Carryall 295 SE et XRT 1550 SE

Transcription

2009-2011
Carryall 295 and XRT 1550
with IntelliTach
Illustrated Parts List
XRT 1550 and Carryall 295 with IntelliTach
Diesel Vehicles
Manual Number 103472619
Edition Code 0508J0112H
USING THE ILLUSTRATED PARTS LIST
ý WARNING
• This manual is to be used only for identification and ordering of service parts. Be sure to read and use
the maintenance and service manual before attempting any vehicle repairs.
This manual covers all 2009-2011 model year XRT1550 and Carryall 295 vehicles equipped with the IntelliTach
accessory mounting system.
The manual is divided into 14 sections. Sections 1 through 13 pertain to service parts for the vehicles, and Section
14 pertains to tools that are used on all Club Car products.
Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table
of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that
section. The index can be used to find specific parts and assemblies. The index is divided into numerical and
alphabetical listings with the page numbers in italic text.
There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an
illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon.
The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding
to the numbers on the illustration), part descriptions, and quantity of parts used.
Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the
numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented
to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level
2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part
quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A
part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of
the vehicle illustrated on that particular spread.
HOW TO ORDER PARTS
Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You
can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our
web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and
Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887.
P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone 706-863-3000
Service Parts Fax 706-855-7413
www.clubcar.com
NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, LLC. is
continually working to further improve its vehicles and other products. These improvements may affect the
parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of
this illustrated parts list.
Club Car, LLC. reserves the right to change specifications and designs at any time without notice and without
the obligation of making changes to units previously sold.
Copyright © 2010 Club Car, LLC.
Club Car is a registered trademark of Club Car, LLC.
This manual effective October 1, 2010.
2009-2011 Carryall 295 IntelliTach Diesel Vehicles Illustrated Parts List
CONTENTS
SECTION 1 – HYDRAULIC ATTACHMENT SYSTEM AND ACCESSORIES
Handbook .........................................................................................................................................................................................
1-3
Attachment – Fork Pallet .............................................................................................................................................................
1-5
Attachment – Bucket ....................................................................................................................................................................
1-7
Attachment – Snow Blade ..........................................................................................................................................................
1-9
Attachment – Broom ....................................................................................................................................................................
1-11
Attachment – Mower ....................................................................................................................................................................
1-13
Accessory Mounting Weldment ...............................................................................................................................................
1-15
Attachment Arm Kit ......................................................................................................................................................................
1-17
Attachment Interface ....................................................................................................................................................................
1-19
Hydraulic Controls .........................................................................................................................................................................
1-21
Accessory Hydraulic System – Standard ................................................................................................................................
1-23
Accessory Hydraulics – Auxiliary ..............................................................................................................................................
1-25
Hydraulic Attachment Angle Kit ...............................................................................................................................................
1-27
Hydraulic Power Unit Components .........................................................................................................................................
1-29
Hydraulic Power Unit with Auxillary Components ............................................................................................................
1-31
Standard to Auxilliary Hydraulic Conversion Kit .................................................................................................................
1-33
SECTION 2 – BODY AND TRIM
Fascia and Fenders – Carryall Vehicles ...................................................................................................................................
2-3
Cowl Assemblies – Carryall Vehicles .......................................................................................................................................
2-5
Cowl Assemblies – XRT Vehicles ...............................................................................................................................................
2-7
Cowl Assemblies – XRT Vehicles ...............................................................................................................................................
2-9
Front Body Components .............................................................................................................................................................
2-11
Dash ....................................................................................................................................................................................................
2-13
Glove Box ..........................................................................................................................................................................................
2-15
Side Stringers ...................................................................................................................................................................................
2-17
Floor Mat ...........................................................................................................................................................................................
2-19
Floorboard ........................................................................................................................................................................................
2-21
Bucket Seats – Gray .......................................................................................................................................................................
2-23
Bucket Seats – Black ......................................................................................................................................................................
2-25
Lower ROPS ......................................................................................................................................................................................
2-27
Seat Belts and ROPS ......................................................................................................................................................................
2-29
ROPS – Head Rests .........................................................................................................................................................................
2-31
Latch Plate and Prop Rod ............................................................................................................................................................
2-33
Tilt Bed, Hinge, and Latch ...........................................................................................................................................................
2-35
Electric Bed Lift ................................................................................................................................................................................
2-37
Box Bed ..............................................................................................................................................................................................
2-39
Side Panels and Rear Fenders ....................................................................................................................................................
2-41
Page 1
CONTENTS
Cargo Box (Steel) .............................................................................................................................................................................
2-43
SECTION 3 – WHEELS AND TIRES
Wheels and Tires .............................................................................................................................................................................
3-3
SECTION 4 – DECALS
Safety Decals .....................................................................................................................................................................................
4-3
Safety Decals, Continued .............................................................................................................................................................
4-5
Badging Decals – Carryall Vehicles ...........................................................................................................................................
4-7
Badging Decals – XRT Vehicles ..................................................................................................................................................
4-9
Badging Decals – Intellitach ........................................................................................................................................................
4-11
SECTION 5 – BRAKE SYSTEMS
Front Brake Assembly ....................................................................................................................................................................
5-3
Rear Brake Assembly ......................................................................................................................................................................
5-5
Master Cylinder with Remote Reservoir .................................................................................................................................
5-7
Master Cylinder with Integral Reservoir .................................................................................................................................
5-9
Hydraulic Brake Lines and Clips .................................................................................................................................................
5-11
Brake Pedal Assembly ...................................................................................................................................................................
5-13
Park Brake System ...........................................................................................................................................................................
5-15
Park Brake Pedal Assembly ..........................................................................................................................................................
5-17
SECTION 6 – STEERING AND SUSPENSION
Steering Column .............................................................................................................................................................................
6-3
Steering Gear Assembly ...............................................................................................................................................................
6-5
Front Suspension – A-Arms .........................................................................................................................................................
6-7
Cv Boot Repair Kits .........................................................................................................................................................................
6-9
Shock Absorbers .............................................................................................................................................................................
6-11
Rear Suspension – Standard .......................................................................................................................................................
6-13
SECTION 7 – ELECTRICAL SYSTEM
Wiring – Diesel Vehicle, Single Piece .......................................................................................................................................
7-5
Wiring – Control Panel ..................................................................................................................................................................
7-9
Wiring – Seat Belt Reminder .......................................................................................................................................................
7-11
Electrical Component Box, Diesel Vehicles ...........................................................................................................................
7-13
Electrical Components ..................................................................................................................................................................
7-15
Battery – Diesel Vehicles ..............................................................................................................................................................
7-17
Page 2
CONTENTS
SECTION 8 – DIESEL ENGINE – CLOSED BREATHER
Kubota D722 Diesel Engine Mounting ...................................................................................................................................
8-3
Crankcase ..........................................................................................................................................................................................
8-5
Oil Pan ................................................................................................................................................................................................
8-7
Cylinder Head ..................................................................................................................................................................................
8-9
Gear Case ...........................................................................................................................................................................................
8-11
Head Cover .......................................................................................................................................................................................
8-13
Dipstick and Guide ........................................................................................................................................................................
8-15
Oil Pump ............................................................................................................................................................................................
8-17
Main Bearing Case .........................................................................................................................................................................
8-19
Camshaft and Idle Gear ................................................................................................................................................................
8-21
Piston and Crankshaft ...................................................................................................................................................................
8-23
Flywheel ............................................................................................................................................................................................
8-25
Shaft ....................................................................................................................................................................................................
8-27
Idle Apparatus .................................................................................................................................................................................
8-29
Stop Solenoid ..................................................................................................................................................................................
8-31
60-Amp Alternator .........................................................................................................................................................................
8-33
Injection Pump ................................................................................................................................................................................
8-35
Speed Control Plate .......................................................................................................................................................................
8-37
Nozzle Holders and Glow Plugs ................................................................................................................................................
8-39
Governor Components ................................................................................................................................................................
8-41
Starter .................................................................................................................................................................................................
8-43
Valves and Rocker Arms ...............................................................................................................................................................
8-45
Diesel Inlet Manifold .....................................................................................................................................................................
8-47
Exhaust Manifold ............................................................................................................................................................................
8-49
Gasket Kits .........................................................................................................................................................................................
8-51
Piston Kit ............................................................................................................................................................................................
8-53
SECTION 9 – FUEL, INTAKE, & GOVERNOR SYSTEM
Fuel System – Diesel ......................................................................................................................................................................
9-3
Fuel Tank – Diesel Vehicles .........................................................................................................................................................
9-5
Cables – Diesel Vehicle .................................................................................................................................................................
9-7
Accelerator Pedal Assembly – Style B .....................................................................................................................................
