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Tracker Off-Road EViS Service & Parts Manual Download Page 20

       

10002662 Service Parts Manual

Page  C-1

BODY

B

A

B

21

Glove Box Assembly (Passenger Side)
includes items 22 - 25

22

25

26

28

27

24

23

A

1

5

13

16

6

14

17

2

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7

10

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Front of Vehicle

8

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4

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Summary of Contents for EViS

Page 1: ...SERVICE PARTS MANUAL TRACKER EViS 10002662 B Revised Aug 2019 Issued Aug 2019 ...

Page 2: ......

Page 3: ...ight to incorporate engineering and design changes to products in this manual without obligation to in clude these changes on units sold previously The information contained in this manual may be revised periodically by the manufacturer and therefore is subject to change without notice The manufacturer DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTA...

Page 4: ...tery charger may remain connected to the vehicle to maintain a full charge on the batteries provided the charger is plugged into an active electrical source If power to the electrical source is disconnected or interrupted the battery charger continues to check the charge on the battery pack This pulls power from the battery pack and eventually drains the batteries if power is not restored in a tim...

Page 5: ...THE 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 ROPS J 1 FRONT AXLE K 1 REAR AXLE L 1 REAR SUSPENSION M 1 SEATING N 1 WEATHER PROTECTION P 1 WHEELS AND TIRES R 1 DECALS AND LABELS S 1 ...

Page 6: ...NOTES Page iv 10002662 Service Parts Manual ...

Page 7: ...ts for all systems of your vehicle USE OF THE 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 situ...

Page 8: ... is the lowest assembly sold by Service Parts and the asterisk indicates 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 Repair and...

Page 9: ...TS The last two digits of the part number for the body part will denote the color code locate the part number for the cowl rear body seat pod side panel or seat wrap then locate your color in the list below replace the last or XX with the two digit color code CODE DESCRIPTION 11 BLACK 98 TRUE TIMBER STRATA ...

Page 10: ...10002662 Service Parts Manual Page A 1 ACCELERATOR 2 2 3 3 1 12 7 8 3 12 4 Front of Vehicle 11 5 6 4 ...

Page 11: ... ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page A 2 ACCELERATOR 10002662 Service Parts Manual 1 656066 Accelerator Pedal Cover Bracket 1 2 00414G6 Hex Head Bolt 1 4 20 x 7 8 Lg Grade 5 2 3 00559G7 Flat Washer 1 4 4 4 14390G4 Lock Nut 1 4 20 4 5 302288 Hex Head Bolt 1 4 20 x 1 Lg Grade 5 2 6 01110G01 Flat Washer 1 4 2 7 0509 173 Accelerator Pedal 1 8 645956 Flanged Hex Nut M8 1 25 2 9 10 11 655658 Acc...

Page 12: ...Page A 3 Notes ACCELERATOR 10002662 Service Parts Manual ...

Page 13: ...Page A 4 Notes ACCELERATOR 10002662 Service Parts Manual ...

Page 14: ...10002662 Service Parts Manual Page B 1 BATTERY SYSTEM 14 15 4 6 6 6 6 6 6 1 4 8 2 3 11 13 16 7 7 2 8 4 Front of Vehicle 5 10 12 ...

Page 15: ...TEM 10002662 Service Parts Manual 1 629435 Battery Hold Down Bracket 4 12V 1 2 631988 Hold Down Bracket 1 12V 2 3 647050 Battery 12V 6 4 70386G01 Tie Down Bolt 5 16 18 x 11 3 4 Lg 6 5 01101G01 Tie Down Bolt 2 6 11027G1 Flanged Lock Nut 5 16 18 8 7 628624 Battery Wire 12 5 Lg 3 8 628628 Battery Wire 16 Lg 2 9 10 628630 Battery Wire 22 Lg 1 11 628631 Battery Wire 32 Lg 1 12 676122 Trojan Hand Pump K...

Page 16: ...10002662 Service Parts Manual Page B 3 BATTERY SYSTEM 1 2 ...

Page 17: ...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 4 BATTERY SYSTEM 10002662 Service Parts Manual 1 645743 Battery Charger D Plug 72V 1500W 1 2 73051G02 Charger Receptacle and Plug Powerwise 1 ...

Page 18: ...Page B 5 Notes BATTERY SYSTEM 10002662 Service Parts Manual ...

