EZGO Textron Electric And 4-Cycle Gasoline powered Golf Car Service Parts Manual

4-CYCLE GASOLINE POWERED GOLF CAR

SERVICE PARTS MANUAL

MODEL YEARS 1991/1992

MANUAL NO. 27150-G01

ISSUED 9/05/91

SERVICE PARTS MANUAL 4-CYCLE GASOLINE POWERED GOLF CAR MODEL YEARS: 1991/1992 MANUAL NO. 27150-G01 ISSUED: 9/05/91

CARS

GX 444 / 4 GX 444F / 4

E-Z-GO DIVISION OF TEXTRON, INC., P.O. BOX 388, AUGUSTA, GEORGIA 30913-2699

Pg. i

LIMITED WARRANTY

WARRANTY TO OBTAIN A COPY OF THE LIMITED WARRANTY THAT IS APPLICABLE TO YOUR VEHICLE, CALL OR WRITE YOUR LOCAL DISTRIBUTOR, BRANCH, OR E-Z-GO WARRANTY DEPARTMENT. THE USE OF NON E-Z-GO PARTS MAY VOID YOUR WARRANTY OVERFILLING OF BATTERIES MAY VOID YOUR WARRANTY TAMPERING WITH OR ADJUSTING OF GOVERNOR TO PERMIT THE VEHICLE TO OPERATE AT ABOVE FACTORY SETTINGS (13-14 M.P.H.) WILL VOID YOUR VEHICLE WARRANTY.

Pg. ii

9/05/91 I I I I 11-141

GENERAL INDEX SECTIONS

Page No.

How to use the E-Z-GO Service Parts Manual ...••.•.........................•.••..•••••••.... vii

ILLUSTRATION

Illustration

Page No.

ACCELERATOR AND HILL BRAKE LINKAGE .•...............•.••..••.......................... A-1 Accelerator Pedal Accelerator Rod BODY AND ASSOCIATED PARTS ••.•......•..............•............................••••• 8-1 Bagwell Center Console Floorboard Direction Selector Indicator Hip Handhold Seat Wrap Vinyl Bumper Body Trim BRAKE LINKAGE ......................................................................... C-1 Brake Linkage Assembly Brake Pedal Assembly Compensating Link Assembly CARBURETOR ................. . .................•.......•.............................. D-1 Jet Kit Throttle Lever Kit CLUTCHES .............•.................•.....................•.....•......•••..•.•••• E-1 Drive Belt Drive Clutch Driven Clutch CYLINDER HEAD AND VALVE ASSEMBLY ...•••••......................•.•...••...••••...••.• F-1 Cylinder Over�aul Kit Gasket Set Intake Manifold Assembly DIRECTION SELECTOR .•.............•......................••••••....•.....•............. G-1 ELECTRICAL SYSTEM .................................................................... H-1 Battery Coil and Bracket Assembly Fuse Holder Ignition Switch lgnitor Unit Voltage Regulator Wiring Harness, Starter/Generator

9/05/91

I I I

111-141

Pg. iii

GENERAL INDEX Illustration

Page No.

ENGINE AND MUFFLER ......................••..••••.....•..••.........•....•.....••••••.. J-1 Air Cleaner Engine Exhaust Tube Muffler Oil Filter Spark Plug Spark Plug Wire ENGINE/STARTER MOUNTING

K-1

Belt, Starter/Generator FRONT SUSPENSION .....•..........................•..•.••.....•......••.....•.......... L-1 Front Axle Assembly Hub Assembly Idler Assembly Leaf Springs Spindle Assembly Tie Rod Assembly FRONT SHIELD ............................................... . ......... . ................ M-1 FRESH AIR INTAKE SYSTEM ...........................•...•............................... N-1 Air Intake Box Air Inlet Funnel Convoluted Hose FUEL SYSTEM ................. . ........................................................ P-1 Choke Cable Fuel Filter Fuel Gauge Fuel Pump Fuel Tank Assembly HORN AND ACCESSORY WIRING

Q-1

Headlamp Horn Rear Lamp Assembly State of Charge Meter Turn Signal Assembly Wire Harness REAR AXLE ............................................................................ R-1 Rear Axle Assembly Rear Axle Shaft Vent Valve

Pg. iv

9/05/91 I I I 11-141

GENERAL INDEX Illustration

Page No.

REAR SUSPENSION

S-1

SEATING •••....•.........................•...........••................................ T-1 STARTER/GENERATOR .................................................................... U-1 Bushing Assembly Pulley Terminal Assembly STEERING ...........................................................................•.. V-1 Rack and Rod Assembly Steering Unit Assembly Steering Wheel WHEEL BRAKE

..................•....•••••••••.••.......•.............................. W-1

Brake Assembly Brake Drum Assembly Brake Shoe Set Lug Bolt WHEELS AND TIRES ............................................. . ....................... X-1 Tire Tire and Wheel Rim Assembly Valve Stem Wheel Rim

APPENDIX SERVICE ACCESSORIES AND SPECIAL TOOLS .......................................... Appendix-1

9/05/91

I I I I 11-141

Pg.

V

HOW TO USE THE E-Z-GO SERVICE PARTS MANUAL

9/05/91 I I I 111-141

vi

HOW TO USE THE E-Z-GO SERVICE PARTS MANUAL This manual is divided into several sections: 1.

GENERAL INFORMATION

2.

ILLUSTRATED PARTS BREAKDOWN FOR 4-CYCLE GASOLINE POWERED GOLF CARS

3.

APPENDIX

The first section, GENERAL INFORMATION, contains the following informations: 1.

WARRANTY INFORMATION

2.

GENERAL INDEX

3.

HOW TO USE THE E-Z-GO SERVICE PARTS MANUAL

The second section, ILLUSTRATED PARTS BREAKDOWN (IPB) FOR 4-CYCLE GASOLINE POWERED GOLF CARS, contains illustrations and parts lists for all systems of the 4-cycle gasoline powered golf cars.

The third section, SERVICE ACCESSORIES AND SPECIAL TOOLS, contains a listing of E-Z-GO service accessories and special tools that may be purchased from the company to aid in the servicing of the vehicle.

USE OF THE MANUAL To use this manual, consult the GENERAL INDEX (located in the first section) to locate the information or illustration required.

Introduction of some revisions varies due to supply of components; therefore, it is possible that various com­ binations of components may be found that are not directly reflected by each illustration. Consult the illustra­ tion that best suits your situation and contact the Service Parts Department. It is important that the serial number of your vehicle and its model number be supplied to Service Parts when ordering any replacement components.

Locate the serial number plate (see Body and Associated Parts located in the IPB section of this manual for its location) and note the complete number shown on the plate.

Each system is listed in the index and has an alphabetical prefix. The illustration always appears first and is followed by its related parts list. Additional illustrations and parts lists with the same prefix indicate significant changes that have taken place since the last issue.

Note that many alphabetical prefixes are omitted. These prefixes have been assigned to systems that are not relevant to your vehicle. The index lists all relevant sections that pertain to your vehicle.

9/05/91

I I I I 11-141

Pg. vii

HOW TO USE THE E-Z-GO SERVICE PARTS MANUAL

TITLE

TITLE

.RIGHT HAND PAGE PARTS LIST

LEFT HAND ILLUSTRATION PAGE (CONTINUED ON RIGHT HAND PAGE IF REQUIRED)

PARTS LIST (CONTINUED ON REAR OF PAGE IF REQUIRED)

1. WHEN THE PART NUMBER IS NOT KNOWN. a. Determine the function and application of the part required. Turn to the General Index and select the most appropriate title. b. Turn to the page number indicated and locate the desired part on the illustration. c. From the illustration, obtain the item number assigned to the desired part. Refer to the accom­ panying description for specific information regarding the part.

2. IF YOU KNOW THE PART NUMBER. Locate th� part number or description in the appropriate column on the parts list page.

NOTE: It i·s · suggested that you confirm that the part selected is correct by verifying it with the pictorial representation on the illustration 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 E-Z-GO and the asterisk (*) indicates that the part depicted is not available for sale by E-Z-GO. 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 or final assembly is reached.

To facilitate the maintenance and repair of vehicle, an Operation and Service Manual is available from the E-Z-GO Service Parts Department.

Pg. viii

9/05/91

I I I 11-141

HOW TO USE THE E-Z-GO SERVICE PARTS MANUAL

ILLUSTRATED PARTS BREAKDOWN 4-CYCLE GASOLINE GOLF CARS

9/05/91

I I I I 11-141

Pg. ix

ACCELERATOR AND HILL BRAKE LINKAGE

4-CYCLE POWERED CAR

17

1-INCLUDES ITEMS 2-8 15-INCLUDES ITEMS 16-21

4

Pg. A-1

25 24

9/05/91

l ! !A!1!-!4!

ACCELERATOR AND HILL BRAKE LINKAGE

4-CYCLE POWERED CAR

PART OF FRAME

43 47

42

40

ACCELERATOR ROD ASSY

38 31-INCLUDES I T EMS 32-41

32

34

�

3 5 ---------

( 48

TO GOVERNOR CONTROL ARM

9/05/91

I I !A!H-141

TO ACCELERATOR CONTROL ARM

Pg. A-2

ACCELERATOR AND HILL BRAKE LINKAGE

C0 tO

4-CYCLE POWERED CAR

tO

I

C')

tO

en

s:t"

:iE

co

.,_

LU

en LU

C

:::,

..J ()

z

T

co co

I

C\I tO

Pg. A-3

9/05/91

! ! lAl1l-!4l

ACCELERATOR AND HILL BRAKE

4-CYCLE POWERED CAR

THE U SE OF NON U.L. PART S WIL L VO ID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

1

18091-G1

ACCELERATOR AND HILL BRAKE ASSEMBLY (INCLUDES ITEMS 2 - 8) .•.

1

2 3

14444-G3

BALL JOINT, SOCKET .....•• • •••.....•••....•...••••....•.....

1

00554-G4

NUT, 5/16 - 24 .............•••.....•........••••••...•.....•

2

4

17677-G1

RETAINER, SPRING ............•..•.•..••........•.....•. . ....

2

5

17979-G1

BUSHING, ACCELERATOR ROD •••..•...........................

1

6

17675-G1

SPRING, COMPRESSION ••...........................•.........

1

7

19710-G1

ROD, ACCELERATOR ....................... . ....................

1

8

10385-G4

YOKE, CLEVIS, REAMED.......................................

1

DESCRIPTION

QTY

9 10 11 12 13

26480-G01

BOLT, CARRIAGE, 1/4 - 20 X 3/4 LG. ..............................

1

14

11027-G2

NUT, LOCK, 1/4 - 20 ............................................

2

15

18083-G1

ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 16 - 21) ..........

1

16

12511-G1

BASE PLATE, ACCELERATOR ...................................

1

17

18084-G1

PEDAL, ACCELERATOR........................................

1

18

15827-G1

PAD KIT, ACCELERATOR PEDAL (INCLUDES RIVET) ................

1

19

12512-G1

PIN, ACCELERATOR PEDAL ....................................

1

20

12513-G1

BEARING, PLASTIC ...........................................

2

21

12064-G1

NUT, PUSH, 1/4..............................................

1

23

17255-G1

WASHER, TEFLON ......••...........................•...........

2

24

10387-G3 : . PIN, COTTER, 3/32 X 3/4 LG. .••...................................

2

25

00559-G8

WASHER, 5/16 •.................................................

3

26

20835-G1

WASHER, NYLON .........•.•••.•••.......••...•••..•..•.........

1

27

19708-G1

ARM, PIVOT •...................................................

1

28

17838-G1

BUSHING, NYLINER...............•...............................

1

29

24030-G1

ROD, LINKAGE ..................................................

1

31

25338-G1

CONTROL ARM ASSEMBLY (INCLUDES ITEMS 32 - 41) ...••...........

1

32

25337-G1

ARM, CONTROL ..............................................

1

33

15944-G3

BALL, BALL JOINT ............................................

1

00559-G8

WASHER, 5/16 ..............................................•

2

22

30

34

9/05/91

! ! !A!1'-!4!

Pg. A-4

ACCELERATOR AND HILL BRAKE LINKAGE

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

35

11098-G1

NUT, LOCK, 5/16 - 24

1

36

25768-G01

ROD, PIVOT ...............................................••

1

37

24621-G1

WASHER, NYLON ........••...................................

1

38

14390-G1

NUT, LOCK, 3/8 - 24 ...••.••.•...........•...................

1

39

10387-G3

PIN, COTTER, 3/32 X 3/4 LG. ..............................•...

1

40

18759-G1

SCREW, STAINLESS STEEL, 1/4 - 20 X 1 LG. ..................•.

1

41

11027-G2

NUT, LOCK, 1/4 - 20 ..............................•..•......

1

42

12064-G3

NUT, PUSH, 3/16 ...............•................................

1

43

10606-G2

MICROSWITCH ......................................•...........

1

44

00957-G1

SCREW, #6 - 32 X 1 1/4 LG.......................................

1

45

00525-G5

NUT, #6 - 32 ...................................................

1

46

00565-G3

WASHER, LOCK, #6 ............•....•............................

1

47

25694-G01

ACCELERATOR CABLE ........•..............................•...

1

48

25956-G01

TIE, NYLON, PUSH MOUNT ..•...•.•...............................

1

49

25653-G01

BRACKET, ACCELERATOR CABLE DIFFERENTIAL ......................

1

52

25690-G1

GOVERNOR CONTROL ARM ASSEMBLY (INCLUDES ITEMS 53 - 58) ......

