Bad Boy Ambush IS Service & Parts Manual Download

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SERVICE PARTS MANUAL

634510

ISSUED NOVEMBER 2013

REVISED SEPTEMBER 2014

AMBUSH

Summary of Contents for Ambush IS

Page 1: ...SERVICE PARTS MANUAL SERVICE PARTS MANUAL 634510 634510 ISSUED NOVEMBER 2013 ISSUED NOVEMBER 2013 REVISED SEPTEMBER 2014 REVISED SEPTEMBER 2014 iS iS AMBUSH AMBUSH...

Page 2: ......

Page 3: ...erious personal injury or death Bad Boy Buggies prohibits and disclaims responsibility for any such modifications or any other alterations which would adversely affect the safety of the vehicle BB Bug...

Page 4: ...n winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain The battery charger...

Page 5: ...DY D BODY FRONT D 1 BODY MID D 3 BODY REAR D 5 BODY ACCESSORIES D 9 BRAKES E CLUTCH F DIRECTION SELECTOR G DIFFERENTIAL LOCK H ELECTRICAL SYSTEM J ENGINE K ENGINE AND MUFLER L FRONT AXLE M FRONT SUSPE...

Page 6: ...Page iv Service Parts Manual NOTES 634510 Service Parts Manual...

Page 7: ...lt the GENERAL INDEX 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 componen...

Page 8: ...er 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...

Page 9: ...e 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 DESCRIPTI...

Page 10: ...Service Parts Manual ACCELERATOR Page A 1 634510 Service Parts Manual ACCELERATOR PEDAL ASSEMBLY includes items 2 13 1 1 2 8 5 6 3 9 4 7 16 21 18 17 19 20 10 11 12 13...

Page 11: ...TEMS 2 13 1 2 626140 ACCELERATOR PEDAL BRACKET 1 3 600019 ROTARY POSITION SENSOR 1 4 600543 TORX BOLT M4 0 75 X 12MM LG 2 5 612889 PEDAL SWITCH 1 6 620030 SOCKET HEAD CAP SCREW M5 0 8 X 10MM LG 2 7 60...

Page 12: ...arts Manual ACCELERATOR Page A 3 634510 Service Parts Manual 8 6 7 10 9 7 13 11 12 16 GOVERNOR BRACKET ASSEMBLY includes items 6 13 5 GOVERNOR ASSEMBLY includes items 2 19 1 Front of Vehicle 2 4 3 17...

Page 13: ...VERNOR ASSEMBLY INCLUDES ITEMS 2 19 1 2 00734G5 LOCK NUT 10 32 1 3 633425 GOVERNOR LEVER WELDMENT 1 4 15944G1 BALL JOINT 1 5 22751G5 GOVERNOR BRACKET ASSEMBLY INCLUDES ITEMS 6 13 1 6 22754G1 BUSHING F...

Page 14: ...Service Parts Manual Notes ACCELERATOR Page A 5 634510 Service Parts Manual...

Page 15: ...Service Parts Manual Notes ACCELERATOR Page A 6 Service Parts Manual 634510 Service Parts Manual...

Page 16: ...Service Parts Manual BATTERY SYSTEM Page C 1 634510 Service Parts Manual A 25 3 1 22 13 15 14 16 1 1 17 28 29 29 27 26 2 31 34 35 33 32 4 9 5 6 6 8 6 6 7 7 10 7 8 9 20 17 17 17 21 B D C A C B D 23...

Page 17: ...ER 5 16 10 7 11098G6 LOCK NUT 5 16 18 6 8 00438G8 HEX HEAD BOLT 5 16 18 X 1 LG 4 9 00715G2 FLANGED HEX HEAD BOLT 5 16 18 X 875 LG 4 10 70200G01 TRUSS HEAD MACHINE SCREW 3 8 16 X 1 LG 2 11 12 13 633190...

Page 18: ...pecify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART N...

Page 19: ...Service Parts Manual Notes BATTERY SYSTEM Page C 4 Service Parts Manual 634510 Service Parts Manual...

Page 20: ...Service Parts Manual BATTERY SYSTEM Page C 5 634510 Service Parts Manual 1 2 2 3 3 6 14 15 To Controller To Solenoid 16 18 19 17...