9-9
Intake Duct and Air Box Assembly – Diesel Vehicles .........................................................................................................
9-11
SECTION 10 – EXHAUST SYSTEM
Exhaust System ...............................................................................................................................................................................
10-3
Exhaust Pipes – Diesel Vehicles .................................................................................................................................................
10-5
Page 3
CONTENTS
SECTION 11 – CLUTCHES
Clutch Cover (Standard) ...............................................................................................................................................................
11-3
Clutch Cover (Sealed) ....................................................................................................................................................................
11-5
Drive Belt ............................................................................................................................................................................................
11-7
Drive Clutch – Diesel Vehicles ....................................................................................................................................................
11-9
Driven Clutch ....................................................................................................................................................................................
11-11
SECTION 12 – DRIVETRAIN COMPONENTS
Forward/Reverse Shifter Assembly ..........................................................................................................................................
12-3
Front Differential Mounting Plate .............................................................................................................................................
12-5
Front Differential (Output Components) ...............................................................................................................................
12-7
Front Differential (Input Components) ...................................................................................................................................
12-9
Prop Shafts ........................................................................................................................................................................................
12-11
Rear Differential ...............................................................................................................................................................................
12-13
Rear Differential, Continued .......................................................................................................................................................
12-15
Transmission – Diesel Vehicles ...................................................................................................................................................
12-17
Transmission – Diesel Vehicles, Continued ...........................................................................................................................
12-19
Transmission – Diesel Vehicles, Shift Shaft and Bell Crank ..............................................................................................
12-21
SECTION 13 – RADIATOR AND COOLANT SYSTEM – DIESEL VEHICLES
Radiator ..............................................................................................................................................................................................
13-3
Coolant Expansion Tank ...............................................................................................................................................................
13-5
Coolant Pipes and Hoses ..............................................................................................................................................................
13-7
Cooling System Clamps, Hoses, and Hardware ...................................................................................................................
13-9
Water Flange and Thermostat ....................................................................................................................................................
13-11
Water Pump ......................................................................................................................................................................................
13-13
Block Coolant Pipe ..........................................................................................................................................................................
13-15
SECTION 14 – MAINTENANCE AND SERVICE TOOLS
Maintenance and Service Tools .................................................................................................................................................
14-3
Maintenance and Service Tools, Continued .........................................................................................................................
14-5
14-7
14-9
14-11
SECTION i – INDEX
Page 4
HYDRAULIC ATTACHMENT SYSTEM
AND ACCESSORIES
1
G
E
D
1
G
E
D
2
3
000558-001
Page 1-2
HANDBOOK
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
N/A
103237501
103237701
Instl, Handbook, Club Car (includes items 2 and 3) .......................................................................
Handbook, Operator, Club Car ........................................................................................................
Weldment, Clip, Handbook ...............................................................................................................
1
1
1
1
G
E
D
Page 1-3
1
G
E
D
4
3
2
4
2
000555-001
Page 1-4
ATTACHMENT – FORK PALLET
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
102930001
102927201
102927301
102927401
Attachment, Fork, Pallet (includes items 2 through 4) .................................................................
Fork Pallet ................................................................................................................................................
Bar, Fork Mount .....................................................................................................................................
Pin, Hair ....................................................................................................................................................
1
2
1
2
Page 1-5
1
G
E
D
1
G
E
D
1
000555-002
Page 1-6
ATTACHMENT – BUCKET
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102930101
Attachment, Bucket ..................................................................................................................................
1
1
G
E
D
Page 1-7
1
G
13
E
3
13
D
14
3
3
9
3
3
2
14
2
14
5
2
6
10
7
7
11
12
8
8
12
4
Page 1-8
000555-003
ATTACHMENT – SNOW BLADE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
102930201
102926601
102927401
102929601
102929801
103243001
103243101
103243201
103243501
103243601
103243701
103243801
103243901
103244001
Attachment, Blade, Snow (includes items 2 through 14) ............................................................
Bearing, Fiber, -12 .................................................................................................................................
Pin, Hair ....................................................................................................................................................
Wldmnt, Mount, Angle .......................................................................................................................
Asm, Adjust, Manual ............................................................................................................................
Bolt, Carriage ..........................................................................................................................................
Bolt, Carriage ..........................................................................................................................................
Nut, Pretrq, Hex Lock ...........................................................................................................................
Wldmnt, Head, Angle ..........................................................................................................................
Wldmnt, Blade, Snow ..........................................................................................................................
Edge, Cutting .........................................................................................................................................
Shoe, Skid ................................................................................................................................................
Pin, 5 In .....................................................................................................................................................
Pin, 3.9 In .................................................................................................................................................
1
6
5
1
1
9
4
13
1
1
1
2
2
3
Page 1-9
1
G
E
D
1
G
9
E
3
9
D
10
3
3
8
3
3
2
10
2
10
7
2
5
6
4
000555-004
Page 1-10
ATTACHMENT – BROOM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102930301
102926601
102927401
102929501
102929601
102929701
102929801
103243501
103243901
103244001
Attachment, Broom, Push (includes items 2 through 10) ...........................................................
Bearing, Fiber, -12 .................................................................................................................................
Pin, Hair ....................................................................................................................................................
Broom, Whisker, 60 In .........................................................................................................................
Wldmnt, Mount, Angle .......................................................................................................................
Wldmnt, Mount, Whisker ...................................................................................................................
Asm, Adjust, Manual ............................................................................................................................
Wldmnt, Head, Angle ..........................................................................................................................
Pin, 5 In .....................................................................................................................................................
Pin, 3.9 In .................................................................................................................................................
1
6
5
1
1
1
1
1
2
3
Page 1-11
1
G
E
D
1
G
E
D
000555-005
Page 1-12
ATTACHMENT – MOWER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102930401
Attachment, Mower ..................................................................................................................................
1
1
G
E
D
Page 1-13
1
G
E
D
5
4
3
8
2
7
8
6
5
4
000552-001
Page 1-14
ACCESSORY MOUNTING WELDMENT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
N/A
102491501
102670701
102786101
102921601
102925201
103355401
96727003
Instl, Weldment, Mount (includes items 2 through 8) ..................................................................
Washer Hard,m10 .................................................................................................................................
Nut Flg M10 X 1.5 Nylon ....................................................................................................................
Ring, Rue, 3/4, Heavy ...........................................................................................................................
Pin, Clevis, 3/4 X 4 .................................................................................................................................
Bolt, Flg, M10x1.5x55, Patch .............................................................................................................
Weldment, Front Mount ....................................................................................................................
Bolt Flg, M10 X 1.5 X 30 ......................................................................................................................
1
4
4
2
2
4
1
4
Page 1-15
1
G
E
D
1
G
E
D
2
3
4
2
3
1
000786-001
Page 1-16
ATTACHMENT ARM KIT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
102923201
102786101
102921601
102923401
Kit, Arm, Attachment (includes items 2 through 4) .......................................................................
Ring, Rue, 3/4, Heavy ...........................................................................................................................
Pin, Clevis, 3/4 X 4 .................................................................................................................................
Asm, Arm, Attachment .......................................................................................................................
1
2
2
1
Page 1-17
1
G
E
D
1
G
E
8
16
D
14
15
11
6
4
10
1
2
15
13
9
12
7
5
000787-001
Page 1-18
ATTACHMENT INTERFACE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
102923301
102786101
102789001
102617001
102789101
102789201
102789301
N/A
102790001
102790801
102790901
102791001
102791301
N/A
102921601
N/A
Kit, Interface, Attachment (includes items 2 through 16) ...........................................................
Ring, Rue, 3/4, Heavy ...........................................................................................................................
Asm, Interface, Attachment (includes items 4 through 14) ..................................................
Nut Flg, M8 X 1.25 Mech Def ......................................................................................................
Pin, Latch ...........................................................................................................................................
Lever, Release ..................................................................................................................................
Link, Chain 2080 .............................................................................................................................
Interface, W/a ..................................................................................................................................
Brace, Cross ......................................................................................................................................
Bolt Flg, M8 X 1.25 X 20 ................................................................................................................
Nut, Flg, 3/8-16 Gr8 .......................................................................................................................
Screw, Shoulder Hex Skt ..............................................................................................................
Spring, Ext, Interface .....................................................................................................................
Decal, Attachment Locking ........................................................................................................
Pin, Clevis, 3/4 X 4 .................................................................................................................................
Instruction, Kit, Attachment .............................................................................................................
