EZGO TEXTRON X-440 x-444 ELECTRIC POWERED GOLF CARS SERVICE MANUAL - PDF DOWNLOAD

X-440.' ·x-444 ELECTRIC POWERED GOLF CARS

SERVICE PARTS MANUAL

MODEL YEAR 1988. MANUAL NO. 23522-G1

ISSUED 9/01/87

SERVICE PARTS MANUAL ELECTRIC POWERED GOLF CARS X-440, X-444 MODEL YEAR 1988 MANUAL NO. 23522-G1

ISSUED 9/01/87

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

E.ZliDii?:;i;t•l:1

LIMITED 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.

I rIDOOir� I

The use of NON E-Z-GO parts may void your warranty.

Overfilling of batteries may void your warranty.

Pg. ii

12/15/90

i ! ! !A!9!EI

GEl'ERAL INDEX Page No.

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

How To Use The E-Z-G0 Service Manual Illustrated Parts Breakdown:

Illustration Accelerator and Hill Brake Linkage Accelerator Switch Assembly Battery Charger, 36 Volt (U. L.) •••••• Body and Associated Parts ••••

V

Al Bl Cl El

Brake Linkage

Fl

Fork Assembly Forward-Neutral-Reverse Switch Assembly

01 Pl

Four Wheel Front Suspension

QI

Model Details

XI

Motor

YI

Power Wiring

BBi

Rear Axle Assembly

CCI

Rear Suspension Components

EEi

Resistor Coil and Housing Assembly

FFI

Seats and Bag Holder

HHI

Steering •••••••••

LLI

Wheel Brake Assembly

NNI

Wheels and Tires

001 PPI

Service Accessories and Special Tools ••

iii

iv

HOW TO USE T1-E E-Z-GO SERVICE PARTS MANUAL

This manual is divided into several sections: I. 2.

3.

GENERAL INFORMATION ILLUSTRATED PARTS BREAKDOWN FOR ELECTRIC POWERED GOLF CAR SERVICE ACCESSORIES AND SPECIAL TOOLS

The first section, GENERAL INFORMATION, contains the following information: I. 2.

3.

WARRANTY INFORMATION GENERAL INDEX HOW TO USE THE E-Z-GO SERVICE PARTS MANUAL

The second section, ILLUSTRATED PARTS BREAKDOWN (IPB) FOR ELECTRIC POWERED GOLF CARS, contains illustrations and parts lists for all systems of the electric powered vehicle.

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 TI-E MANUAL

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

E-Z-GO manuals are revised annually to coincide with the model year change. The new manual reflects revisions made since the last manual and introductory changes that are to be implemented in the new model year.

Revisions that have been made since the last issue are indicated by a / that is placed in the left margin adjacent to the revised part number. If changes are interchangeable with the previous issue, the part number will be revised and marked with a / • Changes that are not interchangeable will be accompanied by a new illustration and parts list with the latest set appearing first. The / in the left margin will always indicate the differences since the earlier issue.

Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your 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 Model Details 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 the latest version always appears first.

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.

V

Title Left Page Illustration

Title

I.

Right Hand Page Parts List Parts List Continued On Rear Page If Required

WHEN TI-E PART NUMBER IS NOT KNOWN. a. Determine the function and application of the part required. the General Index and select the most appropriate title.

Turn to

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 part desired.

Refer to the accompanying description for specific information regarding the part.

2.

IF YOU KNOW TI-E PART NAME OR NUMBER. Locate part number or description in the appropriate column on the right hand page. Note that it is suggested you confirm that the part selected is correct by verifying it with the pictorial representation on the left hand 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" assembl�·sold by E-Z-GO and the asterisk (*) indicates that the part depicted is not available for sale by E-Z-GO. Note that the 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 "final assembly" is reached.

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

ILLUSTRATED PARTS BREAKDOWN ELECTRIC GOLF CAR

--------- E�l5Diia3itt•l:t--------__, vii

V,

)> (')

� �

15 - INCLUDES ITEMS 16-21

�

� m )>

I

�

a Iii

t� r

OJ

� �

•

r

zA

)>

�

-

co V,

co -....J

4 WHEEL VEHICLE

3 WHEEL VEHICLE

30

-----------E�GCii=t:ii;t•J:1----------...1 5

ACCELERATOR AND HILL BRAKE LINKAGE A2

8/15/87

TITLE

ACCELERATOR AND HILL BRAKE LINKAGE

ITEM NO.

/ /

I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

PART NO.

18043-GI 14444-G3 00544-G4 17979-GI 19710-GI 10385-G4 17677-GI 18034-GI 17675-GI

..J

..J

:c 3:

:c 3:

w w

When ordering parts, please specify model and serial no. of vehicle.

DESCRIPTION 1 2 3 4 5

C")

w w

�

QTY.

Accelerator Rod Assembly (Includes Items 2-7) Bal I Joint, Socket . . . . . . . . . . • • . .

I 2 I

I 2 I

X

I

I

X

2 2 I I I I I 2 I

2 2 I I I I I 2 I

2 2 2

2 2 2

I

X

X

I

Washer, Nylon . . . . . . . . . . .. . . . . . . . . . . . .

X I

I I

Bearing, Flanged, Reamed ••

X

I

Nut, 5/16-24

. . . . .

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

Bushing, Accelerator Rod Accelerator Rod Clevis Yoke Retainer, Spring Retainer, Spring Spring, Compression

19706-GI 19707-GI 00414-G6 11027-G2 18083-GI 12511-GI 18084-GI 15827-GI 12512-GI 12513-GI I 2064-G2

Rod, Linkage Rod, Linkage ••••••• Screw, I /4-20 x 3/4 Lg• ••• Nut, Lock, I /4-20 •••••• Accelerator Pedal Assembly (Includes Items 16-21) Base Plate, Accelerator •••••••••••••

17255-GI 00559-G8'· 10387-G3 17838-GI 19708-GI 19709-GI

Washer, Teflon ••••••• Washer, Flat, 5/16 •••••• Cotter Pin, 3/16 x 3/4 Lg. Bushing, Nyliner Arm, Pivot Arm, Pivot

XXXX-XX

Accelerator Switch Assembly (See Accelerator Switch Assembly Illustration)

21957-GI 20835-GI I 0097-G6

Washer, Nylon . . . . • . . . . . . • . . • • . . . • • • .

Pedal, Accelerator

. . . . . . . . . . . • . • • . . •

Accelerator Pedal, Pad Kit (Includes Rivets) •••• Pin, Accelerator Pedal Bearing, Plastic Nut, Push •••

.... .

__________.______ E�GDip:,n!•W --------------5

AJ

8/15/87

5

A4

8/15/87

----

1--� 28

27\

29

I

A

I

i! I

-I 0 :::0

�. ·�

U'-IAr • �I

�

\�o\ A-·· I

Iii

-! � OJ v,

D

�

�

!

�

-CX)

V,

.......

CX)

63

l

�

B

((�

56

tr� :

�:!

TITLE

ACCELERATOR SWITCH ASSEMBLY

When ordering ports, please specify model and serial no. of vehicle.

ITEM NO.

I

I

I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

PART NO.

DESCRIPTION 1 2 3 4 5

I 9255-G2

AceeI erator Switch Assembly •••••••••••••••

18741-G I

Contact Board Assembly••••••••••••••••• Plate, Accelerator Stud, Stop •••••• Washer, Flat, 3/8 Nut, Lock, 3/8-24 Bushing, Shaft . . . . . . . . . . . . . . . . . . .

Nut, 3/4-16 . . . . . . . . . . . . . . . . . . . . .

Washer, Lock, External Tooth 3/4

*

17491-G I 00560-G I 14390-G I 11902-G I 00545-G8 00568-G6

* * *

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

Stud, Contact

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

Washer, Lock, 5/16 ••••••••••••••••• Nut, 5/ 16-24 . . . . . . . . . . . . . . . . . . . .

17973-G I

Shaft and Arm Assembly

17504-G I

Brush and Lead Assembly •• Terminal, Ring, 116 x 5/16 Copper Brush with Lead Spring, Arm Contact •••••••••••• Holder, Brush . . . . . . . . . . . . .. . . .

17663-G I 17655-G I l5944-G3 I 1098-G9 11098-G3

Pivot Arm Assembly •••••••••• Arm, Accelerator Linkage •••••••••••• Ball, Ball Joint ...................

Nut, Lock, 5/16-24 ••••••••••••••••• Nut, Lock, I /2-20

* * * *

I I I I I I 2 2 5 5 5

I I I I I I 2 2 5 5 5

------------------ E�GOiiniit•m --------------82

8/15/87

TITLE

ACCELERATOR SWITCH ASSEMBLY _J

LU W

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

:::c

::

DESCRIPTION 1 2 3 4 5

C")

...J

W LU

:::c

;:

o::r-

QTY.

33 34 35

I 0606-G2

36

17969-GI

37 38

13514-GI

39

00567-G4

40

14628-GI

41

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

Wire Assembly, Black ...............

Switch, Micro

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

Washer, Lock, External Tooth, 118 . . . . . . . . . .

Foston Tab . . . . . . . . . . . . . . . . . . . . . . .

Screw, Brass, Limit Switch

42

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

I

I

I

I

2

2

I

I

I

I

2

2

00139-G2

Screw, //6-32

45

00565-G3

Washer, Lock, 116

2

2

46

00525-G5

Nut, 116-32

2

2

I

I

2

2

2

2

I

I

2

2

2

2

2

2

I

I

3

3

I

I

I

I

I

I

43 44

47 48 49

12914-GI

50

00565-G5

51

00526-G4

52 53 54

11761-GI

55

00414-G6

56

00565-G7:-

57

00532-GI

58

18902-GI

59

17618-GI

60

18834-GI

61

X

I 1/4 Lg.

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

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

Washer, Lock, 1110 . . . . . . . . . . . . . . . . . . .

