Ezgo RXV Electric 611105 Service & Parts Manual Download

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RXV ELECTRIC

SERVICE PARTS MANUAL

ISSUED FEBRUARY 2009 REVISED NOVEMBER 2015

611105

Summary of Contents for RXV Electric 611105

Page 1: ...RXV ELECTRIC SERVICE PARTS MANUAL ISSUED FEBRUARY 2009 REVISED NOVEMBER 2015 611105 ...

Page 2: ......

Page 3: ... revised periodically by the E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI DENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual TO CONTACT US NORTH AMERICA TECHNICAL ASSISTANCE WARRANTY PHONE 1 800...

Page 4: ...proved parts may void the warranty Overfilling batteries may void the warranty 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 As with all electric vehicles...

Page 5: ...te Instrument Panel Instrument Panel Trim Cup Holder BODY MID SECTION C 5 Pedal Cover Floorboard Floormat Rocker Panels BODY REAR C 7 Rear Body Rear Splash Shields Seat Support Bagwell Liner Access Panel Scuff Guards Rear Bumper BODY ACCESSORIES C 11 Side Baskets Sand Bottle Cooler Soft Swipe Divot Repair Club Ball Washer Four Bag Attachment BRAKES PEDAL D 1 Brake Pedal Pad Brake Pedal Assembly Br...

Page 6: ...y Strap Wires ELECTRICAL ACCESSORIES E 7 Horn Assembly Horn Button State of Charge Meter Headlights Tail Lights Turn Signal Switch Headlight Switch ELECTRONIC SPEED CONTROL F 1 Controller Assembly Resistor Assembly Resistor Mounting Bracket Sensor FRONT SUSPENSION STRUTS G 1 Strut Assemblies Spindles A Arm Front Hub Wheel Bolt FRONT SUSPENSION STEERING G 5 Steering Rack Assembly Steering Column St...

Page 7: ...t Hinge Arm Rest Rear Seat Floor Board Assembly Seat Belt REAR FACING SEAT EXCEED MODEL L 9 Rear Facing Floor Board Assembly Rear Facing Seat Bottom Assembly Seat Back Assembly TOW BAR PERMANENT TOWING VEHICLE M 1 Tow Bar Latch Retainer TOW BAR PERMANENT TOWED VEHICLE M 3 Steering Link Front Casting Spacer Rod Ends WEATHER PROTECTION GOLF CAR SUN TOP N 1 Sun Top Top Struts WEATHER PROTECTION SHUTT...

Page 8: ...Page vi TABLE OF CONTENTS SECTION Page No Service Parts Manual FRAME R 1 Frames Seat Frames ...

Page 9: ...ectly reflected by each illustration Consult the illustration that best suits your situation Locate the serial number It is important that the serial number of your vehicle and its model number be sup plied to Service Parts when ordering any replacement components SERIAL NUMBER LOCATION Three serial number and manufacture date code labels are on the vehicle One is placed on the steering column the...

Page 10: ... 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 assemb...

Page 11: ...Page ix Service Parts Manual ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN ...

Page 12: ...Page A 1 Service Parts Manual ACCELERATOR 5 4 1 6 Accelerator Pedal Assembly includes items 2 6 3 2 9 10 7 ...

Page 13: ...DESCRIPTION QTY Page A 2 Service Parts Manual ACCELERATOR 1 626138 ACCELERATOR PEDAL ASSEMBLY BLACK INCLUDES ITEMS 2 6 1 2 612889 ACCELERATOR PEDAL MOLEX SWITCH 1 3 620030 SOCKET HEAD CAP SCREW M5 0 8 X 10 2 4 600019 ROTARY POSITION SENSOR 1 5 600543 BUTTON HEAD TORX BOLT M4 0 75 X 12 2 6 610529 ACCELERATOR PEDAL PAD 1 7 614393 ACCELERATOR PEDAL BOOT 1 8 9 615747 JUMPER HARNESS ACCELERATOR PEDAL S...

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

Page 15: ...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 Service Parts Manual BATTERY CHARGER 1 635671 CHARGER 3 METER CORD 1 2 635672 CHARGER 5 5 METER CORD 1 3 611781 5M GFI CHARGER CORD KIT NOT ILLUSTRATED 1 ...

Page 16: ...Page C 1 Service Parts Manual BODY 19 18 17 11 28 25 26 14 39 27 34 35 7 1 23 38 30 24 31 8 13 4 9 10 6 5 2 17 21 20 22 ...

Page 17: ...GHT WHITE 606959 FLAME RED 606960 STEEL BLUE 608476 PLATINUM 608477 ALMOND 608493 ELECTRIC BLUE 608494 INFERNO RED 617580 SUN BURST ORNAGE 617578 BRITISH RACING GREEN 630161 BARLEY GOLD 630163 OASIS GREEN 630165 JAVA BROWN 630167 METALLIC CHARCOAL 2 6XXXXX FRONT COWL WITH HEADLIGHT OPENING see colors below 1 620227 IVORY 620228 FOREST GREEN 620229 PATRIOT BLUE 620230 BLACK 620231 BURGANDY 620232 B...

Page 18: ...388 ACCESS COVER ASSEMBLY includes item 10 1 10 602100 U CLIP 3 11 606277 BOSS SCREW M6 4 12 13 602387 INSTRUMENT PANEL includes item 14 1 14 602184 SPRING CLIP 4 15 16 17 605935 FRONT BUMPER 1 18 604066 FLAT WASHER M10 O D 30 I D 10 5 THK 1 75 2 19 600525 FLANGED HEX NUT WITH PLASTIC INSERT M10 1 5 2 20 602572 PAN HEAD TORX BOLT M10 15 X 25mm 4 21 70200G01 TRUSS HEAD TORX 3 BOLT 3 8 16 X 3 4 LG 2...

Page 19: ...ndicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 4 Service Parts Manual BODY 34 608528 WARNING AND INSTRUCTION DECAL Freedom vehicles 1 35 608701 WARNING AND INSTRUCTION DECAL PICTOGRAMS CE vehicles 1 36 37 38 607131 GLOVE BOX PASSENGER SIDE 1 39 607533 GLOVE BOX DRIVER SIDE 1 ...