1
2
1
2
2
1
2
1
1
2
1
1
1
1
2
1
Page 1-19
1
G
E
D
1
19
17
G
16
20
25
E
11
5
D
15
4
14
18
7
32
13
12
9
22
8
6
24
30
21
30
3
29
30
30
27
31
28
26
23
Page 1-20
000553-001
HYDRAULIC CONTROLS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
N/A
1011931
1014063
1015720
1016103
101932201
102442001
102854601
102854801
N/A
1012438
1017
102420201
102849801
102850501
102854401
102854501
102854901
102918501
1631
102936801
102937401
102937501
102937601
102967901
103215201
7173
7174
8717
8990
102928301
N/A
Instl, Controls, Hydraulic (includes items 2 through 30) ..............................................................
Washer, 1/4 Flat .....................................................................................................................................
Screw, 1/4-20 X 1.00 Hex Head ........................................................................................................
Screw, #6-32 X 1/2 Hex Washer-Head ...........................................................................................
Screw, Pan Hd Tx, Taptite 6-32 .........................................................................................................
Locknut, #6-32 Nylon ..........................................................................................................................
Pan, Center, Closeout ..........................................................................................................................
Base, Control Box, Joystick ................................................................................................................
Console, Center, Insulator .................................................................................................................
Asm, Controls (includes items 11 through 20) ...........................................................................
Locknut, #10-24 Nylon Insert .....................................................................................................
Nut, #10-24 Stainless-Steel Hex Machine ..............................................................................
Relay, Mini ISO, SPDT ....................................................................................................................
Decal, Controls, Bt ..........................................................................................................................
Screw, Phillips Pn Hd .....................................................................................................................
Switch, Rocker, Svr, DPDT Momentary ...................................................................................
Switch, Rocker, Svr, SPDT, lght ...................................................................................................
Cover, Control Box, Joystick ........................................................................................................
Joystick, 4 Way, W/ Boot ..............................................................................................................
Screw, #10-24 X 0.75 Phillips Pan-Head .................................................................................
Breaker, Circuit, 150-Amp ..................................................................................................................
Wire Asm, #6, Red, Bt ...........................................................................................................................
Wire Asm, #6, Red, Bt ...........................................................................................................................
Wire Asm, #6, Black, Bt ........................................................................................................................
Rivet, Removable, Tuflok 1/4" ..........................................................................................................
Switch, Rocker, Svr, On-off .................................................................................................................
Screw, 5/16-18 X 0.75 Hex-Head Cap ............................................................................................
Lockwasher, 5/16 Split ........................................................................................................................
Locknut, 1/4-28 Nylon Insert ............................................................................................................
Tie Wrap, 8" Nylon ................................................................................................................................
Switch, Sol Act Mtr St, 12vdc .................................................................................................................
Cover, Joystick .............................................................................................................................................
1
2
2
4
4
4
1
1
1
1
4
2
2
1
2
1
1
1
1
4
1
1
1
1
4
1
1
1
2
8
1
1
Page 1-21
1
G
E
D
1
27
G
6
E
26
D
9
8
24
11
20
22
13
16
14
15
10
17
19
5
21
28
3
25
23
4
18
7
5
2
Page 1-22
000554-001
ACCESSORY HYDRAULIC SYSTEM – STANDARD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
N/A
102491001
102617201
102618301
102618601
102784201
102785501
102786101
102787101
102787201
102787501
102787601
102784601
102784701
102784801
102784901
N/A
N/A
102787101
N/A
102787701
102787701
102859101
102921601
102921701
102923001
102923101
96741046
AM1245401
Instl, Hydraulic Sys, Std (includes items 2 through 29) ................................................................
Bolt Flanged Head, 3/8-16x1.0 with Loctite ................................................................................
Nut Flg M10 X 1.5 Mech Def .............................................................................................................
Bolt Flanged Head, M8 X 1.25 X 65 ................................................................................................
Lock Nut, Flg M8 X 1.25 Nylon .........................................................................................................
Tube, Hydraulic -6 JIC 180 End ........................................................................................................
Barrier, Heat, Powerunit .....................................................................................................................
Ring, Rue, 3/4, Heavy ...........................................................................................................................
Mount, Fir Tree, Cable Tie ..................................................................................................................
Mount, Saddle, Fir Tree .......................................................................................................................
Tie, Button Head ...................................................................................................................................
Asm, Hoses, Hydraulic (includes items 13 through 21) ..........................................................
Hose, -6jic Stf -6jic Stm Td ...........................................................................................................
Hose, -6jic Stf -6jic Stf Tr ...............................................................................................................
Hose, -6jic Stf -6jic Stf Ld .............................................................................................................
Hose, -6jic Stf -6jic Stf Lr ...............................................................................................................
Mount, Cable Tie, 8mm Std Trq .................................................................................................
Mount, Hd, Cable Tie, 8mm Bolt ...............................................................................................
Mount, Fir Tree, Cable Tie ............................................................................................................
Mount, Standoff, Dual Tie ...........................................................................................................
Tie, Wide Strap ................................................................................................................................
Tie, Wide Strap .......................................................................................................................................
Bolt, M10 X 1.50 X 70 ...........................................................................................................................
Pin, Clevis, 3/4 X 4 .................................................................................................................................
Weldment, Hydraulic Powerunit .....................................................................................................
Cylinder, Hydraulic, Lift .......................................................................................................................
Cylinder, Hydraulic, Tilt .......................................................................................................................
Washer, M10 Hard ................................................................................................................................
5 Gal, Mobil Dte15m Hyd Fluid .......................................................................................................
1
2
2
1
2
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
2
1
Page 1-23
1
G
E
D
1
G
E
37
34
36
7
32
26
27
D
33
10
35
9
29
31
12
6
23
16
25
14
19
15
18
17
11
19
22
5
24
38
3
30
28
4
21
8
5
2
Page 1-24
000554-002
ACCESSORY HYDRAULICS – AUXILIARY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
38
N/A
102491001
102617201
102618301
102618601
102741601
102784201
102785501
102786101
102787101
102787201
102787501
102787602
102784601
102784701
102784801
102784901
102785001
102785101
N/A
N/A
102787101
N/A
102787701
102787701
102794801
102794901
102859101
102921601
102921701
102922601
102922701
102923001
102923101
102923801
102973501
102973601
96741046
Instl, Hydraulic Sys, Aux (includes items 2 through 38) ...............................................................
Nut Flg M8 X 1.25 Gr 10 ......................................................................................................................
Tube, Hydraulic -6 JIC 180 End ........................................................................................................
Barrier, Heat, Powerunit .....................................................................................................................
Ring, Rue, 3/4, Heavy ...........................................................................................................................
Mount, Fir Tree, Cable Tie ..................................................................................................................
Mount, Saddle, Fir Tree .......................................................................................................................
Tie, Button Head ...................................................................................................................................
Asm, Hoses, Hydraulic W/aux (includes items 14 through 24) ............................................
Hose, -6jic Stf -6jic Stm Td ...........................................................................................................
Hose, -6jic Stf -6jic Stf Tr ...............................................................................................................
Hose, -6jic Stf -6jic Stf Ld .............................................................................................................
Hose, -6jic Stf -6jic Stf Lr ...............................................................................................................
Hose, -6jic Stf -6jic Stf A ...............................................................................................................
Hose, -6jic Stf -8jic Stf B ................................................................................................................
Mount, Cable Tie, 8mm Std Trq .................................................................................................
Mount, Hd, Cable Tie, 8mm Bolt ...............................................................................................
Mount, Fir Tree, Cable Tie ............................................................................................................
Mount, Standoff, Dual Tie ...........................................................................................................
Tie, Wide Strap ................................................................................................................................
Tie, Wide Strap .......................................................................................................................................
Coupling, Female Quick -6jic ............................................................................................................
Coupling, Male Quick -6jic ................................................................................................................
Bolt, M10 X 1.50 X 70 ...........................................................................................................................
Pin, Clevis, 3/4 X 4 .................................................................................................................................
Weldment, Hydraulic Powerunit .....................................................................................................
Bracket, Hydraulic, Auxiliary .............................................................................................................
Fhcs, M8x1.25x20 Lock Patch ...........................................................................................................
Cylinder, Hydraulic, Lift .......................................................................................................................
Cylinder, Hydraulic, Tilt .......................................................................................................................
Nut, Lock, Hyd Tube, 3/4-16 .............................................................................................................
Cap, Quick Connect, Female .............................................................................................................
Cap, Quick Connect, Male .................................................................................................................
Washer, M10 Hard ................................................................................................................................
1
2
2
1
2
2
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
1
2
1
1
1
1
1
2
Page 1-25
1
G
E
D
1
G
E
D
7
2
6
2
3
4
3
3
000556-001
Page 1-26
HYDRAULIC ATTACHMENT ANGLE KIT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102930501
102926301
102926401
102926501
102926601
102926701
102926801
Kit, Angle, Hyd, Attachment (includes items 2 through 7) .........................................................
Fitting, Elbow, 90, Hyd ........................................................................................................................