Nut, III 0-32 . . . . . . . . . . . . . . . . . . . . . . .

Foston Tab

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

Screw, I /4-20 x 3/4 Lg. . . . . . . . . . . . . . . . .

Washer, Lock, 1/4 ..................

Nut, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . .

Wire Harness, Accelerator Switch . . . . . . . . . . . . .....................

Clamp, Nylon Loom, Flex, Zip, 3/4 . . . . . . . . . . . . . . . . . .

Solenoid, 36 Volt

62

18897-G5

Wire Assembly, 4

63

18897-G4

Wire Assembly, 3

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

-------------- E�GDii=>:1ii!•):I ____________.,__,___,_ B3

8/15/87

TITLE

ACCELERATOR SWITCH ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

64 65 66 67 68 69 70

PART NO.

DESCRIPTION 1 2 3 4 5

w w

w w

�

� �

C")

QTY.

18897-G2 18897-G I 17965-G I 13493-G I 00567-G8

Wire Assembly, Lo Speed, Solenoid •• Wire Assembly, Solenoid, F-N-R Switch Washer, Lock, External Tooth, 5/16 ••

00544-G4

Nut, 5/16-24

*

..J

Wire Assembly, 2 •••••••••• Wire Assembly, I

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

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

I I I

·I I I I

8

8

6

6

I

Not available as an individual part.

..__...______.....,_____ E�GDii=nM•W __________......,____ B4

8/15/87

28

-INCLUDES ITEMS 3-80 1�-INCLUDES ITEMS 14-18

3

4

»'. a 29

30.

61

�·

L______ EmtiDii=t:ii;(•]:I BATTERY CHARGER, 36 VOLT Cl

8/15/87

/4

36V CHARGER WIRING DIAGRAM

AMMETER /�

,JJ.�7V,@�� ��

I -<

m

�I <

A

:::.::: (),

� � Iii (')N > D :,J

°'

TIMER

,

,� \>-,,

BLACK

-co

V,

co

-....J

TITLE NOTE:

BATIERY CHARGER, 36 VOLT (STANDARD) THE USE OF NON-U.L. PARTS WILL VOID U.L. LISTING

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

19012-G I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

19096-G I I 9576-G4

* 17077-G I 11559-G I 00372-G4 00565-G4 00526-G I 18768-G2 18489-G I 18488-G I 00567-G7 00532-G2 I 1572-G2 00567-G3 00525-G5 00138-G3 00512-G7 00378-G4°· 00526-G3 00565-GS

18764-G I

*

00525-GS 00565-GS 00526-G4

DESCRIPTION 1 2 3 4 5

QTY.

Battery Charger, 36 Volt (Complete) 10 Ft. D.C. Cord (Includes I terns 3-80) •••••••••••••••••• Cover Assembly, Top Bottom Housing

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

Decal Operating Instructions (Serialized)

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

Capacitor Bracket, Capacitor •••••••••••••••••• Screw, 118-32 x I /2 Lg. ••••••• • ••••••• Washer, Lock, //8 ....................

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

Nut, 118-32 Heat Sink Assembly (Includes Items 14-18) ••••• Heat Sink Diode (Silicon Re ctifier) •••••• Washer, Lock, External Tooth, I /4 Nut, 1/4-28 .....................

Nut, Plastic Expansion ••••••••••••••• Washer, Lock, External Tooth, 116 •••••••••• Nut, 116-32 .......................

Screw, 116-32 x 3/8 Lg. •••••••••••• Screw, Self-Tapping, 118 x 7/8 Lg. ••••••••• Screw, II I 0-24 x I /2 Lg. •••••••••.•••••• Nut, // I 0-24 . . . . . . . . . . . . . . . . . . . . . .

Washer, Lock, II I 0

Ammeter, D. C. Bracket, Ammeter Nut, 116-32 Washer, Lock, II I O •••••••••••••• Nut, //10-32 ...................

I

I

I I 2 2 2 I

I I 2 2 2 I

2 2 2

2 2 2

3

3

2 2 2 3 I I

2 2 2 3 I I

2 2 2

2 2 2

.._______________ E�GDii=niit•W --------------CJ

8/15/87

TITLE NOlE:

BATTERY CHARGER, 36 VOLT (STANDARD) TI-E USE OF NON-U.L. PARTS WILL VOID U.L. LISTING

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

PART NO.

DESCRIPTION 1 2 3 4 5

Wire, 12 Ga., 9", White

18052-GI 00372-G2

Timer Screw, 118-32 x 1/4 Lg. ••••••••••••••••

11575-GI 00486-G4 19363-GI 00372-G5 00565-G4 00526-GI 19361-GI 19434-GI

Knob, Timer Screw, Set, 118-32 x I /2 Lg. •••••••••••••• Screw, /18-32 x 5/8 Lg. •••••••••••••••• Washer, Lock, 118 ••••••••••••• Nut, 118-32 . . . . . . . . . . . . . . . .

Fuse, 15 Amp Label, Fuse Identification

19388-GI 13557-G2 18747-GI

A. C. Cord Strain Relief, Plastic (A. C. Cord) •••••••• D. C. Cord Assembly, IO Ft. (Includes Items 51-63)

14489-G2 13802-GI 18782-GI 18972-GI

D. C. Cord Sub Assembly, 10 Ft. Contact, Connector •••••• Connector Handle Installation Kit (Includes Items 55-63) •• Handle, Half, L.H. Handle, Half, R.H.

* *

00647-G8 00647-G3 I 3521-G5 00650-G2 20628-GI 13557-G3

_, w w ::c ==

C')

'<t'

QTY.

19441-GI

Fuse Block

_, w w ::c ==

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

Screw, Stainless Steel, 116-32 x 7/8 Lg. Screw, Stainless Steel, /16-32 x 3/8 Lg. Nut, lock, Stainless Steel ••••••• Washer, Flat, 115 •••••••••• Label, Caution ••••••••••••• Strain Relief, Plastic (D. C. Cord)

2

2

I I I 2 2 2 2 I

I I I 2 2 2 2 I

I 2 I I

I 2 I I

2 2 4 2 I I

2 2 4 2 I I

-------------- E2GDii�:,i,t•J:I --------------C4

8/15/87

TITLE NOTE:

BATTERY CHARGER, 36 VOLT (STANDARD) TI-E USE OF NON-U.L. PARTS WILL VOID U.L. LISTING

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

PART NO.

DESCRIPTION 1 2 3 4 5

..J

..J

::c

::c

w w

w w

::: ::: C')

q"

QTY.

19928-G I 11027-G2 00414-G5 00614-G4 19362-G I 00559-G3 00526-G4 00565-G4 00526-G I 00372-G6 00372-G3 00565-G4 00526-G I

Screw, 118-32 x 3/4 Lg. Screw, 118-32 x 3/8 Lg. Washer, Lock, 118 Nut, 118-32 •••

19402-G I

Wire Assembly, 16 Ga., Black

*

Not available as an individual part.

••••••••••••••• Transformer Assembly Nut, lock, I /4-20 ••••••••••••••••••• Screw, 1/4-20 x 5/8 •••••••••••••••••• Screw, Self-Tapping, 118 x I /2 Lg. Circuit Breaker, 50 Amp (Includes Items 70, 71) •• Washer, Flat, II IO. Nut, //10-32 • • • . • • . . • • • • • . • • • • • • • Washer, Lock, 118 • • • • • • • • • • • • • • • • • • • Nut, 118-32

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

4 4 4 4 10 10 I I 4 4 2 2 2 2 2 2 2 2 I I

...___.______..._______ E�GOiiHiii•W ---------------

cs

6/15/87

C6

8/15/87

3-WHEEL COWL DETAILS

10

�1r

�

13

CONSOLE DETAILS

--------------E�liDii?:;i;(•):1---------------' 11

BODY AND ASSOCIATED PARTS El

8/15/87

21

27

30

/

/

65

11

8/15/87

HIP RESTRAINT

BATTERY RACKS

--------------E�GDii=,:;i;\•J:1-------------II

BODY AND ASSOCIATED PARTS E3

8/15/87

TITLE

BODY AND ASSOCIATED PARTS

_,w _,w

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

/ /

/

I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

PART NO.

w :c 3:

DESCRIPTION 1 2 3 4 5

C')

�

QTY.

20211-G2 18348-GI I 1027-G2 00560-Gl

Nut, Lock, I /4-20 Washer, Flat, 3/8

Cowl

w :c 3:

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

I 4 2

X X X X

18352-G2 00414-G6 I 1027-G2

Dash Tray ••••••••••••••• Screw, I /4-20 x 3/4 Lg. ••••••••••••••••• Nut, Lock, I /4 x 20 •••••• • •••••••••••••

I 5 3

X 5 3

18799-G3 18796-G2 18436-Gl 16816-GI

Dash Tray Liner Kit (Includes Items 11-13) '· •••••• Liner, Dash Tray •••••••• Rivet, Plastic • . •••••••••••••••••••• Fastener, Ratchet ••••••••••••· ••••••••

I I 2 2

X X X X

15680-G2 15681-G2 00544-G3 I 1027-G2 00106-G6

Splash Panel, Passenger Side Splash Panel, Driver's Side ••••.••••••••••• Nut, 5/I 6-18 •••••••••••••••••••••••• Nut, Lock, I /4-20 ••••••••••••••••• •••• Screw, Self Drill and Tap, //12-24 x 3/4 Lg.