Page 20: ...Page C 5 Service Parts Manual BODY 6 3 1 2 21 20 21 20 12 13 19 14 15 15 16 17 5 7 7 ...

Page 21: ... 3 605957 BUTTON HEAD TORX SCREW THREAD FORMING M8 4 4 5 600253 LOWER ROCKER PANEL DRIVER SIDE 1 6 600257 LOWER ROCKER PANEL PASSENGER SIDE 1 7 605957 BUTTON HEAD TORX SCREW THREAD FORMING M8 6 8 9 10 11 12 601118 FLOORMAT WITHOUT HOLE FOR HORN 1 13 603707 FLOORMAT WITH HOLE FOR HORN 1 14 16816G2 CHRISTMAS TREE RIVET 25 X 88 5 15 16816G1 CHRISTMAS TREE RIVET 25 X 68 2 16 605277 PEDAL COVER PLATE 1...

Page 22: ...Page C 7 Service Parts Manual BODY 18 12 13 25 7 1 2 19 16 15 31 33 26 9 32 6 6 5 41 37 36 44 45 46 23 22 8 48 40 39 38 56 55 57 58 BAGWELL CLOSEOUT ASSEMBLY includes items 56 58 ...

Page 23: ...LACK 614982 BURGANDY 614983 BRIGHT WHITE 614984 FLAME RED 614985 STEEL BLUE 614989 PLATINUM 614988 ALMOND 614987 ELECTRIC BLUE 614986 INFERNO RED 617590 SUN BURST ORNAGE 617592 BRITISH RACING GREEN 630178 BARLEY GOLD 630181 OASIS GREEN 630184 JAVA BROWN 630187 METALLIC CHARCOAL 2 6XXXXX REAR BODY ASSEMBLY WITH LIGHT OPENINGS includes items 5 6 see colors below 1 615014 IVORY 615015 FOREST GREEN 61...

Page 24: ... 88 14 7 600249 REAR BODY ACCESS PANEL 1 8 602409 BARREL CLIP M6 1 2 9 601326 BUTTON HEAD TORX BOLT M6 1 X 20mm LG 2 10 11 12 602572 PAN HEAD TORX BOLT M10 1 5 X 25mm LG 2 13 604066 FLAT WASHER M10 O D 30 I D 10 5 THK 1 75 2 14 15 602558 SEAT HINGE PLATE 1 16 602572 PAN HEAD TORX BOLT M10 1 5 X 25mm LG 4 17 18 601921 FRONT SEAT SUPPORT ASSEMBLY 1 19 602572 PAN HEAD TORX BOLT M10 1 5 X 25mm LG 2 20...

Page 25: ...X SCREW THREAD FORMING M8 4 38 603819 REAR BUMPER 1 39 604266 FLAT WASHER M10 O D 30 I D 10 5 THK 1 75 2 40 603799 HEX HEAD FLANGED BOLT M10 1 5 X 25mm LG 4 41 608313 BUTTON HEAD TORX BOLT M10 1 5 X 25mm LG 2 42 43 44 607859 RXV DECAL 2 45 610521 E Z GO FREEDOM DECAL 2 46 607863 E Z GO 2 2 SHUTTLE DECAL 2 47 48 608993 RED SIDE REFLECTOR DRIVER SIDE 1 49 608996 RED SIDE REFLECTOR PASSENGER SIDE 1 5...

Page 26: ...Side includes items 7 11 6 Beverage Cooler Kit Passenger Side includes items 8 12 7 23 24 25 26 27 21 Sand Bottle Kit includes items 22 27 22 Sand Bottle Assembly includes items 23 24 14 19 18 13 Sand Bottle Kit includes items 14 18 Sand Bottle Kit includes items 15 19 16 17 15 20 ...

Page 27: ...LANGED HEX HEAD BOLT M10 1 5 X 34mm LG 4 9 608520 POLYPROPYLENE WASHER 4 10 606274 FLANGED HEX NUT M10 1 25 4 11 601366 BEVERAGE COOLER 1 12 603777 MOUNTING BRACKET PASSENGER SIDE not shown in illustration 1 13 614179 SAND BOTTLE KIT includes items 14 18 1 14 600612 SAND BOTTLE ASSEMBLY 1 15 28660G01 SAND BOTTLE ASSEMBLY HOLDER 1 16 603800 FLANGE HEAD BOLT M10 1 5 X 50mm LG 1 17 16816G2 RATCHET RI...

Page 28: ...cludes items 16 20 15 Club Ball Washer Kit Passenger Side includes items 17 21 20 19 18 19 16 21 17 17 3 4 6 5 10 1 Divot Repair Kit Driver Side includes items 3 10 2 Divot Repair Kit Passenger Side includes items 4 11 7 Divot Repair Bucket Assembly includes items 8 9 8 9 11 ...

Page 29: ...EAD BOLT M10 1 5 X 34mm LG 4 5 608520 POLYPROPYLENE WASHER 4 6 606274 FLANGED HEX NUT M10 1 25 4 7 605702 DIVOT REPAIR BUCKET ASSEMBLY includes items 8 9 1 8 607635 DIVOT REPAIR BUCKET TOP 1 9 607881 DIVOT REPAIR BUCKET BOTTOM 1 10 74848G01 SCOOP 1 11 603824 MOUNTING BRACKET PASSENGER SIDE 1 12 13 14 604216 CLUB BALL WASHER KIT DRIVER SIDE includes items 16 20 1 15 603252 CLUB BALL WASHER KIT PASS...

Page 30: ...Page C 15 Service Parts Manual BODY E D 8 6 7 12 13 13 D B A C 6 7 8 C 1 2 3 4 A 9 10 11 E 5 7 8 B 16 15 14 ...