1

53

25765-G01

ARM, GOVERNOR CABLE ......................................

1

54

24479-G1

BALL, BALL JOINT ..............................•.... ; ........

1

55

00921-G8

NUT, FLEX LOCK, #10 - 32 ..•••...............................

1

56

00491-G4

SCREW, SET, 1/4 - 20 ••••••••.•..........................••.•

2

57

22751-G2

BRACKET, GOVERNOR ..•..•.••••.............................

1

58

14390-G4:

NUT, LOCK, 1/4 - 20 .........•..•.............................

1

59

12064-G3

NUT, PUSH, 3/16 ................................................

1

60

25738-G01

SPRING ........................................................

1

61

25737-G03

ROD, GOVERNOR LINKAGE ......•...............................•.

1

62

25763-G01

ARM, GOVERNOR PIVOT ..........................................

1

63

14390-G1

NUT, LOCK, 3/8 - 24 ............................................

2

64

25737-G02

ROD, THROTTLE LINKAGE ....•....................................

1

65

25760-G01

ARM, CARBURETOR PIVOT ........................................

1

66

25737-G01

ROD, CARBURETOR LINKAGE ......................•...............

1

50 51

Pg. A-5

9/05/91 I IAI 11-141

ACCELERATOR AND HILL BRAKE LINKAGE

9/05/91

I I !A!1H41

4-CYCLE POWERED CAR

Pg. A-6

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

GX-444

ITEM 1 INCLUDES ITEMS 2 THAU 11

GX -444F (FREEDOM)

Pg. 8-1

E�GDli:f:1is{•l:I

9/05/91 I I Isl 11-141

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

xr

� 5

0

�

100 �

102

,.....99 96 134 13 1'�

9/05/91

!

! !Bl 1!-!4!

Pg. B-2

BODY AND ASSOCIATED PARTS 3 o \_ 28 32 34 )

4-CYCLE POWERED CAR

FENDER AND BAGWELL DETAILS

_5�-----:;;;::;;

55

TRUNK LID HIP RESTRAINT 49-4

45

49

SEAT WRAP 71

Pg. B-3

9/05/91

! ! !B!1!-!4!

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

104 INCLUDES ITEMS 105& 107 130 INCLUDES ITEM 131

9/05/91

I I !Bl 11-141

E�GCliit1is{•l:I

Pg. B-4

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

24579-G1

2

22888-G4

3

1

2

3

4

5

DESCRIPTION

QTY

VINYL BUMPER, TRIM KIT (INCLUDES ITEMS 2- 11)

1

VINYL BUMPER, BULK LENGTH, 71 LG. (INCLUDES MATERIAL TO MAKE ITEMS 3 & 4) .......••..............••.................

1

17203-G1

VINYL BUMPER, BODY TRIM, SIDES ..........................

1

4

17203-G9

VINYL BUMPER, BODY TRIM, DASH TRAY .....................

2

5

22273-G1

VINYL BUMPER, BODY TRIM, BACK OF COWL .....................

1

6

23931-G1

TRIM, FENDER, PASSENGER'S SIDE ............................ .

1

7

23931-G2

TRIM, FENDER, DRIVER'S SIDE ............................•....

1

8

24198-G1

FASTENER, RATCHET TYPE .•..................................

12

9

24620-G1

TRIM, FLOORMAT, PASSENGER'S SIDE ......•..•................

1

10

24620-G2

TRIM, FLOORMAT, DRIVER'S SIDE •........•........•............

1

11

18436-G1

RIVET, PLASTIC, DRIVE, 1/4 ...................................

4

13

23868-G1

ROCKER PANEL, PASSENGER'S SIDE ...............................

1

14

23868-G2

ROCKER PANEL, DRIVER'S SIDE ...................................

1

15

23850-G1

SILL PLATE, ROCKER PANEL, PASSENGER'S SIDE ....•...............

1

16

23850-G2

SILL PLATE, ROCKER PANEL, DRIVER'S SIDE ........................

1

17

00827-G8

BOLT, CARRIAGE, STAINLESS STEEL, 1/4 - 20 X 1 LG. ...............

4

18

23726-G2

SPACER ........................................................

4

19

00660-G7

WASHER, 1/4 ............................•...................••.

4

20

00891-G2

NUT, LOCK, 1/4 - 20 ............•••.•......... ...... ...... ......

4

21

15058-G4

RIVET, ALUMINUM, BLACK ..........••....................•.......

2

23

20514-G1

DECAL, INSTALLATION KIT, TRAPEZOID (SPECIFY NO. 1 THROUGH 200) ..

AR

24

22530-G1

. DECAL, INSTALLATION KIT, RECTANGULAR (SPECIFY NO. 1 THROUGH _;200) ........•............•....................................

AR

23676-G1

LABEL, FREEDOM .......•..........•........................•.•.

2

22229-G1

RESTRAINT, HIP HANDHOLD ASSEMBLY, PASSENGER'S SIDE (INCLUDES ITEM 30) ..........•.................................... · · · · · · ·

23152-G1

HANDGRIP ......................................................

24004-G1

RESTRAINT, HIP HANDHOLD ASSEMBLY, DRIVER'S SIDE (INCLUDES ITEM 34) ..............••............................... · · · · · · ·

12

22

25 26 27 28 29 30 31 32

Pg. B-5

9/05/91 I Isl 11-141

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

33 23152-G1

HANDGRIP ......................................................

36

14776-G1

NUT, "J" TYPE, 1/4 - 20 .................................... . ....

4

37

16705-G1

SCREW, TRUSS, 1/4 - 20 X 1 LG. .................................

6

38

11027-G2

NUT, LOCK, 1/4 - 20 ............................................

2

40

19534-G3

FILLET, TRUNK, PASSENGER'S SIDE ................................

1

41

19534-G4

FILLET, TRUNK, DRIVER'S SIDE .................. . .................

1

42

00106-G6

SCREW, SELF-DRILL AND TAP, #12 - 24 X 3/4 LG. ...................

4

44

19533-G2

TRUNK LID INSTALLATION KIT (INCLUDES ITEMS 45-50) ......••.......

1

45

19554-G2

TRUNK LID .......................................... . .......

1

46

17684-G1

NOISE, SUPPRESSOR, TRUNK LID ...............................

4

47

24722-G1

NUT, "U" TYPE, #10 - 12 X 1/32 THK. ..........................

2

48

24722-G2

NUT, "U" TYPE, #10 - 12 X 1/8 THK. •..........................

2

49

00923-G6

SCREW, SELF-TAPPING, #10 - 12 X 3/4 LG. .....................

4

50

22455-G1

SOUND PANEL, TRUNK LID .....................................

1

54

19034-G1

BAGWELL, PLASTIC ...•.•..........................•......••...•.

1

55

19524-G1

MOUNT, BAGWELL ........•..••••.•..............................

2

56

13437-G4

. SCREW, LOCK, 3/8 - 16 X 1 LG• •••••.............·................

2

57

11027-G5

NUT, LOCK, 3/8 - 16 ..................••...............•........

2

58

18436-G1

RIVET, PLASTIC, DRIVE, 1/4 ............................•..........

4

59

15058-G1

RIVET, ALUMINUM, BLACK, 3/16 ...................................

4

10669-G6

WASHER, SPECIAL •....•........................................

6

65

00414-G6

SCREW, 1/4 - 20 X 3/4 LG. ...•.•.....•...........................

6

66

11027-G2

NUT, LOCK, 1/4 - 20 ............••.•..•.........................

34 35

39

43

51 52 53

:

60 61 62 63 64

9/05/91

I I !Bl 1!-141

Pg. B-6

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

67

15058-G1

RIVET, ALUMINUM, BLACK, 3/16 .......•...........................

2

68

14705-G1

TRIM STRIP .....................................................

2

69

14601-G2

RIVET, ALUMINUM ............•.....•••••••...••....••..•.•...•••

4

23791-G4

INDICATOR, DIRECTION SELECTOR ................... . ........... . .

1

73

12064-G3

RETAINER, PUSHON .....•......•.••..............................

3

74

18787-G1

SCUFFGUARD, SEAT WRAP ..•................ . .......... . ........

1

75

25091-G1

FLOORMAT, 3/16 .............•.............. . . • .................

1

77

24967-G1

CONSOLE, 4-CUP, ..............................................

1

78

24968-G1

DECAL, SAFETY (INCLUDED IN ITEM 77) ..... . . . ......... . .......

1

79

18436-G1

RIVET, PLASTIC, DRIVE, 1/4 .................. .....................

4

80

00559-G7

WASHER, 1/4 .......................................·............

2

82

00414-G6

SCREW, 1/4 - 20 X 3/4 LG. ................... . ...................

5

83

11027-G2

NUT, LOCK, 1/4 - 20 ............................................

3

86

00559-G8

WASHER, 5/16 ......••.•••......................................

5

87

11027-G2

NUT, LOCK, 1/4 - 20 .......•....................................

13

88

11027-G2

NUT, LOCK, 1/4 - 20 ...........................•....•...........

8

89

14700-G1

FENDER CAP, FLEXIBLE, PASSENGER'S SIDE ........................

1

90

14700-G2

. FENDER CAP, FLEXIBLE DRIVER'S SIDE •......•.....·................

1

91

23800-G3

BUMPER, REAR .............••...................................

1

92

00106-G6

SCREW, SELF-DRILL AND TAP, #12 - 24 X 3/4 LG. ...................

6

93

11027-G2

NUT, LOCK, 1/4 - 20 ............................................

4

94

24070-G3

FENDER, PASSENGER'S SIDE ......................................

1

95

24070-G4

FENDER, DRIVER'S SIDE ..........................................

1

96

24031-G6

SEAT WRAP (FREEDOM ONLY) ................ . ...................

1

99

24031-G2

SEAT WRAP ....................................•...............

1

100

22744-G1

PANEL, BAGWELL ............•...••............ . ..•.............

1

70 71 72

76

81

84 85

97 98

Pg. B-7

E�GDiii:,M•W

9/05/91

I Isl 11-141

BODY AND ASSOCIATED PARTS

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

101

22428-G1

PANEL, SOUND, FRONT

102

23451-G1

PANEL, SOUND, INTAKE

105

22911-G1

LINER, DASH TRAY ..............................................

1

106

18436-G1

RIVET, PLASTIC, DRIVE, 1/4 .......................................

2

107

16816-G1

FASTENER, RATCHET ............................................

2

110

19817-G1

NAMEPLATE, E-Z-GO ............................................

1

111

12064-G3

NUT, PUSHON ...................................................

3

112

20271-G4

PLUG, BUTTON .........................................••.......

4

114

00414-G6

SCREW, 1/4 - 20 X 3/4 LG. ...........•...........................

9

115

00559-G7

WASHER, 1/4 ..........•..•.....................................

18

116

14390-G4

NUT, LOCK, 1/4 - 20

9

118

23063-G5

COWL ......................•..................................

1

119

23148-G1

COWL SUPPORT .....•••.........•....................•..........

1

120

11027-G2

NUT, LOCK, 1/4 - 20 ...•........................................

4

121

00560-G1

WASHER, 3/8 ...................................................

2

122

18353-G2

DASH TRAY ...•..•••••.••..................................•....

1

123

22914-G1

CAP, COWL ....................•....•..........................

1

124

23674-G1

. CAP, COWL (FREEDOM ONLY) ....................-................

1

126

15536-G1

TOP RAIL, PASSENGER'S SIDE ..........•••........................

1

127

15536-G2

TOP RAIL, DRIVER'S SIDE .........................................

1

128

24236-G1

SIDE RAIL, PASSENGER'S SIDE ....................................

1

129

24236-G2

SIDE RAIL, DRIVER'S SIDE ........................................

1

130

15671-G2

FLOORBOARD ASSEMBLY (INCLUDES ITEM 131) ......................

1

131

14776-G1

NUT, "J' TYPE, 1/4 - 20 ......•...............................

2

132

00106-G6

SCREW, SELF-DRILL AND TAP, #12 - 24 X 3/4 LG. ...................

23

133

21748-G1

FLEXIBLE FENDER CAP, PASSENGER'S SIDE (FREEDOM ONLY) .........

1

134

21748-G2

FLEXIBLE FENDER CAP, DRIVER'S SIDE (FREEDOM ONLY) .............

1

103 104

108 109

113

117

125

9/05/91

I I Isl 11-141

Pg. B-8

;J

m

0 I

)>

:x,

.....

/

/

/

/\

\

7 \\ �/ /6

4

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\

3

m

\

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C) m

20/

\

)

...

i� .....

(0

� �

2

t -, INCLUDES ITEMS 2-11 VEHICLES WITHOUT BRAKE LIGHifS'

13 - INCLUDES ITEMS 14-39 15 - INCLUDES ITEM 18 VEHICLES WITH BRAKE LIGHTS

.,,0

� m ::u m C

£

m

" z"r :0 )>

m

)> G)

95

A

/

r-----... --

�

56

.....-

' \

I

67 50- INCLUDES ITEMS 52,54,56-74

7� � � -

µI�

86- INCLUDES ITEMS 87-91

,

/._ ,

68

52- INCLUDES ITEMS 54,56,57,58-63,64,65,66

<j) I\)

"�

--J

/ L�

66

�

I

�- ··� i r;:,�' 1,J �}� �J

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I

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'65

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@

93

69

� 74

72

\,

70

� I

Q 0 r m

-a 0

:e

m lJ m 0 < m

:::c

0 r

m

BRAKE LINKAGE

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO. 25253-G1

1

2

3

4

5

DESCRIPTION

QTY

BRAKE PEDAL ASSEMBLY, VEHICLES WITHOUT BRAKE LIGHTS (INCLUDES ITEMS 2 - 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .

1

23037-G2

PEDAL, BRAKE (WITH PAD, ITEM 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

15813-G1

PEDAL, HILL BRAKE (WITH PAD, ITEM 6) . . . . . . . . . . . . . . . . . . . . . . . . .

1

15826-G1

BRAKE/HILL BRAKE PEDAL PAD KIT (INCLUDES ITEMS 5 - 8) . . . . . . • •

1

5

PAD, BRAKE PEDAL . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

6

PAD, HILL BRAKE . . . • • • . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .

1

2 3

4

7

15766-G1

RIVET, SMALL HEAD . . • . . . . . . . . . • . . . . • . . . . . . . . . . . . • . . . . . . . .

3

8

16409-G1

RIVET, LARGE HEAD . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . .

6

9

15932-G1

PIN, HILL BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

10

11737-G1

SPRING, TORSION . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

11

12064-G1

NUT, PUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

22449-G1

BRAKE PEDAL ASSEMBLY, VEHICLES WITH BRAKE LIGHTS (INCLUDES ITEMS 14 - 39) . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . . . . . .

1

12 13 14

22357-G1

PEDAL, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

15

15813-G2

PEDAL, HILL BRAKE (WITH PAD, ITEM 18) . . . . . . . . . . . . . . . . . . . . . . • •

1

16

15826-G1

BRAKE/HILL BRAKE PEDAL PAD KIT (INCLUDES ITEMS 17 - 20) . . . . • .

1

17

PAD, BRAKE PEDAL • . • • . • • • • • • . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

18

PAD, HILL BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

19

15766-G1

RIVET, SMALL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .

3

20

16409-G1

RIVET, LARGE HEAD . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . .

6

PLATE, BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

15923-G1

PIN, HILL BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . .

1

23

11737-G1

SPRING, TORSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

24

12064-G1

NUT, PUSH . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

25

00737-G7

SCREW, #10 - 24 X 3/4 LG. . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .

4

26

00739-G1

NUT, CAPTIVE, #10 - 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

27

22362-G1

STANDOFF, BRAKE PEDAL . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . . . . .

2

28

24938-G1

SPRING, CONICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

29

11098-G7

NUT, LOCK, #10- 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

30

10606-G1

SWITCH, MICRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

31

00139-G2

SCREW, #6 - 32 X 1 1/4 LG. • . • • • . • . . . • • • • . . . . . . . . . . . . . . . . . . . .

2

32

00559-G3

WASHER, #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

33

00565-G3

WASHER, LOCK, #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . .

2

21

22

Pg. C-3

.

E�l:iDii:£,M•W

9/05/91

I lcl 11-141

BRAKE LINKAGE

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

34

00525-G5

NUT, #6 - 32 ............................................... .

2

35

13514-G1

SCREW, BRASS ..............................................

2

36

00567-G3

WASHER, LOCK, #6 ..........................................

2

37

14628-G1

TAB, FASTON ................................................

2

38

22447-G1

WIRE HARNESS, BRAKE •...••.......................•........•

1

39

17618-G1

CLAMP, NYLON ....•..••.•..••.•..••••••.....•...............

3

42

14158-G1

BOLT, SHOULDER, 3/8 - 16 .....................•..............

1

43

11079-G1

BUSHING, FLANGED, NYLON ..................................•

2

44

25292-G1

SPRING, TORSION ............................................

1

45

13521-G4

NUT, LOCK, 3/8 - 16

1

47

10386-G3

PIN, CLEVIS .................................................

48

10387-G3

PIN, COTTER, 3/32 X 3/4 LG. ..................................

25101-G4

BRAKE LINKAGE ASSEMBLY (INCLUDES ITEMS 52 - 67) ..............•

23062-G1

COMPENSATING LINK ASSEMBLY (INCLUDES ITEMS 54 - 67) ........

23175-G1

ROD .................................... · · ••· · · ··· · · · ···

56

00544-G4

NUT, 5/16 - 24 ......••.••................................

1

57

10385-G4 :·

YOKE, CLEVIS ........................... ; ....... .........

1

58

23030-G1

YOKE, BRAKE ..........•.•..........•....................

1

59

15121-G1

WASHER, 5/16 ...........................................

2

60

23061-G2

TUBE ....................................................

1

61

23463-G1

SPRING, COMPRESSION ............................•.......

1

62

00532-G4

NUT, LOCK, 5/16 - 24 .....................................

2

63

17979-G1

BUSHING, ACCELERATOR ROD ............................•.

1

64

13659-G1

BAR, EQUALIZER ..........................................

1

65

10386-G3

PIN, CLEVIS ..................... . ........................

1

66

10387-G3

PIN, COTTER, 3/32 X 3/4 LG. ...............................

1

67

17255-G1

WASHER, NYLON ...•.....•...•...........................

3

40 41

46

49 50 51 52 53 54 55

9/05/91 I I I I I

.

Ei2!GDii:£,M•W

Pg. C-4

BRAKE LINKAGE

4-CYC LE POWERED CAR

THE USE OF NON U.L. PARTS WI L L VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

68

17255-G1

WASHER, NYLON .............................................

8

69

00559-G8

WASHER, FLAT ..............................................

2

70

25789-G02

CABLE, BRAKE, PASSENGER'S SIDE ............................

1

72

25789-G01

CABLE, BRAKE, DRIVER'S SIDE .................................

1

73

10386-G3

PIN, CLEVIS .................................................

2

74

10387-G3

PIN, COTTER, 3/32 X 3/4 LG. ..................................

2

75

12305-G1

RING, RETAINING .............................................

2

76

10097-G6

BEARING, FLANGED ..............................................

2

77

25103-G1

CAM, HILL BRAKE ...............................................

1

78

14134-G2

SPACER ........................................................

1

79

00491-G4

SETSCREW, 1/4 - 20 X 3/8 LG. ........................... . .......

2

80

00414-G6

SCREW, 1/4 - 20 X 3/4 LG. .......................................

2

81

00565-G7

WASHER, LOCK, 1/4 .............................................

2

82

15022-G1

BRACKET, CATCH ...............................................

1

83

11027-G2

NUT, LOCK, 1/4 - 20 ............................................

2

86

14061-G1

PEDAL BUMPER SERVICE KIT (INCLUDES ITEMS 87 - 91) ..............

1

87

00150-G6

SCREW, #10 - 24 X 3/4 LG. ...................................

1

88

00559-G5

WASHER, #10 ...............................................

1

89

14061-G1

BUMPER, RUBBER ...........•................................

1

90

00565-G5

WASHER, LOCK, #10 .........................................

1

91

00526-G3 :-

NUT, #10 - 24 ..............................•................

1

71

84 85

92 93

10386-G3

PIN, CLEVIS ....................................................

2

94

10387-G3

PIN, COTTER, 3/32 X 3/4 LG. .....................................

2

95

12305-G1

RING, RETAINING ................................................

2

Pg. C-5

9/05/91 I lcl 11-141

BRAKE LINKAGE

9/05/91

I I lcl 11-141

4-CYCLE POWERED CAR

Pg. C-6

CARBURETOR

4-CYCLE POWERED CAR

34 8

kl r� I

� '-

21-i

'�

·

22

17

27�

18

--23 •

---1-- I i)

28

�

��

I ®--19

30

31

l-20

Pg. 0-1

E2!6Dii:f:1ist•]:I

9/05/91

I I 10111-141

CARBURETOR

4-CYC LE POWERED CAR

THE USE OF NON U.L. PARTS WI L L VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

1

26645-G01

CARBURETOR ASSEMBLY (INCLUDES ITEMS 2 - 32)

2

26748-G01

VALVE, THROTTLE ......................•.............•...

1

3

26749-G01

SCREW ..................................................

3

4

26750-G01

RING, OV ................................................

1

5

26751-G01

COLLAR ...................••••••.....•..........•.......

2

6

26752-G01

SPRING, THROTTLE RETURN .•.•••........•..................

1

7

26753-G01

SHAFT, THROTTLE.......••.....•..........................

1

8

26754-G01

SHAFT, CHOKE ...........................................

1

9

26755-G01

BUSHING .................................................

1

10

26756-G01

COLLAR .................................................

1

12

26757-G01

SPRING, CHOKE RETURN ...................................

1

13

26758-G01

SPRING ..................................................

2

14

26759-G01

SCREW ...........•......................................

1

15

26835-G01

SCREW, PILOT ......................................•.....

1

16

26836-G01

VALVE, CHOKE .........•.................................

1

17

26837-G01

NOZZLE. MAIN ............................................

1

18

26646-G01

JET, MAIN (#88) ..........................................

1

19

26838-GO1

GASKET .................................................

1

20

26839-G01

SCREW ................................•......•..........

1

21

26647-G01

VALVE, NEEDLE ..........................................

1

22

26840-G01

PIN......................................................

1

23

26648-G01

FLOAT..........•........................................

1

24

26841-G0t

PLUG...................................... ; ......... ····

1

25

26842-G01

GASKET .................•...•...........................

1

26

26649-G01

JET, SLOW (#46) ......•..................................

1

27

26843-G01

WASHER, THRUST .................•.......................

1

28

26844-G01

CHAMBER, FLOAT ........••.......•••..........••.....•...

1

29

26650-G01

TUBE, CARBURETOR VENT ...•..............................

1

30

26845-G01

SPRING ......•...........................................

1

31

26846-G01

SCREW, DRAIN ...........................................

1

32

26637-G01

INSULATOR ..................................................

1

33

26725-G01

GASKET.....................................................

1

34

26726-G01

GASKET.....................................................

1

DESCRIPTION

QTY 1

11

9/05/91

I I lol 11-141

..

E�GDii:£,M•W

Pg. D-2

CLUTCHES

EARLY PRODUCTION

4-CYCLE POWERED CAR

VEHICLE CLUTCHES ARE MATCHED UNITS. DO NOT ATTEMPT TO SUBSTITUTE ANOTHER VERSION OF EITHER THE DRIVE OR DRIVEN CLUTCHES.

VEHICLES WITH SERIAL NUMBERS 679642 AND LATER, USE ITEMS 18 AND 19

IDENTIFY DRIVE SET BY RIBED FACE OR RED DOT ON FACE OF DRIVE CLUTCH

Pg. E-1

9/05/91

I !El 1!-141

CLUTCHES - EARLV PRODUCTION

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

23817-G1

CLUTCH, DRIVE, COMET ...••................••........•........•.

2

23212-G1

WASHER, PILOT .............•...................................

5

00566-G2

WASHER, LOCK, 7/16 .......•....................................

6

00473-G9

SCREW, 7/16 - 20 X 6 1/2 LG. •...................................

7

XXXX-XX

BELT, STARTER/GENERATOR (SEE SECTION U FOR PART NUMBER AND QUANTITY) ...••......................•........

8

25632-G01

DRIVEN CLUTCH ASSEMBLY (INCLUDES ITEM 10 - 17) .•........... . ..

1

9

25632-G02

DRIVEN CLUTCH ASSEMBLY (INCLUDES ITEMS 10 - 15, 18, 19) ........

1

10

24594-G1

RING, RETAINING .......................... . ..................

1

11

25612-G1

SPRING, COMPRESSION .................... . .......•... . ......

1

12

24600-G1

WASHER, SPACER ............................................

2

3 4 1

CAM ...................................... . ................

1

SHEAVE, MOVABLE ....................... . . ..................

1

15

* * *

SHEAVE, FIXED POST ..............•............. ; ............

1

16

25613-G1

BUTTON, RAMP ..............••..............................

3

17

24598-G1

SCREW, #8 - 32 X 3/4 LG. ....................................

3

18

26479-G01

BUTTON, RAMP ..............................................

3

19

00979-G01

SCREW,#10 - 24 .................... . ........................

3

20

22496-G1

WASHER, RETAINING ..............................•..............

1

21

00565-G8

WASHER, LOCK, 5/16 ......•••.......................•...........

1

22

00441-G8

SCREW, 5/16 - 18 X 4 LG. ..••.................................•.

1

23

27077-G02

**

BELT, DRIVE ........••..............•................. . .........

1

PULLER, CLUTCH .....................•..........................

AR

**

SEE APPENDIX FOR SERVICE ACCESSORIES AND SPECIAL TOOLS

13 14

24

9/05/91

I I !El 1!-141

Pg. E-2

CLUTCHES

FIRST USED ON 1992 MODEL

4-CYCLE POWERED CAR

VEHICLE CLUTCHES ARE MATCHED UNITS. DO NOT ATTEMPT TO SUBSTITUTE ANOTHER VERSION OF EITHER THE DRIVE OR DRIVEN CLUTCHES ..

IDENTIFY DRIVE SET BY BLACK BAND AND NO RED DOT ON FACE OF DRIVE CLUTCH

Pg. E-3 I

9/05/91 !El 11-141

CLUTCHES - FIRST USED ON 1992 MODEL

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

1

26952-G01

CLUTCH, DRIVE, E-Z-GO .......................••.••.....•.......

1

2

23212-G1

WASHER, PILOT .................................................

1

5

00566-G2

WASHER, LOCK, 7/16 ............................................

1

6

00473-G9

SCREW, 7/16 - 20 X 6 1/2 LG. ....................•.•.............