I X I X 4 X 16 13 4 X

23063-G2 23148-GI l 1027-G2 00560-Gt

Cowl •• • •

X

I

X

I

Nut, Lock, I /4-20 Washer, Flat, 3/8

X X

4 2

18353-G2 22914-GI 00414-G5 00561-G7 11027-G2 15058-G4

Dash Tray Cap, Cowl •••••••••••••••••••••• Screw, I /4-20 x 5/8 Lg. ••••••••••••••••• Washer, Flat, 1/4 •••••••••••••••••••••• Nut, Lock, I /4-20 Rivet, Aluminum, Black ••••••••••••••••••

X X X X X X

I I 7 7 7 2

e

•

•

•

•

•

•

e

•

0

•

0

e

•

0

O

O

O

O

•

•

•

•

o

o

o

o

o

Cowl Support • • • • • • • • • • • • • • • • • • • • • • • •

o

o

Cowl Support

o

•

•

•

•

•

•

•

•

o

•

•

•

•

•

•

•

•

•

o

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

o

•

•

•

•

•

•

•

•

•

• • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • • • • • • • • • •

°' • • • •

......................... o

•

•

•

--------------e�ma,;�:,,,t•J:1 __________..__......__ E4

8/15/87

TITLE

BODY AND ASSOCIATED PARTS

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I I

I

33 .34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

.J w w

.J w w

C")

q"

:I:

:I:

::: :::

PART NO.

DESCRIPTION 1 2 3 4 5

23150-G2 22911-GI 18436-GI 16816-GI

Dash Tray Liner Kit (Includes Items 34-36) Liner, Dash Tray Rivet, Plastic •••••••••••• Fastener, Ratchet •••••••••

X

I

X

I

X

I

X

2

19817-GI 12064-G3 I 2088-G3

Emblem, E-Z-GO Nut, Push-On Plug, Button •••••

I 3 4

I 3 4

18487-GI 18487-G2 I 8487-G3 I 8487-G4 20405-GI 18275-GI 00559-G7

Console, Center (Does Not Accept Ashtray) Console, Center (Does Not Accept Ashtray) ••• Console, Center (Accepts Ashtray) ••••••••• Console, Center (Accepts Ashtray) ••••••••• Decal, Safety (Included In Items 47, 48, 49, 50) ••

I

X

X

I

I

X

X

I

I

I

I

I

Washer, Flat, 1/4 ••••

2

2

18436-GI 17581-G t:·

Rivet, Drive, Plastic Ashtray •••••••

6 I

6 I

15533-GI 15533-G2 15536-GI 15536-G2

Side Side Top Top

Ball Holder

Rail Rail Rail Rail

QTY.

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

(Passenger Side) •• (Driver's Side) ••• (Passenger Side) •• (Driver's Side) •••

_________...______ E�liDii�:,i;t•]:I ____________...__ 11

ES

8/15/87

TITLE

BODY AND ASSOCIATED PARTS

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

DESCRIPTION 1 2 3 4 5

65

15671-G2

Floorboard Assembly (Includes Item 66) •.•••••••

66

14776-GI

Nut,"J" Type, I /4-20 •••••..•••••••••••

67

00106-G6

Screw Self-Drill and Tap, 1112-24 x 3/4 Lg. ••••••

22229-GI

Restraint, Hip-Hand Hold Assembly (Includes Items

..J

..J

::c 3:

::c 3:

w w C")

w w

�

QTY.

I

I

23

23

4 6 2

4 6 2

2

2

68 69 70 71

72 and 73) . . . . . . . . . . . . . . . . . . . . . . . .

I

72

22227-GI

Restraint, Hip-Hand Hold (Passenger Side)

73

23152-GI

Handgrip . . . . . . . . . . . . . . . . • . . . . . . . .

74 75

22229-G2

Restraint, Hip-Hand Hold Assembly (Includes Items 76 and 77)

I

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

76

22228-GI

Restraint, Hip-Hand Hold (Driver's Side)

11

23152-GI

Handgrip

78

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

79

14776-GI

Nut, "J" Type, I /4-20

80

16705-GI

Screw, Truss, I /4-20 x I Lg. •••••••••••••••

81

11027-G2

Nut, Lock, I /4-20

83

19534-G3

Fillet, Trunk (Passenger Side) •••••••••••••••

I

I

84

19534-G4

Fillet, Trunk (Driver's Side) ••••••••••••••••

I

I

85

00106-G6

Screw, Self-Drill and Tap, 1112-24 x 3/4 Lg. ••••••

4

4

87

I 9533-G2

Trunk Lid Installation Kit (Includes Items 88-92) ••••

88

19554-G2

Trunk Lid . . . . . . . . . • . . . . . . • . . . . . . . .

I

I

I

I

89

17684-GI

Noise, Suppressor, Trunk Lid •••••••••••••

90

15844-GI

Nut, "U" Type, Ill 0-16 x I /32 ••••••••••••

91

19599-GI

Nut, "U" Type, Ill 0-16 x I /8 •••••••••••.••

92

00598-G6

Screw, Self-Tapping, 1110-16 x 3/4 Lg• ••••••••

4 2 2 2

4 2 2 2

••••••••••••••••••••

82

86

I

93

I I 23259-GI ./ 95 Scuffguard, Trunk Lid •••••••.••••••••• I I ,/ 96 23457-GI Scuffguard Strip, Fillet •••••••••••••••• 2 2 ...__......_____....______ E�GDii�:,i,t•J:I __________......_,__..., 11

94

23282-GI

Scuffguard Kit (Includes Items 95, 96)

E6

8/15/87

TITLE

BODY AND ASSOCIATED PARTS

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129

PART NO.

DESCRIPTION 1 2 3 4 5

C')

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

19034-Gl 19524-GI 13437-G4 l 1207-G5 18436-GI 15058-Gl

Screw Lock, 3/8-16 x I Lg. ••••••••••••••• Nut, Lock, 3/8-16 .....................

Rivet, Plastic, Drive, I /4 •••••.•.••••••••• Rivet, Aluminum, Black, 3/16 ••••••••••..••

18817-G2 11027-G2 00414-G6

Angle, Side, Seat Frame Nut, Lock, I /4-20 .....................

Screw, I /4-20 x 3/4 Lg.

20297-G2 11027-G2 14700-GI 14700-G2 14726-Gl 00414-G6 l 1027-G2 15058-GI 14705-Gl 14601-G2

Bagwell, Plastic

_, w w :::c 3:

_, w w :::c 3:

o:t'

QTY.

I 2 2 2

I 2 2 2

4 4

4 4

Seat Wrap . . . . . . . • . • • . . . . . . . . . . . . . . .

I

I

Nut, Lock, I /4-20 .....................

8

8

Fender Cap, Flexible (Passenger Side) •••••••••• Fender Cap, Flexible (Driver's Side) ••.••••••••

I

I

I 2 6 6 2 2

I 2

2 2

4

4

I

I

I I

I I

4 4

4 4

I

I

I 2

I 2

Mount, Bagwe11

Plate, Mounting

• • • • • • • • • • • • • • • • • • • • • •

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

Screw, 1/4-20 x 3/4 Lg. ••••••••••••••••• Nut, Lock, I /4-20 .....................

Rivet, Aluminum, Black ••••••••••••••••• Trim Strip

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

Rivet, Aluminum

I 9755-G2 19555-G3 I 9555-G4 00106-G6 11027-G2

Bumper, Rear

17026-GI 17026-G2 15528-G2

Battery Rack, Inner (Passenger Side) ••••••••••• Battery Rack, Inner (Driver's Side) •••••••••••• Battery Rack, Outer ••••••••••••••••••••

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

Fender (Passenger Side) •••••••••••••••••• Fender (Driver's Side) ••••••••••••••••••• Screw, Self-Drill and Tap, 1112-24 x 3/4 Lg. •••••• Nut, Lock, I /4-20 .....................

6 6

-------------- E�GCii�:1i;\•]:i --------------11

E7

8/15/87

11

ES

8/15/87

°' 1 INCLUDES ITEMS 2-11

yI 10

I

co

m

--

D

�

.,, r

-00

V,

00

I

2

\. ,\.<._ I

1/liQ

lf/�19

TITLE

BRAKE LINKAGE

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I

I I I

I I

I I

./

PART NO.

DESCRIPTION 1 2 3 4 5

2 3 4

23033-GI 23037-GI 15813-GI 15826-GI

Brake Pedal Assembly (Includes Items 2-1 !)

Pedal, Brake (Complete with Pad, Item 4) •••••.

Pedal, Hill Brake (Complete with Pad, Item 6) Brake/Hill Brake Pedal Pad Kit (Includes

5 6

* *

7 8 9 10 II 12 13 14

15766-GI 15767-GI I 5932-GI 11737-GI 12064-GI 14158-G I 11079-GI 13197-GI

15 16

I 3521-G4

Rivet, Small Head Rivet, Large Head Pin, Hill Brake Pedal •• Spring, Torsion •••••••••••••••• Push Nut ...................

Bolt, Shoulder, 3/8-16 •••••••••.•••••.

Bushing, Flanged, Nylon Spring, Torsion ••.

Nut, Lock, 3/8-16

I 0386-G3 I 0387-G3

Pin, Clevis Cotter Pin, 3/32 x 3/4 Lg.

23026-G2

Brake Linkage Assembly (Includes Items 22-39)

I

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

23062-G2 23059-G2

w w

..J

::c

::c

M

<t

w w

;: I s: QTY.

I terns 5-8) . . . . . . . . . . . . . . . . . . . .

Pad, Brake Pedal •.• Pad, Hill Brake Pedal

Compensating Link Assembly (Includes Items 23-34) Rod, Weldment •••

00544-G4

Nut, 5/16-24 •••••

I 0385-G4 23030-G I 15121-GI 23061-GI 23463-GI 15126-GI 13659-GI

Yoke, Clevis Yoke, Brake •••• Washer, Flat, 5/16 Tube Spring, Compression Nut, Lock, 5/16-24 Bar, Equalizer •• Pin, Clevis •••••

I 0386-G3

_J

I I I

I I I

3 6 I 2 I I 2 I I

3 6 I 2 I I 2

I

I

I I

I I

I I I 2 I I I

I I

I I

I 2 I I I

__...____________ E.ZGDii:niit•i:I ____________...__ 6

F2

8/15/87

TITLE

BRAKE LINKAGE

When ordering parts, please specify model and serial no. of vehicle.