Page 31: ...SEMBLY 1 2 608956 BOTTOM RACK ASSEMBLY 1 3 17651G2 CLEVIS PIN 5 16 X 1 250 1 4 28129G01 CAP NUT 5 16 PLASTIC 1 5 17651G2 CLEVIS PIN 5 16 X 1 250 1 6 17651G3 CLEVIS PIN 5 16 X 0 625 2 7 00559G8 FLAT WASHER 5 16 3 8 28129G01 CAP NUT 5 16 BLACK 3 9 17651G1 CLEVIS PIN 3 8 X 1 250 2 10 00560G1 FLAT WASHER 3 8 2 11 28128G02 CAP NUT 3 8 BLACK 2 12 17641G1 STRAP 2 13 75337G01 KNOB 5 16 18 THRU HOLE 2 14 6...

Page 32: ...Page C 17 Service Parts Manual Notes BODY ...

Page 33: ...Page C 18 Service Parts Manual Notes BODY ...

Page 34: ...Page D 1 Service Parts Manual BRAKES 6 3 4 1 2 17 16 15 13 12 11 5 Brake Pedal Assembly includes items 2 10 7 9 10 8 ...

Page 35: ...LECTRIC INCLUDES ITEMS 2 10 1 2 610471 BRAKE PEDAL PAD 1 3 600019 ROTARY POSITION SENSOR 1 4 600543 BUTTON HEAD TORX BOLT M4 7 X 13 2 5 607605 BRAKE PEDAL SWITCH 1 6 620030 SOCKET HEAD CAP SCREW M5 0 8 X 10 2 7 609226 SWITCH BUTTON BRACKET 1 8 604097 REBOUND BUMPER 2 9 613231 BOLT HEX HD M6 1 X 20 2 10 601327 LOCK WASHER 6MM 2 11 605688 BRAKE PEDAL COVER 1 12 600543 BOLT HEX HD M6 1 X 20 2 13 6052...

Page 36: ...Page D 3 Service Parts Manual BRAKES 6 5 4 3 1 ...

Page 37: ...le as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page D 4 Service Parts Manual BRAKES 1 610065 6 MOTOR BRAKE 1 2 3 73715G01 FLANGED HEX HEAD SCREW M6 1 X 60 3 4 00664 G7 LOCK WASHER STAINLESS STEEL 1 4 3 5 612842 BRAKE COVER PLATE 1 ...

Page 38: ...remove battery wires ALWAYS turn key to OFF before disconnecting or reconnecting battery wires ELECTRICAL ARC or BATTERY EXPLOSION can occur if key is not in the OFF position Failure to follow these instructions can result in SERIOUS INJURY or DEATH Turn the ignition key to the N position and chock tires to prevent inadvertent movement Remove this plastic cover by removing 3 plastic fasteners See ...

Page 39: ...NESS 48V INCLUDES ITEMS 8 11 15 1 8 608899 REVERSE WARNING INDICATOR KIT INCLUDES ITEMS 9 10 1 9 608882 REVERSE WARNING INDICATOR 1 10 608896 WATERPROOF BUTT SPLICE 2 11 608900 RUN TOW SWITCH KIT INCLUDES ITEMS 12 14 1 12 606980 RUN TOW SWITCH 1 13 608896 WATERPROOF BUTT SPLICE 2 14 605969 RUBBER BOOT 1 15 608039 RUN PLUG JUMPER 1 16 605969 RUBBER BOOT RUN TOW SWITCH 1 17 01051G1 PAN HEAD PHILLIPS...

Page 40: ...able electrical system turn key switch to OFF and remove battery wires ALWAYS turn key to OFF before disconnecting or reconnecting battery wires ELECTRICAL ARC or BATTERY EXPLOSION can occur if key is not in the OFF position Failure to follow these instructions can result in SERIOUS INJURY or DEATH Turn the ignition key to the N position and chock tires to prevent inadvertent movement Remove this ...

Page 41: ...WITCH DECAL 1 5 609987 MAINTENANCE TOWING DECAL 1 6 609694 TOWING INSTRUCTION NOTICE DECAL 1 7 618950 MAIN ELECTRICAL HARNESS 48V INCLUDES ITEMS 8 11 15 1 8 608899 REVERSE WARNING INDICATOR KIT INCLUDES ITEMS 9 10 1 9 608882 REVERSE WARNING INDICATOR 1 10 608896 WATERPROOF BUTT SPLICE 2 11 608900 RUN TOW SWITCH KIT INCLUDES ITEMS 12 14 1 12 606980 RUN TOW SWITCH 1 13 608896 WATERPROOF BUTT SPLICE ...

Page 42: ...Parts Manual ELECTRICAL 1 2 3 4 1 2 3 4 1 2 3 4 610990 610991 32 41 35 36 33 42 34 Charger Receptacle State of Charge Meter Kit Includes Item 44 Solenoid 40 44 49 50 43 Speedometer Kit Includes Items 49 and 50 48 47 46 ...

Page 43: ...WITCH R N F 1 33 612956 KEY 1 34 602529 CHARGER RECEPTACLE 48V DELTA Q 1 35 602409 BARREL CLIP M6 1 1 36 601326 BUTTON HEAD TORX BOLT M6 1 X 20mm LG 4 37 38 39 40 607707 WHITE WIRE ASSEMBLY 10 AWG X 260mm 1 41 609682 KEY SWITCH R N F 1 42 609680 KEY 1 43 610583 STATE OF CHARGE METER KIT INCLUDES ITEM 44 1 44 612314 STATE OF CHARGE METER 1 45 46 610991 CE SPALSH SHEILD WARNING 1 47 610990 CE BRAKE ...

Page 44: ...Page E 7 Service Parts Manual ELECTRICAL 1 4 18 25 21 12 9 10 7 8 22 21 11 14 17 28 13 2 3 4 12V BATTERY SYSTEM 30 24 26 ...

Page 45: ...ERY 12V 175AMP 1 9 641824 BATTERY US 12V 4 10 641825 BATTERY US 12V 4 11 601695 BATTERY HOLD DOWN 1 12 602896 BATTERY HOLD DOWN ROD 3 13 00571G2 FLAT WASHER 5 16 3 14 11098G6 LOCK NUT 5 16 18 3 15 16 600525 LOCK NUT M10 1 5 NOT ILLUSTRATED 2 17 608315 BATTERY STRAP 1 18 602572 PAN HEAD TORX BOLT M10 1 5 X 25mm LG 2 19 20 21 602930 BLUE WIRE ASSEMBLY 6 GA X 261mm 2 22 607057 BLUE WIRE ASSEMBLY 6 GA...