1

7

XXXX-XX

BELT, STARTER/GENERATOR (SEE SECTION U FOR PART NUMBER AND QUANTITY) .•...•..••..........................

26301-G01

DRIVEN CLUTCH ASSEMBLY (INCLUDES ITEMS 10 - 19) ...............

1

RING, RETAINING .....................................•.......

1

SPRING, COMPRESSION .......................................

1

BUTTON, RAMP ..............................................

3

SCREW, #10 - 32 X 3/4 LG. ...................................

3

WASHER, SPACER ............................................

2

DESCRIPTION

QTY

3 4

8 9

*

10

* * *

11 12 13 14 15

*

16

*

17

CAM .....•.................................................

1

SHEAVE, MOVABLE ...........................................

1

SHEAVE AND POST ...........................................

1

19

* *

20

22496-G1

WASHER, RETAINING ..........................................•..

1

21

00565-G8

WASHER, LOCK, 5/16 ............................................

1

22

00441-G8

SCREW, 5/16 - 18 X 4 LG. .......................................

1

27077-G02_

**

BELT, DRIVE .....•........................•.....................

1

PULLER, CLUTCH .........•.•.•••••........••....................

AR

**

SEE APPENDIX FOR SERVICE ACCESSORIES AND SPECIAL TOOLS

18

23 24

9/05/91

I I !El 1!-141

Pg. E-4

CYLINDER HEAD AND VALVE ASSEMBLY

Pg. F-1

EeGl:lii:f:1i,t•]:I

4-CYCLE POWERED CAR

9/05/91

I I !F!H-141

CYLINDER HEAD AND VALVE ASSEMBLY

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1 2

26740-G01

CYLINDER HEAD WITH VALVES ASSEMBLY (INCLUDES ITEMS 3 - 13) ....

1

3

26616-801

INTAKE VALVE ..... • .........................................

2

4

26617-G01

EXHAUST VALVE ........... • .................................

2

5

26618-G01

SPRING, VALVE ......... • • • ..................................

4

6

26619-G01

RETAINER, VALVE SPRING .....................................

4

8

26598-G01

HEAD ASSEMBLY (INCLUDES ITEMS 9 - 13) ......................

1

9

26659-G01

VALVE GUIDE, OVERSIZED .................................

4

10

26714-G01

SEAL, VALVE STEM ........ • ................ . .............

4

11

26667-G01

STUD, CYLINDER HEAD ............................ ........

2

12

26715-G01

SEAL, OIL ... • • • ............................. • .. . ........

1

13

26668-G01

PLUG, #3, CYLINDER HEAD .................................

1

14

26621-G01

ROCKER ARM ASSEMBLY (INCLUDES ITEMS 15, 16) ...................

1

15

26622-G01

SCREW, ADJUSTING (SPECIAL) .................................

4

16

26623-G01

NUT, ROCKER ARM (SPECIAL) ..................................

4

18

26624-G01

SPACER, ROCKER SHAFT .........................................

2

19

26625-G01

SPRING, ROCKER SHAFT ..........................................

1

20

26620-G01

ROCKER, SHAFT ..... • • • . • • ............................ • .. • .. • . • .

1

22

26674-G01

BOLT, FLANGED, MS X 1.25 X 60 MM LG.

23

26673-G01

BOLT, FLANGED, MS X 1.25 X 50 MM LG. ..........................

4

24

26679-G0t

BOLT, COVER (SPECIAL) ..........................................

1

25

26678-G01

.BOLT, FLANGED, M6 X 1.0 X 12 MM LG. ...........................

6

26

26599-G01

COVER, CAMSHAFT ........ • • . • . • ............................... •

1

27

26718-G01

GASKET, COVER, CAM ...........................................

1

28

26716-G01

GASKET, HEAD .................. • ..............................

1

7

17

21

9/05/91

! ! !F!1H4!

Pg. F-2

DIRECTION SELECTOR

4-CYCLE POWERED CAR

�o

N�

Pg. G-1

9/05/91

I 1&111-141

DIRECTION SELECTOR

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

2

25684-G01

BRACKET, DIRECTION SELECTOR.................................

1

3

25664-G1

BUSHING, . • .... •.............................................

1

4

00414-G6

SCREW, 1/4 - 20..............................................

2

5

00559-G7

WASHER, 1/4 .................................................

2

6

25745-G01

CAM, DIRECTION SELECTOR ....... • • • • • • . •. • . •.... • ............

1

7

14390-G1

NUT, 3/8 - 24 ................................................

1

8

11027-G2

NUT, LOCK, 1/4 - 20 ...................... • ...................

2

9

17940-G1

BUZZER......................................................

1

10

00138-G4

SCREW, #6 - 32 ..............................................

2

11

23176-G1

PIN, CLEVIS ........................ . ........................ •

2

12

10606-G1

SWITCH, MICRO ...................................... • .. . .....

1

13

00567-G3

WASHER, LOCK, EXTERNAL TOOTH ..............................

2

14

14628-G1

TAB, FASTON ........... •.....................................

1

15

13514-G1

SCREW AND WASHER ..........................................

2

16

00139-G2

SCREW, 1/8 X 1 1/4 ...........................................

2

17

27151-G01

SPACER, MICRO SWITCH ............... •.......................

2

18

00565-G3

WASHER, LOCK, #6............................................

4

19

00525-G5

NUT, #6 - 32 .................................................

4

20

26422-G01

HANDLE ASSEMBLY, DIRECTION SELECTOR ........................

1

21

11989-G1

KNOB, PLASTIC ...........................................

1

22

25748-G01

HANDLE, DIRECTION SELECTOR ........... • .................

1

23

25677-G01

SHAFT, DIRECTION SELECTOR .... •. •. •..........................

1

24

17618-G1

. TIE, WIRE ................................................. • ...

1

25

27170-G01

�IT. CABLE (INCLUDES ITEMS 26, 30 - 33) ........................

2

26

25691-G01

CABLE, SHIFTER CONTROL......................................

2

27

26830-G01

NUT, SHIFT LEVER .............................................

1

28

25946-G01

LEVER, SHIFTER ...............................................

1

30

25721-G01

SPRING, SHIFTER CABLE........................................

2

31

26521-G01

SPACER, SHIFTER .............................................

2

32

25727-G01

WASHER, CUP ................................................

4

33

11098-07

NUT, LOCK, 10 - 24 ................. • .........................

2

34

10387-G8

PIN, COTTER..................................................

2

DESCRIPTION

QTY

1

29

9/05/91

I I lgl11-l41

E�GCii:£1M•W

Pg. G-2

;J

m r­ m

J:

�

.....I

l:J

0 )>

rcn

3-INCLUDES ITEMS 4-18 5-INCLUDES ITEMS 6-15 19-INCLUDES ITEMS 7,8,9,10,?,0,21 66-INCLUDES ITEM 67 69-INCLUDES ITEMS 70-74

�

-I

m 3:

29

m

fJ Iii

I a

16

...

g I

r m

i� en

co .....

.,,

�

--\,_/

58

0 �

m ::D m 0

� ::D

4-CYCLE POWERED CAR

ELECTRICAL SYSTEM

BATTERY

IGNITOR

BLK

RED/WHT

J -1-- - BLK

I

+ WHT/ORN WHT

RED

SOLENOID I I I I RED

I

4 Pin Connector

RED

BLK RED/WHT BLK I

�=��

BLK

I I I I I I I I I I

BLU

KEY LIMIT WITCH S SWITCH � RE

BLK

RED

IGNITION COIL

BLK

2 Pin Connector

REVERSE WARNING DOF

SPAR K

• • • • ru&g

VOLTAGE REGULATOR

D+

DWS : 2w

NOTE: The ignitor of early production models were wired as shown by the - - line. Later models are wired as shown by the solid line. Early models may be re­ wired as shown by the solid line during routine servicing.

9/05/91

I I IHI 11-141

Pg. H-2

ELECTRICAL

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

QTY

DESCRIPTION

XXXX-XX

DIRECTION SELECTOR (SEE SECTION G FOR PART NUMBER AND QUANTITY)

3

25952-G01

PLATE ASSEMBLY, ELECTRICAL (INCLUDES ITEMS 4 -18) .............

1

4

25939-G01

IGNITOR.........•......•.•••••...•.••.•..••................

1

5

25893-G01

SOLENOID ASSEMBLY (INCLUDES ITEMS 6-14) ..................

1

6

16542-G1

SOLENOID .•..•..................................•.•....

1

7

24882-G1

WIRE, 18 GAUGE••.••..•..............•......•••.•••.....

1

8

12914-G1

TAB, FASTON ..........................................•

3

9

00565-G5

WASHER, LOCK, #10 •.................•......•.•.........

2

10

00526-G4

NUT, #10 -32 ...........•....•..........................

2

11

25887-G03

WIRE, #6 ................•..••.•.•..••............•.....

1

13

00544-G4

NUT, 5/16 - 24 ......................•....••.............

2

14

00567-G8

WASHER, LOCK, 5/16, EXTERNAL TOOTH•....•..............

2

1 2

12

15 16

*

PLATE, ELECTRICAL .........................................

1

17

00532-G1

NUT, 1/4 - 20 ............•••••••....•••....•....•......•...

6

18

00565-G7

WASHER, LOCK, 1/4 ...............................•......••.

6

19

25892-G01

20

16530-G1

REGULATOR, VOLTAGE........•..............................

1

21

25889-G01

WIRE, #16...........•.•..•.....................•.•.....•.•.

1

22

17618-G1

CLAMP, NYLON ........................•.......................

4

23

17421-G1

IGNITION SWITCH ASSEMBLY (INCLUDES ITEMS 24 - 26) .............

1

24

17063-G1

KEY, IGNITION ......................•.......................

2

25

17137-G1

NUT, 3/4 .....•..............................•.....•..••....

1

26

00568-G6

WASHER, LOCK, EXTERNAL TOOTH, 3/4 ........................

1

XXXX-XX

SWITCH, MICRO (SEE SECTION A FOR PART NUMBER AND QUANTITY) ..

VOLTAGE REGULATOR ASSEMBLY (INCLUDES ITEMS 7 - 10, 20, 21) ..

.

27 28 29

25932-G01

HARNESS, WIRING ......•................... ....................

1

30

13514-G1

SCREW, #6 BRASS ........••••...•.................•...••••.•••

2

31

00567-G3

WASHER, LOCK, EXTERNAL TOOTH ...............................

2

32

XXXX-XX

REVERSE WARNING BUZZER (SEE SECTION G FOR PART NUMBER AND QUANTITY) •.••.••••.......................................

33

26583-G01

HARNESS WIRING, JUMPER.......................................

Pg. H-3

E�GCii:£Ht(•W

1

9/05/91

I IHI 11-141

ELECTRICAL

4-CYCLE POWERED CAR

THE U SE OF NO N U.L. PART S WIL L VOID ANY U.L . LISTING. W hen ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

1

2

3

4

DESCRIPTION

5

QTY

ITEM

PART NO.

33

26583-G01

HARNESS WIRING, JUMPER ....•...•••.•.•........•...............

1

34

11027-G2

NUT, LOCK, 1/4 -20 ........•..........•........................

4

35

00565-G7

WASHER, LOCK ..................................••.•••..•••...

4

36

00106-G6

SCREW, SELF TAPPING ...••••••••••.••.•.••.....•...............

1

37

27044-G01

CABLE, NEGATIVE BATTERY ......................................

1

38

25945-G01

WIRE HARNESS ............•....•....•.........................

1

39

25936-G01

FUSE HOLDER ASSEMBLY (INCLUDES ITEM 40) ....•................

1

40

18392-G6

FUSE, 7 AMP ...............................................

1

11845-G1

CLAMP, CABLE CLIP, 3/4 ...........•.••.........................

44

24775-G1

BATTERY, 12 VOLT ...............•.....................•.......

1

45

00962-G1

SCREW, 5/16 - 18 X 1 1/4 LG. ...................................

2

46

00664-G8

WASHER, LOCK, 5/16 ...........................................

2

47

00669-G3

NUT, 5/16 - 18 ................................................

2

48

14390-G4

NUT, LOCK, 5/16 ......•.•...•.•......•.........................

2

49

00571-G2

WASHER, 5/16 .•..•..........•.......•.••..•..•...•............

2

50

18258-G2

RETAINER, BATTERY ..........................•.................

1

51

18261-G3

ROD, HOLD DOWN BATTERY

2

53

00414-G5

BOLT, 1/4 - 20 X 1/2 LG. .......................................

1

54

00660-G7

WASHER, 1/4 ...............................••..•••............

1

55

00567-G7

WASHER, LOCK, EXTERNAL TOOTH, 1/4 ....••.....................

1

56

00532-G1

NUT, 1/4 - 20 .................................................

1

58

17618-G1

CLAMP, NYLON ................................................

2

59

25682-G1

COVER, TERMINAL ..............................................

3

60

25887-G01

WIRE, 6 GAUGE ................................................

1

61

26702-G01

WASHER, 6.5 MM ..........•......•............................

4

62

51400-G1

WASHER, LOCK, 6 MM

.....................................•...

4

63

13632-G1

NUT, M6 X 1 ..........•...•.•......•.•..•.....................

4

64

XXXX-XX

STARTER/GENERATOR (SEE SECTION U FOR PART NUMBER AND QUANTITY) ................................................

26651-G01

IGNITION PICKUP ASSEMBLY (INCLUDES ITEM 67) ....................

41 42 43

52

57

65 66

9/05/91

! ! !H!1H4!