Page 21: ...rt Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 634715 WIRE 2AWG 71 LG 2 2 634718 WIRE 2AWG 10 LG 2 3 634717 WIRE 2AWG 16 LG 3 4 5...

Page 22: ...Service Parts Manual Notes BATTERY SYSTEM Page C 7 634510 Service Parts Manual...

Page 23: ...Service Parts Manual Notes BATTERY SYSTEM Page C 8 Service Parts Manual 634510 Service Parts Manual...

Page 24: ...rvice Parts Manual Page D 1 634510 Service Parts Manual 1 5 Front of Vehicle 6 11 12 8 9 4 20 6 6 14 5 26 22 23 21 25 19 7 10 13 6 6 18 INSTRUMENT PANEL ASSEMBLY includes items 15 17 15 17 16 BODY FRO...

Page 25: ...20 7 626663 BBB COWL DECAL 1 8 617643 COWL GRILL COVER 1 9 71597G01 SELF THREADING NUT 5MM X 10MM 2 10 630285 BBB COWL STRIP DECAL 2 11 633268GXX ACCESS COVER See COLOR CODE in HOW TO USE Section of...

Page 26: ...Service Parts Manual Page D 3 634510 Service Parts Manual BODY MID Front of Vehicle 1 2 3 3 6 21 7 8 10 22 9 11 12 13 14 15 15 18 19 19 23 24 25 26 20 43 17 27...

Page 27: ...EL PASSENGER SIDE 1 9 71440G03 PANEL BRACE DRIVER SIDE 1 10 71440G04 PANEL BRACE PASSENGER SIDE 1 11 15058G6 RIVET ALUMINUM 625 2 12 00789G2 PHILLIPS HEAD SCREW 10 24 X 1 1 4 LG 2 13 14390G10 LOCK NUT...

Page 28: ...Service Parts Manual Page D 5 634510 Service Parts Manual 3 5 6 7 8 9 10 13 14 15 16 Body Trim Installation for 2 Passenger Vehicle 11 22 23 25 24 25 2 Front of Vehicle 1 BODY REAR...

Page 29: ...35691 SEAT FILLER PANEL PASSENGER SIDE 1 3 10570G10 RIVET 5 32 X 9 16 LG 8 4 5 633104 REAR FENDER 2 PASS DRIVER SIDE 1 6 633125 REAR FENDER 2 PASS PASSENGER SIDE 1 7 00414G6 HEX HEAD BOLT 1 4 20 X 3 4...

Page 30: ...Service Parts Manual Page D 7 634510 Service Parts Manual Body Trim Installation for 4 Passenger Vehicle 6 3 5 7 8 9 10 13 14 16 17 9 2 Front of Vehicle 1 BODY REAR...

Page 31: ...ormation ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 635690 SEAT FILLER PANEL DRIVER SIDE 1 2 635691 SEAT FILLER PANEL PASSENGER SIDE 1 3 10570G10 RIVET 5 32 X 9 16 LG 8 4 5 633072 REAR FENDER 4 PASS DRI...

Page 32: ...Service Parts Manual Page D 9 634510 Service Parts Manual 1 BODY ACCESSORIES...

Page 33: ...rdering parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional i...

Page 34: ...Service Parts Manual Notes BODY Page D 11 634510 Service Parts Manual...

Page 35: ...Service Parts Manual Notes BODY Page D 12 Service Parts Manual 634510 Service Parts Manual...

Page 36: ...al BRAKES Page E 1 634510 Service Parts Manual Front of Vehicle 23 DISC BRAKE ASSEMBLY includes items 24 30 19 14 11 10 15 20 21 2 9 15 13 10 12 10 16 17 3 5 18 17 6 19 4 7 1 29 30 29 28 24 25 27 26 F...

Page 37: ...11098G5 LOCK NUT 3 8 16 1 6 13437G3 FLANGED BOLT 5 16 18 X 1 LG 4 7 14390G4 LOCK WASHER 1 4 20 2 8 610471 BRAKE PEDAL COVER 1 9 613292 BANJO BOLT M10 1 25 X 20MM LG 2 10 613293 CRUSH WASHER M10 6 11...

Page 38: ...Service Parts Manual BRAKES Page E 3 634510 Service Parts Manual 4 1 4 3 8 8 6 2 5...

Page 39: ...es 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 1 627393 PARK BRAKE 1 2 63303...