Page 46: ...Page E 9 Service Parts Manual ELECTRICAL 6 8V BATTERY SYSTEM 4 4 2 20 1 8 9 12 6 29 24 21 23 14 19 17 15 25 7 10 11 3 4 30 26 28 ...

Page 47: ... 8 627656 BATTERY TRAY WELDMENT 1 9 628617 BATTERY TRAY WELDMENT GALVANIZED 1 10 624288 BATTERY RETAINER SHORT 1 11 628619 BATTERY RETAINER SHORT GALVANIZED 1 12 614457 SNAKE HYDROLINK 1 13 14 01101G01 TIE DOWN BOLT 2 15 11027G1 FLANGED LOCK NUT 5 16 18 2 16 17 602572 PAN HEAD TAPTITE BOLT M10 1 5 X 25MM LG 2 18 19 603799 HEX HEAD BOLT M10 1 5 X 25MM LG 2 20 603818 BARREL CLIP M10 1 5 2 21 612867 ...

Page 48: ...embly 8 7 5 2 9 10 4 Horn Assembly Kit includes items 5 10 13 DC to DC Converter Kit includes items 14 28 19 DC to DC Converter Assembly includes items 20 27 25 26 20 27 15 18 14 25 21 22 23 24 17 16 28 For Models before 02 October 2013 For Models from 02 October 2013 ...

Page 49: ...RX BOLT M6 1 X 20mm LG 1 8 601476 LOCK NUT M6 1 1 9 01072G01 CABLE CLIP 3 10 608397 HORN PLATE 1 11 12 13 628607 DC TO DC CONVERTER KIT INCLUDES ITEMS 14 28 1 14 608290 SELF TAPPING SCREW 10 16 2 15 16816G5 RATCHET RIVET 0 187 X 0 550 1 16 00702G2 HEX NUT 5 16 18 2 17 25682G01 RUBBER TERMINAL BOOT 2 18 608182 DC DC HARNESS 20A 1 19 632184 DC DC CONVERTER ASSEMBLY INCLUDES ITEMS 20 27 1 20 632183 D...

Page 50: ...il Light Kit includes items 16 22 16 Tail Light Hardware Kit includes items 17 18 19 Tail Light Assembly Driver Side includes items 21 22 20 Tail Light Assembly Passenger Side includes items 21 22 2 Headlight Kit includes items 3 12 3 Headlight Assembly Driver Side includes items 5 11 13 4 Headlight Assembly Passenger Side includes items 6 13 1 13 ...

Page 51: ...608322 BULB RETAINER 1 9 608328 BUTTON HEAD TORX SCREW PLASTITE 1 10 607487 TURN SIGNAL WIRE HARNESS 1 11 607434 HEADLIGHT RETAINING CLIP 4 12 607437 GASKET PASSENGER SIDE 1 13 615459 COLLAR HEADLIGHT 1 14 15 607450 TAIL LIGHT KIT INCLUDES ITEMS 16 22 1 16 607474 TAIL LIGHT HARDWARE KIT INCLUDES ITEMS 17 18 1 17 601326 BUTTON HEAD TORX BOLT M6 1 X 20mm LG 8 18 602409 BARRELL CLIP M6 8 19 603325 TA...

Page 52: ...Page E 15 Service Parts Manual ELECTRICAL 2 1 3 ...

Page 53: ...t 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 E 16 Service Parts Manual ELECTRICAL 1 638233 ELECTRONICS BOX 1 2 639384 USB PORT 1 3 17618G1 NYLON CLAMP 2 4 638585 USB HARNESS NOT ILLUSTRATED 1 ...

Page 54: ...Page E 15 Service Parts Manual Notes ELECTRICAL ...

Page 55: ...Page E 16 Service Parts Manual Notes ELECTRICAL ...

Page 56: ...Page F 1 Service Parts Manual ELECTRONIC SPEED CONTROL 1 4 CURTIS CONTROLLER KIT includes items 3 5 22 2 CURTIS CONTROLLER KIT includes items 4 5 22 11 18 14 13 5 2 6 10 15 3 19 7 9 12 16 17 8 22 23 20 ...

Page 57: ... SCREW M8 2 6 73876G01 FLANGED BOLT M6 1 00 X 12mm LG 6 7 619001 RESISTOR 86 OHM RATING 1 8 00571G2 FLAT WASHER 5 16 4 9 00565G8 LOCK WASHER 5 16 2 10 606264 HEX FLANGED BOLT M6 1 X 20mm LG 4 11 623433 HEAT SHIELD 1 12 607707 WHITE WIRE ASSEMBLY 10AWG 1 13 623213 CONTROLLER BRACKET RH 1 14 623170 CONTROLLER BRACKET LH 1 15 624618 BLACK WIRE ASSEMBLY 6AWG 830mm 1 16 624611 WHITE WIRE ASSEMBLY 10AWG...

Page 58: ...Page F 3 Service Parts Manual ELECTRONIC SPEED CONTROL 1 DANAHER TO CURTIS CONTROLLER SWAP KIT 350A includes items 2 20 2 4 10 13 14 18 15 16 11 19 20 17 5 12 9 7 8 3 6 ...

Page 59: ...RNESS ASSEMBLY 1 4 626118 ADAPTOR 23 PIN TO 23 PIN 1 5 624611 WHITE WIRE ASSEMBLY 10AWG 400mm 1 6 645964 HEAT SHIELD 1 7 623213 CONTROLLER BRACKET RH 1 8 623170 CONTROLLER BRACKET LH 1 9 619001 RESISTOR 86 OHM RATING 1 10 614898 SPLICE 2 OR 3 WIRE 2 11 608290 SELF TAPPING SCREW 10 16 X 780 LG 2 12 607707 WHITE WIRE ASSEMBLY 10AWG 1 13 606264 HEX FLANGED BOLT M6 1 X 20mm LG 4 14 605957 BOSS SCREW M...