Pg. H-4

ELECTRICAL

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

DESCRIPTION

QTY

26707-G01

BOLT, WASHER, MS X .8 X 10 MM ••.......•....•...........•.

1

68

26676-G01

SCREW, M6 X 1 X 23 MM ..........•.•............•....•........

1

69

26652-G01

IGNITION COIL (INCLUDES ITEMS 70 - 74) .........................

1

COIL IGNITION .......•..••....••...............•............

1

SPACER ••...••••.•........................................

1

WASHER, LOCK .............................................

1

NUT .......................................................

1

SCREW ....................................................

1

NUT, M6 X 1

2

ITEM

PART NO.

67

70 71 72 73 74 75 76

Pg. H-5

* * * * *

13632-G1

1

2

3

4

5

9/05/91

I !H!1H41

ELECTRICAL

9/05/91

I I IHI 1!-141

4-CYCLE POWERED CAR

Pg. H-6

ENGINE AND MUFFLER

Pg. J-1

4-CYCLE POWERED CAR

E�GCllii:tit{•l:I

9/05/91

I I IJIH-141

ENGINE AND MUFFLER

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

26700-G01

ENGINE, 295 CC, 4-CYCLE

3

26631-G01

GROMMET, TIMING BELT COVER ................................•••

1

4

26634-G01

BOX, AIR CLEANER ....•..•.••..•................•...............

1

5

26735-G01

CLIP, AIR CLEANER BOX ••••••••••.•....•......•..................

2

6

26635-G01

ELEMENT, AIR CLEANER ..........................................

1

8

13632-G1

NUT, M6 X 1 .........................................•.........

2

9

26702-G01

WASHER, 6.5 X 1 .............................................. .

2

10

51400-G1

WASHER, LOCK, 6 MM ...........................................

2

11

26636-G01

BAFFLE, AIR CLEANER ..............•....................•.......

1

12

26676-G01

BOLT, FLANGED, M6 X 1 X 23 LG. .................................

2

13

26671-G01

BOLT AND WASHER, M6 X 1 X 30 LG. .......................•......

2

14

26701-G01

WASHER, 6.5 MM X 20 ...........................................

2

15

26728-'301

GASKET, AIR CLEANER ...........................................

1

16

26727-G01

GASKET, CARBURETOR/AIR BOX .....•.............................

1

19

26657-G01

BRACKET, IGNITION COIL .......................................•.

20

XXXX-XX

CARBURETOR (SEE SECTION D FOR PART NUMBER AND QUANTITY) .....

2

1

2

3

4

5

DESCRIPTION

QTY

7

17 18

21

26719-G01

GASKET, VALVE COVER .........................................•

1

22

26676-G01

BOLT, FLANGED, M6 X 1 X 23 LG. ..............••..•..............

6

23

26601-G01

CAP, OIL FILLER .................................................

1

24

26720-GOl

"O" RING .....................................•................

1

25

26600-G01

COVER, VALVE ..•.....•............•...........................

1

26

26736-G01

LABEL, ENGINE OIL ..............................................

1

27

17014-G1

WIRE, SPARK PLUG (CUT TO LENGTH) ..••..........................

2

28

25523-G01

SPARK PLUG ••.•.••.••......•....•.•............................

2

30

25532-G1

BOLT AND WASHER, MS X 1.25 X 18 LG. ..............•............

2

31

26344-G01

MUFFLER .....•.....•....•.•...•................................

1

32

25532-G1

BOLT AND WASHER, MS X 1.25 X 18 LG. •..........................

2

33

25531-G1

GASKET, EXHAUST ..............................................

1

34

00764-G1

BOLT, CARRIAGE, 5/16 - 18 X 3/4 LG. .............................

2

29

9/05/91

I I IJI 11-141

Pg. J-2

ENGINE AND MUFFLER

4-CYCLE POWERED CAR

THE U SE OF NON U.L. PARTS WILL VOID ANY U .L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

35

00559-G8

WASHER, 5/16 ..................................................

2

36

00931-G2

WASHER, LOCK, 5/16 ............................................

2

37

00532-G3

NUT, 5/16 - 18 .................................................

2

38

25655-G01

BRACKET, PIVOT ................................................

1

39

00931-G2

WASHER, LOCK, 5/16 ............................................

2

40

00276-G6

SCREW, 5/16 - 24 X 3/4 LG. ......................................

2

41

26630-G01

COVER, TIMING BELT .............................................

1

42

26626-G01

BELT, TIMING ...................................................

1

43

26678-G01

BOLT, M6 X 1 X 12 LG. ..........................................

3

44

25654-G01

BRACKET, STARTER/GENERATOR ADJUSTMENT ......................

1

45

00931-G2

WASHER, LOCK, 5/16 ............................................

2

46

00276-G6

SCREW, 5/16 - 24 X 3/4 LG. ......................................

2

49

26591-G01

FILTEA, OIL .....................................................

1

50

26680-G01

BOLT AND WASHER, M6 X 1 X 12 LG. ..............................

3

51

26710-G01

"O" RING, OIL FILTER ............................................

1

52

26602-G01

PIPE, BREATHER .................................................

1

53

18292-G1

CLAMP, HOSE ..................................................

2

47 48

Pg. J-3

9/05/91

I IJIH-141

ENGINE AND MUFFLER

9/05/91

I I IJI 11-141

4-CYCLE POWERED CAR

Pg. J-4

ENGINE/STARTER MOUNTING

4-CYCLE POWERED CAR

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r� , ' ' \l //,-:::__---:, I

I

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2.7 24/�

Pg. K-1

E�GDiiilitt•l:I

9/05/91

I !K!H-141

ENGINE/STARTER MOUNTING

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

1

25656-G01

GUARD, ENGINE ................................................

1

2

00463-G4

SCREW, 7/16 - 14 X 1 1/2 LG ••.••...............................

4

3

00566-G2

WASHER, LOCK, 7/16 ...................................•.......

8

4

00922-G3

WASHER, 7/16 .••.•................•......•....................

8

5

25674-G01

BRACKET, FRONT ENGINE MOUNTING ..•...........................

1

6

00288-G8

SCREW, 7/16 - 14 X 1 LG ...........•............•..••..........

4

7

14390-G1

NUT, LOCK, 3/8 - 24 ...........................................

1

8

XXXX-XX

STARTER/GENERATOR (SEE SECTION U FOR PART NUMBER AND QUANTITY} ................................................

9

00938-G4

SCREW, 1/2 - 13 X 8 LG. .......................•...............

1

10

00560-G3

WASHER, 1/2 ........•.•..................•....................

2

12

00566-G3

WASHER, LOCK, 1/2 ............................................

1

13

00533-G1

NUT, 1/2 - 13 ..............•.........•........................

1

14

25708-G01

YOKE, CLEVIS ...•....•..•••••.................................

1

15

24667-G1

PIN, ADJUSTING ................................................

1

16

00532-G6

NUT, 3/8 - 24 .................................................

1

17

00566-G1

WASHER, LOCK, 3/8 ....................................•...•...

1

18

14443-G3

PIN, CLEVIS, 5/16 X 1 LG. .......................................

1

19

00642-G8

WASHER, 5/16 .................................................

1

20

10387-G4

PIN, COTTER ..........................................•........

1

21

26414-G01

BELT, STARTER/GENERATOR •.••••.••••....•.....................

1

22

25675-G01

BRACKET, REAR ENGINE MOUNTING •....•.........................

1

23

00427-G8 :·

SCREW, 3/8 - 16 X 2 LG. ..••...•...............................

4

24

00560-G1

jVASHER, 3/8 ..................•...............................

8

26

00566-G1

WASHER, LOCK, 3/8 ............................................

4

27

00550-G5

NUT, LOCK, 3/8 - 16 ...........................................

4

28

14601-G5

RIVET, 3/16 X 13/32 LG. ........................................

16

29

14137-G1

MOUNT, ISOLATION, 25 LB. ......................................

3

30

14137-G2

MOUNT, ISOLATION, 35 LB. •.....••.•............................

1

31

XXXXX-XX

SEE SECTION A FOR PART NUMBER AND QUANTITY ..................

QTY

11

25

9/05/91

I I !Kl 1!-141

Pg. K-2

FRONT SUSPENSION

4-CYCLE POWERED CAR

1 - INCLUDES ITEMS 2-45 34 - INCLUDES ITEMS 35-45 47 - INCLUDES ITEMS 48-58

Pg. L-1

E�l:iDiii:1it{•J:I

9/05/91

I ILl11-l41

FRONT SUSPENSION

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

24054-G5

2 3

23918-G2

AXLE ................... ·� ......................................

1

25177-G2

KING PIN ....................................................

2

8

16982-G1

BEARING, THRUST . • . • ........................................

2

9

00879-G7

WASHER, 7/8 ................................................

2

10

00886-G1

NUT, SLOTTED, 5/8 - 18 ....................... ...............

2

11

19060-G1

PIN, COTTER, 1/4 X 1 1/2 LG. .... • .................... ........

2

12

00879-G5

WASHER, 5/8 ................................................

2

23925-G1

SPINDLE ASSEMBLY, DRIVER'S SIDE (INCLUDES ITEMS 15 - 18) .....

1

SPINDLE, DRIVER'S SIDE ...................................

1

FRONT AXLE ASSEMBLY (INCLUDES ITEMS 2 - 45)

1

4

5 6 7

13 14

*

15 16

16623-G1

BEARING, BRONZE ........................................

2

17

10389-G3

FITTING, GREASE ........... • . • . • .........................

1

18

16626-G1

SEAL ...................................................

1

19

23924-G2

SPINDLE ASSEMBLY, PASSENGER'S SIDE (INCLUDES ITEMS 20 - 23) .

1

SPINDLE, PASSENGER'S SIDE ...................... • ........

1

*

20 21

16623-G1

BEARING, BRONZE ..................... • • .................

2

22

10389-G3

FITTING, GREASE ....................... • . ................

1

SEAL ...................................................

1

HUB ASSEMBLY (INCLUDES ITEMS 26,27) ........................

2

BOLT, HUB, 1/2 - 20 ......................................

4

RACE, BEARING ....... • • • • • • .............................

2

23

16626-G1

24

:

25

19932-G1

26

19862-G1

*

27

.

28

50892-G1

BEARING AND RACE ASSEMBLY (INCLUDES ITEMS 29,30) ..........

2

29

11750-G2

ROLLER, BEARING . • ... • ...................... • ............

2

RACE, BEARING . • ... • ....................................

2

*

30 31

12093-G1

NUT, SLOTTED, 1 - 14 .. • ........ • • ..... • • ....................

2

32

00798-G8

PIN, COTTER, 5/32 X 1 3/4 LG. ................................

2

33

25146-G1

SEAL .......................................................

1

19202-G1

TIE ROD ASSEMBLY (INCLUDES 35 - 45) .........................

1

34

9/05/91

I I IL111-141

E�GClii:f:dt(•W

Pg. L-2

FRONT SUSPENSION

4-CYCLE POWERED CAR

THE U SE OF NON U.L. PARTS WILL VOID ANY U .L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

35

20795-G1

36

18434-G1

NUT, 9/16 - 18, L.H. • ...................................

1

37

50641-G1

BOOT, RUBBER ...••••••••.............................

1

38

50209-G1

NUT, SLOTTED, 7/16 - 20 ...............................

1

39

10387-G2

PIN, COTTER, 3/16 X 1 LG. •................................

1

40

20795-G2

TIE ROD END ASSEMBLY, R.H. (INCLUDES ITEMS 41 - 44) ......

1

41

18434-G2

NUT, 9/16 - 18, R.H. ........•........................•.

1

42

50641-G1

BOOT, RUBBER ........................................

1

43

50209-G1

NUT, SLOTTED, 7/16 - 20 ...............................

1

44

10387-G2

PIN, COTTER, 3/16 - 1 LG. ............... .. ................

1

45

10389-G3

FITTING, GREASE ................... • .....................

2

47

18377-G1

TIE ROD ASSEMBLY (INCLUDES ITEMS 48 - 58) .......... . ...........

1

48

20795-G1

TIE ROD END ASSEMBLY, L.H. (INCLUDES ITEMS 49 - 52) ..........

1

49

18434-G1

NUT, 9/16 - 18, L.H. ......................................

1

50

50641-G1

BOOT, RUBBER ............................••.............

1

51

50209-G1

NUT, SLOTTED, 7/16 - 20 ..................................

1

52

10387-G2

PIN, COTTER, 3/16 X 1 LG. ...............•..................•.

1

53

20795-G2

TIE ROD END ASSEMBLY, R.H. (INCLUDES ITEMS 54 - 57) .........

1

54

18434-G2

NUT, 9/16 - 18, R.H. ......................................

1

55

50641-G1

BOOT, RUBBER •••••••........•..............••...........

56

50209-G1

NUT, SLOTTED, 7/16 - 20 ...............•.•••..............

1

57

10387-G2

PIN, COTTER, 3/16 X 1 LG. ................................••..

1

58

10389-G3

FITTING, GREASE ...........•...•............ : ................

2

59

23929-G1

IDLER ASSEMBLY (INCLUDES ITEMS 60, 61) ..............•..........

1

60

15012-G1

BUS HING, FLANGED ........................•.................

2

61

10389-G3

FITTING, GREASE .............................................

1

62

16417-G2

S HAFT, IDLER •......•......................•................•...

1

63

13221-G1

WAS HER, WAVE TYPE, SPRING, .............•.............•.......

1

64

10387-G1

PIN, COTTER, 1/4 X 1 1/2 LG. .....•...............................