Page 19: ...Page B 6 Notes BATTERY SYSTEM 10002662 Service Parts Manual ...

Page 20: ...10002662 Service Parts Manual Page C 1 BODY B A B 21 Glove Box Assembly Passenger Side includes items 22 25 22 25 26 28 27 24 23 A 1 5 13 16 6 14 17 2 15 7 10 9 9 11 2 Front of Vehicle 8 3 4 18 29 ...

Page 21: ... 8 14601G11 Rivet 3 16 x 9 16 3 9 613373 Pan Head Tapping Screw M4 8 1 6 x 22mm Lg 4 10 71055G01 Black Aluminum Rivet 3 16 x 38 Grip 2 11 648561 Compartment Tray Panel 1 12 13 655917G01 Upper Rocker Panel Driver Side 1 14 655917G02 Upper Rocker Panel Passenger Side 1 15 18436G1 Plastic Drive Rivet 1 4 x 3 4 3 16 664361G01 Fender Mud Flap Driver Side 1 17 664361G02 Fender Mud Flap Passenger Side 1 ...

Page 22: ...10002662 Service Parts Manual Page C 3 BODY 1 8 9 10 13 16 16 14 12 10 9 4 2 3 5 5 5 6 7 4 17 15 Front of Vehicle Front of Vehicle ...

Page 23: ...rew M6 1 x 23 4mm Lg 2 3 602409 Barrel Clip M6 1 2 4 71597G01 Self Threading Nut 5mm x 10mm x 15mm 3 5 01038G01 Flanged Hex Head Thread Forming Screw 1 4 20 x 7 Lg 4 6 666244 Instrument Panel Support Bracket 1 7 01038G01 Flanged Hex Head Thread Forming Screw 1 4 20 x 7 Lg 2 8 664620 Brushguard 1 9 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 6 10 600525 Flanged Lock Nut M10 1 5 6 11 12...

Page 24: ...10002662 Service Parts Manual Page C 5 BODY 4 7 5 Front of Vehicle 8 8 10 5 5 1 2 3 3 11 ...

Page 25: ... information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 6 BODY 10002662 Service Parts Manual 1 652443G103 Battery Tray Bracket Driver Side 1 2 652443G203 Battery Tray Bracket Passenger Side 1 3 00715G2 Hex Washer Head Bolt 5 16 18 x 80 Lg 4 4 640553 Upper Floor Panel 1 5 14601G11 Large Dome Head Rivet SS 3 16 x 9 16 7 6 7 70451G06 Lower Floor Panel 1 8 14601G11 Large Dome Head Rivet SS 3 16 x 9...

Page 26: ...10002662 Service Parts Manual Page C 7 BODY 22 23 24 23 21 Battery Rack Weldment 6 17 11 1 21 3 12 16 16 3 15 15 7 7 18 6 10 3 3 3 2 Front of Vehicle 17 ...

Page 27: ... M6 1 x 30mm Lg 6 3 10570G10 Large Dome Head Rivet SS 5 32 x 25 Grip 10 4 5 6 71609G01 Seat Hinge Plate 2 7 10570G11 Large Dome Head Rivet SS 3 16 x 5 Grip 4 8 9 10 652716G04 Side Panel Driver Side 1 11 652716G05 Side Panel Passenger Side 1 12 10570G12 Dome Head Aluminum Rivet 1 4 x 34 Grip 4 13 14 15 662216 Side Panel Bracket 1 16 608290 Self Tapping Screw 10 16 x 3 4 Lg 2 17 667879 Side Panel Cl...

Page 28: ...e C 9 BODY 25 26 28 29 30 31 27 27 Frame shown for reference only 19 20 Frame shown for reference only Front of Vehicle Frame shown for reference only 1 14 12 4 6 7 6 13 2 8 9 10 11 15 16 17 18 21 22 23 24 Front of Vehicle 16 17 18 17 ...

Page 29: ...Lock Washer 3 8 4 11 641848 Thread Insert Hex Nut 3 8 16 4 12 16816G2 Ratchet Rivet 25 x 887 4 13 303459 Hex Head Bolt 1 4 20 x 1 5 Lg Grade 5 2 14 15058G6 Domed Rivet 3 16 x 75 Grip 2 15 642437 Seat Support 1 16 00463G11 Hex Head Bolt 7 16 14 x 1 5 Lg Grade 5 6 17 306982 Flat Washer 7 16 12 18 00734G1 Lock Nut 7 16 14 6 19 629351 Seat Frame Bracket 2 20 01006G02 Hex Washer Head Bolt 3 8 16 x 1 5 ...