Page 40: ...Service Parts Manual Notes BRAKES Page E 5 634510 Service Parts Manual...

Page 41: ...Service Parts Manual Notes BRAKES Page E 6 Service Parts Manual 634510 Service Parts Manual...

Page 42: ...Service Parts Manual CLUTCH Page F 1 634510 Service Parts Manual 1 16 15 12 11 10 9 3 4 5 6 25 22 23 19 7 8 9 2 13 14...

Page 43: ...RY CLUTCH 1 3 632613 SECONDARY CLUTCH 1 4 631808 CVT BELT 1 5 636512 CLUTCH FRONT COVER 1 6 635530 FLANGED HEX HEAD BOLT 10 32 X 11 16 LG 8 7 629495 HEX HEAD BOLT 7 16 20 X 7 LG 1 8 00566G2 SPRING LOC...

Page 44: ...Service Parts Manual Notes CLUTCH Page F 3 634510 Service Parts Manual...

Page 45: ...Service Parts Manual Notes CLUTCH Page F 4 Service Parts Manual 634510 Service Parts Manual...

Page 46: ...TION SELECTOR Page G 1 634510 Service Parts Manual 16 18 21 1 5 17 18 18 19 19 19 19 24 25 26 19 22 4 3 9 14 15 12 11 11 10 10 8 2 6 20 21 21 ELECTRIC DIRECTION SELECTOR SHIFT ASSEMBLY includes items...

Page 47: ...EMBLY INCLUDES ITEMS 9 15 1 9 633258 DIRECTION SELECTOR CLEVIS ROD WELDMENT 1 10 25727G01 CUP WASHER 4 11 636045 COMPRESSION SPRING 2 12 00734G5 LOCK NUT 10 32 1 13 633009 NEUTRAL BRACKET WITH BUSHING...

Page 48: ...Service Parts Manual Notes DIRECTION SELECTOR Page G 3 634510 Service Parts Manual...

Page 49: ...Service Parts Manual Notes DIRECTION SELECTOR Page G 4 Service Parts Manual 634510 Service Parts Manual...

Page 50: ...Service Parts Manual DIFFERENTIAL LOCK Page H 1 634510 Service Parts Manual 1 2 3 6 15 14 7 8 2 3 11 11 12 12 13 13 16 17 17 21 Rear Cable Details Front Cable Details...

Page 51: ...NO 1 2 3 4 5 DESCRIPTION QTY 1 632886 DIFFERENTIAL LOCK POD 1 2 633163 REAR DIFFERENTIAL LOCK CABLE 1 3 633164 FRONT DIFFERENTIAL LOCK CABLE 1 4 5 6 75697G01 DIFFERENTIAL LOCK TRIM PLATE 2 7 71055G01...

Page 52: ...Service Parts Manual Notes DIFFERENTIAL LOCK Page H 3 634510 Service Parts Manual...

Page 53: ...Service Parts Manual Notes DIFFERENTIAL LOCK Page H 4 Service Parts Manual 634510 Service Parts Manual...

Page 54: ...Service Parts Manual ELECTRICAL SYSTEM Page J 1 634510 Service Parts Manual DC DC CONVERTOR includes items 6 8 5 3 5 12 9 15 15 11 16 17 10 14 13 6 8 7 2 1...

Page 55: ...NO 1 2 3 4 5 DESCRIPTION QTY 1 632232 MAIN HARNESS 1 2 632738 FUSE BOX 1 3 12547G4 HEX HEAD CAP SCREW M6 1 X 30MM LG 2 4 5 632683 DC DC CONVERTOR INCLUDES ITEMS 6 8 1 6 FLAT WASHER 2 7 HEX NUT 2 8 CO...

Page 56: ...Service Parts Manual ELECTRICAL SYSTEM Page J 3 634510 Service Parts Manual Main Harness POWER OUTLET 2 1 14 15 13 12 12 11 13 14 9 7 6 5 8 3 18 19 20 21 20 18...

Page 57: ...QTY 1 71078G01 POWER OUTLET 12V 1 2 600543 BUTTON HEAD TORX SCREW M4 0 75 X 12MM LG 2 3 602053 LOCK NUT M4 0 7 2 4 5 626864 FUSE 1 6 00379G2 PAN HEAD PHILLIPS SCREW 10 24 X 1 1 4 LG 2 7 628113 FUSE HO...