Asm, Hose, Ang, Hyd ...........................................................................................................................
Cylinder, Attach, Ang, Hyd ................................................................................................................
Bearing, Fiber, -12 .................................................................................................................................
Coupler, Ff, Male, 1/2 ...........................................................................................................................
Coupler, Ff, Fem, 1/2 ............................................................................................................................
1
2
2
1
4
1
1
Page 1-27
1
G
E
D
1
4
5
7
2
G
E
3
D
6
9
10
8
000788-001
Page 1-28
HYDRAULIC POWER UNIT COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102784001
102928001
102928101
102928201
102928301
102928401
102928501
102928601
102928901
1308
Power Unit, DC Hydraulic Std (includes items 2 through 8) .......................................................
Clamp, Hose, Worm, Rsv, M-ser .......................................................................................................
Plug, Resv, Breather-filler ...................................................................................................................
Motor, Dc, 12v, 4.5 In, I Trm ...............................................................................................................
Switch, Sol Act Mtr St, 12vdc ............................................................................................................
Strap, Motor-solenoid Conn .............................................................................................................
Asm, Ctrlwire, 16awg, Hs, Ring ........................................................................................................
Asm, Valve, 4w/4w, Cartridge (includes items 9 and 10) ........................................................
Coil, 10vdc, #8, 2lead, Diode ......................................................................................................
Nut, 1/2-20 Hex ...............................................................................................................................
1
1
1
1
1
1
1
1
6
6
Page 1-29
1
G
E
D
1
4
5
7
2
G
E
3
D
6
9
10
10
8
000788-002
Page 1-30
HYDRAULIC POWER UNIT WITH AUXILLARY COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
N/A
102928001
102928101
102928201
102928301
102928401
102928501
102928601
102928901
1308
102928701
Power Unit, DC Hydraulic with Auxillary (includes items 2 through 11) ...............................
Clamp, Hose, Worm, Rsv, M-ser .......................................................................................................
Plug, Resv, Breather-filler ...................................................................................................................
Motor, Dc, 12v, 4.5 In, I Trm ...............................................................................................................
Switch, Sol Act Mtr St, 12vdc ............................................................................................................
Strap, Motor-solenoid Conn .............................................................................................................
Asm, Ctrlwire, 16awg, Hs, Ring ........................................................................................................
Asm, Valve, 4w/4w, Cartridge (includes items 9 and 10) ........................................................
Coil, 10vdc, #8, 2lead, Diode ......................................................................................................
Nut, 1/2-20 Hex ...............................................................................................................................
Asm, Valve, 4w Section .......................................................................................................................
1
1
1
1
1
1
1
1
6
6
1
Page 1-31
1
G
E
D
1
G
E
D
11
10
9
3
8
7
13
14
2
12
2
2
5
2
4
15
6
000557-001
Page 1-32
STANDARD TO AUXILLIARY HYDRAULIC CONVERSION KIT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
102785401
102025401
102741601
102784003
102785001
102785101
102794801
102794901
102922601
102922701
N/A
102923801
102973501
102973601
103409001
Kit, Hydraulic, Aux (includes items 2 through 15) ..........................................................................
Tie Wrap, Heavy Duty ..........................................................................................................................
Nut Flg M8 X 1.25 Gr 10 ......................................................................................................................
Power Unit, DC Hydraulic, Auxillary ...............................................................................................
Hose, -6jic Stf -6jic Stf A ......................................................................................................................
Hose, -6jic Stf -8jic Stf B ......................................................................................................................
Coupling, Female Quick -6jic ............................................................................................................
Coupling, Male Quick -6jic ................................................................................................................
Bracket, Hydraulic, Auxiliary .............................................................................................................
Fhcs, M8x1.25x20 Lock Patch ...........................................................................................................
Instruction, Hyd, Aux ...........................................................................................................................
Nut, Lock, Hyd Tube, 3/4-16 .............................................................................................................
Cap, Quick Connect, Female .............................................................................................................
Cap, Quick Connect, Male .................................................................................................................
Screw,1/4-20 X 3.5 Hex, Cap .............................................................................................................
1
8
2
1
1
1
1
1
1
2
1
2
1
1
3
Page 1-33
1
G
E
D
1
G
E
D
BODY AND TRIM
2
G
E
D
2
G
E
D
17
11
9
3
3
6
17
9
11
3
3
4
15
5
16
2
5
2
3
8
18
16
12
7
10
14
2
3
5
13
000559-001
Page 2-2
FASCIA AND FENDERS – CARRYALL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
N/A
1011578
102289001
102292356
102297230
102866901
102867001
102867602
102882401
102885001
102895101
102895401
102978801
102978901
103213201
103213501
103218107
808
Instl, Fascia & Fenders, Ca It (includes items 2 through 18) ........................................................
Washer, 5/16 Type B Flat ....................................................................................................................
Screw, M8X1.25X30, Hex ....................................................................................................................
Screw-1/4-20x56 Hwh Self Drill .......................................................................................................
Screw,m6,torx,interlock,thread .......................................................................................................
Fender, Front, Pass, AWD ...................................................................................................................
Fender, Front, Drv, AWD .....................................................................................................................
Fascia, Dueal Round w/ Cut ..............................................................................................................
Bracket, Latch, Draw ............................................................................................................................
Headlight, Round, 4" ...........................................................................................................................
Latch, Draw, Hood ................................................................................................................................
Screw, D50x16, Torx PN Hd PT .........................................................................................................
Grill, Hex Cut, DS ...................................................................................................................................
Grill, Hex, Cut, PS ...................................................................................................................................
Harness, Bct/huv Restyle Headlight ..............................................................................................
Harness, Headlight, Bct ......................................................................................................................
Screw, #8x2.00 AB Thd, Hex Hd .......................................................................................................
Washer, 3/8 Type B Flat .......................................................................................................................
1
4
13
2
4
1
1
1
2
4
2
6
1
1
1
4
4
2
Page 2-3
2
G
E
D
2
G
E
D
11 22 33 44
17 28 39
6
5
16 27 38
7
18 29 40
2
9
20 31 42
4
15 26 37
8
3
13 24 35
19 30 41
14 25 36
10 21 32 43
000508-001
Page 2-4
COWL ASSEMBLIES – CARRYALL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
38
39
40
41
42
43
44
N/A
102292701
102292801
102297230
102866510
102866610
102866710
102866810
102896401
102896501
102967901
N/A
102292701
102292801
102297230
102866514
102866614
102866714
102866814
102896401
102896501
102967901
N/A
102292701
102292801
102297230
102866518
102866618
102866718
102866818
102896401
102896501
102967901
N/A
102292701
102292801
102297230
102866518
102866618
102866718
102866818
102896401
102896501
102967901
Option, Color, CA, Dark Grn (includes items 2 through 11) ........................................................
Clip-body-trim .......................................................................................................................................
Pin, Bow Tie Locking - .072 ................................................................................................................
Hood, Dark Green .................................................................................................................................
Panel, Cowl, Center, Dark Green ......................................................................................................
Panel, Cowl, Passenger-Side, Dark Green ....................................................................................
Panel, Cowl, Driver-Side, Dark Green .............................................................................................
Weldment, Hinge, Hood ....................................................................................................................
Prop, Hood ..............................................................................................................................................
Option, Color, CA, Dark Gray (includes items 13 through 22) ....................................................
Clip-body-trim .......................................................................................................................................
Hood, Dark Gray ....................................................................................................................................
Panel, Cowl, Center, Dark Gray .........................................................................................................
Panel, Cowl, Passenger-Side, Dark Gray .......................................................................................
Panel, Cowl, Driver-Side, Gray ..........................................................................................................
Prop, Hood ..............................................................................................................................................
Option, Color, CA, Real Tree Camo (includes items 24 through 33) ........................................
Clip-body-trim .......................................................................................................................................
Hood, Real Tree Camo ........................................................................................................................
Panel, Cowl, Center, Real Tree Camo .............................................................................................
Panel, Cowl, Passenger-Side, Real Tree Camo ............................................................................
Panel, Cowl, Driver-Side, Real Tree Camo ....................................................................................
Prop, Hood ..............................................................................................................................................
Option, Color, CA, Dlx Real Tree Camo (includes items 35 through 44) .................................
Clip-body-trim .......................................................................................................................................
Prop, Hood ..............................................................................................................................................
1
4
2
4
1
1
1
1
1
1
4
1
4
2
4
1
1
1
3
2
1
4
1
4
2
4
1
1
1
1
1
1
4
1
4
2
4
1
1
1
1
1
1
4
Page 2-5
2
G
E
D
2
G
E
D
10
5
4
6
1
8
7
3
2
9
000508-004
Page 2-6
COWL ASSEMBLIES – XRT VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102292701
102292801
102297230
102866518
102866618
102866719
102866819
102896401
102896501
102967901
Clip-body-trim ............................................................................................................................................