Page 30: ...Page C 11 Notes BODY 10002662 Service Parts Manual ...

Page 31: ...Page C 12 Notes BODY 10002662 Service Parts Manual ...

Page 32: ...002662 Service Parts Manual Page D 1 BRAKES Front of Vehicle Front of Vehicle 13 12 11 10 14 9 19 5 21 1 23 6 2 16 16 3 2 3 15 16 20 20 7 3 4 Front of Vehicle 6 18 18 17 16 Calliper Front of Vehicle 7 4 2 ...

Page 33: ... 18 18 x 1 12 Lg Grade 5 2 7 613231 Hex Head Bolt M6 1 x 20mm Lg 1 8 12416G2 Nylon Clamp 11 8 Lg To Secure Brake Lines to Frame Not Illustrated 12 9 635177 Shoulder Bolt 1 2 x 2 3 8 16 x 2 Lg 1 10 11098G5 Lock Nut 3 8 16 1 11 00643G1 Flat Washer 3 8 1 12 70581G02 Flanged Bushing I D 510 x O D 795 x 75 Lg 2 13 640478 Pedal Grip 1 14 637808 Brake Pedal Weldment 1 15 10386G2 Clevis Pin 245 x 68 Lg 1 ...

Page 34: ...Page D 3 Notes BRAKES 10002662 Service Parts Manual ...

Page 35: ...Page D 4 Notes BRAKES 10002662 Service Parts Manual ...

Page 36: ...rvice Parts Manual Page E 1 ELECTRICAL 7 Front Grille with HI LO LED Assembly includes items 2 4 Charger Receptacle Assembly includes items 10 11 16 16 22 19 21 25 23 20 18 27 15 8 11 10 12 17 2 13 7 1 9 7 4 14 3 ...

Page 37: ...651437 Lens Cover 2 5 6 7 71597G01 Self Threading Nut 226 9 8 660162 Cover Receptacle 1 9 658089 Charger Receptacle Assembly Includes Items 10 11 1 10 658956 Charger Harness 1 11 663285 Charging Receptacle 1 12 71055G01 Black Aluminum Rivet 3 16 x 38 Grip 4 13 71781G02 Vinyl Tape 2 14 654465 Jumper Harness 2 15 652987G02 Gauge Panel 1 16 602184 Clip 2 17 649803 Pan Head Torx Screw M6 2 65 x 25mm L...

Page 38: ...rvice Parts Manual Page E 3 ELECTRICAL Front of Vehicle Part of Control Harness 14 15 Front of Vehicle Floor Panel 8 Front of Vehicle 10 9 8 DC DC Converter 72V includes item 9 11 12 Front of Vehicle 4 3 1 5 6 2 5 ...

Page 39: ...N QTY Page E 4 ELECTRICAL 10002662 Service Parts Manual 1 671775 72V Off Road Control Harness 1 2 16816G2 Ratchet Rivet 25 x 887 1 3 655498G01 Contactor 72V 1 4 800296 Pan Head Phillips Screw 10 24 x 3 4 Lg 2 5 00660G5 Flat Washer 10 4 6 14390G10 Lock Nut 10 24 2 7 8 633778 DC DC Converter 72V Includes Item 9 1 9 Hex Nut 1 4 20 2 10 23726G11 Spacer 30 Lg 2 11 629148 Taillight Assembly 1 12 71055G0...

Page 40: ...Page E 5 Notes ELECTRICAL 10002662 Service Parts Manual ...

Page 41: ...Page E 6 Notes ELECTRICAL 10002662 Service Parts Manual ...

Page 42: ...10002662 Service Parts Manual Page F 1 ELECTRONIC SPEED CONTROL 23 23 10 22 Front of Vehicle Controller Bracket Part of Frame 26 27 28 3 4 7 1 25 6 8 20 23 16 15 19 17 13 11 21 Front of Vehicle 21 18 ...