I I I

DESCRIPTION 1 2 3 4 5

ITEM NO.

PART NO.

33

10387-G3

Cotter Pin, 3/32 x 3/4 Lg.

34

17979-G I

Bushing, Accelerator Rod

..J

M

<t

w w ::c 3:

QTY.

35 36

23084-G I

Cable, Brake, Passenger Side

37

23084-G2

Cable, Brake, Driver's Side

38

I 0386-G3

Pin, Clevis

39

10387-G3

Cotter Pin, 3/32 x 3/4 Lg.

40

I 0386-G3

Pin, Clevis

41

10387-G3

Cotter Pin, 3/32 x 3/4 Lg.

42

12305-G I

Ring, Retaining

45

16172-G I

Clamp, Nylon

46

00414-G6

Screw, Hex, I /4-20 x 3/4 Lg••••••..•••••.••

47

I I 845-G2

Clip, Cable

48

11027-G2

Nut, Lock, I /4-20

49

I 1845-G4

Clip, Cable

51

I 0097-G6

Bearing, Flanged

52

12156-G I

Cam, Hill Brake

53

14134-G2

Spacer

54

00491-G3

Setscrew, I /4-20 x 3/8 Lg. •

57

00414-G6

Screw, Hex, I /4-20 x 3/4 Lg.

58

00565-G7

Washer, Lock, I /4

59

15022-G I

Bracket, Catch ••.•••••••••••••••

60

11027-G2

Nut, Lock, I /4-20 ••••••••••••••••

63

14061-G1-

Pedal Bumper Service Kit (Includes Items 64-68)

64

00l 50-G6

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

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

43

44

./

..J

w w ::c 3:

50

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

••

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

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

• • . . . • • . . . • .

55

2 2 2 2 4

2 2 2 2

I

I

4

3

3

I

I

3

3

2

2

2 I I 2

I I I 2

2 2 I

2 2 I

56

2

2

61 62 Screw, Ill 0-24 x 3/4 Lg.

••.••••••••

..__..,_______.______ E�GClii�:,iit•W ____________.__.__ 6

F3

8/15/87

TITLE

BRAKE LINKAGE

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

65

00559-G5

66 67 68

13728-G I 00565-G5 00526-G3

*

DESCRIPTION 2 3 4 5

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

Bumper, Rubber •• . . . . . . . . . . . . . . . . . . .

Washer, Lock, Ill 0 . . . . . . . . . . . . . . . . . . .

Nut, Ill 0-24 . . . . . . . . . . . . . . . . . . . . . . .

Washer, Flat, II IO •

..J

w w

w w

C')

�

:c

:c

QTY.

I I I I

I I I I

Not available as an individual part.

:

E�GDii=>:1i;\•]:i 6

F4

8/15/87

10 5

I l

(

8/15/87

TITLE

FORK ASSEMBLY

ITEM NO.

PART NO.

DESCRIPTION 1

2

3

4

...J

...J

:c 3:

:c 3:

w w

When ordering parts, please specify model and serial no. of vehicle.

M

5

w w

":f

QTY.

I

17533-GI

2

17537-GI

Fork

I

X

3

17542-GI

Axle Bracket Assembly (Passenger Side) •.•••

I

X

4

17542-G2

Axle Bracket Assembly (Driver's Side) •••••

I

X

5

19796-GI

Shock Absorber Assembly (Includes Items 6-8)

2

X

6

17907-GI

Shock Absorber

I

X

7

19794-G2

Spring, Compression

X

8

17816-GI

Retainer, Spring ••

X

10

00557-GI

Nut, Lock, I/2-13 ••••

II

15588-GI

Bushing, Pivot

12

00560-GS

Washer, Flat, 5/8

13

14390-G7

14

00492-G6

IS

00544-GI

16

00378-G4

17

Fork Assembly (Includes Items 2-15)

X

9

4 4

X X

Nut, Lock, 5/8-1I

2

X

Setscrew, Square Head, 1/4-20 x I 3/4 Lg• ••

2

X

2

X

Screw, Ill 0-24 x I/2 Lg. ••••••••

4

X

00565-GS

Washer, Lock, II I 0

4

X

18

00526-G3

Nut, Ill 0-24

19

11081-GI

Nut, Lock, 3/4-16

4

X

20

00560-G6

Washer, Flat, 3/4 •••

21

17650-GI

Ring, Adjuster

22

17535-GI

Hub and Axle Assembly (Includes Items 23-30) •••••

••

2

Nut, 1/4-20 .................

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

X

2

X

4

X

2

X

I

X

4

X

2

X

2

X

23

00545-G8

Nut, 3/4-16 .......................

24

I 0223-GS,-

Axle, Front

25

17536-GI

Spacer, Axle

26

19471-GI

Seal, Grease

27

50908-GI

Bearing, Race Assembly

•••••••••••••••

2

X

28

19888-GI

Hub Assembly (Includes I tern 29). •••••••••••

I

X

29

19862-GI

4

X

30

11655-GI

2 I

X

31

13136-GI

••••••..•.••.•.......•

Bolt, Hub, 1/2-20 Spacer, Axle Spacer

•.•••

••••••••••••••••

I

X

X

_________....______ E�GDi•Hii!•):1-------------02

8/15/87

TITLE

FORK ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle J ITEM NO.

32 33 34 35 36

PART NO.

11103-GI 10669-G3 11098-Gl 18256-GI 15643-GI

DESCRIPTION 1 2 3 4 5

.J

.J

::c 3:

::c 3:

w w (")

................ ...................... . . . .. . . . . . . . . ·• . . . . . . . .................... ...........................

Bearing, Roller, Complete Washer, Special · Nut, Lock, I 3/8-12 Retainer, Axle Nut Shield

w w

�

QTY.

2 1 I 2 I

X X X X X

E�GDii=>:,i,t•]:I 03

8/15/87

E�liDii=t:;i;t•]:i 04

8/15/87

,,,,_ .,,. ..... ,,,,,, -

/M

-- -..

I / It)

'

C')

C')

C\I ...

00) ...

C') C\I

0 C')

""" C\I

-----------E.ZGDiii:fi;t•J:t-----------FORWARD-NEUTRAL-REVERSE SWITa-t ASSEMBLY Pl

8/15/87

TITLE

FORWARD-l'EUTRAL-REVERSE SWITCH ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I

I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

PART NO.

DESCRIPTION 1 2 3 4 5

QTY.

20270-G2 14651-GI 14654-GI 00565-G7 00532-GI

Forward-Neutral-Reverse Switch Assembly Complete •• Contact Board Assembly .•••••••••••••• Stop •••••••••••••••••••••••• Washer, Lock, I /4 •••••••• Nut, 1/4-20 •••••••••••

I I 2 2 2

I I 2 2 2

12835-GI 19470-GI 00560-GI 14390-GI

Forward-Neutral-Reverse Switch Cam Assembly ••• Shaft, Forward-Neutral-Reverse Switch ••••••• Washer, Flat, 3/8 ••••••••••••••••••• Nut, Lock, 3/8-24 ••••••••••••••••••••

I I I I

I I I I

10606-G2 00139-G6 12806-GI 00565-G3 00525-G5

Switch, Micro •••••• Screw, 116-32 x 1 3/4 Lg. Spacer, Micro Switch Washer, Lock, 116 Nut, 116-32 ••

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

2

2

4 4

4 4

17940-GI 00l38-G5 00565-G3 00525-G5

Buzzer Screw, 116-32 x 5/8 Lg. •••••• Washer, Lock, 116 ••••••••• Nut, /16-32 . . . . . . . . . . . . .

•

•

•

•

•

•

•

•

•

•

0

•

•

•

4 4

4 4

..........

I 2 2 2

I 2 2 2

12863-GI 15461-Gf 00415-G2 00559-G7 00565-G7 00532-GI

•••••••••••••••••• Bracket, Mounting Support, Bracket Mounting • ••••••••••••• ••••••••••••• Screw, I /4-20 x I I /4 Lg. Washer, Flat, 1/4 Washer, Lock, 1/4 Nut, I /4-20 ••••

I 2 2 4 2 2

I 2 2 4 2 2

13514-GI 14628-GI 00567-G3

Screw, Brass, 116-32 x .22 Lg. F aston Tab ••••••••••••••• Washer, Lock, External Tooth, 116

4 2 2

4 2 2

O

•

0

•

•

•

•

•

•

•

•

•

•

•

•

•

•

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

0

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

0

0

0

0

0

0

0

0

0

0

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

....,_...______...______ E�ma,,�:,i,t•J:1 __________.....__...____ P2

8/15/87

TITLE

FORWARD-NEUTRAL-REVERSE SWITCH ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

33 34

20325-G I

35

19886-G I

36

00740-G4

DESCRIPTION 2

3

4

.J

w w

w w

M

�

5

QTY.

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

Handle, Plastic . . . . . . . . . . . . . . . . . .

Screw, fl I 0-32 x 1/2 Lg. ............

Switch Handle Kit

I

I

I

I

I

I

'

E�GDii=>:1i;\•]:I P3

8/15/87

P4

8/15/87

,I:-

26 /

2 3*

/

11

.,,

0

�rn m�.

0

-

r ·� .,, Iii

::o

a

�

�

ijrn

�

�

2

0) V, 0)

*VERIFY R.H. OR L.H. THREAD PRIOR TO ORDERING ITEMS 16,17,22 AND 23.

52 1 - INCLUDES ITEMS 2-26 3 - INCLUDES ITEMS 5-8 4 - INCLUDES ITEMS 5-8 15 - INCLUDES ITEMS 16-23 16 AND 17 - INCLUDES ITEMS 18-23 25 - INCLUDES ITEM 26 29 - INCLUDES ITEM 30 35 - INCLUDES ITEMS 36-37

TITLE

FOUR WHEEL FRONT SUSPENSION

When ordering parts, please specify model and serial no. of vehicleITEM NO.