Pin, Bow Tie Locking - .072 .....................................................................................................................
Screw,m6,torx,interlock,thread .............................................................................................................
Hood, Real Tree Camo ..............................................................................................................................
Panel, Cowl, Center, Real Tree Camo ...................................................................................................
Panel, Cowl, Ps, Moff .................................................................................................................................
Panel, Cowl, Drv, Moff ...............................................................................................................................
Weldment, Hinge, Hood ..........................................................................................................................
Prop, Hood ...................................................................................................................................................
Rivet, Removable, Tuflok 1/4" ................................................................................................................
4
2
4
1
1
1
1
1
1
4
Page 2-7
2
G
E
D
2
G
E
D
11 22 33 44
17 28 39
6
5
16 27 38
7
18 29 40
2
9
20 31 42
4
15 26 37
8
3
13 24 35
19 30 41
14 25 36
10 21 32 43
000508-001
Page 2-8
COWL ASSEMBLIES – XRT VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
38
39
40
41
42
43
44
N/A
102292701
102292801
102297230
102866510
102866610
102866710
102866810
102896401
102896501
102967901
N/A
102292701
102292801
102297230
102866515
102866615
102866715
102866815
102896401
102896501
102967901
N/A
102292701
102292801
102297230
102866518
102866618
102866718
102866818
102896401
102896501
102967901
N/A
102292701
102292801
102297230
102866518
102866618
102866718
102866818
102896401
102896501
102967901
Option, Color, XRT, Dark Green (includes items 2 through 11) .................................................
Clip-body-trim .......................................................................................................................................
Hood, Dark Green .................................................................................................................................
Panel, Cowl, Center, Dark Green ......................................................................................................
Panel, Cowl, Passenger-Side, Dark Green ....................................................................................
Panel, Cowl, Driver-Side, Dark Green .............................................................................................
Prop, Hood ..............................................................................................................................................
Option, Color, XRT, Red (includes items 13 through 22) ..............................................................
Clip-body-trim .......................................................................................................................................
Hood, Red ................................................................................................................................................
Panel, Cowl, Center, Red .....................................................................................................................
Panel, Cowl, Passenger-Side, Red ...................................................................................................
Panel, Cowl, Driver-Side, Red ...........................................................................................................
Prop, Hood ..............................................................................................................................................
Option, Color, XRT, Real Tree Camo (includes items 24 through 33) .......................................
Clip-body-trim .......................................................................................................................................
Prop, Hood ..............................................................................................................................................
Option, Color, XRT, Dlx Real Tree Camo (includes items 35 through 44) ...............................
Clip-body-trim .......................................................................................................................................
Prop, Hood ..............................................................................................................................................
1
4
2
4
1
1
1
1
1
1
4
1
4
2
4
1
1
1
1
2
1
4
1
4
2
4
1
1
1
1
1
1
4
1
4
2
4
1
1
1
1
1
1
4
Page 2-9
2
G
E
D
2
G
E
D
12
16
16
13
10
8
3
11
9
16
8
14
10
8
16
16
9
6
7
8
4
9
15
5
2
2
000521-001
Page 2-10
FRONT BODY COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
N/A
1016967
102298401
102298720
102323501
102491301
102491302
102491501
102617201
102618301
102935501
102977201
102983201
102983601
103296001
96715552
Instl, Cowl Weldmnt/Splash Guard (includes items 2 through 16) ..........................................
Blind Rivet, Push Type .........................................................................................................................
Nut,m8,all Metal Lock .........................................................................................................................
M8-1.25x20 Taptite ..............................................................................................................................
Washer, Flat, 3/8, Blk Fin .....................................................................................................................
Bolt, M10x1.50x100 (Black) ...............................................................................................................
Bolt, M10 X 1.50 X 110 Black .............................................................................................................
Washer Hard,m10 .................................................................................................................................
Weldment, Dash, Front .......................................................................................................................
Bracket, Column, Steering .................................................................................................................
Weldment, Front, Base, ROPS, Right-Hand ..................................................................................
Weldment, Front, Base, ROPS, Left-Hand .....................................................................................
Guard, Splash, Gas Injection .............................................................................................................
Bolt, M10 X 1.50 X 65 ...........................................................................................................................
1
4
2
2
2
3
1
12
10
2
1
1
1
1
1
8
Page 2-11
2
G
E
D
2
G
E
D
4
13
5
7
2
7
8
6
11
16
14
12
15
19
3
6
18
9
10
7
17
10
9
000519-001
Page 2-12
DASH
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
N/A
1016916
101804301
102045001
102048401
102289001
102297230
102298580
102491501
102618601
102867101
102867301
102883401
103233001
103179901
103180001
103253801
103268001
8233
Instl, Dash (includes items 2 through 19) ..........................................................................................
Screw, 1/4-20 X 1.50 Hex-Head Cap ...............................................................................................
Screw, #8 X 0.500, Hex-Head Hi-Lo ................................................................................................
Cap, 1/4" Plastic Screw Head ............................................................................................................
Washer, 1/4 Id Scalloped Plast .........................................................................................................
Screw, M8X1.25X30, Hex ....................................................................................................................
M8-1.25 X 80 Sems ...............................................................................................................................
Washer Hard,m10 .................................................................................................................................
Dash, Design A ......................................................................................................................................
Support, Structural ..............................................................................................................................
Cup Holder, Utility ................................................................................................................................
Asm, Brush, Fnr (includes items 15 and 16) ................................................................................
Brush, Strip, FNR .............................................................................................................................
Holder, Brush, Strip, Fnr ...............................................................................................................
Bracket, Hood Support .......................................................................................................................
Rod, Connection, Dash .......................................................................................................................
1
1
2
1
1
6
5
1
2
2
1
1
2
2
2
2
1
1
1
Page 2-13
2
G
E
D
2
G
E
D
4
1
2
3
000789-001
Page 2-14
GLOVE BOX
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
102867202
103182701
103182702
103182801
Cover, Storage, Dash, Blk, Cci .................................................................................................................
Latch, Push Close .......................................................................................................................................
Latch, Push Close W/ Key ........................................................................................................................
Keeper, Latch, Push Close .......................................................................................................................
1
1
1
1
Page 2-15
2
G
E
D
2
G
E
D
3
2
2
3
1
000527-001
Page 2-16
SIDE STRINGERS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
102491701
103485501
103487501
Well Nut 1/4-20 ...........................................................................................................................................
Stringer, Side, 1200mm ............................................................................................................................
Screw, 1/4-20 X 1.0, Black ........................................................................................................................
8
2
8
2
G
E
D
Page 2-17
2
G
E
D
3
2
1
000520-001
Page 2-18
FLOOR MAT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
1015392
102025801
102895701
Rivet, 3/16 Pop ............................................................................................................................................
Screw, 1/4-20 X .75 Torx Pn Hd ..............................................................................................................
Floor Mat .......................................................................................................................................................
4
2
1
2
G
E
D
Page 2-19
2
G
5
E
D
6
6
4
8
2
3
7
000790-001
Page 2-20
FLOORBOARD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
N/A
1011578
102618601
103319601
103319701
103400001
N/A
103423701
Instl, Floorboard (includes items 2 through 8) ................................................................................
Floorboard, Lower ................................................................................................................................
Floorboard, Upper ................................................................................................................................
3/16 X 1.19 Alum Rivet, Blk ...............................................................................................................
Bracket, Support, Floorboard ...........................................................................................................
Bolt, M8 X 1.25 X 110 ...........................................................................................................................
1
1
1
1
1
6
1
1
Page 2-21
2
G
E
D
2
15
24
G
15
23
7
28
23
13
E
17
26
14
22
D
9
21
6
20
19
25
21
10
10
12
11
19
20
8
21
20
10
5
27
16
18
19
-
4
28
5
-
17
33
33
32
31
30
3
36
2
30
29
34
35
1
000524-001
Page 2-22
BUCKET SEATS – GRAY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
101887601
102059001
102442001
102473701
1011652
102047001
102059401
102061101
102298130
102298401
102456001
102458901
102473501
102473601
102475901
103267001
451
N/A
1011652
1012830
1013734
102023703
102047001
102059401
102061101
102458901
103267001
451
102670601
102718101
102732401
102763701
102967901
103216401
332
96742515
Locknut, M6-1.00 Nylon Insert ..............................................................................................................
Seat Holder Base ........................................................................................................................................
Pan, Center, Closeout ................................................................................................................................
Asm, Bucket Seat Adjustable (includes items 5 through 17) .....................................................
Hinge Plate .............................................................................................................................................