Page 43: ...28671 Motor Wire Front U 1 7 628669 Motor Wire Front V 1 8 628670 Motor Wire Front W 1 9 10 672599G007 Controller 72V 4WD Off Road 1 11 00797G2 Hex Head Bolt 1 4 20 x 1 5 Lg Grade 5 4 12 13 11027G2 Flanged Lock Nut 1 4 20 4 14 15 628668 Motor Wire Rear U 1 16 628665 Motor Wire Rear V 1 17 628667 Motor Wire Rear W 1 18 628680 Control Wire B to Solenoid 1 19 628676 Control Wire B to Control B 1 20 6...

Page 44: ...Page F 3 Notes ELECTRONIC SPEED CONTROL 10002662 Service Parts Manual ...

Page 45: ...Page F 4 Notes ELECTRONIC SPEED CONTROL 10002662 Service Parts Manual ...

Page 46: ...10002662 Service Parts Manual Page G 1 FRONT SUSPENSION AND STEERING 1 4 5 12 12 19 5 10 3 6 6 8 8 20 18 21 6 Front of Vehicle 16 13 13 22 22 23 23 9 7 7 23 11 ...

Page 47: ...eldment 1 4 638383G01 Control Arm Weldment 1 5 637745 Control Arm Bushing 4 6 10387G2 Cotter Pin 094 x 1 1 7 306982 Flat Washer 34 x 92 x 06 6 8 608005 Castle Nut M12 1 25 1 9 00463G11 Hex Head Bolt 7 16 14 x 1 5 Lg Grade 5 3 10 11098G5 Lock Nut 3 8 16 2 11 00429G4 Hex Head Bolt 3 8 16 x 3 5 Lg Grade 5 2 12 638223 Split Spacer 3 8 x 2 390 2 13 00560G1 Flat Washer 3 8 4 14 15 16 00734G1 Lock Nut 7 ...

Page 48: ...10002662 Service Parts Manual Page G 3 FRONT SUSPENSION AND STEERING Front of Vehicle 1 2 ...

Page 49: ...roduct 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 G 4 FRONT SUSPENSION AND STEERING 10002662 Service Parts Manual 1 635491 Flanged Castle Nut M16 1 5 1 2 10387G1 Cotter Pin 125 x 1 5 1 ...

Page 50: ...senger Side includes items 3 23 25 37 2 Brake Caliper includes item 30 11 Part of Frame Strut Bearing Assembly Driver Side includes items 26 27 29 Strut Bearing Assembly Passenger Side includes items 26 28 24 25 29 28 26 27 32 34 31 37 14 21 22 10 16 5 7 8 9 20 23 20 15 13 19 17 18 3 3 11 12 4 33 35 38 41 39 40 37 37 Hub Assembly includes items 38 41 ...

Page 51: ...mm 1 9 645047 Strut Ball Joint 1 10 616073 Strut Bump Stop 1 11 638129 Brake Caliper Includes Item 30 1 12 616451 Caliper Mounting Bracket 1 13 616596 Socket Head Bolt 3 8 24 x 3 4 Lg 2 14 616672 Hex Head Bolt M8 1 25 x 60mm Lg 2 15 616673 Lock Nut M8 2 16 618346 Coil Spring 1 17 626725 Steering Arm Short 1 18 630803 Lock Nut 5 16 18 2 19 630804G01 Flanged Hex Head Bolt 5 16 18 x 2 Lg 2 20 616597 ...

Page 52: ...for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY FRONT SUSPENSION AND STEERING 10002662 Service Parts Manual 32 636610 Flat Washer 3 8 1 33 616701 Rubber Washer 1 5mm x 76mm 1 34 629592 Strut Bushing Female 1 35 629593 Strut Bushing Male 1 36 37 633792G02 Hub Assembly Includes Items 38 41 1 38 636096 Hex Head Bolt M8 1 25 x 20mm Lg 4 39 19862G2 Wheel Hub Bolt 1 2 20 x 1 718 Lg 4 4...

Page 53: ...Page G 8 Notes FRONT SUSPENSION AND STEERING 10002662 Service Parts Manual ...

Page 54: ...10002662 Service Parts Manual Page G 9 FRONT SUSPENSION AND STEERING Steering Column Assembly includes items 5 9 4 Front of Vehicle 6 9 11 5 3 2 1 10 8 8 7 ...