I 2

PART NO.

DESCRIPTION 1 2 3 4 5

.J

C')

�

w w J: 3:

w w J: 3:

QTY.

Front Axle Assembly (Includes Items 2 - 26) ••••••

3 4 5

19518-GI 19385-GI 16625-GI 19397-GI 16626-GI

6

16623-GI

X

I

X

I

Spindle Assembly, Driver's Side (Includes Items 5-8)

X

I

Spindle Assembly, Passenger Side (Includes Items 5-8)

X

I

X

2

X

4

Axle Weldment

Seal

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

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

Bearing, Bronze

7

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

10389-G3 16982-GI 00879-G5 00886-GI

Grease Fitting Bearing, Thrust ••••••••• Washer, Flat, 5/8 ••••• Nut, Slotted, 5/8-18

X

2

X

2

X

2

X

2

Cotter Pin, Stainless Steel, I /4 x I I /2 Lg. Nut, Slotted, 7/16-20 ••••••••••.•••••• Cotter Pin, 3/16 x I Lg.

X

2

X

2

14

19060-GI 50209-GI I 0387-G2

X

2

15

18377-GI

Tie Rod Assembly (Includes Items 16 - 23) Includes Quantity I L.H. and I R.H. Rod End • Tie Rod End, L.H. Thread, Quantity I per

X

I

8

I I I

.J

9 10 II 12 13

16 17

20795-GI 20795-G2

Assembly Tie Rod End, R.H. Thread, Quantity I per Assembly

18 19

10389-G3 50641-GI

20

50209-GI

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

Grease Fitting, Quantity 2 per Assembly •• Boot, Rubber . . . . . . . . . . . . . . . . . .

22 23

10387-G2 18434-GI 18434-G2

X X

I

X

2

X

2

X X X

2 I

X

I

X

2

2

Nut, Slotted, 7/16-20, Quantity 2 per Tie Rod Assembly

21

X

. • • • • . . • . . • .. • . • . . .

Pin, Cotter, 3/16 x I Lg. Quantity 2 per Tie Rod Assembly •••••••••••••••• Nut, 9/16-18, L.H. Thread •••••••••• Nut, 9/16-18, R. H. Thread

24 25

19202-GI

Tie Rod with Tow Pin Assembly (Includes Item 26) Includes Quantity I L.H. and Quantity I R.H.

Rod End . . . . . . . . . . . . . . . . . . . . . . .

26 27

10389-G3

Grease Fitting •••

--------------- E�GDiiHiit•):I --------------4

Q2

8/15/87

TITLE

FOUR WHEEL FRONT SUSPENSION

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I I I

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

PART NO.

DESCRIPTION 1 2 3 4 5

QTY.

50892-G I 19932-G I 19862-G I 19472-G I 12093-G I I 0387-G I

Bearing and Race Assembly ••••••••••••••• Hub Assembly (Includes Item 30) •••••••••••• Bolt, Hub, I /2-20 •••••••••••••••••••

X

4

X

2

X

8

X

2

Nut, Slotted, 1-14 •••••••••••••••••• Cotter Pin, 1/4 x I 1/2 Lg•••••••••••••••••

X

2

X

2

19306-G I 10389-G3 15012-G I 13221-G I 16417-G I 15023-G2

Idler Assembly (Includes Items 36 and 37) Grease Fitting Bushing, Flanged Washer, Spring Wave Shaft, Idler •••• Retainer, Spring

X

00876-G4 00878-G I 00877-G5 10387-G6 18219-G I

Screw, 3/8-16 x I I /2 Lg. . . . . . . . . .

Washer, Lock, 3/8 Nut, 3/8-16 ••• Pin, Cotter, 3/8 x I I /2 Lg. Pivot Arm Assembly

X

I I

15707-G I 10435-G I I 0194-G I 00532-G6 12091-G I 00427-G6 00566-G I 00532-G5 14723-G I

Shock Absorber • . . • . • . . . . . . • . . . . • • • • . .

X

2

Washer, 13/32

X

8

Bushing, Rubber . . . . . . . . . . . . . . . . . . .

X

8

Nut, 3/8-24

X

4

X

6

X X

6 6

X

8

X

2 2

17989-G I 15040-G I

Seal, Grease

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

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

Cap, Spindle

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

Screw, 3/8-16 x 2 Lg. Washer, Lock, 3/8 Nut, 3/8-16 Nut, Lug, I /2-20

••••••••

Spring, Leaf (Utility Vehicles Only) ••••••• Spring, Leaf (Got f Cars Only) •••••••••

X X X X X

I 2 I I 4

X X X X

8

X

X

8 8

2

--------------- E�GClii,.:,iit•):I __________...____ 4

Q3

8/15/87

4

Q4

8/15/87

N

�0 �.m

� Gi

�B � r D

> � �

-00

u, 00

17 16 - INCLUDES ITEMS 17- 27

,,,.r..·./ !

·- ·

� 1 .i I �

1

i

_;�

4 WHEEL SHOWN PICTORIALLY

TITLE

MODEL DETAILS

When ordering parts please specify model and serial no. of vehicle.

ITEM NO.

I I

PART NO.

19882-GI

Indicator, Forward-NeutraI-Reverse

C")

'11:t'

w w :c ;:

2

12064-G3

3

•••••••••••

I

I

Retainer, Push On . . . . . . . . . . . . . . . . . . . . .

3

3

18787-GI

Scuff Guard, Seat Wrap

I

I

4

18350-GI

Floormat, 3/16 . . . . . . . . . . . . . . . . . . . . . . .

I

I

5

16816-GI

Fastener, Ratchet Type ••••••••••••••••••

2

2

6

20063-GI

Decal Installation Kit, Golf Ball (Specify No. I through

8

I 00), Optional 20514-GI

•••••••••••••••••

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

Decal Installation Kit, Trapezoid (Specify No. I through

I 00), Optional

9

I

...I

w w :c ;:

QTY.

I

7

I

DESCRIPTION 1 2 3 4 5

...I

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

10

15929-GI

Shield

X

I

11

00414-G8

Screw, Hex, I /4-20 x I Lg.

X

4

12

14390-G4

Nut, Lock, I /4-20 ••••••

X

4

23336-GI

Bumper Installation Kit Front, Optional

X

16

22329-G4

Vinyl Bumper Trim Kit (Includes Items 17-26)

X

17

I 7203-G5

Vinyl Bumper, Body Trim (Sides) ••••••

X

2

18

22273-GI

Vinyl Bumper, Body Trim (Back of Cowl) ••

X

I

19

17203-G9

Vinyl Bumper, Body Trim (Dash Tray)

X

2

20

15058-G2

Rivet, Aluminum, Black •••••••••••

X

4

21

22223-GI

Trim, Rocker Panel, Passenger Side •

X

I

22

22223-G2

Trim, Rocker Panel, Driver's Side ••

X

I

23

16705-GI

Screw, Stainless Steel, I /4-20 x I Lg.

X

4

24

12905-GI

Spacer, Neoprene

X

4

25

00559-G7

Washer, Flat, I /4

X

4

26

14390-G4

Nut, Lock, I /4-20

X

4

27

15058-G4

Rivet, Aluminum, Black ••••••••••••••••

X

2

28

22329-GI

Vinyl Bumper Trim Kit (Includes Items 29-38) •••••

I

X

29

17203-G6

Vinyl Bumper, Body Trim (Sides and Front)

30

22273-GI

Vinyl Bumper, Body Trim (Back of Cowl)

I

X

31

17203-G9

Vinyl Bumper, Body Trim (Dash Tray)

2

X

32

15058-G2

Rivet, Aluminum, Black •••

4

X

13 14 15

. .. . . . . . .

X

---------------E�GDii=>:1i;t•]:I -------------12

X2

8/15/87

TITLE

MODEL DETAILS

When ordering ports, please specify model and serial no. of vehicle.

ITEM NO.

33 34 35 36 37 38

PART NO.

22223-GI 22223-G2 16705-GI 12905-GI 00559-G7 l4390-G4

.J

.J

�

�

w w

3:

DESCRIPTION 1 2 3 4 5

C")

w w

3:

'IS'

QTY.

Trim, Rocker Panel, Passenger Side ••••••••• Trim, Rocker Panel, Driver's Side •••••••••• · Screw, Stainless Steel, I /4-20 x I Lg. • ••••••• Spacer, Neoprene •• • •• Washer, Flat, 1/4 •••• Nut, Lock, I /4-20

I I

4 4 4 4

X X X X X X

-------------- E�GDii=>:1i,t•]:I -------------12

X3

8/15/87

12

X4

8/15/87

X

U::

u.

::, Cl)

_.w

0 0 �

MOTOR YI

8/15/87

TITLE

MOTOR

ITEM NO.

I

PART NO.

DESCRIPTION 1 2 3 4 5

I

22858-GI

Motor

2

16922-GI

3

13483-GI

4

16919-GI

5

I 5437-GI

6

15438-GI

7

15440-GI

8

23234-GI

9

15442-GI

10

16917-GI

11

16916-GI

12

15446-GI

13

51333-GI

IS

* *

16

23235-G I

14

17 18

16948-GI

19

23237-GI

20

16918-GI

21

16930-GI

22

23236-GI

*

..J

:c

:c

w w

::: :::

q"

C')

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

Endshield, Commutator End. . . . . . . . . . . . . . .

Washer ........................

Screw, Motor Clamp .................

Bushing, Insulator . . . . . . . . . . . . . . . . . . . .

Washer, Insulator ...................

Nut, Lock .......................

Screw, Pole Piece . . . . . . . . . . . . . . . . . . .

Washer, Insulator, Terminal .............

Brush Assembly . . . . . . . . . . . . . . . . . . . . . .....................