Rivet, 1/4 X .438 Blind .........................................................................................................................
Screw, 6m-1.00 X 10mm Hex Head ................................................................................................
Seat Holder Cup ....................................................................................................................................
Bolt, Flange Head, M8 X 30.0 ............................................................................................................
Pan, Seat, Driver Asm ..........................................................................................................................
Decal, Hot Surface Warning ..............................................................................................................
Adjuster, Forward/Aft ..........................................................................................................................
Adjuster, Slider ......................................................................................................................................
Washer, Bell .............................................................................................................................................
Seat, Bucket, Gray .................................................................................................................................
Lockwasher, 1/4 Split ..........................................................................................................................
Assembly, Bucket Seat w/Spacers (includes items 19 through 28) .........................................
Hinge Plate .............................................................................................................................................
Screw, M8-125 X 22 Hex-Head .........................................................................................................
Lockwasher, 8mm Split ......................................................................................................................
Pan, Seat, Passenger ............................................................................................................................
Rivet, 1/4 X .438 Blind .........................................................................................................................
Seat Holder Cup ....................................................................................................................................
Seat, Bucket, Gray .................................................................................................................................
Bracket, Seatbelt, Bolt-On .......................................................................................................................
Washer, Hard, M10, Zn-Ni/Blk ................................................................................................................
Bolt, M10 X 45, Zn-Ni (Black) ..................................................................................................................
Cover, Center Console ..............................................................................................................................
Nut, Flanged, M10 x 1.5, Black ...............................................................................................................
Washer, 1/4 Type A Narrow Flat ............................................................................................................
Bolt, M6 X 1 X 45 .........................................................................................................................................
2
2
1
1
2
4
1
1
4
4
1
1
1
1
4
1
1
1
2
4
4
1
4
1
1
1
1
1
1
2
2
1
4
2
2
2
Page 2-23
2
G
E
D
2
21
30
G
21
29
13
34
29
19
E
23
32
20
28
D
15
27
12
26
25
31
27
16
16
18
17
25
26
14
27
16
11
26
33
22
24
25
-
10
34
11
23
-
8
8
7
6
5
3
36
2
5
4
9
35
1
000524-002
Page 2-24
BUCKET SEATS – BLACK
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
101887601
102059001
102442001
102670601
102718101
102732401
102763701
102967901
103216401
103218901
1011652
102047001
102059401
102061101
102298130
102298401
102456001
102458901
102473501
102473601
102475901
103267002
451
N/A
1011652
1012830
1013734
102023703
102047001
102059401
102061101
102458901
103267002
451
332
96742515
Seat Holder Base ........................................................................................................................................
Pan, Center, Closeout ................................................................................................................................
Bracket, Seatbelt, Bolt-On .......................................................................................................................
Washer, Hard, M10, Zn-Ni/Blk ................................................................................................................
Bolt, M10 X 45, Zn-Ni (Black) ..................................................................................................................
Cover, Center Console ..............................................................................................................................
Nut, Flanged, M10 x 1.5, Black ...............................................................................................................
Asm, Bracket Seat, Adj, Blk (includes items 11 through 23) .......................................................
Hinge Plate .............................................................................................................................................
Rivet, 1/4 X .438 Blind .........................................................................................................................
Seat Holder Cup ....................................................................................................................................
Pan, Seat, Driver Asm ..........................................................................................................................
Adjuster, Forward/Aft ..........................................................................................................................
Adjuster, Slider ......................................................................................................................................
Washer, Bell .............................................................................................................................................
Seat, Bucket, Black ...............................................................................................................................
Asm, Bracket Seat, Passenger, Blk (includes items 25 through 34) ..........................................
Hinge Plate .............................................................................................................................................
Screw, M8-125 X 22 Hex-Head .........................................................................................................
Lockwasher, 8mm Split ......................................................................................................................
Pan, Seat, Passenger ............................................................................................................................
Rivet, 1/4 X .438 Blind .........................................................................................................................
Seat Holder Cup ....................................................................................................................................
Seat, Bucket, Black ...............................................................................................................................
Bolt, M6 X 1 X 45 .........................................................................................................................................
2
2
1
1
2
2
1
4
2
1
2
4
1
1
4
4
1
1
1
1
4
1
1
1
2
4
4
1
4
1
1
1
1
1
2
2
Page 2-25
2
G
E
D
2
G
E
D
8
7
9
8
10
9
10
6
2
5
1
3
4
000560-001
Page 2-26
LOWER ROPS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
N/A
102491301
102491501
102617201
102718101
103361701
N/A
102988701
103216401
103377501
Instl, Rops, Lower (includes items 2 through 6) ..............................................................................
Bolt, M10x1.50x100 (Black) ...............................................................................................................
Washer Hard,m10 .................................................................................................................................
Washer, Hard, M10, Zn-Ni/Blk ..........................................................................................................
Weldment,seat Support,hs,rops .....................................................................................................
Instl, Rear Brace, Head Rest (includes items 8 through 10) .........................................................
Bolt, Flanged, M10 X 1.5 X 65 ...........................................................................................................
Nut, Flanged, M10 x 1.5, Black .........................................................................................................
Brkt, Spprt, Rear, Rops, Fin .................................................................................................................
1
4
4
4
4
1
1
2
2
2
Page 2-27
2
G
E
D
2
G
9
E
9
9
12
D
9
11
10
10
9
11
11
9
3
2
4
7
5
6
000560-002
Page 2-28
SEAT BELTS AND ROPS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
N/A
102324401
102671201
103210801
103210802
103210901
103211101
103215901
102988701
103192101
103216401
103225801
Instl, Seat Belt, 3 Point (includes items 2 through 7) .....................................................................
Lock Nut, 7/16-20 Nylon Black .........................................................................................................
Screw,m12x1.75x30 Thd Form Blk .................................................................................................
Spacer, .69 Od X .5 Id X .60 ................................................................................................................
Spacer, .69 Od X .5 Id X .20 ................................................................................................................
Seat Belt, 3 Pt, Lock Tongue ..............................................................................................................
Screw, 7/16-20 X 1.75 ..........................................................................................................................
Kit, ROPS, Domestic (includes items 9 through 11) .......................................................................
Bolt, Flanged, M10 X 1.5 X 65 ...........................................................................................................
Tube, Side Support Short, ROPS .....................................................................................................
Asm, Top, ROPS ...........................................................................................................................................
1
2
2
2
2
2
2
1
8
2
8
1
Page 2-29
2
G
E
D
2
G
E
D
4
2
2
4
7
6
6
7
8
5
3
1
2
-
4
000029-005
Page 2-30
ROPS – HEAD RESTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
103274602
102490101
103274502
96741046
N/A
102988701
103216401
103283801
Kit, Head Restraint, Black (includes items 2 through 4) ...............................................................
Bolt, M10 X 1.5 X 20 Loctite ..............................................................................................................
Asm, Head Restraint, Black ................................................................................................................
Washer, M10 Hard ................................................................................................................................
Kit, Rear Brace, ROPS (includes items 6 through 8) .......................................................................
Bolt, Flanged, M10 X 1.5 X 65 ...........................................................................................................
Asm, Rear Brace .....................................................................................................................................
1
4
2
4
1
2
2
1
Page 2-31
2
G
E
D
2
G
E
D
5
10
7
6
12
11
8
10
4
1
2
9
11
11
3
000036-001
Page 2-32
LATCH PLATE AND PROP ROD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
1015277
1016078
101835601
101958602
102301401
102323101
102418101
102426601
102493801
102618301
102618601
334
Latch Plate, Tilt Bed ...................................................................................................................................
Latch Plate Shim .........................................................................................................................................
Locknut, 1/4-20 Hex Whiz .......................................................................................................................
Bolt, Carriage, 1/4-20 X 1.0 .....................................................................................................................
Rod, Prop .......................................................................................................................................................
Pin, Bow Tie Locking .................................................................................................................................
Track, Prop Rod ...........................................................................................................................................
Bumper, Bed, Mtg, Front ..........................................................................................................................
Bracket, Latch, Bed ....................................................................................................................................
Bolt Flanged Head, M8 X 1.25 X 65 ......................................................................................................
Lock Nut, Flg M8 X 1.25 Nylon ..............................................................................................................
Washer, 3/8 Type A Flat ............................................................................................................................
2
1
4
4
1
1
1
2
2
3
5
1
Page 2-33
2
G
E
D
2
G
E
4
9
14
12
13
11
8
7
6
15
10
15
5
D
2
20
19
17
1
2
16
3
18
000037-001
Page 2-34
TILT BED, HINGE, AND LATCH
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1012303
1015583
102065901
102171503
1010435
1014471
1015258
N/A
N/A
1015399
1015400
101835601
102426901
403
7473
102614101
103538701
103538901
8754
8755
Bushing, Steel ..............................................................................................................................................