Page 58: ...Service Parts Manual ELECTRICAL SYSTEM Page J 5 634510 Service Parts Manual To Main Harness Main Harness CONTROL PANEL ASSEMBLY includes items 2 12 Front of Vehicle 1 2 12 11 3 13 10 4 7 5 7 8 5 6 9...

Page 59: ...Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 628708G03 CONTROL PANEL ASSEMBLY INCLUDES ITEMS 2 12 1 2 632268 LED LIGHT INDICATOR 1 3 627699 PAN HEAD...

Page 60: ...Service Parts Manual ELECTRICAL SYSTEM Page J 7 634510 Service Parts Manual Front of Vehicle 5 1 2 6 3 4 7 HEADLIGHT PASSENGER SIDE includes item 2 HEADLIGHT DRIVER SIDE includes item 2 1 3...

Page 61: ...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 1 614497 HEADLIGHT PASSENGER SIDE...

Page 62: ...Service Parts Manual ELECTRICAL SYSTEM Page J 9 634510 Service Parts Manual 2 3 3 4 9 12 8 7 10 10 11 1 5 6 W W V V U U CONTROLLER MOTOR To Battery To Battery...

Page 63: ...dual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 632556 CONTROLLER 48V 1 2 00415G2 HEX HEAD CAP SCREW 1 4 20 X 1 1 4 LG 4 3 0...

Page 64: ...Service Parts Manual Notes ELECTRICAL SYSTEM Page J 11 634510 Service Parts Manual...

Page 65: ...Service Parts Manual Notes ELECTRICAL SYSTEM Page J 12 Service Parts Manual 634510 Service Parts Manual...

Page 66: ...Service Parts Manual ENGINE Page K 1 634510 Service Parts Manual SUBARU ENGINE EH722 includes items 2 21 1 2 3 4 5 7 6 29 30 23 26 24 25 27 Front of Vehicle...

Page 67: ...G NOT ILLUSTRATED 1 10 635777 IGNITION COIL NOT ILLUSTRATED 1 11 635780 MAGNETIC SWITCH NOT ILLUSTRATED 1 12 635761 CRANKCASE OIL SEAL NOT ILLUSTRATED 1 13 635762 MAIN BEARING COVER GASKET NOT ILLUSTR...

Page 68: ...Service Parts Manual ENGINE Page K 3 634510 Service Parts Manual 1 10 2 3 4 5 7 6 6 6 7 7 11 15 17 17 20 21 25 32 Front of Vehicle 24 25 26 6 29 26 34 11 13 36 37 39 16 16 16 39 23...

Page 69: ...NUT M10 1 5 4 4 628915 TUBE PLUG PLASTIC 1 5 O D 2 5 00428G8 HEX HEAD BOLT 3 8 16 X 2 1 4 LG 4 6 00560G1 FLAT WASHER 3 8 20 7 11098G5 LOCK NUT 3 8 16 8 8 9 10 632160 REAR POWERTRAIN SUPPORT WELDMENT 2...

Page 70: ...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 32 00463G4...

Page 71: ...Service Parts Manual Notes ENGINE Page K 6 Service Parts Manual 634510 Service Parts Manual...

Page 72: ...Service Parts Manual ENGINE MUFFLER Page L 1 634510 Service Parts Manual Front of Vehicle 1 9 7 7 8 10 2 7 4 3 13 4 3 14 13 15 13 10 8 14...

Page 73: ...as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 632302 EXHAUST MANIFOLD 1 2 632218 MUFFLER 1 3 632666 MUFFLER H...

Page 74: ...Service Parts Manual Notes ENGINE MUFFLER Page L 3 634510 Service Parts Manual...

Page 75: ...Service Parts Manual Notes ENGINE MUFFLER Page L 4 Service Parts Manual 634510 Service Parts Manual...

Page 76: ...Service Parts Manual FRONT AXLE Page M 1 634510 Service Parts Manual Front of Vehicle Motor 12 1 4 11 Part of Frame 13 3 2 10 9 1 INDEPENDENT DIFFERENTIAL includes items 2 3...

Page 77: ...ult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 631489G02 INDEPENDENT DIFFERENTIAL INCLUDES ITEMS 2 3 1 2 OIL FILL PLUG 1 3 OIL DRAIN PLUG 1 4 63366...

