Page D-6
Repair and Service Manual
B
BODY
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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
Ratchet ........................................................................ 1
Socket, 7/16" ............................................................... 2
Socket, 1/2" ................................................................. 2
Socket, 9/16" ............................................................... 2
Torque Wrench ............................................................ 1
Refer to TORQUE SPECIFICATIONS in Section A for standard
torque values unless otherwise noted in manual text.
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.
Disconnect the four-pin connector from the Speed con-
trol 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 .............................................. 1
Ratchet, 3/8" Drive ...................................................... 1
Wrench, 3/8" ................................................................ 1
Wrench, 1/2" ................................................................ 1
Tool List
Qty.
Wrench, 9/16" ..............................................................1
Rivet Gun .....................................................................1
Phillips Screwdriver......................................................1
Pry Bar .........................................................................1
Torque Wrench.............................................................1
Refer to TORQUE SPECIFICATIONS in Section A for standard
torque values unless otherwise noted in manual text.
To prevent possible injury or death from bat-
tery explosion. The battery should always be
removed before any servicing that will gener-
ate sparks. It is important to use a sharp drill
bit when removing the rivets on the side of the
vehicle. 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. Exces-
sive pressure could result in the drill bit being
forced through the body panel and penetrating
the battery. As extra protection, it is recom-
mended 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 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
NOTICE
NOTICE
NOTICE
NOTICE