Page 55: ...2 3 4 5 DESCRIPTION QTY Page G 10 FRONT SUSPENSION AND STEERING 10002662 Service Parts Manual 1 639439 Steering Wheel Cover 1 2 601709 Lock Nut M16 2 1 3 639437 Steering Wheel 1 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 10mm 2 9 608655 Hex Nut M10 1 5 1 10 603799 Flan...

Page 56: ...Page G 11 Notes FRONT SUSPENSION AND STEERING 10002662 Service Parts Manual ...

Page 57: ...Page G 12 Notes FRONT SUSPENSION AND STEERING 10002662 Service Parts Manual ...

Page 58: ...10002662 Service Parts Manual Page H 1 MOTOR 4 5 1 Differential 13 14 11 Differential FRONT MOTOR REAR MOTOR 12 2 15 3 ...

Page 59: ...artment for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page H 2 MOTOR 10002662 Service Parts Manual 1 680639 Motor 72V 1 2 658445 Differential Gasket 1 3 668275 End Cap 1 4 00915G1 Bonded Seal Washer 3 5 616716 Hex Head Bolt M6 1 x 16mm Lg 3 6 7 8 9 10 11 680639 Motor 72V 1 12 655677 Sealed E Brake 1 13 00915G1 Bonded Seal Washer 3 14 73715G01 Flanged Hex Head Bolt M6 1 x 60mm L...

Page 60: ...Page H 3 Notes MOTOR 10002662 Service Parts Manual ...

Page 61: ...Page H 4 Notes MOTOR 10002662 Service Parts Manual ...

Page 62: ...10002662 Service Parts Manual Page J 1 ROPS A A B B 1 2 3 4 5 6 6 25 11 7 8 9 10 12 13 14 15 16 16 17 20 25 19 21 22 23 1 24 Front of Vehicle Part of Frame Part of Frame Part of Frame 18 ...

Page 63: ...er Net Bracket 1 7 602415 Flanged Hex Head Bolt M10 1 5 x 80mm Lg Grade 12 9 4 8 600525 Flanged Lock Nut M10 1 5 4 9 612635 Button Head Torx Bolt M6 1 x 20mm Lg 1 10 601476 Lock Nut M6 1 1 11 612635 Button Head Torx Bolt M6 1 x 20mm Lg 2 12 601476 Lock Nut M6 1 2 13 603799 Flanged Hex Head Bolt M10 1 5 x 25mm Lg Grade 8 8 4 14 600525 Flanged Lock Nut M10 1 5 4 15 00427G2 Hex Head Bolt 3 8 16 x 1 2...

Page 64: ...10002662 Service Parts Manual Page J 3 ROPS Front of Vehicle 3 1 2 6 6 4 3 5 5 6 6 5 Upper Hardware Kit includes items 5 6 ...

Page 65: ...es consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page J 4 ROPS 10002662 Service Parts Manual 1 666355 Rear Upper Weldment 1 2 666354 Front Upper Weldment 1 3 630449 Socket Head Bolt M10 1 5 X 45mm Lg Grade 12 9 4 4 668186 Upper Hardware Kit Includes Items 5 6 1 5 630449 Socket Head Bolt M10 1 5 x 45mm Lg Grade 12 9 8 6 616675 Lock Nut M10 1 5...

Page 66: ...10002662 Service Parts Manual Page J 5 ROPS 11 3 4 7 Front of Vehicle 7 12 6 8 1 10 1 9 1 6 8 9 8 9 1 9 9 6 6 5 Hardware Kit includes items 6 12 ...

Page 67: ...e J 6 ROPS 10002662 Service Parts Manual 1 682415 Seat Belt Retractor 1 2 651519 Front Door Net Not Illustrated 1 3 660063G01 Side Bracket Weldment Driver Side 1 4 660063G02 Side Bracket Weldment Passenger Side 1 5 667166 Hardware Kit Includes Items 6 12 1 6 610753 Hex Head Bolt 7 16 20 x 1 Lg Grade 5 8 7 00559G7 Flat Washer 1 4 12 8 00560G3 Flat Washer 3 8 6 9 00734G3 Lock Nut 7 16 20 12 10 60956...

Page 68: ...Page J 7 Notes ROPS 10002662 Service Parts Manual ...

Page 69: ...Page J 8 Notes ROPS 10002662 Service Parts Manual ...

