WASHER 6 32043 G1 BUZZER BRACKET 17940 G1 REVERSE WARNING BUZZER 00138 G4 SCREW 6 32 X 1 2 LG 00565 G3 LOCK WASHER 6 00525 G5 NUT 6 32 N m N N N N fF O A N O Ff 19886 1 DIRECTION SELECTOR HANDLE 00740 G4 SCREW 10 32 X 1 2 LG STAINLESS STEEL 30318 G2 SPACER 00753 G7 SCREW 1 4 20 X 2 1 2 LG STAINLESS STEEL m Service Parts Manual DIRECTION SELECTOR When ordering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part G Indicates consult Customer Service Department for additi
18. onal information ITEM PART NO 12 345 DESCRIPTION QTY 31 01110 G01 WASHER 1 4 STAINLESS STEEL 32 00550 G1 LOCK NUT 1 4 20 33 34 35 00565 G8 LOCK WASHER 5 16 36 00544 G3 JAM NUT 5 16 18 Page E 3 Service Parts Manual DIRECTION SELECTOR Service Parts Manual Page E 4 ELECTRICAL SYSTEM ON BOARD BATTERIES MOTOR TERMINALS Solenoid Part of dn Frame Battery Charger sy gt 4 KEY SWITCH Control Harness LIFT OUT BATTERIES Battery Terminal BATTERY TERMINAL Ref Ele 16 1 Page F 1 Service Parts Manual ELECTRICAL SYSTEM 45 31 Incudes Items 33 32 Includes Items 33 51 Includes Items 52 50 65 LIGHT SWITCH HEADLIGHTS STROBE LIGHT Hitch Panel TAILLIGHT Page F 2 Service Parts Manual ELECTRICAL SYSTEM Control Panel Part of Frame HORN BUTTON Item 67 Includes Items 68 71 Item 73 Includes Items 74 75 HOUR METER AND STATE OF CHARGE METER Ref Ele 16 3 Page F 3 Service Parts Manual ELECTRICAL SYSTEM When ordering parts please specify the model and serial number of 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 23 4 5 DESC
19. onent that is not available as an individual part G Indicates consult Customer Service Department for additional information ITEM PART NO 2 3 4 5 DESCRIPTION 36015 G01 REAR AXLE ASSEMBLY INCLUDES ITEMS 2 8 28584 G01 DIFFERENTIAL COVER ASSEMBLY INCLUDES ITEMS 3 5 28583 G01 DIFFERENTIAL COVER 28582 G01 28581 G01 15558 G1 20377 G5 AXLE SHAFT LEFT SIDE 20377 G6 AXLE SHAFT RIGHT SIDE AON BR N 00559 G7 WASHER 1 4 STAINLESS STEEL 00565 G7 LOCK WASHER 1 4 STAINLESS STEEL a A 00797 G2 BOLT 1 4 20 X 1 1 4 LG N 00427 G2 BOLT 3 8 16 X 1 1 4 LG 00643 G1 WASHER 3 8 ek 11098 G5 NUT 3 8 16 Service Parts Manual Page K 2 WHEELS AND TIRES Page L 1 Service Parts Manual WHEELS AND TIRES When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION E 600424 TIRE AND WHEEL ASSEMBLY INCLUDES ITEMS 2 4 TIRE 4 80 8 33678 WHEEL RIM 4 LUG 886735 VALVE STEM 14723 G1 LUG NUT 1 2 20 600450 TIRE AND WHEEL ASSEMBLY 4 8 8 FOAM FILLED Service Parts Manual Page L 2 A Textron Company E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTA
20. rder 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 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 Page ii Service Parts Manual TABLE OF CONTENTS SECTION Page No HOW TO USE THE SERVICE PARTS MANUAL tacitus s docta o c paces dace e vii ILLUSTRATED PARTS BREAKDOWN 3 i4 eee ta ones PD eua td ix ACCELERATOR anta Mod orsa di Aida idee A 1 BATTERY CHARGER PORTABEE avus a hoo ER der ane DEAD doa a aces d ed ooi B 1 BATTERY CHARGER ON BOAPBD Duet qe Law E editae B 3 BODY dfe ud darle adhi Gea oud duse deabus desu at esatta d educ defert asi C 1 BRAKES koes Rinus d Du CEU eee de ceu A Da dfe onan ant D 1 DIBECTIONL SEEEG TOR uode pascua dou taque tone DTA duae re E 1 ELECTRICAL SYSTEM io ami te Maree dus epe Sod aite cadet F 1 ELECTRONIC SPEED CONTROL ETC aes ed UM Eae SM E dana G 1 FRONT FORK AND STEERING 2d A EO ad H 1 MOTOR Uds da Vea nae et Si en J 1 HEAR Ur Ud ces ee K 1 WHEEESOAND TIRES 2 02 wood o gu Descente oven ure camas og Bele Ene ee et ci
21. rial number of 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 2 3 4 5 DESCRIPTION m 50641 G1 RUBBER BOOT 10389 G3 GREASE FITTING STRAIGHT 50209 G2 CASTELLATED NUT 7 16 20 10387 G1 COTTER PIN 1 8 X 1 1 2 LG 18434 G4 JAM NUT 9 16 18 RIGHT HAND THREAD Service Parts Manual Page H 6 1 Includes Items 2 11 Ref Mtr 16 Page J 1 Service Parts Manual When ordering parts please specify the model and serial number of 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 2 3 4 5 DESCRIPTION E 73445 G01 MOTOR FLEET SPEED NON VENTED INCLUDES ITEMS 2 11 73120 G01 ARMATURE 73120 G29 FRAME AND FIELD COIL INCLUDES HARDWARE 73120 G03 BRUSH SPRING 73120 G15 BRUSH PLATE AND BOX 73120 G25 BRUSH REPLACEMENT KIT INCLUDES HARDWARE 73120 G06 SNAP RING 73120 G07 BEARING 73120 G08 COVER COMMUTATOR END 73120 G09 COVER PLATE AND SCREW 73120 G16 ON oa BR ES Je Vs Ji 25 N 24261 G1 Service Parts Manual Page J 2 REAR AXLE 1 Includes Items 2 8 Service Parts Manual Page K 1 REAR AXLE When ordering parts please specify the model and serial number of the product Indicates a comp
22. um d L 1 Service Parts Manual Page iii TABLE OF CONTENTS Page iv Service Parts Manual HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections GENERAL INFORMATION TABLE OF CONTENTS HOW TO USE THE SERVICE PARTS MANUAL ILLUSTRATED PARTS BREAKDOWN Contains illustrations and parts lists for all systems of the vehicle USE OF THE MANUAL To use this manual consult the TABLE OF CONTENTS page iii 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 Locate the serial number plate see BODY located in the Illustrated Parts Breakdown section of this manual for its location and note the complete number shown on the plate It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components Service Parts Manual Page v HOW USE THE SERVICE PARTS MANUAL Left hand illustration page continued on right hand page Parts list continued on if required rear of page if required 1 WHEN THE PART NUMBER IS NOT KNOWN Determine the function and application of the part required Turn to the TABLE OF CONTENTS and select the most appropriate component description

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