Bushing, Urethane .....................................................................................................................................
Locknut, 3/8-16 Flanged Dimple ..........................................................................................................
Tilt Bed Assembly (includes items 5 through 15) ...........................................................................
Bolt, Carriage, 5/16-18 X 1.00 ...........................................................................................................
Tape, Vinyl Foam 1/8" x 3/4" * ..........................................................................................................
Plate, Floor Bed .....................................................................................................................................
Frame Assembly ....................................................................................................................................
Extension, Spring Latch ......................................................................................................................
Screw, 5/16-18 X 0.88 Torx Truss-Head .........................................................................................
Grip, Tilt Latch Hand ............................................................................................................................
Locknut, 1/4-20 Hex Whiz .................................................................................................................
Ltch Weld Asm Tlt Bd ..........................................................................................................................
Screw, 1/4-20 X 0.625 Hex-Head Cap ............................................................................................
Locknut, 5/16-18 Nylon Insert .........................................................................................................
Plate, Back .....................................................................................................................................................
Extra, Bracket, Hinge, Bed .......................................................................................................................
3/8-16 X 3.5 Carr Blt Gr5 Zn ....................................................................................................................
Locknut, 3/8-16 Hex ..................................................................................................................................
Screw, 3/8-16 X 3.375 Hex Cap ..............................................................................................................
2
2
4
1
4
1
1
1
2
4
1
4
1
4
8
2
2
4
2
2
* Note: Item not shown.
Page 2-35
2
G
E
D
2
G
1
16
6
6
E
D
7
6
10
9
8
15
15
4
6
15
6
16
3
5
2
14
14
16
15
5
13
2
8
11
12
17
000158-002
Page 2-36
ELECTRIC BED LIFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1010200
1016603
1017162
1017167
1017774
102066001
102426601
102465701
102614101
102618601
102629001
102882501
103227001
357
8754
8755
8990
Bolt, 3/8-16 X 4.25 Hex Head .................................................................................................................
Bushing Long ..............................................................................................................................................
Actuator Assembly, Electric ....................................................................................................................
Actuator Adapter .......................................................................................................................................
Body Spacer .................................................................................................................................................
Washer, 3/8 Type B Hard Flat .................................................................................................................
Bumper, Bed, Mtg, Front ..........................................................................................................................
Weldment, Bracket, Actuator .................................................................................................................
Plate, Back .....................................................................................................................................................
Tie Wrap, 8.00" With Mount ....................................................................................................................
Switch, Rocker, Spring Return, Bed Lift ..............................................................................................
Harness, AWD Bedlift ................................................................................................................................
Lockwasher, 3/8 Split ................................................................................................................................
Locknut, 3/8-16 Hex ..................................................................................................................................
Screw, 3/8-16 X 3.375 Hex Cap ..............................................................................................................
Tie Wrap, 8" Nylon .....................................................................................................................................
1
2
1
1
8
8
2
1
1
2
2
1
1
2
9
6
5
Page 2-37
2
G
E
D
2
33
G
34
E
D
40
31
37
30
32
4
5
6
8
29
35
41
11
36
2
43
10
2
3
38
24
7
8
17
10
26
27
16
9
14
10
12
13
42
39
15
21
22
28
42
19
18
25
20
23
Page 2-38
000532-001
BOX BED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
38
39
40
41
42
43
N/A
1010435
1010934
1014321
1014387
1014415
1014537
1015399
101894302
101963401
102030101
102030201
1013317
1015246
N/A
7973
103191401
1010434
1011990
1015313
1015363
1015390
1015400
103191201
1032
103379401
N/A
1231
103191501
1010434
1011990
1015245
1015363
1015390
1015400
103191301
1032
103379401
N/A
1231
332
7049
8233
Install, Box Bed (includes items 2 through 43) ................................................................................
Bolt, Carriage, 5/16-18 X 1.00 ...........................................................................................................
Screw, 5/16-18 X 1.00 Hex Cap ........................................................................................................
Screw, #10 Truss-Head Torx ..............................................................................................................
Cap, Corner .............................................................................................................................................
Screw, 1/4-20 X 0.75 Torx Truss-Head ...........................................................................................
Stud, Self-Clinching Flush Head ......................................................................................................
Box Bed Tailgate Angle .......................................................................................................................
Locknut, 5/16-18 Hex Flange ...........................................................................................................
Panel, Front .............................................................................................................................................
Tailgate Asm (includes items 13 through 16) .............................................................................
Decal, Logo, Tailgate .....................................................................................................................
Plate, Tailgate Latch Wear ...........................................................................................................
Tailgate Weldment .........................................................................................................................
Rivet, 3/16 X .400 Blind ................................................................................................................
Asm, Panel, Side, Left (includes items 18 through 28) ............................................................
Barrel - Plastic ..................................................................................................................................
Washer, 3/8 Flat ...............................................................................................................................
Latch, Tailgate, Left-Hand ............................................................................................................
Bushing, Snap-In ............................................................................................................................
Compression Spring Latch Tilt ..................................................................................................
Grip, Tilt Latch Hand ......................................................................................................................
Weldment, Panel, Side, Left ........................................................................................................
Bushing, Nylon ................................................................................................................................
Rivet, 1/4 X 0.30, Blind ..................................................................................................................
Asm, Tlgt, Mtg Brkt, Ca Lh ...........................................................................................................
Pin, 1/8 X 1.00 Split Roll ...............................................................................................................
Asm, Panel, Side, Right (includes items 30 through 40) .........................................................
Barrel - Plastic ..................................................................................................................................
Washer, 3/8 Flat ...............................................................................................................................
Latch, Tailgate, Right-Hand ........................................................................................................
Bushing, Snap-In ............................................................................................................................
Compression Spring Latch Tilt ..................................................................................................
Grip, Tilt Latch Hand ......................................................................................................................
Weldment, Panel, Side, Right .....................................................................................................
Bushing, Nylon ................................................................................................................................
Rivet, 1/4 X 0.30, Blind ..................................................................................................................
Asm, Tlgt, Mtg Brkt, Ca Rh ...........................................................................................................
Pin, 1/8 X 1.00 Split Roll ...............................................................................................................
Washer, 1/4 Type A Narrow Flat ......................................................................................................
Bushing, Nylon ......................................................................................................................................
1
11
2
4
2
4
2
16
1
33
1
1
1
2
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
4
2
4
Page 2-39
2
G
E
D
2
G
E
D
9
16 26
5
15 25
9
8
19 29
16 26
31
2
3
13
23
4
14
24
3
7
6
17
12 22
13 23
18 28
27
10 20
30
10 20 30
000518-001
Page 2-40
SIDE PANELS AND REAR FENDERS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
N/A
1014306
102491701
102913801
102913901
102914001
102914101
102914102
103200501
8251
N/A
1014306
102491701
102913801
102913901
103200501
103289001
103289101
103289103
8251
N/A
1014306
102491701
102913801
102913901
103200501
103289002
103289102
103289104
8251
103331201
Instl, Panels, Fenders, Blk (includes items 2 through 10) .............................................................
Washer, 1/4" Type B Flat .....................................................................................................................
Well Nut 1/4-20 .....................................................................................................................................
Left Rear Fender (Black) ......................................................................................................................
Right Rear Fender (Black) ..................................................................................................................
Panel, Front, Kick (Black) ....................................................................................................................
Panel, Side, Molded, Driver (Black) .................................................................................................
Panel, Side, Molded, Passenger (Black) .........................................................................................
Screw, Tuflok, 10mm ...........................................................................................................................
Screw, 1/4-20 X 1.0 Truss-Head Machine .....................................................................................
Instl, Panels, Fenders, Rthwd (includes items 12 through 20) ...................................................
Well Nut 1/4-20 .....................................................................................................................................
Screw, Tuflok, 10mm ...........................................................................................................................
Panel, Front, Kick (Realtree Camo) ..................................................................................................
Panel, Side, Molded, Driver (Realtree Camo) ..............................................................................
Panel, Side, Molded, Passenger (Realtree Camo) ......................................................................
Instl, Panels, Fenders, Moff (includes items 22 through 30) .......................................................
Well Nut 1/4-20 .....................................................................................................................................
Screw, Tuflok, 10mm ...........................................................................................................................
Panel, Front, Kick, Moff .......................................................................................................................
Pnl, Side, Mld, Drv, Moff .....................................................................................................................
Pnl, Side, Mld, Pass, Moff ....................................................................................................................
Closeout, Extrusion ...................................................................................................................................