Page 60: ...uspension Assembly Driver Side includes items 2 16 Front Suspension Assembly Passenger Side includes items 18 32 44 Strut Spindle Assembly Passenger Side includes items 18 20 22 32 45 42 Strut Spindle Assembly Driver Side includes items 2 4 6 16 43 43 45 13 13 14 10 Hub Assembly includes items 11 14 26 Hub Assembly includes items 27 30 30 19 20 3 4 ...

Page 61: ...25 X 145MM LG 1 9 600549 HEX FLANGE NUT M12 1 25 1 10 609603 HUB ASSEMBLY INCLUDES ITEMS 11 14 1 11 19862G1 WHEEL STUD 4 12 602340 HUB CAST MACH 1 13 602341 BALL BEARING 47 X 20 X 14 2 14 602342 TUBE BEARING SPACER 1 15 615109 LOCK NUT M16 2 1 16 12091G2 SPINDLE CAP 1 17 620672 SHOCK ABSORBER ASSEMBLY PASSENGER SIDE INCLUDES ITEMS 18 32 1 18 610802 SPINDLE ASSEMBLY PASSENGER SIDE 1 19 632925 FLANG...

Page 62: ...091G2 SPINDLE CAP 1 33 602415 HEX HEAD FLANGE BOLT M10 1 5 X 80 2 34 600525 LOCK NUT M10 1 5 2 35 36 608089 A ARM ASSEMBLY 2 37 601340 A ARM BUSHING 4 38 602085 A ARM CARRIER TUBE 2 39 601754 HEX HEAD FLANGE BOLT M10 1 5 X 90 2 40 600525 LOCK NUT M10 1 5 6 41 602415 HEX HEAD FLANGE BOLT M10 1 5 X 80 4 42 638947 STRUT SPINDLE ASSEMBLY DRIVER SIDE INCLUDES ITEMS 2 4 6 16 43 1 43 639431 STRUT ASSEMBL...

Page 63: ...te stop BEFORE shifting the direction selector Operate from the driver s seat ONLY Operate from the driver s seat ONLY PARKING PARKING ALWAYS fully engage the parking brake and remove the key BEFORE leaving the vehicle In an electric ALWAYS fully engage the parking brake and remove the key BEFORE leaving the vehicle In an electric vehicle set the direction selector to neutral and in a gasoline veh...

Page 64: ...ELLOWS CLIP large end 1 8 9 602020 TORX SOCKET HEAD CAP SCREW M10 1 5 X 80 3 10 608005 CASTLE HEX NUT M12 1 25 2 11 10387G2 COTTER PIN 2 12 13 14 600333 STEERING COLUMN ASSEMBLY INCLUDES ITEMS 15 20 1 15 608117 STEERING COLUMN SUB ASSEMBLY 1 16 604613 YOKE SUB ASSEMBLY KIT INCLUDES ITEMS 17 20 1 17 608114 STEERING YOKE 1 18 608653 SOCKET HEAD BOLT M10 1 5 X 35MM LG 2 19 608654 LOCK WASHER M10 5 2 ...

Page 65: ...Page G 6 Service Parts Manual Notes FRONT SUSPENSION ...

Page 66: ...Page H 1 Service Parts Manual MOTOR 2 4 3 1 ...

Page 67: ...vice Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page H 2 Service Parts Manual MOTOR 1 611355 48V AC ELECTRIC MOTOR 1 2 605714 FLEXLOOM SLEEVE 1 3 601327 LOCK WASHER M6 6 4 605741 HEX HEAD BOLT M6 1 X 25 grade 10 9 6 5 17618G1 NYLON CLAMP NOT ILLUSTRATED 1 6 27327G02 TWISTED CLAMP NOT ILLUSTRATED 1 7 32372G6 VINYL TRIM 6 25 NOT ILLUSTRATED 1 ...

Page 68: ...44 45 46 11 10 47 49 50 50 51 51 53 54 12 LIGHT DUTY ELECTRIC AXLE ASSEMBLY 16 99 1 includes items 2 55 1 LIGHT DUTY ELECTRIC AXLE 16 99 1 includes items 10 55 9 14 22 26 31 INPUT GEAR KIT includes items 15 20 INTERNAL GEARS KIT includes items 15 23 24 BALL BEARING KIT includes items 19 20 27 29 DIFFERENTIAL COVER ASSY KIT includes items 32 33 41 10 ...

Page 69: ...ASHER 64 I D X 1 34 O D 2 7 8 9 630902 LIGHT DUTY ELECTRIC AXLE 16 99 1 INCLUDES ITEMS 10 55 1 10 AXLE HOUSING 1 11 15118G1 FLANGED HEX HEAD BOLT 3 8 16 X 2 12 LG 4 12 618650 AXLE BRACKET LOCATING PIN 13 14 620329 INPUT GEAR KIT INCLUDES ITEMS 15 20 1 15 620327 INPUT GEAR 1 16 620328 OIL SEAL 1 17 23530G1 RETAINING RING 1 DIA 1 18 24628G1 O RING SEAL 1 8 I D 1 19 23519G2 BALL BEARING 0 984 I D X 1...

Page 70: ...COVER PLATE 1 34 35 36 608811 END CAP PLUG 2 37 614208 AXLE SHAFT DRIVER SIDE LONG 1 38 614209 AXLE SHAFT PASSENGER SIDE SHORT 1 39 620342 RETAINING RING 4 40 620343 BALL BEARING 2 41 620344 OIL SEAL 2 42 620345 O RING 2 43 44 614059 CARRIER LSD W CC CLUTCHES 1 45 601084 LOCK NUT 3 8 24 4 46 620335 FLANGED HEX HEAD BOLT 3 8 24 X 1 25 LG 4 47 620346 SELF TAPPING FLANGED HEX HEAD BOLT 5 16 18 X 0 75...

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

Page 72: ...Page K 1 Service Parts Manual REAR SUSPENSION 6 7 1 2 5 22 24 23 23 9 9 10 11 12 18 15 16 15 17 19 For models manufactured before 5th March 2013 Front of vehicle ...