Brush Rigging ....................

Brush Spring Screw, Brush Rigging Mount . . . . . . . . . . . . .

Field Pole Pieces ...................

Shell, Stator .....................

Field Coils (Set) ..................

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

Armature . . . . . . . . . . . . . . . . . . . . . . . .

Ball Bearing, Commutator End ...........

Retainer, Bearing ...................

Screw, Bearing Retainer ..............

Gasket

'

..J

w w

When ordering parts, please specify model and serial no. of vehicle.

QTY.

I

I

I

I

4

4

2

2

4

4

4

4

4

4

8

8

4

4

2

2

I

I

4

4

2

2

4

4

I

I

I

I

4

4

I

I

I

I

I

I

3

3

Not available as an individual part.

E�GDii�:1iit•):I 3

Y2

8/15/87

33- CONTROL WIRING HARNESS, F&R SWITCH (INCLUDES ITEMS 34,35,36,&37) 38- WIRING, F&R SWITCH (INCLUDES ITEMS 39-43)

� OJ ::0

�:e

� �

�

.,••. ,

IA2

............... s1

-(X)

0,

(X)

'-I

SEE RESISTOR ASSY. FOR P/N

---'-ti:

M

I

I

M (',I

\ POWER WIRING 882

8/15/87

TITLE

POWER WIRING

When ordering ports, please specify model and serial no. of vehicle.

_, _,w

w w ::c 3:

w ::c 3:

PART NO.

DESCRIPTION 1 2 3 4 5

I

18840-GI

Receptacle and Harness Assembly ••••••••••••

I

I

2

18724-GI

Charger Receptacle Holder ••••••••••••••

I

I

3

18841-GI

Wiring Harness Charger Connector

•••••••••

I

I

4

14852-GI

Wire Assembly (CR-)

•••••••.••••••

I

I

5

14852-G2

Wire Assembly (CL+)

I

I

6

18782-GI

Connector, Anderson

•••••••••••••••

I

I

7

14390-G9

8

00559-G3

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

Washer, Flat 116 ••••••••••••••••••••

9

00645-G2

Screw, //6-32 x I I /4 Lg.

2 2 2

2 2 2

2

2

ITEM NO.

C')

QTY.

Nut, Lock, /16-32

10 11

I 1885-G4

Wire Assembly

12

I 1885-G2

Wire Assembly

13

11893-GI

Wire Assembly

14

11894-GI

Wire Assembly

15

00702-G2

16

o:S'

••••••••••••••

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

I

I

Nut, Heavy, 5/I 6-18 ••••••••••.••••••.••

12

12

00270-G6

Screw, 5/16-18 x 3/4 Lg. •••••••••••••••••

12

12

12649-GI

Bolt, Battery, Square Head, 5/16-18 x I Lg.

12

12

22

15736-GI

Battery Hold Down

23

15734-G2

J Bolt, Battery

24

00559-G8

Washer, Flat, Narrow, 5/16 ••••.•••••••••••

25

00565-G8

Washer, Lock, 5/16 .....................

26

00702-G2

Nut, Heavy, 5/16-18 ••••••••••.•••.•••••

2 2 2 2 2

2 2 2 2 2

00532-G3

Nut, 5/16-18

4

4

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

17 18 19 20 21

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

27 28 29 30 31 32

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

--------------- E�GtiiiHiit-J:I --------------BB3

8/15/87

TITLE

POWER WIRING ..J

When ordering parts, please specify model and serial no. of vehicle.

w w

w w

M

�

::c ==

::c ==

PART NO.

DESCRIPTION 1 2 3 4 5

17868-G I 14619-G2

Control Wiring Harness, F-N-R Switch Wire Assembly (light Blue) •••••

I I

I I

17870-G I

Wire Assembly (Yellow) •••••••

36 37 38 39 40 41 42 43

14615-GI 17869-G I 18894-GI 17855-G I 17856-GI 18834-G3 17618-GI 17858-G I

Wire Assembly (Black) Wire Assembly (Red and White) ••• Wiring Harness, F-N-R Switch Wire Assembly (SI) •••• Wire Assembly (A2)

I I I I I I I 5 I

I I I I I I I 5 I

44 45 46 47 48

14610-GI 18518-G I 17421-Gl 17137-GI 17063-GI

Wire Assembly ••••••

I I I I I

I I I I I

I

I

2 I

2 I

3 I

3 I

NA NA NA NA

NA NA NA

ITEM NO.

33 34 35

QTY.

Loom, Flex, Zip

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

Clamp, Nylon (Black) •••••••••••••••••• Wire Assembly (S2) ••••••••••••••••••• Wire Assembly Ignition Switch Kit Face Nut •••• Ignition Key

49 50 51 52 53 54

l 7314-G8

loom Flex

16172-G I 18908-GI

Clamp, Nylon

16172-G I I 7314-G6

** ** ** **

**

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

Wire Assembly, (A1-4) (Includes Items 53, 54) ••••• Clamp, Nylon•••••••••••• loom, Flex ••••• Related Test Equipment

:

••••••••• Current Indicator Battery Tester (Discharge Machine) Hydrometer ••••••••

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

Ohm Meter (Multi-Meter)

NA

See Service Accessories and Special Tools Section.

________...._____ E�GDii�:,i,t•]:I -------------B84

8/15/87

V,

48

50 51

.

�:�

'

JI

5• y 53

-1 INCLUDES ITEMS 2-54 -7 INCLUDES ITEMS 8-54 -9 INCLUDES ITEMS10-54 -10 INCLUDESITEMS11-13

'- � "'--

'I -

52

','

.

'----,\��. ,, \, 49 �� -� H:Jtt. : �

FR

�

X ()

�

-�

() � rn

ffl

�

I

�

-< •

�

-.

36

�

29 10

-00

V,

00

-..J

43

� 42

28

TITLE

REAR AXLE ASSEMBLY, HELICAL

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

2 3 4 5

6 7 8 9 10

II 12

13

14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30

31 32

PART NO.

23133-GI XXXXX-XX 00559-G7 00565-G7 00797-G2

23524-GI XXXXX-XX 23092-GI 23501-GI 23503-GI 23505-GI 20376-GI

23520-GI 23519-GI 23525-GI

23526-GI 23521-GI 23530-GI 23531-G I 17473-GI

18463-GI 13108-GI 13106-GI 13104-GI 18060-GI 13105-G I 13107-G I

13102-GI

Mi.

DESCRIPTION 1 2 3 4 5

Rear Axle Motor and Brake Assembly (Includes Items

2-54)

�I�I �I� !

1j

-"2'

QTY.

j

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

Motor (See Motor Section) Washer, Flat, I /4 •••••• Washer, Lock, 1/4 •••••

Screw, I /4-20 x I I /4 Lg.

3 3

3 3

3 2 2 3

3

2 2 3

2

2

3

3

Rear Axle and Brake Assembly (Includes Items 8-54) Brake Set (See Wheel Brake Assembly Section) • Rear Axle Assembly (Includes Items I 0-54) • Gear Set (Includes Items I 1-13) Gear, Input Gear, Intermediate Gear, Output

Ball Bearing, Input Gear •

Ball Bearing, Input Gear, Motor Side Seal, "0" Ring . . . . . . . . . . . .

Seal, "0" Ring . . . . . . . . . . .

Ball Bearing, Intermediate Gear Retaining Ring •••••••••• Cover, Dust •••••••••• Ball Bearing, Output Gear

Differential Assembly (Includes I terns 25-31) Case, Differential •••••••••••••• I I I I 12 2 I Washer, Thrust Pinion Gear •••• 2 2 Washer, Thrust Differential Gear 2 I 2 Gear, Differential 1 1 2 2 Gear, Pinioin ••• I Shaft, Pinion Gear Pin, Locking ••••

...__...._______.______ E�GDiiHiiM:I __________......,_,...__, 5

CC2

8/15/87

TITLE

REAR AXLE ASSEMBLY, 1-ELICAL

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

PART NO.

00433-GI 00532-G6

*

..J

J:

w w

J:

M

-=I'

w w

3:

DESCRIPTION 1 2 3 4 5

3:

QTY.

Screw, 3/8-24 x I I /8 Lg. Nut, 3/8-24 •••••••••

..........

4 4

4 4

2 4

2 4

37 and 38) •••.••••••.•••

15118-GI 23529-GI 23528-GI 20536-GI 23527-GI 15558-GI 20377-G3 20377-G4 15114-GI 15113-GI 15112-GI 15485-G I 15487-GI 15483-GI I 0387-GI

* **

..J

Axle Housing Assembly (Includes Items

*

** **

-�-

:

Retainer, Bearing •••••••••••• Screw, 3/8-16 x 2 I /8 Lg••••••••••

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

Plug, Vent .

Dipstick Sealant (Enough for I Application) Cover Plate Screw, 5/16-18 X 3/4 Lg. Shaft, Axle, Driver's Side Shaft, Axle, Passenger Side Seal, Axle ••••••••• Retaining Ring ••••• Ball Bearing, Axle •••• Washer, Flat, 20mm •• Washer, Brake Drum, 5/8 Nut, Slotted, 5/8-18 •• Cotter Pin, I /8 x I I /2 Lg. Slide Hammer Kit • Tool, Seal Removal

I I I I I I I I 10 10 I I I I 2 2 4 4 2 2 2 2 2 2 2 2 2 2 �/A N/A N/A N/A

Not available as an individual part.

See Service Accessories and Special Tools.