1

65

15023-G2

RETAINER, SPRING .••••....••....................................

2

66

00876-G4

SCREW, BLACK, 3/8 - 16 X 1 1/2 LG. ..............................

8

67

00878-G1

WAS HER, LOCK, BLACK, 3/8 ......................................

8

68

00877-G5

NUT, BLACK, 3/8 - 16 ...........•..•............................

8

TIE ROD END ASSEMBLY, L.H. (INCLUDES ITEMS 36 - 39)

46

Pg. L-3

E�Gtni=E,M•W

9/05/91

I IL111-l41

FRONT SUSPENSION

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

69

15023-G2

RETAINER, SPRING ......•...........•••..........................

2

70

00532-GS

NUT, 3/8 - 16 ................•....••...........................

6

71

00566-G1

WASHER, LOCK, 3/8 .................•...........................

6

72

00427-G6

SCREW, 3/8 - 16 X 2 LG. •.•••••.•...............................

6

24025-G1

SPRING, LEAF ........•......•.•.................................

2

12091-G1

CAP, SPINDLE .....................•............................

2

78

15707-G1

SHOCK ABSORBER ...........................•...................

2

79

10435-G1

WASHER, 13/32 .................................................

8

80

10194-G1

BUSHING, RUBBER ...............................................

8

81

00532-G6

NUT, 3/8 - 24 ..................................................

4

82

14723-G1

NUT, LUG, 1/2 - 20 ..............................................

8

73 74 75 76 77

9/05/91

! ! !L!1H4!

Pg. L-4

FRONT SHIELD

Pg. M-1

4-CYCLE POWERED CAR

9/05/91

I I f.1111-141

FRONT SHIELD

4-CYCLE POW ERED CAR

THE USE OF NON U .L. PARTS W I LL VOID ANY U.L. LIST ING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM 1

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

23881-G1

SHIELD ..............••.............•..........................

3

00414-G8

SCREW, 1/4 - 20 X 1 LG. ..........................•.•...........

2

4

00559-G7

WASHER, 1/4 ..............••••................................•

2

5

14390-G4

NUT, LOCK, 1/4 - 20 ......••.••..................•..............

2

25054-'31

SUPPORT, SHIELD ...............................................

11

00426-G8

SCREW, 3/8 - 16 X 1 LG. ........................................

2

12

00560-G1

WASHER, 3/8 ..................................................•

2

13

00566-G1

WASHER, LOCK, 3/8 ........•••..................................

2

14

00532-GS

NUT, 3/8 - 16 ..................•...............................

2

2

6 7 8 9 10

9/05/91

I I fJl11-l41

Pg. M-2

FRESH AIR INTAKE

4-CYCLE POWERED CAR

EARLY PRODUCTION

11

10

2

Wiiii;i)- - -

3 4

7

Pg. N-1

E�GDii:£1i,{•]:I

9/05/91

I !NI 1!-141

FRESH AIR INTAKE - EARLY PRODUCTION

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1 2

26481-G01

BOX, AIR INTAKE ...........-· � .... -� ................................

4

25729-G01

HOSE, AIR ......................................................

1

5

17618-G1

CLAMP, NYLON .......•.•........................•..............

1

7

14390-G4

NUT, LOCK, 1/4 - 20 ............•.•............................•

1

8

00559-G?

WASHER, 1/4 ..............................................•....

1

9

00559-G4

WASHER, 5/8 ................................•..................

2

10

00614-G5

SCREW, SELF DRILL AND TAPPING, 5/8 .......•.•...................

2

12

26412-G01

GASKET, AIRBOX ................................................

13

26458-G01

BRACKET, SUPPORT, AIRBOX ..................................... .

3

6

11

9/05/91

I I !NI 1 l-141

Pg. N-2

FRESH AIR INTAKE

Pg. N-3

FIRST USED ON 1992 MODEL

4-CYCLE POWERED CAR

9/05/91

!N!H-141

FRESH AIR INTAKE - FIRST USED ON 1992 MODEL

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1 2

26481-G01

BOX, AIR, INTAKE ..•...._..•..• � .� •.•............................

4

25560-G01

HOSE, AIR ......................................................

1

5

17618-G1

CLAMP, NYLON ..........•.•....................................

2

7

14390-G4

NUT, LOCK, 1/4 - 20 ............................................

1

8

00559-G7

WASHER, FLAT, 1/4 ............................................ .

1

9

00559-G4

WASHER .......................................................

2

10

00614-GS

SCREW, SELF DRILL AND TAPPING, 5/8 .............................

2

3

6

11 12 13

26412-G01 26458-G01

9/05/91

! ! !N!1H4!

GASKET, AIR BOX ...............................................

BRACKET SUPPORT AIRBOX ......................................

I

I

Pg. N-4

FUEL SYSTEM

4-CYCLE POWERED CAR

Cl) C\I

Pg. P-1

9/05/91

! !P!1!-!4!

FUEL SYSTEM

4-CYCLE POWERED CAR

18827-G1 WARNING: AVOID FIRE HAZARD , H GASOUN[ PUMP IS ,JSfD Bf SURE I� IS GROUNDED

DO NOT RrFUEL VJHEN ENGINE IS HOT

If GASOLINE_ IS SPll LED tl JSH THOROUCHl Y ,JITH ,'JATfR Bl FORE_ STARTING ENGINE

26459-G01

y

FILL WITH GASOLINE ONL MIN. 87 OCTANE UNLEADED _,

9/05/91

l l tPt1l-t4l

Pg. P-2

FUEL SYSTEM

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

2

18293-G1

TANK, FUEL SYSTEM ....••

3

14099-G2

GAUGE, FUEL ..................•....••..........................

1

4

14091-G1

WASHER, NEOPRENE •.........................................•.•

1

5

00439-G1

SCREW, 5/16 - 18 X 1 1/8 LG. ...............•....................

1

6

00559-G8

WASHER, 5/16 .................................................•

2

7

11098-G6

NUT, LOCK, 5/16 - 18 ...........................................

1

8

18302-G2

STRAP, FUEL TANK ....................................•.........

1

9

14390-G4

NUT, LOCK, 1/4 - 20 ............................................

1

10

17618-G1

CLAMP, NYLON .................................................

2

11

19678-G3

LOOM, FLEX, ZIP ........................................•.......

1

13

18827-G1

LABEL, WARNING: AVOID FIRE HAZARD .............................

14

26459-G01

LABEL, GASOLINE ONLY ..........................................

16

25294-G6

PUMP, FUEL AND FILTEA ASSEMBLY (INCLUDES ITEMS 17 - 22) ........

1

17

12902-G1

FILTER ......................................................

1

18

18292-G1

CLAMP, TUBING ..............•...............................

2

19

25683-G1

PUMP, FUEL ...............•.................................

1

20

11391-G1

CLAMP, TUBING ..............................................

1

TUBE, FUEL, 13.25" LG. ......................................

1

TUBE, FUEL, 6.25" LG. .......................................

1

DESCRIPTION

QTY

1 J

•

•

• J�

• ••

•

•

•

•

•

•

• ••

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

1

12

15

21 22

* *

23

25346-G7

TUBE, FUEL, PULSE, 31" LG. .................................... .

1

24

25693-G01·

CHOKE, CONTROL ASSEMBLY (INCLUDES ITEMS 25) .•.•..........••..

1

25

00544-G4

NUT, JAM, 5/16 - 21 ..................•......................

2

26

00568-34

WASHER, LOCK, EXTERNAL TOOTH, 9/16 ...........................

1

27

22070-G1

CLAMP, CABLE .................................................

1

28

00545-G4

NUT, 9/16 - 18 ...............•.................................

1

29

17470-G1

TUBE, BULK (ORDER TO THE NEAREST FOOT} .......................

AR

30

11027-G2

NUT, LOCK, 1/4 - 20 ............................................

2

Pg. P-3

9/05/91

I !Pl 1!-141

FUEL SYSTEM

9/05/91

! ! !P!1H4!

4-CYCLE POWERED CAR

Pg. P-4

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

ACCESSORY WIRING HARNESS

LIG HT SWITCH

HOUR METER

G REEN

HOUR METER WIRING +��) FROM SOLENOID

GRY

_

12V DC---­

I I

Pg. Q-1

9/05/91

I I k:il1'-l41

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

HEAD AND TAILLIGHTS ASSEMBLY, 4-WHEEL GOLF CARS ONLY (COMES COMPLETE WITH HARNESS, HEADLIGHTS, AND TAILLIGHTS)

r

- -� ,

11·. .··

-l

rk

��··

���

7

17

TURN SIGN AL 24

21

TAILLIGHT

HORN SWITCH

9/05/91

I I lol11-l41

Pg. Q-2

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

50 INCLUDES ITEM 51

4-WHEEL HEADLAMP

NOTE: TO IN STALL HEADLIGH T, REMOVE AND DISCARD EXISTING SCREW S AND REPLAC E THEM WITH ITEM 27 AFTER IN STALLATION.

Pg. Q-3

9/05/91

I lal11-l41

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

ACCESSORY HARNESS CONNECTIONS

59 INCLUDES ITEMS 60 TO 70 61 INCLUDES ITEMS 62 TO 65

HARNESS GROUND WIRE

9/05/91

I I lol 11-141

Pg. Q-4

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

* Indicates a component that is not available as an individual part.

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

22069-G1

WIRING HARNESS ....................................••..........

1

2

11845-G5

CLIP, CABLE INSULATED ..........................................

3

3

18436-G1

RIVET, DRIVE, PLASTIC .......................................•..•

3

4

17618-G1

CLAMP, NYLON ................................................•

5

5

19318-G2

HOUR METER KIT (INCLUDES ITEMS 6 - 9) .........................•

1

6

21573-G1

HOUR METER (INCLUDES MOUNTING HARDWARE) .................

1

7

18001-G1

BRACKET, HOUR METER .................. . ....................

1

8

00414-G4

SCREW, 1/4 - 20 X 1/2 LG. ...................................

2

9

11027-G2

NUT, LOCK, 1/4 - 20 .......................•.....•...........

2

10

18431-G1

SWITCH, HEADLAMP ....................... • ........ . ............

1

11

18392-G1

FUSE, 15 AMP (HOUR METER) .....................................

1

12

22674-G1

FUSE BLOCK ............................................•.......

1

13

00138-G4

SCREW, #6 - 32 X 1/2 LG. .......................................

2

14

00565-G3

WASHER, LOCK, #6 ..............................................

2

15

00525-G5

NUT, #6 - 32 ............................................•......

2

20062-G1

HEADLIGHT AND TAILLIGHT ASSEMBLY ..............................

1

21

18927-G1

MOUNTING KIT, TURN SIGNAL ...............................•......

2

22

21806-G1

BRACKET, TURN SIGNAL ..................................•.......

2

23

00598-G4

SCREW, SELF DRILL AND TAP, #8 - 18 X !/2 LG. ....................

4

24

19180-G2

. SIGNAL LAMP, SIGNAL ..........•................·...............•

2

26

23686-G1

HEADLAMP (REQUIRES ITEM 27 FOR INSTALLATION) .•...........•....

2

27

00906-G6

SCREW, #10 - 16 X 1 LG. ................................••......

2

28

18392-G2

FUSE, 20 AMP (HEADLAMPS AND TAILLIGHTS) .......................

1

29

22000-G1

LENS, TAILLIGHT ................................................

2

30

21999-G1

GROMMET ......................................................

2

31

21759-G1

BULB .......................................•..................

2

32

21998-G2

SOCKET ........................................................

2

16 17 18 19 20

25

33 34

Pg. Q-5

EeGDU:£,i.(•W

9/05/91

I lol 11-141

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

35

22242-G1

SWITCH, HORN (INCLUDES WIRES) .....................•...........

2

36

14601-G8

RIVET ...................•..••.....•••.•..•••...................

2

37

20961-G3

COVER, STEERING COLUMN (WITHOUT TURN SIGNALS) ..•.............

1

38

32860-G1

HORN .............•..•••.....................................•.

1

39

13437-G9

SCREW, 1/4 - 20 X 3/4 LG. •......................................

1

40

11027-G2

NUT, LOCK, 1/4 - 20 .............•..............................

1

41

23276-G1

SPACER ••....................•.•...............................

1

44

24626-G1

CLIP, CABLE INSULATED ..........................................

2

45

10570-G2

RIVET, 3/16 - 3/8 ...............................................

2

46

24605-G1

WIRING HARNESS ................................................

1

50

17867-G1

SWITCH, TURN SIGNAL ASSEMBLY (INCLUDES ITEM 51) ...............

1

51

21640-G1

FLASHER, TURN SIGNAL .......................................

1

52

00372-G4

SCREW, #8 - 32 X 1/2 LG. .......................................

1

53

00565-G4

WASHER, LOCK, #8 ..........•..•.•................... ...........

1

54

00526-G1

NUT, #8 - 32 ...................................................

1

55

20965-G3

COVER, STEERING COLUMN (WITH TURN SIGNALS) ...................

1

56

18392-G2

FUSE, 20 AMP (TURN SIGNALS) ...................................

1

57

19344-G1

TAPE, VINYL ..•................•................................

AR

42 43

47 48 49

58

:

59

20570-G2

:rURN SIGNAL ASSEMBLY (INCLUDES ITEMS 60 - 70) ................•.

2

60

18995-G1

TERMINAL, MALE .........•...................................

1

61

20574-G2

TURN SIGNAL, AMBER (INCLUDES ITEMS 62 - 65) .................