Page 73: ... U BOLT M10 1 5 X 115 6 MM LG 2 6 612765 LEAF SPRING PLATE 2 7 614974 LOCK NUT M10 1 5 4 8 9 620160 FLANGED BUSHING LARGE 4 10 620161 SPLIT STEEL SPACER 394 I D X 51 O D X 2 65 LG 2 11 601754 FLANGED HEX HEAD BOLT M10 1 5 X 100 MM LG 2 12 614974 LOCK NUT M10 1 5 2 13 14 15 624030 FLANGED BUSHING SMALL 8 16 620161 SPLIT STEEL SPACER 394 I D X 51 O D X 2 65 LG 4 17 603648 SHACKLE PLATE 4 18 601754 F...

Page 74: ...Page K 3 Service Parts Manual REAR SUSPENSION Front of Vehicle 20 2 3 For models manufactured after 5th March 2013 15 3 12 17 18 16 21 11 5 8 4 7 1 6 13 ...

Page 75: ...PRING 2 3 614974 LOCK NUT M10 1 5 6 4 603648 SHACKLE PLATE 4 5 624030 FLANGED BUSHING SMALL 8 6 620160 FLANGED BUSHING LARGE 4 7 601754 FLANGED HEX HEAD BOLT M10 1 5 X 100 MM LG 6 8 620161 SPLIT STEEL SPACER 394 I D X 51 O D X 2 65 LG 6 9 10 11 625658 SHOCK MOUNT PLATE PASENGER SIDE 1 12 625657 SHOCK MOUNT PLATE DRIVER SIDE 1 13 626422 AXLE SUPPORT BRACKET 2 14 15 76418G01 SHOCK ABSORBER 2 16 1043...

Page 76: ...TING BASKET 35 36 34 38 40 21 22 23 24 25 34 18 18 16 14 14 39 8 7 11 11 5 2 3 4 1 10 9 15 28 6 33 1 Seat Bottom Assembly includes items 2 11 21 Seat Back Assembly includes items 22 26 32 Sweater Basket Assembly includes items 33 36 32 ...

Page 77: ...4 605502 SEAT BOTTOM WOODEN BASE ASSEMBLY 1 5 602551 SEAT BOTTOM COVER PLATE 1 6 16816G2 RATCHET RIVET 25 X 887 4 7 71610G01 SEAT HINGE 2 8 00720G08 FLAT HEAD PHILLIPS TAPPING SCREW 12 14 X 1 LG 6 9 617645 HIP RESTRAINT DRIVER SIDE 1 10 617644 HIP RESTRAINT PASSENGER SIDE 1 11 600530 BUTTON HEAD TORX BOLT M10 1 5 X 25 MM LG 8 12 13 14 602413 SEAT BACK SUPPORT STRUT 2 15 603800 FLANGED HEX HEAD BOL...

Page 78: ...4 605550 SEAT BACK WOODEN BASE ASSEMBLY 1 25 605529 SEAT BACK BLACK PLASTIC COVER 1 26 23222G1 FLAT STAPLE SS 3 8 NOT ILLUSTRATED AR 27 28 600527 BUTTON HEAD TORX BOLT M10 1 5 X 60 MM LG 4 29 30 31 32 602742 SWEATER BASKET ASSEMBLY includes items 33 36 1 33 610607 SWEATER BASKET 1 34 608051 BAG STRAP CLAMP 2 35 16816G1 CHRISTMAS TREE RIVET 2 36 604102 BAG STRAP 1 37 38 600530 BUTTON HEAD TORX BOLT...

Page 79: ...EVER leave children unattended Children may need assistance to remain properly seated and holding on AVOID standing in front of or behind vehicle ONLY 2 occupants per seat Always remain PROPERLY SEATED and HOLDING ON 608537 608820 www ezgo com 12 13 19 1 37 30 31 32 33 34 35 17 14 20 20 8 9 7 21 5 5 8 6 2 3 23 24 25 26 21 41 40 27 16 23 Seat Bottom Assembly includes items 24 26 30 Seat Back Assemb...

Page 80: ... 1 5 4 10 11 604457 REAR FACING SEAT FLOORBOARD ASSEMBLY includes items 12 15 1 12 611116 FOOTREST WELDMENT 1 13 608537 REAR FACING SEAT WARNING DECAL 1 14 19853G1 END CAP 2 15 640653 FOOTREST GRIPTAPE 1 16 604407 RUBBER FLOORMAT 1 17 603799 HEX HEAD FLANGED BOLT M10 1 5 X 25 MM LG 4 18 19 608820 2 2 WARNING DECAL CE 1 20 602415 HEX HEAD FLANGED BOLT M10 1 5 X 80 MM LG 2 21 600525 LOCK NUT M10 1 5...

Page 81: ...SSEMBLY select color below 1 605548 STONE BEIGE SEAT BACK ASSEMBLY 608012 OYSTER SEAT BACK ASSEMBLY 31 SEAT BACK VINYL COVER select color below 1 605537 STONE BEIGE SEAT BACK VINYL COVER 608006 OYSTER SEAT BACK VINYL COVER 32 71754G01 SEAT BACK FOAM 1 33 605550 SEAT BACK WOODEN BASE ASSEMBLY 1 34 605529 SEAT BACK BLACK PLASTIC COVER 1 35 603000 BUTTON HEAD TORX SCREW M6 15 4 36 37 600530 BUTTON HE...

Page 82: ...AYS drive straight up and down slopes not exceeding 14 25 grade Do not coast use BRAKE when going down a slope NEVER drive this vehicle under the influence of drugs or alcohol AVOID FALLS from the vehicle DO NOT start moving until all occupants are PROPERLY SEATED with SEAT BELT FASTENED and HOLDING ON KEEP entire body INSIDE VEHICLE while moving Failure to follow these instructions can result in ...