_________...______ E�GDii:t:1iiM:I --------------5

CC3

8/15/87

5

CC4

8/15/87

TICAL. PASSENGER SIDE SHOWN. DRIVERS SIDE IDEN32 THAU 26 S ITEM OMIT LE VEHIC 4 WHEEL AND 40 THAU 44, ADD ITEM 33

____,

�

> � ::o

I �m �

40

�

_ 'Z� Iii m D mo z ()

0

�

16 17

;

I

� �

-ex> u, ex> --.J

4 WHEEL VEHICLE

\\ \ \

12

� '

/ �

TITLE

REAR SUSPENSION COMPONENTS

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

DESCRIPTION 1

2

3

4

5

Leaf Spring Heavy Duty Leaf Spring

19675-GI

8

19676-GI

Spring Shackle (Includes Items 6-8) Stud Plate, Shackle Plate, Shackle Nut, Lock, 3/8-24 ••

20098-GI 15727-GI 00566-GI 00532-G5

Bushing, Rubber Bolt, Shoulder, 3/8-16.

Washer, Lock, 3/8 Nut, 3/8-16

20278-GI 20279-GI 00428-G4 00560-GI 00550-G5 10435-GI 10194-GI 00532-G6

Shock Absorber Shock Absorber, Heavy Duty Screw, 3/8-16 X 2 I /2 Lg•• Washer, Flat, 3/8 Nut, Lock, 3/8-16 Washer, Shock Absorber Bushing, Shock Absorber Nut, 3/8-24

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

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

:

14770-GI 00532-G5 10435-GI I 0194-GI 10840-G3 10579-G6 17141-GI

3:

�

2 2

2 2

2 2 2 4

2 2 2 4

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

12 12 2 2 2 2 2 2

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

2 2 2 2 2 4 4 2

2 2 2 2 2 4 4 2

2

X

4

X

8

X

8

X

2

X

2

X

2

X

Stabilizer Bar Spring Bracket Assembly (Includes I terns 27-32) . . . . . . . . . . . . . . . . . .

Nut, 3/8-16 ........................

Washer, Shock Absorber Bushing, Shock Absorber Spacer

3:

QTY.

20398-GI I 1645-G2

*

w

M

I 2 3 4 5 6 7

'!I'

.J

w w

• • • • • • . • • • • . • • •

Rod, Threaded • • • • • • • • • • Bracket, Spring Retainer

--------------- E�GDii=>:1itt•]:I --------------EE2

8/15/87

TITLE

REAR SUSPENSION COMPOl'ENTS

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

-I

-I

::c

::c

w w

w w

;r: ;r:

PART NO.

DESCRIPTION 1 2 3 4 5

33 34

17034-G I

Plate, Spring Retainer

35 36

12058-G2 00532-G5 00566-G I

"U" Bolt, Axle Nut, 3/8-16 Washer, Lock 3/8

39 40 41 42 43

11640-G I 17284-G I 11155-Gl

Bracket, Stabilizer Bar • Stabilizer Bar Assembly (Includes Items 42-43) Bushing, Stabilizer Bar, Stab iiizer

2 I 2

X

I

X

44

11027-G4

Nut, Lock, 5/16-24

4

X

37 38

*

*

C')

OS'

QTY.

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

X

2

4 8

4 8 8

8

X X

Not available as an individual part.

--------------- E�GDiiHM•W --------------EE3

8/15/87

EE4

8/15/87

13 l!----+;-14

a-INCLUDES ITEMS 9-23

14

15

-----------EeGDii=t:ii;\•l:1----------RESISTOR COIL AND HOUSING ASSEMBLY FFI

8/15/87

TITLE

RESISTOR COIL AND HOUSING ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I 2 3 4 5 6

I I I I I I I I I I I I j

I

j

7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

PART NO.

00661-G6 00664-G7 00660-G7 00709-GI 23319-GI 00883-GI 00664-G7 22951-GI 00661-GS 18814-GI 18812-GI 23302-GI 00883-G3 00882-G8 00660-G8 00880-GI 18811-GI 23293-GI 23294-GI 23295-GI 00883-G3:· 00882-GS

DESCRIPTION 1 2 3 4 5

QTY.

· Screw, Stainless Steel, I /4-20 x 3/4 Lg. Washer, Lock, Stainless Steel, I /4 Washer, Flat, Stainless Steel, 1/4 Nut, 'U', I /4-20.................

Resistor Coil Assembly (Includes Items 9-23) Nut, I /4-20 .................

Washer, Lock, Stainless Steel, 1/4 •••••••••• Strip, Support ••••••••••••• Screw, Stainless Steel, 1/4-20 x I Lg. Shield, Resistor Housing, Resistor ••••••••••••••••••• Resistor Board Assembly (Includes Items 16-23) •• Nut, 5 / 16-18 .......... . .........

Washer, Lock, 5/16 ••••••••• Washer, Flat, Stainless Steel 5/16 ••••••• Screw, Lock, 5/16-18 x I I /2 Lg. •••••••• Board, Resistor Coil, Resistor, Light Coil, Resistor, Medium Coil, Resistor, Heavy ••••••••••••• Nut, 5/ 16-18 . . . . . . . . . . . . . . . . .. . . . . . .

Washer, Lock, 5/ 16 . . . . . . . . . . . . . . . . . . . . .

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

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

4 4 4 4

4 4 4 4

I

I

8

8

8 2 4 I I I 4 4

8

2 4 I I I 4 4

8

8

4 I I I I 4 4

4 I I I I 4 4

..,___._____________ E�GDii�:,i;t•J:1----------....__.___ 3

FF2

8/15/87

1 - BACK REST ASSEMBLY 28 - SE AT BOTTOM ASSEMBLY

8>

7

m

-� I� � z ·�.

GIB

V,

:i:o

I cc

I

0

�

;o

-00 Ln

00 '-1

D \ .

•

34

8 ,�3 /' /� �39

30

TITLE

SEATS AND BAG HOLDER

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I 2 3 4 5 6 7 8 9 IO 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

PART NO.

I9232-G2 14371-GI 14370-GI 19226-GI

* *

I9056-G3 00666-G6 00414-G8 00565-G7 00559-G7

DESCRIPTION 1 2 3 4 5

.J

::c ;:

::c ;:

w w C')

w w

�

QTY.

Back Rest Assembly (Includes Items 2-6) •• Cover, Back Rest Cushion Cushion, Foam, Back Rest Plywood Seat Back••••• Nut, Tee . . . . . . . . . . . . . . . . . . . . . .

Bag, Plastic . . . . . . . . . . . . . . . . . . . . . . . .

Cover, Back Rest . . . . . . . . . . . . . . . . . . . . .

Screw, Truss, Stainless Steel, III0-16 x 3/4 Lg. •••• Screw, I/4-20 x I Lg. ••••••••••••••••••• Washer, Lock, I/4 Washer, Flat, 1/4

16924-G2 14643-G2 15902-GI 16610-GI 17226-GI 16920-GI 15058-GI 16935-GI 00763-G4 11027-GI 00427-G4 11027-G5 I3437-G2

Screw, Truss, 5/16-18 x I 1/2 Lg• •••••••••••• Nut, Lock, 5/16-18 ••••••••••••••••••••• Screw, 3/8-16 x I 1/2 Lg•••••••••••••••••• Nut, Lock, 3/8-16 ••••••••••• Screw, Lock, 5/16-18 x I I/2 Lg.

15159-G2 15146-GI 15145-GI

Seat Bottom Assembly (Includes Items 29-37) Cover, Seat Bottom Cushion Cushion, Foam

Seat Back Bracket and Bag Holder Extrusion, Vinyl Strap •• Anchor Plate •••••• Rivet Strap Retainer Rivet, Aluminum, Black •••••••••••••••••• Nut, Tee

..J

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

2 I I I 2 I 2 4 4 4 4

2 I I I 2 I 2 4 4 4 4

2 2 4 4 2 4 2 2 2

2 2 4 4 2 4 2 2 2

--------------E�GCJii�:,it{•]:1------------.....HH2

8/15/87

TITLE

SEATS AND BAG HOLDER

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

31 32 33 34 35 36 37 38 39

DESCRIPTION 1 2 3 4 5

PART NO.

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

Plywood, Seat Bottom .

Webbing .

Trim, Vinyl Bag, Plastic Staple Staple, Flat (I /8 x I) Soiling Slab Bracket, Seat Hinge Screw, Set f-Tapping, 1/4-10 X I 1/4 Lg.

12441-G2 11394-G I 17113-GI

* * *

17074-GI 18250-GI 00l 15-G2

*

..J

w w

w w

M

q"

:c 3:

:c 3:

QTY.

I I I I I I I I 24 24 10 10 2 2 2 2 4 4

Not available as an individual part.

.

E�GCJii�:,it\•]:I HH3

8/15/87

HH4

8/15/87

45

\R

V,

°'\58�49 57

m

�

r � �

C� C)

i .

STEERING WHEEL DETAIL

44

(X) --­ l..n --­ (X)

14 - INCLUDES COMPLETE ASSEMBLY EXCEPT PARTS SHOWN IN STEERING WHEEL DETAIL AND ITEM 12 15 - INCLUDES ITEMS 16-20 43 - INCLUDES ITEM 44

�./7:(' 12 U!r @ 28

TITLE

STEERING

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I

==

==

C')

w w :::c

�

QTY.

Plate, Scorecard Holder Assembly (Includes Items 2-5) .

Clip, Scorecard •••

I I

I I

Spring, Stainless Steel Screw, Stainless Steel Plate, Scorecard Holder •.•••• Screw, Self-Tapping, 118 x 7/8 Lg• ••

2 2 I 2

2 2 I 2

9 10

23225-GI

Hub, Cover Extension

11 12 13 14

23172-GI 00545-G6

Steering Wheel •.

Nut, 5/8 x 18

19152-G I

Steering Unit Assembly (Includes Items I 5-58) ••••••

I

I

I I

I I

2 I

2 I

I

I

I I 4 4

I I 4 4

2

2

3

I I

DESCRIPTION 1 2 3 4 5

..J

w w :::c

18322-GI 18409-G I 18410-GI 18411-GI 18412-G I 18464-GI

2

I

PART NO.