1

SCREW ..................................................

2

LENS, TURN SIGNAL .......................................

1

BULB ....................................................

1

HOUSING, TURN SIGNAL ....................................

1

* *

62 63 64

21760-G1

*

65 66

00563-G7

WASHER, LOCK, 1/4 .........................................

1

67

20606-G1

WIRE, JUMPER ..................••...........................

1

68

00532-G1

NUT, LOCK, 1/4 - 20 .........................................

1

9/05/91

I I 19111-141

Pg. Q-6

HORN AND ACCESSORY WIRING

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

69 70

PART NO.

1

20606-G1 00532-G1

2

3

4

5

DESCRIPTION

QTY

WIRE, JUMPER ...............•.•.............................

NUT, LOCK,

1/4 - 20

.........................................

1 1

:

.

Pg. Q-7

9/05/91

I 1§111-141

HORN AND ACCESSORY WIRING

9/05/91

I I lol 11-141

4-CYCLE POWERED VEHICLE

Pg. Q-8

REAR AXLE

Pg. R-1

4-CYCLE POWERED CAR

9/05/91

I !RI 1!-141

REAR AXLE

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

2

AXLE, REAR (INCLUDES.JTEMS 2 ·"" 33) ....... • .. • ..................

1

14601-G1

RIVET .......... • ...........................................

2

4

00559-G5

WASHER, #10 ...... • .... • . • . • ...............................

2

5

13728-G1

BUMPER ....................... • ......... • . • • .. • ............

2

6

26815-G01

BRACKET, SHIFTER CABLE .....................................

1

7

26823-G01

BOLT, FLANGE, MS X 1.25 X 100 MM

8

8

26824-G01

BOLT, FLANGE, MS X 1.25 X 110 MM ...........................

1

9

26825-G01

BOLT, FLANGE, MS X 1.25 X 120 MM ...........................

1

10

26826-G01

WASHER, LOCK, 8 MM ........................................

12

11

26827-G01

NUT, MS X 1.25 MM ..........................................

12

12

26772-G01

PLUG, OIL FILL ...............................................

1

14

26767-G01

STUD, M10 X 1.5 X 40 MM ....................................

10

15

26828-G01

WASHER, 10 MM .............................................

10

16

26829-GO1

NUT, 10 MM X 1.5 MM ........................................

10

18

26812-G01

CASE, AXLE, LEFT COMPLETE .............. • ..................

1

19

26809-G01

SHAFT, AXLE, LEFT, COMPLETE ................................

1

20

26813-G01

CASE, AXLE, RIGHT, COMPLETE ................................

1

21

26810-G01

SHAFT, AXLE, RIGHT, COMPLETE .... • .... • .....................

1

22

26768-G01

PLUG, OIL CHECK ..... • .... • • • • • . • • ..........................

1

23

26770-G01

PLUG, OIL DRAIN .............................................

1

24

26814-G01

RING, RETAINING ............... • • ............................

4

25

26811-G01

BALL BEARING ... • • .... • • • . • . • • ..............................

2

26

15485-G1

WASHER, 20 MM .............................................

2

27

24939-G1

ADAPTER, SPINDLE CAP • ... • . • ................................

2

29

21830-G1

WASHER, BRAKE DRUM ...... • ................................

2

30

00518-GS

NUT, SLOTTED, 3/4 - 16 ......................................

2

31

10387-G1

PIN, COTTER ................... • ............................

2

32

12091-G1

CAP, SPINDLE .... • .... • ........ • ............................

2

33

26766-G01

SEAL, OIL, 28 X 47 X 8 .......................................

2

3

25696-G01

13

17

.

28

9/05/91

I I !R!1H41

E�Gtni:S:•M•W

Pg. R-2

REAR SUSPENSION

Pg. S-1

4-CYCLE POWERED CAR

9/05/91

l l lSl1l-l4l

REAR SUSPENSION

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

1

25673-G01

FRAME, INNER (WITH FACTORY INSTALLED ENGINE MOUNTS) .........

1

2

00428-G8

SCREW, 3/8 - 16 X 3 LG. .......................................

4

4

00560-G1

WASHER, LOCK, 3/8 - 16

4

5

00550-GS

NUT, LOCK, 3/8 - 16 ........•.•.•.•............................

4

8

24957-G1

ABSORBER, SHOCK ..........•.......••.........................

2

9

00560-G3

WASHER, FLAT, 1/2 ...........................................•

2

10

00551-G1

NUT, LOCK, 1/2 - 13 ...............•..•........................

2

11

00550-GS

NUT, LOCK, 3/8 - 16 ...........................................

2

12

00560-G1

WASHER, LOCK, 3/8 - 16 ...•...................................

2

13

00428-G4

SCREW, 3/8 - 16 X 2 1/2 LG. ....................................

2

14

14462-G1

SPRING, COMPRESSION ..........................................

2

15

00560-G3

WASHER, 1/2 ..•....•..........................................

2

16

00551-G1

NUT, LOCK, 1/2 - 13 ........................................•..

2

17

00406-G4

SCREW, 1/2 - 13 X 4 1/2 LG. ....................•..............

2

18

12302-G2

MOUNT, ISOLATION ....................•........................

4

19

00566-G3

WASHER, LOCK, 1/2 ....................•.......................

2

20

00551-G1

NUT, LOCK, 1/2 - 13 ...........................................

2

00560-G3

WASHER, 1/2 ...•...................•.....•....................

00551-G1

NUT, LOCK, 1/2 - 13

DESCRIPTION

QTY

3

6 7

21

22

23

9/05/91

I I 1s111-141

'

Pg. S-2

4-CYCLE POWERED CAR

SEATS AND BAG HOLDER

16

31

/67 ///� 68

v

/ 48 49 50 51

55 � 58 �"

Pg. T-1

\;_

1

59

9/05/91

! l lTl1l-l2!

SEATS AND BAG HOLDER

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

24115-G2

BACK REST ASSEMBLY, WHITE (INCLUDES ITEMS 6, 11 - 14)

2

2

24115-G6

BACK REST ASSEMBLY, OYSTER (INCLUDES ITEMS 7, 11 - 14) ......

2

3

24115-G7

BACK REST ASSEMBLY, TAN (INCLUDES ITEMS 8, 11 - 14) ....•••.•

2

4

24115-G8

BACK REST ASSEMBLY, GRAY (INCLUDES ITEMS 9, 11 - 14) ........

2

6

14371-G1

COVER, BACK REST CUSHION, WHITE ........................

1

7

14371-G4

COVER, BACK REST CUSHION, OYSTER .......................

1

8

14371-G5

COVER, BACK REST CUSHION, TAN .........• • ..•............

1

9

14371-G6

COVER, BACK REST CUSHION, GRAY .........................

1

11

25433-G1

CUSHION FOAM, BACK REST .............•. . . ............••

1

12

19226-G1

PLYWOOD SEAT BACK ...........•........ • ................

1

NUT, TEE .•.•.................................•.......

2

STAPLE, FLAT ............................................

60

5

10

* *

13 14 15

00924-G6

SCREW, SELF-TAPPING, STAINLESS STEEL, #8 - 15 X 3/4 LG. ......

4

16

19056-G3

COVER, BACK REST, BLACK ......••••.........................

2

17

00666-G6

SCREW, SELF-TAPPING, STAINLESS STEEL, #10 - 16 X 3/4 LG. .....

4

18

00414-G8

SCREW, 1/4 - 20 X 1 LG. ....•............•...........•••.....

4

19

00661-G8

SCREW, STAINLESS STEEL, 1/4 - 20 X 1 LG. (FREEDOM ONLY) .••••

4

20

00565-G7

WASHER, LOCK, 1/4 .••..............••••........•..••••......

4

21

00664-G7

WASHER, LOCK, STAINLESS STEEL, 1/4 (FREEDOM ONLY) ...••....

4

22

00559-G7

WASHER, LOCK, 1/4 ............•••.........•...•••...........

4

23

00660-G7

WASHER, STAINLESS STEEL, 1/4 (FREEDOM ONLY) ....•...........

4

24

00763-G4

SCREW, TRUSS, 5/16 - 18 X 1 1/2 LG. ...•.•...................

2

25

00762-G4

. SCREW, TRUSS, STAINLESS STEEL, 5/16 - 18 X 1 1/2 LG. (FREEDOM ONLY) .............•.............................•

2

26

16924-G2

SEAT BACK BRACKET AND BAG HOLDER •...............•........

1

27

14643-G2

EXTRUSION, VINYL ............•..•..••...........•............

1

28

15902-G1

STRAP, RETAINER ...............•.•.•.•...........••.........

1

29

16610-G1

ANCHOR, PLATE .............••.•..............•.............

1

30

17226-G1

RIVET .......................................................

2

31

16920-G1

RETAINER, STRAP •.......................................••..

2

32

15058-G1

RIVET, ALUMINUM BLACK •.•.•.•••.............................

4

33

16935-G1

NUT, TEE ........................•..................••......

4

34

00439-G6

SCREW, LOCK, 5/16 - 18 X 1 3/4 LG. ...........................

4

9/05/91

I I ITI 11-141

E�GClii:£,M•W

Pg. T-2

SEATS AND BAG HOLDER

4-CYCLE POWERED CAR

THE U SE OF NO N U.L. PART S WIL L VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM 35

PART NO.

1

2

3

4

5

DESCRIPTION

SCREW, LOCK, STAINLESS STEEL, 5/16 - 18 X 1 3/4 LG., (FREEDOM ONLY) ............................................

00685-G7

QTY

2

4

36

11027-G1

NUT, LOCK, 5/16 - 18 ........................................

37

00891-G3

NUT, LOCK, 5/16 - 18 (FREEDOM ONLY) .........................

4

38

00427-G4

SCREW, 3/8 - 16 X 1 1/2 LG. ..••••....................•......

2

39

00665-G4

SCREW, STAINLESS STEEL, 3/8 - 16 X 1 1/2 LG. (FREEDOM ONLY)

2

40

11027-G5

NUT, LOCK, 3/8 - 16 ....•....••.•.•..........................

2

41

00891-G5

NUT, LOCK, 3/8 - 16 (FREEDOM ONLY) ..........................

2

43

22460-G02

SEAT BOTTOM ASSEMBLY, WHITE (INCLUDES ITEMS 48, 53 - 59, 62 - 65) .....................................•......

44

22460-G06

SEAT BOTTOM ASSEMBLY, OYSTER (INCLUDES ITEMS 49, 53 - 59, 62 - 65) ............................................

45

22460-G07

SEAT BOTTOM ASSEMBLY, TAN (INCLUDES ITEMS 50, 53 - 59, 62 - 65) ............•................••.............

46

22460-G08

SEAT BOTTOM ASSEMBLY, GRAY (INCLUDES ITEMS 51, 53 - 59, 62 - 65) ............................................

42

47 48

15146-G1

COVER, SEAT BOTTOM CUSHION, WHITE ........•.•..........

1

49

15146-G2

COVER, SEAT BOTTOM CUSHION, OYSTER ............•.......

1

50

15146-G3

COVER, SEAT BOTTOM CUSHION, TAN .......................

1

51

15146-G4

COVER, SEAT BOTTOM CUSHION, GRAY ......................

1

25432-G1

CUSHION FOAM ..........••................•............•.

52 53 54 55

11394-G1

56

17113-G1

57 58 59 60

* * *

:

.

WEBBING ...................•••••••......................

1

TRIM, VINYL ...........•....•.............................

1

STAPLE .•......•...•••.•••.................•.•..........•

24

STAPLE ............................••••..................

4

STAPLE, FLAT ...........................................•

110

GASKET, SEAT, REAR ••....................•...••..........

1

STAPLE .........................•....••..................

71

61 62 63

17283-G1

*

64 65

Pg. T-3

12441-G2

PLYWOOD, SEAT BOTTOM .....•••........................•.

E�GDU:£1M•W

09/05/91

! !T!1l-!4!

SEATS AND BAG HOLDER

4-CYC LE POWERED CAR

THE U SE OF NO N U.L. PART S WIL L VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

66 67

18250-G1

BRACKET, SEAT HINGE ...••.••.••.•...........................

2

68

00114-G6

SCREW, SELF-TAPPING, 1/4 - 10 X 3/4 LG• •••••...•.•..•.•......

4

' .

9/05/91

I I !Tl 1!-141

Pg. T-4

STARTER/GENERATOR

Pg. U-1

4-CYCLE POWERED CAR

9/05/91

! ! !U!1!-l4l

STARTER/GENERATOR

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

1

25533-G3

STARTER / GENERATOR ASSEMBLY (INCLUDES ITEMS 2 - 42) .........

1

2 3

26870-G01

ARMATURE ASSEMBLY {INCLUDES ITEMS 3 - 5) .................

1

26871-G01

BALL BEARING, REAR •....................................

1

4

26872-G01

BALL BEARING, FRONT .....•••.•.....•.•..................

1

5

26873-G01

HOLDER, BEARING .......................................

1

7

26874-G01

COIL, FRAME AND FIELD ASSEMBLY (INCLUDES ITEMS 8 - 14) .....

1

8

26875-G01

COIL, FIELD ....................................•........

1

9

26876-G01

BRUSH "F", INSULATING ASSEMBLY (INCLUDES ITEMS 10 - 14)

2

DESCRIPTION

QTY

6

* * * *

10 11 12 13

NUT ......•......••.................................

2

WASHER, LOCK ..........•..............•............

2

WASHER ..............•.............................