Page 83: ... 2 5 611254 SEAT BELT RETRACTOR ASSENBLY 4 6 602415 FLANGED HEX HEAD BOLT M10 1 5 X 80 MM 4 7 600525 FLANGED LOCK NUT M10 1 5 4 8 604066 FLAT WASHER M10 4 9 00560G2 FLAT WASHER 3 8 16 10 620770 HEX HEAD SHOULDER BOLT 7 16 20 X 2 28 LG 4 11 612346 HEX HEAD BOLT 7 16 20 X 2 50 LG 2 12 610753 HEX HEAD CAP SCREW 7 16 20 X 1 LG 8 13 00734G3 LOCK NUT 7 16 20 14 14 605686 VINYL CAP 4 15 612194 CUP HOLDER...

Page 84: ...Page L 9 Service Parts Manual REAR FACING SEAT EXCEED MODEL 1 2 3 4 5 6 7 8 9 9 10 10 10 11 12 13 14 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33 27 FOR LATER MODELS ...

Page 85: ...R M10 X 22 X 2 5 MM 4 8 602415 HEX FLANGE BOLT M10 1 5 X 80 2 9 600530 BULK HEAD TORQUE BOLT M10 1 5 X 25 6 10 600525 PULSE LOCK NUT M10 1 5 8 11 71609G01 SEAT HINGE PLATE 2 12 10570G11 RIVET 3 16 X 70 TYPE B SS 4 13 603818 BARREL CLIP M10 1 5 2 14 603799 HEX HEAD FLANGE BOLT M10 1 5 X 25 6 15 18436G1 PLASTIC DRIVE RIVET 8 16 REAR FACING SEAT BOTTOM INCLUDES ITEMS 17 25 1 610678 OYSTER 609513 BEIG...

Page 86: ... consult Customer Service Department for additional information ITEM PART N O 1 2 3 4 5 DESCRIPTION QTY REAR FACING SEAT EXCEED MODEL 28 SEAT BACK ASSEMBLY INCLUDES ITEMS 29 33 1 615573 BEIGE 615574 OYSTER 29 23222G1 FLAT STAPLE 3 8 AR 30 71754G01 SEAT BACK FOAM PADDING 1 31 605550 SEAT BACK WOOD BASE 1 32 605529 SEAT BACK COVER 1 33 SEAT BACK VINYL COVER 620914 BEIGE 71753G03 OYSTER ...

Page 87: ...Page L 12 Service Parts Manual Notes REAR FACING SEAT EXCEED MODEL ...

Page 88: ...age M 1 Service Parts Manual TOW BAR 4 PERMANENT REAR TOW BAR includes items 5 20 17 11 19 5 1 8 2 12 14 13 15 14 23 22 26 3 10 7 16 18 6 25 29 33 21 32 27 24 9 20 Front Of Vehicle Front of Vehicle 28 35 ...

Page 89: ...SHER 1 2 2 8 613215 TOW BAR PULL HANDLE 1 9 617787 FLANGED LOCK NUT M12 1 75 1 10 75065G01 COMPRESSION SPRING 1 11 614893 FRONT PIN GUIDE 1 12 75360G01 PIVOT PIN 1 13 608793 SPIROL PIN 3MM X 22MM 1 14 75340G01 DELRIN WASHER M10 22MM 2 15 625458 TOW BAR SWIVEL 1 16 800178 PHILLIPS HEAD SCREW 8 32 X 1 2 LG 1 17 624868 TOW BAR WARNING DECAL 1 18 614454 TIE ROD HOLDER 1 19 606265 HEX HEAD BOLT M6 1 X1...

Page 90: ...f 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 TOW BAR 32 625066 TOW BALL ASSEMBLY 1 33 614394 HITCH BALL SPACER 34 9MM 1 34 35 639520 TIE ROD SPACER 1 ...

Page 91: ...Page M 4 Service Parts Manual Notes TOW BAR ...

Page 92: ...Page M 5 Service Parts Manual TOW BAR 1 PERMANENT FRONT TOW BAR includes items 2 12 Front Of Vehicle 2 TOW BAR STEERING LINK includes items 3 8 11 12 18 19 14 8 5 7 3 14 10 6 4 17 ...

Page 93: ...WED VEHICLE INCLUDES ITEMS 2 12 1 2 601624 TOW BAR STEERING LINK INCLUDES ITEMS 3 8 1 3 603297 TOW BAR TIE ROD 1 4 603322 LEFT HAND TIE ROD END 1 5 601266 RIGHT HAND TIE ROD END 1 6 603487 JAM NUT M12 1 25 LH THREAD 1 7 603488 JAM NUT M12 1 25 RH THREAD 1 8 608739 SPACER 28MM 1 9 10 601389 FRONT TOW BAR CASTING 1 11 606073 BEARING 1 12 607322 INTERNAL SNAP RING 1 13 14 617787 HEX NUT M12 1 75 2 15...

Page 94: ...eceiver Spindle Arm Rear Body REMOVABLE TOW BAR ASSEMBLY includes items 19 30 15 33 16 15 14 8 7 9 10 11 3 12 32 34 17 2 1 4 18 FRONT TOW BAR ASSEMBLY includes items 6 17 5 26 28 27 26 29 21 25 22 20 23 24 19 Front of Vehicle Front of Vehicle 13 6 ...

Page 95: ...42G01 FLAT WASHER 1 75 O D X 781 I D 1 11 00518G8 CASTLE NUT 3 4 16 1 12 10387G1 COTTER PIN 125 X 1 50 1 13 601709 LOCK NUT M16 2 1 14 635464 PIVOT BOLT 1 15 617787 LOCK NUT M12 1 75 2 16 639520 TIE ROD SPACER 1 17 639552 TIE ROD 1 18 635736 REMOVABLE TOW BAR ASSEMBLY INCLUDES ITEMS 19 30 1 19 635428 TOW BAR TONGUE WELDMENT 1 20 635461 TOW BAR COUPLING WELDMENT 1 21 620161 SPLIT STEEL SPACER 1 22 ...

Page 96: ...al 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 NO 1 2 3 4 5 DESCRIPTION QTY TOW BAR 32 635757 DRILL TEMPLATE 1 33 614714 TIE ROD SPACER 1 34 617752 TIE ROD 1 ...

Page 97: ...Page M 10 Service Parts Manual Notes TOW BAR ...