Page 78: ...Service Parts Manual Notes FRONT AXLE Page M 3 634510 Service Parts Manual...

Page 79: ...Service Parts Manual Notes FRONT AXLE Page M 4 Service Parts Manual 634510 Service Parts Manual...

Page 80: ...N 1 634510 Service Parts Manual 15 A ARM ASSEMBLY includes items 3 4 STEERING RACK WITH SPACER includes items 24 25 Female Bushing Retaining Nut Male Bushing 35 36 25 24 27 28 36 37 9 1 8 10 11 40 41...

Page 81: ...389G3 GREASE FITTING 2 5 616036 BUSHING 0 84 OD X 0 512 ID 8 6 7 8 631703G01 STICK STOPPER DRIVER SIDE 1 9 631703G02 STICK STOPPER PASSENGER SIDE 1 10 628915 PLASTIC TUBE PLUG 1 5 OD 2 11 14158G1 HEX...

Page 82: ...sult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 32 33 630450 FLANGED LOCK NUT M10 1 5 3 34 35 01066G01 HEX HEAD BOLT M12 1 75 X 1 6 LG 6 36 306982 FL...

Page 83: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page N 4 Service Parts Manual 634510 Service Parts Manual...

Page 84: ...SPENSION AND STEERING Page N 5 634510 Service Parts Manual 5 17 15 21 3 4 10 11 13 26 7 16 22 23 14 27 18 19 9 FRONT STRUT ASSEMBLY DRIVER SIDE includes items 3 5 27 1 FRONT STRUT ASSEMBLY PASSENGER S...

Page 85: ...4 27 1 3 632410G01 STRUT BASE DRIVER SIDE 1 4 632410G02 STRUT BASE PASSENGER SIDE 1 5 616053 STRUT WASHER 52MM 1 6 7 618346 SPRING 1 8 9 616040 LONG SHOCK STRUT 1 10 616041 WHEEL BEARING 1 11 626725...

Page 86: ...Service Parts Manual FRONT SUSPENSION AND STEERING Page N 7 634510 Service Parts Manual 11 STEERING COLUMN ASSEMBLY includes items 6 10 5 1 13 3 6 7 10 12 8 9 Front of Vehicle 2...

Page 87: ...partment for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 71147G01 STEERING WHEEL COVER 1 2 601709 LOCK NUT M16 2 1 3 602980 STEERING WHEEL 1 4 12719G1 ANTI SEIZE COMPOUND NOT ILLUS...

Page 88: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page N 9 634510 Service Parts Manual...

Page 89: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page N 10 Service Parts Manual 634510 Service Parts Manual...

Page 90: ...of Vehicle 11 7 8 9 13 14 12 18 1 6 10 CARB FUEL TANK ASSEMBLY WITH SWITCH includes items 3 5 14 3 5 FLUOR FUEL TANK WITH SENDER UNIT includes items 6 FUEL SENDER UNIT 4 2 FOR VEHICLES MANUFACTURED F...

Page 91: ...ION QTY 1 633216 CARB FUEL TANK ASSEMBLY WITH SWITCH INCLUDES ITEMS 3 5 14 1 FOR VEHICLES MANUFACTURED FROM 24TH NOVEMBER 2014 2 72229G01 FUEL TANK ADAPTER 1 3 633024G03 PRESS FIT FUEL SENDER 1 4 2004...

Page 92: ...FUEL SYSTEM Page P 3 634510 Service Parts Manual Front of Vehicle Fuel Filter To Engine To Fuel Pump Part of Frame 3 7 1 4 6 9 8 2 15 26 16 16 14 28 4 1 7 5 27 15 15 4 4 15 4 9 11 10 1 7 3 20 19 23 24...

Page 93: ...BING CLAMP 9 5 70483G01 SPACER 5 16 18 X 66 LG 1 6 634061 FUEL HOSE 1 4 I D X 17 4 LG 1 7 00559G8 FLAT WASHER 5 16 8 8 611181 FUEL SHUT OFF VALVE 1 9 615350 FUEL HOSE 2 2 10 606071 CARBON CANISTER 1 1...

Page 94: ...Service Parts Manual Notes FUEL SYSTEM Page P 5 634510 Service Parts Manual...

Page 95: ...Service Parts Manual Notes FUEL SYSTEM Page P 6 Service Parts Manual 634510 Service Parts Manual...