Page 70: ...10002662 Service Parts Manual Page K 1 FRONT AXLE 6 5 5 6 3 4 4 Front of Vehicle 2 7 8 1 11 ...

Page 71: ...ormation ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page K 2 FRONT AXLE 10002662 Service Parts Manual 1 653033 CV Axle Assembly 2 2 601327 Lock Washer 6mm 6 3 605741 Hex Head Bolt M6 1 x 25mm Lg 6 4 306835 Hex Head Bolt 3 8 16 x 1 25 Lg Grade 5 8 5 608654 Split Lock Washer 10mm 8 6 00571G3 Flat Washer 5 16 8 7 629151 Independent Differential Hardened Gears 1 8 616705 Breather Hose 1 9 31539G1 Nylon Cl...

Page 72: ...Page K 3 Notes FRONT AXLE 10002662 Service Parts Manual ...

Page 73: ...Page K 4 Notes FRONT AXLE 10002662 Service Parts Manual ...

Page 74: ...10002662 Service Parts Manual Page L 1 REAR AXLE 5 5 3 4 4 Front of Vehicle 2 7 8 1 6 ...

Page 75: ... additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page L 2 REAR AXLE 10002662 Service Parts Manual 1 653033 CV Axle Assembly 2 2 601327 Lock Washer 6mm 6 3 605741 Hex Head Bolt M6 1 x 25mm Lg 6 4 306835 Hex Head Bolt 3 8 16 x 1 1 4 Lg Grade 5 6 5 608654 Split Lock Washer 10mm 6 6 11391G4 Hose Clamp 25 Dia 1 7 629151 Independent Differential Hardened Gears 1 8 616705 Breather Hose 1 9 ...

Page 76: ...Page L 3 Notes REAR AXLE 10002662 Service Parts Manual ...

Page 77: ...Page L 4 Notes REAR AXLE 10002662 Service Parts Manual ...

Page 78: ...Driver Side includes items 3 25 37 1 Rear Strut Assembly Passenger Side includes items 3 22 26 37 2 14 3 Strut Bearing Assembly Driver Side includes items 27 29 25 Strut Bearing Assembly Passenger Side includes items 28 30 26 27 30 28 29 6 7 8 21 22 10 16 38 41 39 40 37 Hub Assembly includes items 38 41 4 Brake Caliper includes item 5 ...

Page 79: ... 2 1 8 616060 Strut Washer Coil Spring 52mm 1 9 649721 Strut Ball Joint 1 10 616073 Strut Bump Stop 1 11 71883G01 Rubber Washer 3 12 616451 Caliper Mounting Bracket 1 13 616596 Socket Head Bolt 3 8 24 x 3 4 Lg 2 14 616672 Hex Head Bolt M8 1 25 x 60mm Lg 2 15 616673 Lock Nut M8 2 16 616062 Coil Spring 1 17 634928 Rear Steering Arm 1 18 630803 Lock Nut 5 16 18 2 19 630804G01 Flanged Hex Head Bolt 5 ...

Page 80: ...rtment for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY REAR SUSPENSION 10002662 Service Parts Manual 32 636610 Flat Washer 3 8 1 33 616701 Rubber Washer 1 5mm x 76mm 1 34 629592 Strut Bushing Female 1 35 629593 Strut Bushing Male 1 36 37 633792G02 Hub Assembly Includes Items 38 41 1 38 636096 Hex Head Bolt M8 1 25 x 20mm Lg 4 39 19862G2 Wheel Hub Bolt 1 2 20 x 1 718 Lg 4 40 63271...

Page 81: ...Page M 4 Notes REAR SUSPENSION 10002662 Service Parts Manual ...

Page 82: ...10002662 Service Parts Manual Page M 5 REAR SUSPENSION 5 1 Tie Rod Assembly includes items 9 13 8 16 18 17 17 7 8 8 2 3 3 11 6 4 15 13 9 12 10 ...

Page 83: ...embly 1 2 11098G5 Lock Nut 3 8 16 2 3 00560G1 Flat Washer 3 8 4 4 00429G4 Hex Head Bolt 3 8 16 x 3 5 Lg Grade 5 2 5 638223 Split Seam Spacer 3 8 x 2 39 2 6 637745 Control Arm Bushing 4 7 00798G3 Cotter Pin 3 32 x 1 2 Lg 1 8 70904G06 Tie Rod Assembly 10 91 Includes Items 9 13 1 9 70855G05 Threaded Tie Rod 1 10 70902G01 Tie Rod End LH 1 11 70902G02 Tie Rod End RH 1 12 01069G01 Jam Nut LH M12 x 1 25 ...