Page 98: ...TION 1 Stone Beige Sun Top Kit includes items 2 7 7 Strut Kit includes items 8 11 11 Sun Top Hardware Kit includes items 12 16 3 Oyster Sun Top Kit includes items 4 7 5 Black Sun Top Kit includes items 6 7 14 9 10 8 2 12 15 16 4 6 13 14 14 13 13 ...

Page 99: ...98 SUN TOP STONE BEIGE 1 3 608695 SUN TOP KIT OYSTER includes items 4 7 1 4 608015 SUN TOP OYSTER 1 5 613233 SUN TOP KIT BLACK includes item 6 7 1 6 613227 SUN TOP BLACK 7 608677 SUN TOP STRUT KIT includes items 8 11 1 8 603203 FRONT STRUT 1 9 614310 REAR STRUT PASSENGER SIDE 1 10 614309 REAR STRUT DRIVER SIDE 1 11 607013 SUN TOP HARDWARE KIT includes items 12 16 1 12 602415 HEX HEAD FLANGED BOLT ...

Page 100: ... 2 2 2 Oyster Sun Top Kit includes items 4 14 21 1 2 2 Stone Beige Sun Top Kit includes items 3 14 8 2 2 Sun Top Hardware Kit includes items 9 13 14 2 2 Sun Top Hardware Kit includes items 15 20 6 3 21 5 4 20 4 3 5 6 5 6 10 3 9 7 17 19 16 18 11 12 13 ...

Page 101: ...EAR STRUT DRIVER SIDE 1 6 604424 2 2 REAR STRUT PASSENGER SIDE 1 7 603800 HEX HEAD FLANGED BOLT M10 1 5 X 50 1 8 610468 2 2 SUN TOP HARDWARE KIT includes items 9 13 1 9 601414 HEX HEAD FLANGED BOLT M10 1 5 X 65 4 10 602415 HEX HEAD FLANGED BOLT M10 1 5 X 80 4 11 600525 FLANGED LOCK NUT M10 1 5 4 12 602770 STRUT GROMMET DRIVER SIDE 1 13 602992 STRUT GROMMET PASSENGER SIDE 1 14 610472 2 2 SUN TOP HA...

Page 102: ...Page N 5 Service Parts Manual WEATHER PROTECTION 1 2 ...

Page 103: ...s 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 N 6 Service Parts Manual WEATHER PROTECTION 1 604666 BAG COVER KIT STONE BEIGE 1 2 620604 BAG COVER KIT OYSTER 1 ...

Page 104: ...e N 7 Service Parts Manual WEATHER PROTECTION 4 11 12 10 8 5 6 1 Split Windshield Kit includes items 2 11 2 Split Windshield Assembly includes items 3 5 9 Split Windshield Hardware Kit includes items 10 12 ...

Page 105: ... Service Parts Manual WEATHER PROTECTION 1 606584 SPLIT WINDSHIELD KIT includes items 2 11 1 2 606623 SPLIT WINDSHIELD ASSEMBLY includes items 3 5 1 3 603738 SPLIT WINDSHIELD 1 4 603201 LOWER WINDSHIELD LATCH 2 5 603198 UPPER WINDSHIELD LATCH 2 6 604115 WINDSHIELD ISOLATOR 2 7 8 603852 WINDSHIELD ATTACHMENT SASH 2 9 607014 SPLIT WINDSHIELD HARDWARE KIT includes items 10 11 1 10 604116 GROMMET 2 11...

Page 106: ...SEMBLY includes items 25 27 22 19 15 9 1 2 5 6 13 20 21 10 11 LINKS STONE BEIGE WHEEL TIRE ASSEMBLY includes items 9 10 13 LINKS WHITE WHEEL TIRE ASSEMBLY includes items 9 11 13 USA STONE BEIGE WHEEL TIRE ASSEMBLY includes items 9 10 15 USA WHITE WHEEL TIRE ASSEMBLY includes items 9 11 15 ...

Page 107: ...STONE BEIGE WHEEL TIRE ASSEMBLY includes items 9 10 15 1 6 28842G01 USA WHITE WHEEL TIRE ASSEMBLY includes items 9 11 15 1 7 8 9 11657G2 VALVE STEM 1 10 603172 STONE BEIGE WHEEL 1 11 28759G01 WHITE WHEEL 1 12 13 28764G01 CARLISLE LINKS TIRE 18 X 8 5 8 1 14 15 28764 G08 CARLISLE USA TRAIL TIRE 18 5 X 8 5 8 1 16 17 18 19 607096 HUB CAP SILVER 4 20 14723 G1 LUG NUT 1 2 20 UNF 4 21 74175 G01 DUST CAP ...

Page 108: ...Page P 3 Service Parts Manual WHEELS AND TIRES 2 3 1 4 ...

Page 109: ...ividual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page P 4 Service Parts Manual WHEELS AND TIRES 1 608291 WHEEL COVER CHROME SS 8 4 2 608292 WHEEL COVER CHROME E Z GO 8 4 3 608627 WHEEL COVER CHROME SILVER E Z GO 8 4 4 608629 WHEEL COVER CHROME SILVER SS 8 4 ...

Page 110: ...Page R 1 Service Parts Manual FRAME 5 4 8 6 3 2 7 9 1 For models manufactured after 5th March 2013 For models manufactured before 5th March 2013 ...

Page 111: ...e R 2 Service Parts Manual FRAME 1 618726 FRAME WELDMENT For models manufactured before 5th March 2013 1 2 631180 FRAME WELDMENT For models manufactured after 5th March 2013 1 3 614597 IP SUPPORT WELDMENT 1 4 600218 SEAT SUPPORT BRACKET DRIVER SIDE 1 5 628614 SEAT SUPPORT BRACKET PASSENGER SIDE 1 6 601275 SEAT SUPPORT BRACE 1 7 602572 PAN HEAD TORX BOLT M10 1 5 X 25mm LG 4 8 603799 HEX HEAD FLANGE...

Page 112: ...Page R 3 Service Parts Manual Notes FRAME ...

Page 113: ......

Page 114: ...al may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA ...

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