2

INSULATOR ..........................................

1

14

26877-G01

SCREW, POLE CORE SET .................................

4

15

26878-G01

COVER, FRONT ........••..•................................

1

16

26879-G01

COVER, REAR ..............................................

1

17

26880-G01

TERMINAL, "A", ASSEMBLY (INCLUDES ITEMS 18 - 23) ..•........

2

TERMINAL.................................•............ · .

2

INSULATOR .............................................

2

INSULATOR ...........................•.................

2

WASHER.......................•........................

4

WASHER, LOCK...................•.••...................

4

NUT..........•.•.......................................

4

HOLDER, BRUSH, ASSEMBLY (INCLUDES ITEMS 26 - 28) ..........

1

* * * * * *

18 19 20 21

22

23 24

:

.

25

26881-G01

26

26658-G01

BRUSH ..........................••..............•......

4

27

26882-G01

SPRING, BRUSH..........................................

4

28

26883-G01

CONNECTOR, BRUSH .....................................

2

30

26884-G01

KEY .......................................................

1

31

26885-G01

PULLEY .................•..................................

1

32

26886-G01

PULLEY ASSEMBLY (INCLUDES ITEMS 33 - 37) ..................

1

NUT....................................................

1

WASHER, LOCK..........................................

1

29

33

34

9/05/91

I I lul 11-141

* *

E�GDii½:!M•W

Pg. U-2

STARTER/GENERATOR

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM 35 36 37

PART NO.

* * *

1

2

3

4

5

DESCRIPTION

QTY

SCREW .••...•..•..•.••.••••••...••.....................

3

SCREW .................................................

4

SCREW .....................................•...........

2

38

26887-G01

COVER, BRUSH, 1 ...........................................

3

39

26888-G01

COVER, BRUSH, 2 ...........................................

1

40

26889-G01

BOLT (INCLUDES ITEMS 41 AND 42) ...........................

2

WASHER ................................................

2

WASHER, LOCK ..........................................

2

COVER, TERMINAL ......................................... .

4

41 42 43

Pg. U-3

* *

26889-G01

9/05/91 I lul 11-141

STARTER/GENERATOR

9/05/91

l l !Ut1!-t4t

4-CYCLE POWERED CAR

Pg. U-4

�1 'f

...a.

"'-i 2 INCLUDES ITEMS 2-5 13 INCLUDES ITEMS 15-5 7 (VEHICLES WITH HORN) 14 INCLUDES ITEMS 15- 21, 23-57 (VEHICLES WITHOUT HORN) 43 INCLUDES ITEM 44 45 INCLUDES ITEMS 48-57

m m ::0

z

G) 45

� I 49

\� 58 I 57

m I Iii a

I

STEERING WHEEL DETAIL

28

.a:{

i� ...a.

12

��@

t � m

'U 0 � m ::JJ m 0

� ::JJ

STEERING

4-CYCLE POW ERE D CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LIST ING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

27102-01

2

18409-01

CLIP, SCORECARD ..........................................

1

3

18410-01

SPRING, STAINLESS STEEL ...........................•......•

2

4

18411-01

SCREW, STAINLESS STEEL, #6 - 18 X 3/4 LG. ..................

2

5

27101-01

PLATE, SCORECARD HOLDER ................................ .

1

6

18464-01

SCREW, SELF-TAPPING, #8 X 7/8 LG. ..........•..................

2

23225-01

HUB, COVER EXTENSION ........................................

1

11

23172-01

WHEEL, STEERING ............................................. .

1

12

14390-02

NUT, LOCK, 5/8 - 18 ...........................................

1

13

19152-03

STEERING UNIT ASSEMBLY (VEHICLES WITH HORN (INCLUDES ITEMS 15 - 57) ......................................

1

STEERING UNIT ASSEMBLY (VEHICLES WITHOUT HORN (INCLUDES ITEMS 15 -21, 23 - 57) ...............................

1

STEERING, SHAFT ASSEMBLY (INCLUDES ITEMS 16 - 20) .........

1

SHAFT, STEERING ....................................... .

1

PIN, DOWEL, 1/4 .........................................

2

COUPLING .................••.•....••.....•..........•..

1

WASHER, THRUST ....................................... .

1

PINION, STEERING ........................................

1

PLATE, SCORECARD HOLDER ASSEMBLY (INCLUDES ITEMS 2 - 5)

1

7 8 9 10

14 15

19152-01 17163-01

* * * * *

16 17 18 19 20 21

19153-01

22

19153-04

*

23

:

.

STEERING COLUMN UNIT

1

STEERING COLUMN UNIT ..•......•..............•...•........

1

GREASE FITTING ............................................

1

SCREW, 5/16 - 24 X 1 LG. •..................................

4

24

00444-08

25

00565-08

WASHER, LOCK, 5/16 .......•................................

4

27

17140-01

SLEEVE ....................................................

1

28

17161-01

BUSHING AND SEAL .........................................

1

51294-G1

WASHER, WAVE TYPE, SPRING ............................... .

2

26

29 30 31 32

9/05/91

I I lvl11-l41

Pg. V-2

STEERING

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

33 34

23279-G1

GEAR, REDUCTION ...•................•.....................

35

13059-G2

WASHER, THRUST ...........................................

37

19154-G1

GASKET, HOUSING ..........................................

38

17618-G1

CLAMP, NYLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

13097-G1

HOUSING ASSEMBLY (INCLUDES ITEM 44) .......................

1

44

13570-G2

COVER, RACK ...........................................

1

45

15407-G1

RACK AND ROD ASSEMBLY (INCLUDES ITEMS 48 - 57) ...........

1

48

18456-G1

GREASE FITTING 90 ° .....................................

49

50641-G1

RUBBER BOOT, TIE ROD END ..............................

17617-G1

BELLOWS ........•...........•.....•.•..................

11391-G1

CLAMP, HOSE ...........................................

1

36

39 40 41 42

46 47

50 51 52 53 54 55 56

:

57

50209-G1

NUT, SLOTTED, 7/16 - 20 .................................

1

58

10387-G2

COTTER PIN, 3/16 X 1 LG. ......••••.............................

1

60

00276-G6

SCREW, 5/16 - 24 X 3/4 LG. ......••••...........................

3

61

00565-G8

WASHER, LOCK, 5/16 ...........................................

3

59

Pg. V-3

9/05/91 I 1Y111-l41

STEERING

9/05/91

I I lvl 11-141

4-CYCLE POWERED CAR

Pg. V-4

:e:::c: m m r

SELF-ADJUSTING BRAKES <DRIVER'S SI DE SHOWN)

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28

r¾ 29

40 REAR OF VEHICLE

ADJUSTER DETAIL

1 - INCLUDES ITEMS 2-8, 14-30 9 - INCLUDES ITEMS 10-30

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WHEEL BRAKE

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

1

22997-G2

BRAKE ASSEMBLY, PASSENGER'S SIDE (INCLUDES ITEMS 2 - 8,14 - 30)

2 3

22518-G1

BACKING PLATE., PASSENGEB'_S SIDE ...................•..••.•.

23360-G1

ADJUSTER, PASSENGER'S SIDE •••..•.........................

23357-G1

LEVER ASSEMBLY, PASSENGER'S SIDE (INCLUDES ITEMS 5 - 8) ..•

4

QTY

7

* * *

8

23536-G1

SPRING, TORSION, PASSENGER'S SIDE ......................

9

22997-G1

BRAKE ASSEMBLY, DRIVER'S SIDE (INCLUDES ITEMS 10 - 30) ........

10

22519-G1

BACKING PLATE, DRIVER'S SIDE ...............................

11

23361-G1

ADJUSTER, DRIVER'S SIDE ...................................

12

23358-G1

LEVER ASSEMBLY, DRIVER'S SIDE (INCLUDES ITEMS 5 - 7 AND 13)

13

23537-G1

SPRING, TORSION, DRIVER'S SIDE ..........................

14

23363-G1

ADJUSTER BODY ........•...................................

15

23382-G1

WASHER ...................................................

16

23362-G1

WASHER, THRUST ...........................................

18

22519-G1

COVER, DUST ..............................................

1

19

23356-G1

BLOCK, ANCHOR .•••.............................••..••••...

1

20

00565-G1

WASHER, LOCK, 1/4 .....•••.•.••.....•.••...............•...

2

21

13632-G1

NUT, 6 MM .................................................

2

23

23359-G1

SPRING, BRAKE, ADJUSTER ...................................

1

24

17290-G1 ,.

SPRING, BRAKE, ANCHOR .................................•..

1

25

17291-G1

SPRING, SHOE, CLAMP .......................................

2

26

17292-G1

PIN, TENSION ...............................................

2

28

23364-'31

BRAKE SHOE SET (INCLUDES ITEMS 29, 30) ...............•.....

1

29

23355-G1

BRAKE SHOE, LEADING ..•••.....•........•..•.••...•...•.

1

30

23354-G1

BRAKE SHOE, TRAILING ....•.•.............•..............

1

17083-G1

BOLT, 5/16 - 24 X 3/4 LG. ......................................

8

15126-G1

NUT, LOCK, 5/16 - 24 ....................•.....................

8

5 6

SPRING .............•...•••••...........................

RETAINER .....................•.........................

WASHER, SHOULDER ...•••.•.•......•....................

17

22

.

27

31 32

33

34

9/05/91

I I w111-l41

Pg. W-2

WHEEL BRAKE

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

35 36 37

15485-G1

WASHER .................••.........................••..•••...

2

40

21807-G1

BRAKE DRUM ASSEMBLY, 4-CYCLE (INCLUDES ITEM 41) .............

41

19862-G1

LUG BOLT, 1/2 - 20 X 1 7/32 LG. .•..•.•......................

2 4

38 39

42 43

XXXXX-XX

WASHER (SEE SECTION R FOR PART NUMBER AND QUANTITY)

44

XXXXX-XX

NUT, SLOTTED (SEE SECTION R FOR PART NUMBER AND QUANTITY)

XXXXX-XX

COTTER PIN (SEE SECTION R FOR PART NUMBER AND QUANTITY)

45

Pg. W-3

9/05/91

I 1&111-141

WHEEL BRAKE

9/05/91

I I WI 11-141

4-CYCLE POWERED CAR

Pg. W-4

WHEELS AND TIRES

4-CYCLE POWERED CAR

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I

9/05/91

I I !X!1!-l41

WHEEL AND TIRES

4-CYCLE POWERED CAR

THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product.

Indicates a component that is not available as an individual part.

*

ITEM

PART NO.

1

2

3

4

5

DESCRIPTION

QTY

1

1517 0-G1

2

1159 4-G1

18 X 8.50 X 8 TIRE., STANDARD RIB .............................

AR

3

1469 7-G2

18 X 8.50 X 8 TIRE AND WHEEL RIM ASSEMBLY, SOFTRAC ......•.....

AR

4

1469 7-G1

18 X 8.50 X 8 TIRE, SOFTRAC .............................•...

AR

7

14728-G2

18 X 8.50 X 8 TIRE AND WHEEL RIM ASSEMBLY, POWER RIB ...........

AR

8

14728-G1

18 X 8.50 X 8 TIRE, POWER RIB •...............................

AR

9

20258-G1

18 X 8.50 X 8 TIRE AND WHEEL RIM ASSEMBLY, TERRA GUARD ........

AR

10

20259-G1

18 X 8.50 X 8 TIRE, TERRA GUARD ....................•........

AR

11

15169-G1

WHEEL RIM, 1 PIECE 8.50 / 9.50 X 8 , STANDARD (INCLUDES IN ITEMS 1, 3, 7 , 9 AND 13) ................ .........

AR

18 X 8.50 X 8 TIRE AND WHEEL RIM ASSEMBLY, STANDARD RIB

AR

5 6

12

11657-G1

VALVE STEM (INCLUDED IN ITEMS 1, 3, 7 , 9 AND 13) . . ...........

AR

13

14728-G4

18 X 8.50 X 8 TIRE AND WHEEL RIM ASSEMBLY POWER RIB, WHITE WALL .........................................

AR

18 X 8.50 X 8 TIRE, POWER RIB, WHITE WALL ......•.............

AR

14

14728-G3

9/05/91

! ! !X!1H4!

Pg. X-2

WHEELS AND TIRES

Pg. X-3

4-CYCLE POWERED CAR

9/05/91 I I lxl 11-141

APPENDIX SERVICE ACCESSORIES AND SPECIAL TOOLS

9/05/91

!A!P!X!1!-!4!

Appendix-1

SERVICE ACCESSORIES AND SPECIAL TOOLS

4-CYCLE POWERED CAR

SPECIAL TOOLS

PART NO.

CURRENT INDICATOR ...........................................•...•....•.•......... 16489-G2 PULLER, DRIVE CLUTCH ...........................................•................. 19779-G2 PULLER, FLYWHEEL ..••.•....................•.•••.................................. 17086-G1 SLIDE HAMMER KIT .(AXLE PULLER) .........••..• -�·" .,....•.........•.•................ 15947-G1 TOOL KIT, METRIC (295 cc ENGINE, INCLUDES CLUTCH PULLER) .......................... 14708-G2 VOLT OHM METER (VOM) .....................•••.................................... 51020-G2

PAINT CONTACT CUSTOMER REPRESENATIVE FOR COLOR SPECIFICATIONS AND PART NUMBERS

Appendix-2

9/05/91

!A!P!X!1!-!4!

E-Z-GO Division of Textron Inc. P.O. BOX 388 Augusta, Georgia 30913-2699