Page 84: ...Page M 7 Notes REAR SUSPENSION 10002662 Service Parts Manual ...

Page 85: ...Page M 8 Notes REAR SUSPENSION 10002662 Service Parts Manual ...

Page 86: ...2662 Service Parts Manual Page N 1 SEATING 1 Seat Bottom Assembly includes items 2 12 14 Seat Back Assembly includes items 15 17 15 16 17 2 7 7 8 5 12 11 8 3 4 Front of Vehicle 20 19 20 19 23 24 21 21 22 22 ...

Page 87: ... 1 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 11 10435G1 Shock Absorber Washer 1 25 4 12 615417 Button Head Torx Bolt M10 1 5 x 25mm Lg 4 13 14 641897G0006 Seat Back Assembly Black Includes Items 15 17 1 15 605529 Cover Plastic Black 1 16 644268 Base Assembly 1 1...

Page 88: ...10002662 Service Parts Manual Page N 3 SEATING Flip Seat Bottom includes items 4 7 3 Flip Seat Bottom Assembly includes items 2 10 1 4 5 7 2 11 12 13 13 8 10 8 8 9 ...

Page 89: ...RIPTION QTY Page N 4 SEATING 10002662 Service Parts Manual 1 615822 Flip Seat Bottom Assembly Includes Items 2 10 1 2 617137 Deck Board Assembly 1 3 621036 Flip Seat Bottom Includes Items 4 7 1 4 645820 Seat Bottom 1 5 617401 Seat Bottom Foam 1 6 7 615648 Seat Bottom Vinyl 1 8 16705G1 Truss Head Phillips Screw SS 1 4 20 x 1 Lg 5 9 617402 Seat Strap 1 10 00559G7 Flat Washer 1 4 1 11 619756 Rubber B...

Page 90: ...10002662 Service Parts Manual Page N 5 SEATING Front of Vehicle Front of Vehicle 16 Front of Vehicle 18 17 3 1 2 12 11 18 16 14 6 15 13 8 7 7 7 ...

Page 91: ...TING 10002662 Service Parts Manual 1 661524 Seat Belt Latch Buckle 6 1 2 00734G3 Lock Nut 7 16 20 1 3 610753 Hex Head Bolt 7 16 20 x 1 Lg Grade 5 1 4 5 6 617679 Plug 2 7 630643 Flanged Lock Nut 3 8 16 3 8 630674 Hex Head Bolt 3 8 16 x 3 25 Lg 1 9 10 11 609787 Rear Seat Belt Bracket 1 12 00427G2 Hex Head Bolt 3 8 16 x 1 25 Lg Grade 5 2 13 671897 Footboard Assembly 1 14 671536 Flip Seat Armrest 1 15...

Page 92: ...10002662 Service Parts Manual Page N 7 SEATING 10 11 10 11 10 13 16 10 2 10 11 19 18 17 Front of Vehicle 9 2 10 22 Seat Mount Bracket 15 5 1 6 6 15 12 21 8 ...

Page 93: ...8 16 x 1 25 Lg Grade 5 4 3 4 5 629112 Flip Seat Edge Reinforcement 1 6 629275 Deck Board Filler 2 7 8 16705G5 Truss Head Phillips Screw SS 1 4 20 x 1 50 Lg 4 9 14390G4 Lock Nut 1 4 20 4 10 00643G1 Flat Washer 3 8 6 11 11098G5 Lock Nut 3 8 16 7 12 00427G8 Hex Head Bolt 3 8 16 x 2 Lg Grade 5 3 13 01110G01 Flat Washer 1 4 4 14 15 71425G01 Tapping Screw 8 18 x 75 Lg 10 16 74971G01 Seat Back Support 1 ...

Page 94: ...Page N 9 Notes SEATING 10002662 Service Parts Manual ...

Page 95: ...Page N 10 Notes SEATING 10002662 Service Parts Manual ...

Page 96: ...2662 Service Parts Manual Page P 1 WEATHER PROTECTION A B 2 Canopy Top Kit includes items 2 7 1 A Hardware Kit includes items 8 11 7 5 8 6 3 9 4 9 10 11 B Front of Vehicle Front of Vehicle Front of Vehicle ...