Page 96: ...Service Parts Manual MOTOR Page Q 1 634510 Service Parts Manual 1 2 3 4 5 8 7...

Page 97: ...mponent 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 1 615557 MOTOR 72V 1 2 629597 MOTOR...

Page 98: ...Service Parts Manual Notes MOTOR Page Q 3 634510 Service Parts Manual...

Page 99: ...Service Parts Manual Notes MOTOR Page Q 4 Service Parts Manual 634510 Service Parts Manual...

Page 100: ...Parts Manual OPERATOR PROTECTION SYSTEM Page R 1 634510 Service Parts Manual 24 3 27 20 23 Part of frame Part of Frame 22 5 4 1 16 15 11 13 2 26 8 7 7 14 22 20 23 6 12 30 28 31 29 Front of Vehicle 25...

Page 101: ...BAR TUBE 1 6 00427G2 HEX HEAD BOLT 3 8 16 X 1 1 4 LG 4 7 00571G2 FLAT WASHER 5 16 8 8 11098G5 LOCK NUT 3 8 16 4 9 10 630397 OP INSTRUCTION DECAL 1 11 00439G2 HEX HEAD BOLT 5 16 18 X 1 1 4 LG 2 12 0057...

Page 102: ...rts Manual OPS Bottom Ref only ACCESSORIES OPS KIT includes items 13 24 OPS ACCESSORY HARDWARE KIT includes items 18 21 12 17 OPS UPPER HARDWARE KIT includes items 8 9 7 OPS UPPER KIT includes items 2...

Page 103: ...RONT CONNECTOR PASSENGER SIDE 1 5 609080 REAR CONNECTOR DRIVER SIDE 1 6 609079 REAR CONNECTOR PASSENGER SIDE 1 7 629328 UPPER OPS HARDWARE KIT INCLUDES ITEMS 8 9 1 8 630642 HEX HEAD BOLT 3 8 16 X 2 1...

Page 104: ...Service Parts Manual Notes OPERATOR PROTECTION SYSTEM Page R 5 634510 Service Parts Manual...

Page 105: ...Service Parts Manual Notes OPERATOR PROTECTION SYSTEM Page R 6 Service Parts Manual 634510 Service Parts Manual...

Page 106: ...Service Parts Manual REAR AXLE Page S 1 634510 Service Parts Manual Front of Vehicle 1 INDEPENDENT DIFFERENTIAL MANUAL includes items 2 4 1 8 9 5 4 13 15 14 Part of Frame 10...

Page 107: ...vice Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 631810 INDEPENDENT DIFFERENTIAL MANUAL INCLUDES ITEMS 2 4 1 2 OIL FILL PLUG NOT ILLUSTRATED 1 3 OIL DRAIN PLUG NOT I...

Page 108: ...Service Parts Manual Notes REAR AXLE Page S 3 634510 Service Parts Manual...

Page 109: ...Service Parts Manual Notes REAR AXLE Page S 4 Service Parts Manual 634510 Service Parts Manual...

Page 110: ...ice Parts Manual 1 2 STRUT ASSEMBLY REAR DRIVER SIDE includes items 3 25 STRUT ASSEMBLY REAR PASSENGER SIDE includes items 5 27 1 2 3 26 4 27 5 6 10 11 12 13 14 7 9 8 25 21 22 23 24 15 17 20 16 33 37...

Page 111: ...5 616041 WHEEL BEARING 1 6 616044 HUB ASSEMBLY 1 7 616451 BRAKE CALIPER BRACKET 1 8 616064 STRUT BALL JOINT 1 9 616040 STRUT SHOCK LONG 1 10 616073 STRUT BUMP STOPS 1 11 616053 SPRING WASHER 2 63 1 12...

Page 112: ...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 32 632591 A ARM SWAY B...

Page 113: ...Service Parts Manual Notes REAR SUSPENSION Page T 4 Service Parts Manual 634510 Service Parts Manual...

Page 114: ...Service Parts Manual REAR SUSPENSION Page T 5 634510 Service Parts Manual 1 2 4 6 8 17 19 18 13 13 11 14 15 16 12 5 7 Front of Vehicle 3 TIE ROD ASSEMBLY includes items 4 8...