..J

4 5 6 7 8

IS 16 17 18 19 20

17163-GI

* * * * *

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

Steering Shaft Assembly (Includes Items 16-20) Shaft, Steering Pin, Dowel, I /4 Coupling

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

Washer, Thrust

Pinion, Steering

21

22

/

23 24 25 26 27

19153-G2

*

00444-G8 00565-G3

Steering Column Assembly (Service) •••••••••• Grease Fitting Screw, 5/16-24 x I Lg. Washer, Lock, 5/16 Sleeve

28

17140-G I 17161-GI

29 30 31 32

51294-GI

Washer, Wave Type Spring

Bushing and Seal Assembly

--------------- E�GDii:r,iit•W ___________...__..___.

LL2

8/15/87

TITLE

STEERING

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

I

/

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61

PART NO.

DESCRIPTION 1 2 3 4 5

Gear, Reduction Washer, Thrust

19154-G I 17618-GI

Gasket, Housing Clamp, Nylon

13097-GI 13570-GI 15407-GI

Housing Assembly (Includes Item 44)•••••••••• Cover, Rack . . . . . . . . . . . . . . . . . . . .

Rack and Rod Assembly (Includes Items 48-57)••••

18456-GI 50641-GI

Grease Fitting 90° Rubber Boot, Tie Rod End

17617-GI

Bellows

11391-GI

Clamp, Hose

*

..J

(')

�

w w J: 3:

w w J: 3:

QTY.

23279-GI 13059-G2

50209-GI I 0387-G2 00 l 18-G2 00276-G6 00565-G8

..J

Nut, Slotted, 7/16-20 Cotter Pin, 3/16 x I Lg. •• Screw, Self-Tapping, 116-18 x 1/4 Lg. Screw, 5/16-24 x 3/4 Lg. ••••• Washer, Lock, 5/16 ••••••••••

I I I 3 3

I I I 3 3

Not available as an individual part.

-------------- E�GDii:nM•W --------------LL3

8/15/87

LL4

8/15/87

w

NOTE: 1988 SELF-ADJUSTING BRAKES

:r ·.

\t.

FRONT OF

v:c� LE

.

-�

1),1

THIS SHOE ALWAYS FACES FRONT

co :::0

m

�

Iii

REAR OF �3'\H:,: : E

..

·',.

THIS SHOE ALWAYS FACES REAR

�

28

r½o 29

INSTALL ADJUSTER SPRING WITH LONG END TOWARD REAR AND CLEAR OF OBSTRUCTIONS 38 �

�� - rn

r;;

SELF-ADJUSTING BRAKES <D RIVER'S SIDE SHOWN)

REAR OF VEHICLE

� ADJUSTER DETAIL

1 - INCLUDE� ITEMS 2- 8 , 14-30 9 - INCLUDES ITEMS 10 -30

-

V,

{X) --..J

TITLE

WHEEL BRAKE ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

DESCRIPTION 1 2 3 4 5

..I

..I

C')

,ct

w w :r: ==

QTY.

I

I

22997-G2

Brake Assembly, Driver's Side (Includes Items 2-8, 14-30)

I

./ ./

2 3 4

22518-GI 23360-GI 23357-GI

Backing Plate, Driver's Side ••••••••••••• ••••••••• Adjuster Assembly, Driver's Side Lever Assembly, Driver's Side (Includes Items 5-8) Spring . . . . . . . . . . . . . . . . . . . . . .

Retainer Washer, Shoulder

I I

5 6

./ ./

I

./

./ ./

I I

* * *

I

23536-GI 22997-GI 22519-GI

II

23361-GI

Spring, Torsion, Driver's Side ••••••••• Brake Assembly, Passenger Side (Includes Items I0-30).

Backing Plate, Passenger Side•••••••••••• Adjuster Assembly, Passenger Side •••••••••

12

23358-GI

Lever Assembly, Passenger Side (Includes Items

I I

5-7 and 13) . . . . . . . . . . . . . . . . . . . .

13

23537-GI

14 15

23363-GI

16

23382-GI 23362-GI

Spring, Torsion, Passenger Side

••••

Adjuster Body ••••••••••••••• Washer Washer,

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

Thrust . . . . . . . . . . . . . . . . . . . .

18

22519-GI

Dust Cover

19 20 21

23356-GI 00565-GI 13632-GI

Anchor Block ••••• Washer, Lock, I /4 Nut, 6mm

22 23

I 2 2

I 2 2

23359-GI :·

Spring, Brake, Adjuster

I

I

Spring, Brake, Anchor •••

I

25 26

17290-GI 17291-GI 17292-GI

Spring, Shoe, Clamp ••• Pin, Tension

2 2

I 2

27 28

23364-GI

Brake Shoe Set

24

I

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

7 8 9 10

17 ./

w w :r: ==

29 30

* *

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

2

Brake Shoe, Leading Brake Shoe, Trailing

31 32

--------------- E�GDiini;M:I -------------3

NN2

I 1/15/87

TITLE

WHEEL BRAKE ASSEMBLY

When ordering parts, please specify model and serial no. of vehicle.

..,w w

w w

3: C')

3:

�

ITEM NO.

PART NO.

DESCRIPTION 1 2 3 4 5

33

17083-G 1

Bolt, 5/16-24 x 3/4 Lg••

8

8

34

15126-G 1

Nut, Lock, 5/16-24 ••••••••••••••••••••

8

8

37

15485-G 1

Washer

2

2

38

19186-G I

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

Brake Drum Assembly (Includes Item 39) ••••••••

39

19862-G 1

QTY.

35 36

Lug Bott

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

40

2 4

2 4

41 42 43

44

45

XXXXX-XX

Washer (See Rear Axle Illustration for Part Number)••

2

XXXXX-XX

Nut, Slotted (See Rear Axle Illustration for Part Number)

2

2 2

XXXXX-XX

Cotter Pin (See Rear Axle Illustration for Part Number)

2

2

*

Not available as an individual part.

---------------- E.Z.GDii=>:1i,t•]:I --------------3

NN3

8/15/87

E�GDiini;l·l:t 3

NN4

8/15/87

� --Cl ---· ----� :::::::� CD

&

&&

Cl ·�

z

(J)

a: <C :::>

C, <C

a

an

a: a:

- C')

'r--

'

O')

\

I

)

I

----------EeGDii?:;i;{•]a----------_, Wt-EELS AND TIRES 001

8/15/87

TITLE

WHEELS AND TIRES

When ordering ports, please specify model and serial no. of vehicle.

ITEM NO.

PART NO.

DESCRIPTION 1 2 3 4 5

_, w w

_, w w

C')

�

::c 3:

::c 3:

QTY.

I 2 3 4 5 6 7 8 9 10 11

15170-GI 11594-GI 14697-G2 14697-GI

18 x 8.50 x 8 Tire and Wheel Assembly, (Standard) •• 18 x 8.50 x 8 Tire, (Standard) 18 x 8.50 x 8 Tire and Wheel Assembly, (Softrac) 18 x 8.50 x 8 Tire, (Softrac) ••••••••••

AR AR AR AR

AR AR AR AR

14728-G2 14728-GI 20258-GI 20259-GI 15169-GI

AR AR AR AR AR

AR AR AR AR AR

12

11657-GI

18 x 8.50 x 8 Tire and Wheel Assembly, (Power Rib)•• 18 x 8.50 x 8 Tire, (Power Rib) 18 x 8.50 x 8 Tire and Wheel Assembly, (Terra Guard) 18 x 8.50 x 8 Tire, (Terra Guard) Wheel Rim, I Piece 8.50/9.50 x 8, (Standard) (Standard with items I, 3, 7 and 9) Valve Stem, (Standard with items I, 3, 7 and 9)

...........

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

AR AR

.,__..._______.______ E�GDiiHi:t•W--------------002

8/15/87

E�GDii=t:ii;t·]:i 13

PPI

8/15/87

SERVICE ACCESSORIES AND SPECIAL TOOLS

---------EeGDii=t:;i;\•J:1--------13

PP2

8/15/87

13

PP3

8/15/87

PART II SPECIAL TOOLS Current Indicator •

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

16489-G2

Multi-Meter (Ohm Meter) Seal Installation Tool (Rear Axle Shaft Seal)

51020-G2 18739-G I

Slide Hammer Kit (Axle Puller)

18753-G I

PAINT Primer (Spray Can) •••••••••• Paint, Gloss Black (Spray Can) Paint, Glenwood Green (Spray Can)

50633-G I 50628-G I

Paint, Mist Blue (Spray Can) •• Paint, Pure White (Spray Can)

50630-G I 50632-Gl

Paint, Flat Black (Spray Can)

15430-G I

Paint, Paint, Paint, Paint, Paint, Paint, Paint,

50628-G3

Glenwood Green (Quarts) Glenwood Green (Gallons) Mist Blue (Quarts) Mist Blue (Gallons) Pure White (Quarts) Pure White (Gallons) Flat Black (Gallons)

....

51130-Gl

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

Paint, Gloss Black (Quarts) Paint, Gloss Black (Gallons) Paint, Special Color (Quarts) •• ••••••••••• •••• Paint, Special Color (Gallons) ••••••••••••••••••••••• Paint Flat Black (Quarts) •••••••••••••••••••••••••

5062 -G4 50630-G3 50630-G4 50632-G3 50632-G4 15632-G2 50633-G3 50633-G4 50634-G3 50634-G4 15632-G I

Quote Color chip number for all special colors.

--------------EaliDiii:;i;t•l:1--------------..., 13

SERVICE ACCESSORIES AND SPECIAL TOOLS PP4

8/15/87

13

SERVICE ACCESSORIES AND SPECIAL TOOLS PPS

8/15/87

E-Z-GO Division of Textron Inc. P.O. BOX 388 Augusta, Georgia 30913-2699 Copyright 1993 This manual may not be reproduced in whole or in part without the express written permission of E-Z-GO Division of Textron Inc. Technical Communications Department