Page 97: ... 5 DESCRIPTION QTY Page P 2 WEATHER PROTECTION 10002662 Service Parts Manual 1 668077 Canopy Top Kit Includes Items 2 7 1 2 627077 Canopy Top 1 3 668116 Front Mounting Clamp 2 4 668126 Front Mounting Bracket 2 5 668129 Rear Mounting Clamp 2 6 668130 Rear Mounting Bracket 2 7 668729 Hardware Kit Includes Items 8 11 1 8 602409 Barrel Clip M6 8 9 606264 Flanged Hex Head Bolt M6 1 x 20mm Lg Grade 8 8 ...

Page 98: ...Page P 3 Notes WEATHER PROTECTION 10002662 Service Parts Manual ...

Page 99: ...Page P 4 Notes WEATHER PROTECTION 10002662 Service Parts Manual ...

Page 100: ...t Driver Side includes items 3 4 Wheel and Tire Assembly Front Passenger Side includes items 3 4 Wheel and Tire Assembly Rear Driver Side includes items 7 8 Wheel and Tire Assembly Rear Passenger Side includes items 7 8 1 5 6 7 10 3 9 Style of wheels tires may differ from those shown 8 4 ...

Page 101: ...N QTY Page R 2 WHEELS AND TIRES 10002662 Service Parts Manual 1 639550 Wheel and Tire Assembly Front Driver Side Includes Items 3 4 1 2 639548 Wheel and Tire Assembly Front Passenger Side Includes Items 3 4 1 3 631041 Wheel 12 x 7 1 4 639540 Tire 25 x 8 12 1 5 639551 Wheel and Tire Assembly Rear Driver Side Includes Items 7 8 1 6 639549 Wheel and Tire Assembly Rear Passenger Side Includes Items 7 ...

Page 102: ...Page R 3 Notes WHEELS AND TIRES 10002662 Service Parts Manual ...

Page 103: ...Page R 4 Notes WHEELS AND TIRES 10002662 Service Parts Manual ...

Page 104: ...EDIATELY IF NOT ON LEVEL GROUND Move vehicle to desired location and park it properly on level ground chock tires IMMEDIATELY DISCONNECT AUXILIARY POWER AND RECONNECT PRIMARY POWER 1 2 FOR SAFETY AND TO AVOID BATTERY DRAIN Reconnect the Weather Pack Seal 4 to the Auxiliary Power line 3 and perform required service procedures following all Safety guidelines as outlined in your repair manual Identif...

Page 105: ...DECALS AND LABELS 10002662 Service Parts Manual 1 695306 Dash Panel Label 1 2 637067 12V Outlet CE Label 1 3 667079 Tow Switch Decal 1 4 685698 Made in USA Decal 1 5 6 7 695284 Steering Wheel Decal 1 8 666372 Fuse Block Label 1 9 609694 Towing Instruction Notice Label 1 10 11 692808G1XX Seat Wrap Decal Driver Side See COLOR CODE in HOW TO USE section 1 12 692808G2XX Seat Wrap Decal Passenger Side ...

Page 106: ...nstability or tip over Drive slowly straight up or down slopes and in turns NEVER allow passengers to ride on load deck 630398 2 Seat Wrap Failure to follow these instructions could result in DEATH or SERIOUS INJURY ALWAYS remain PROPERLY SEATED with SEAT BELT FASTENED and HOLDING ON ONLY 2 occupants on bench seat Children may need assistance to remain PROPERLY SEATED with SEAT BELT FASTENED and H...

Page 107: ...tes 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 S 4 DECALS AND LABELS 10002662 Service Parts Manual 1 628943 Flip Seat Warning Label 2 2 630398 Load Deck Limit Warning Label 1 3 4 640561 Euro Battery Label 1 ...

Page 108: ...Page S 5 Notes DECALS AND LABELS 10002662 Service Parts Manual ...

Page 109: ...Page S 6 Notes DECALS AND LABELS 10002662 Service Parts Manual ...

Page 110: ...SA 30906 3852 Dealer 800 296 4804 Consumer 877 394 6727 Owner s Guides and Repair Manuals are available from the manufacturer Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of the manufacturer MANUFACTURER INFORMATION ...

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