Page 115: ...EERING ROD MOUNTING BRACKET 1 2 13437G3 HEX HEAD FLANGED BOLT 5 16 18 X 1 LG 4 3 633535 TIE ROD ASSEMBLY INCLUDES ITEMS 4 8 2 4 632114 THREADED TIE ROD 1 5 70902G01 TIE ROD END DRIVER SIDE 1 6 70902G0...

Page 116: ...Service Parts Manual REAR SUSPENSION Page T 7 634510 Service Parts Manual Part of SWAY BAR ASSEMBLY Part of SWAY BAR ASSEMBLY Front of Vehicle 4 SWAY BAR ASSEMBLY includes items 5 8 1 2 5 7 6 8 3...

Page 117: ...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 1 00428G8 HEX HEAD BOLT 3 8 16 X 3...

Page 118: ...Service Parts Manual Notes REAR SUSPENSION Page T 9 634510 Service Parts Manual...

Page 119: ...Service Parts Manual Notes REAR SUSPENSION Page T 10 Service Parts Manual 634510 Service Parts Manual...

Page 120: ...Y includes items 2 10 1 SEAT BOTTOM ASSEMBLY includes items 2 3 5 10 37 36 2 3 4 37 5 7 8 9 10 BACK REST ASSEMBLY includes items 12 17 11 6 15 13 12 16 14 SEAT BOTTOM ASSMBLY includes items 23 26 22 S...

Page 121: ...1 SEAT HINGE 2 6 00720G08 FLAT HEAD PHILLIPS SCREW 12 14 X 1 LG 6 7 71012G01 SEAT BOTTOM TRIM 1 8 17074G1 SOILING SLAB 2 9 FLAT STAPLE AR 10 FLAT STAPLE AR 11 BACK REST ASSEMBLY INCLUDES ITEMS 12 17 2...

Page 122: ...rt Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 27 16705G1 TRUSS HEAD MACHINE SCREW SS 1 4 20 X 1 LG 4 28 29 619756 RUBBER BUMPER 2 3...

Page 123: ...Service Parts Manual Notes SEATING Page U 4 Service Parts Manual 634510 Service Parts Manual...

Page 124: ...t of Vehicle SEAT BACK FRAME BRACKET REF 31 34 32 33 12 13 Lower OPS 10 Front of Vehicle 44 46 41 43 42 45 A Upper OPS Front of Vehicle 38 A 37 35 1 15 24 13 2 28 26 11 24 3 8 8 9 5 4 4 6 5 16 17 20 2...

Page 125: ...1 1 4 LG 2 8 00427G8 HEX HEAD BOLT 3 8 16 X 2 LG 4 9 11027G5 LOCK NUT 3 8 16 4 10 610753 HEX HEAD BOLT 7 16 20 X 1 LG 4 11 00560G3 FLAT WASHER 1 2 6 12 635789 SEAT BELT RETRACTOR 112 2 13 00734G3 LOC...

Page 126: ...tomer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 32 635630 HEX HEAD BOLT 7 16 20 X 1 1 4 LG 2 33 00560G2 FLAT WASHER 3 8 4 34 00734G3 LOCK NUT 7 16 20 2 35 62...

Page 127: ...Service Parts Manual Notes SEATING Page U 8 Service Parts Manual 634510 Service Parts Manual...

Page 128: ...rts Manual SEATING Page U 9 634510 Service Parts Manual 4 6 1 7 8 9 10 Front of Vehicle 11 11 2 3 13 5 4 4 12 6 1 17 18 19 20 For vehicles manufactured from June 2014 For vehicles manufactured before...

Page 129: ...ION QTY 1 14390G4 LOCK NUT 1 4 20 8 2 609854 SEAT BELT LATCH BUCKLE 6 2 3 609787 REAR SEAT BELT BRACKET 1 4 16705G9 PAN HEAD SCREW SS 1 4 20 X 1 1 4 LG 12 5 627804 SEAT BACK WELDMENT 1 6 01110G01 FLAT...

Page 130: ...Service Parts Manual Notes SEATING Page U 11 634510 Service Parts Manual...

Page 131: ...Service Parts Manual Notes SEATING Page U 12 Service Parts Manual 634510 Service Parts Manual...

Page 132: ...des items 3 12 Front of Vehicle PLASTIC BED MANUAL LIFT ASSEMBLY includes items 2 27 1 34 Front of Vehicle A C Front of Vehicle Seat support Frame B B A 3 7 4 8 44 45 10 5 6 11 12 9 B A C 22 31 30 29...

Page 133: ...3455G01 TAILGATE CABLE 2 7 73450G01 ANGLE 1 8 16705G2 PAN HEAD SCREW SS 1 4 20 X 5 8 LG 4 9 73449G01 EXTRUSION CHANNEL 1 10 16816G5 RATCHET FASTENER 0 187 X 0 550 LG 4 11 73448G01 PLASTIC TAILGATE 40...

Page 134: ...icates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 32 33 34 71095G03 PLASTIC BED LATCH INCLUDES ITEMS 35 41 1 35 633698 BED LATCH 1 36 71477G0...

Page 135: ...Service Parts Manual Notes TRUCK BED Page V 4 Service Parts Manual 634510 Service Parts Manual...

Page 136: ...1 634510 Service Parts Manual Front of Vehicle A B A Front of Vehicle 14 WINDSHIELD KIT FULL includes items 2 14 1 WINDSHIELD KIT SPLIT includes items 19 38 18 8 7 13 9 6 2 5 12 3 4 14 10 11 25 26 33...

Page 137: ...INCLUDES ITEMS 2 14 1 2 WINDSHIELD 1 3 AWNING MOLDING ALUMINUM 1 4 TEXTILE SKIRT PLACEHOLDER 1 5 PLASTIC CLAMP 1 75 4 6 HEX NUT M6 6 7 WASHER 6MM 12 8 HEX HEAD BOLT M6 X 30MM LG 4 9 WINDSHIELD GROMME...

Page 138: ...specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART...

Page 139: ...Service Parts Manual Notes WEATHER PROTECTION Page W 4 Service Parts Manual 634510 Service Parts Manual...

Page 140: ...Service Parts Manual WEATHER PROTECTION Page W 5 634510 Service Parts Manual B A A B A A TOP CANOPY KIT includes items 2 3 1 HARDWARE KIT includes items 4 9 3 4 5 6 9 8 2...

Page 141: ...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 1 628584 TOP C...

Page 142: ...Service Parts Manual Notes WEATHER PROTECTION Page W 7 634510 Service Parts Manual...

Page 143: ...Service Parts Manual Notes WEATHER PROTECTION Page W 8 Service Parts Manual 634510 Service Parts Manual...

Page 144: ...ion Style of tire may differ from tire shown BLACK WHEEL AND MUDLITE TIRE ASSEMBLY STEEL DRIVER SIDE includes items 3 4 1 BLACK WHEEL AND MUDLITE TIRE ASSEMBLY STEEL PASSENGER SIDE includes items 3 4...

Page 145: ...nt for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY 1 631042 BLACK WHEEL AND MUDLITE TIRE ASSEMBLY STEEL DRIVER SIDE INCLUDES ITEMS 3 4 2 2 631045 BLACK WHEEL AND MUDLITE TIRE ASSEMBL...

Page 146: ...MUDLITE TIRE ASSEMBLY ALUMINUM PASSENGER SIDE includes items 3 4 2 BRUSHED WHEEL AND MUDLITE TIRE ASSEMBLY ALUMINUM DRIVER SIDE includes items 18 19 7 BRUSHED WHEEL AND MUDLITE TIRE ASSEMBLY ALUMINUM...

Page 147: ...120 MUDLITE TIRE 25 X 10 X 12 1 4 616116 BLACK WHEEL RIM ALUMINUM 12 X 7 1 5 6 7 627555 BLACK WHEEL AND JOURNEY TIRE ASSEMBLY ALUMINUM INCLUDES ITEMS 8 9 4 8 627556 JOURNEY TIRE 25 X 10 X 12 1 9 61611...

Page 148: ...ing parts please specify the model and serial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional infor...

Page 149: ...Service Parts Manual Notes WHEELS AND TIRES Page Y 6 Service Parts Manual 634510 Service Parts Manual...

Page 150: ...Service Parts Manual Notes WHEELS AND TIRES Page Y 7 634510 Service Parts Manual...

Page 151: ......

Page 152: ...parts and repair contact your local dealer To locate a local dealer please go online to our website www BADBOYBUGGIES COM Copyrighted Material This manual may not be reproduced in whole or in part wi...

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Bad Boy Ambush IS, Service & Parts Manual

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Summary of Contents for Ambush IS

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