1
4
8
1
1
1
1
1
6
8
1
4
8
1
1
6
1
1
1
8
1
4
8
1
1
6
1
1
1
8
1
Page 2-41
2
G
E
D
2
G
2
5
E
25
D
27
12
10
26
11
23
19
18
6
9
8
21
22
14
13
24
4
5
7
16
17
26
20
7
26
3
15
000038-001
Page 2-42
CARGO BOX (STEEL)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
N/A
1010435
1010436
1014306
1014415
1014537
1015399
101894304
101963401
102221301
102221401
102221501
102221701
102222001
102239901
102614401
1013366
1014415
N/A
102221801
102222101
102222201
102673201
8233
332
7473
8233
Instl, Steel Box, XRT (includes items 2 through 27) ........................................................................
Bolt, Carriage, 5/16-18 X 1.00 ...........................................................................................................
Bumper, Rubber ....................................................................................................................................
Screw, 1/4-20 X 0.75 Torx Truss-Head ...........................................................................................
Stud, Self-Clinching Flush Head ......................................................................................................
Box Bed Tailgate Angle .......................................................................................................................
Locknut, 5/16-18 Hex Flange ...........................................................................................................
Front Panel Weldment ........................................................................................................................
Left Panel Weldment ...........................................................................................................................
Right Panel Weldment ........................................................................................................................
Front Corner Cap ..................................................................................................................................
Slam Latch ...............................................................................................................................................
Washer, Rubber, 3/8 .............................................................................................................................
Assembly, Tailgate (includes items 17 through 24) .................................................................
Hair Pin Clip ......................................................................................................................................
Screw, 1/4-20 X 0.75 Torx Truss-Head .....................................................................................
Tailgate, Weldment ........................................................................................................................
Tether Assembly .............................................................................................................................
Spring Latch Left ............................................................................................................................
Spring Latch Right .........................................................................................................................
Decal, Club Car Tailgate ...............................................................................................................
Locknut, 1/4-20 Nylon Insert .....................................................................................................
Washer, 1/4 Type A Narrow Flat ......................................................................................................
Locknut, 5/16-18 Nylon Insert .........................................................................................................
1
13
4
4
8
4
18
1
4
1
1
1
2
2
4
1
4
4
1
2
1
1
1
4
4
31
4
Page 2-43
2
G
E
D
2
G
E
D
WHEELS AND TIRES
3
G
E
D
3
G
E
D
5
VALVE
STEM
4
RIM
3
TIRE
2
FOR DRIVERS OR
PASSENGERS SIDE
1
13
VALVE
STEM
12
RIM
11
10
9
VALVE
STEM
8
RIM
7
TIRE
TIRE
FOR PASSENGERS
SIDE ONLY
6
FOR DRIVERS
SIDE ONLY
000506-001
Page 3-2
WHEELS AND TIRES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102736901
102943807
102943101
103234503
7310
N/A
102945701
103234503
7310
N/A
102945701
103234503
7310
Nut, Lug, 1/2-20 SAE J2283 ....................................................................................................................
Black Tire Asm HDAT 10.5 In (includes items 3 through 5) .........................................................
Heavy Duty All Terrain Tire, 25" .......................................................................................................
Wheel, All trail, 10 Window, Black ...................................................................................................
Valve Stem ..............................................................................................................................................
Black Tire Asm Mud 11.0 In Left-Hand (includes items 7 through 9) ......................................
Mud Tire, 25" ..........................................................................................................................................
Valve Stem ..............................................................................................................................................
Black Tire Asm Mud 11.0 In Right-Hand (includes items 11 through 13) ..............................
Mud Tire, 25" ..........................................................................................................................................
Valve Stem ..............................................................................................................................................
16
4
1
1
1
2
1
1
1
2
1
1
1
Page 3-3
3
G
E
D
3
G
E
D
DECALS
4
G
E
D
4
G
9
E
5
D
3
10
4
6
1
2
8
7
000561-002
Page 4-2
SAFETY DECALS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
1011553
101609401
102224001
102459301
102459401
N/A
102930801
102950601
102961201
103188601
Decal, Trailer Hitch .....................................................................................................................................
Decal, Crush Area Warning .....................................................................................................................
Decal, Rotating Parts Warning ..............................................................................................................
Decal, Bed Crush Area Warning ............................................................................................................
Decal, Young Driver Warning ................................................................................................................
Decal, Attachment Locking ....................................................................................................................
Decal, Loading, Intellitach ......................................................................................................................
Decal, Hydra Pump ....................................................................................................................................
Decal, Warning, AWD ROPS ....................................................................................................................
Decal, Warn, Rollover & Attach .............................................................................................................
1
2
1
1
1
1
1
1
1
1
Page 4-3
4
G
E
D
4
G
E
D
4
6
7
8
2
3
1
5
000561-001
Page 4-4
SAFETY DECALS, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102458901
102459001
102459101
102459201
102459501
102460201
103188701
103319901
Decal, Hot Surface Warning ...................................................................................................................
Decal, Hot Manifold Warning ................................................................................................................
Decal, Frame Ground Warning ..............................................................................................................
Decal, Diesel Explosion/Fire Warning .................................................................................................
Decal, Rotating Parts and Hot Exhaust Warning ............................................................................
Decal, Rotating Parts Warning ..............................................................................................................
Decal, Operator Instructions, Intellitach ............................................................................................
Decal, Joystick, On Off ..............................................................................................................................
3
1
1
1
1
1
1
1
Page 4-5
4
G
E
D
4
G
E
D
3
7
2
4
6
8
000562-001
Page 4-6
BADGING DECALS – CARRYALL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
N/A
103233614
103233714
103234201
N/A
103233617
103233717
103234201
Instl, Decal, Bed, Cait,dkgray (includes items 2 through 4) .........................................................
Decal, Badge, CA 295, Driver-Side, Dk Gray ................................................................................
Decal, Badge, CA 295, Passenger-Side, Dk Gray ........................................................................
Decal, Badge, 4x4 .................................................................................................................................
Instl, Decal, Ca It, Stl, Ntrl (includes items 6 through 8) ...............................................................
Decal, Badge, CA 295, Driver-Side, Ntrl ........................................................................................
Decal, Badge, CA 295, Passenger-Side, Ntrl ................................................................................
Decal, Badge, 4x4 .................................................................................................................................
1
1
1
2
1
1
1
2
Page 4-7
4
G
E
D
4
G
E
D
3
7
11
2
4
8
6
10
12
000562-002
Page 4-8
BADGING DECALS – XRT VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
N/A
103233410
103233510
103234201
N/A
103233415
103233515
103234201
N/A
103233417
103233517
103234201
Instl, Decal, Bed, Xrtit,dkgrn (includes items 2 through 4) ..........................................................
Decal, Bed, XRT 1550, Dk Grn, Ds ....................................................................................................
Decal, Bed, XRT 1550, Dk Grn, Ps ....................................................................................................
Decal, Badge, 4x4 .................................................................................................................................
Instl, Decal, Bed, Xrt It, Red (includes items 6 through 8) ............................................................
Decal, Bed, XRT 1550, Red, Ds ..........................................................................................................
Decal, Bed, XRT 1550, Red, Ps ...........................................................................................................
Decal, Badge, 4x4 .................................................................................................................................
Instl, Decal, Bed, Xrt It,ntrl (includes items 10 through 12) ........................................................
Decal, Bed, Xrt1550, Ntrl, Ds .............................................................................................................
Decal, Bed, XRT 1550, Ntrl, Ps ...........................................................................................................
Decal, Badge, 4x4 .................................................................................................................................
1
1
1
2
1
1
1
2
1
1
1
2
Page 4-9
4
G
E
D
4
G
E
D
2
000562-003
Page 4-10
BADGING DECALS – INTELLITACH
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
N/A
102925601
Instl, Decal, Intellitach (includes item 2) ............................................................................................
Decal, Brand, IntelliTach .....................................................................................................................
1
2
4
G
E
D
Page 4-11
4
G
E
D
BRAKE SYSTEMS
5
G
E
D
5
G
E
4
D
1
6
2
3
4
5
000067-001
Page 5-2
FRONT BRAKE ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102367601
102488001
102491601
102493301
102714001
103418801
Brake Caliper, Front, with Brake Pads ..................................................................................................
Bolt, Banjo, M10x1x19 ..............................................................................................................................
Washer, Copper, M10 Crush ...................................................................................................................
Bolt Flange Head, 3/8-24x.750 with Loctite .....................................................................................
Service Kit, Brake Pad (4 Pads) ...............................................................................................................
Pin, Slide, 7/16 .............................................................................................................................................
2
2
4
4
1
2
Page 5-3
5
G
E
D
5
G
2
E
5
1
D
5
8
6
4
3
000068-001
Page 5-4
REAR BRAKE ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102399201
102399202
102488001
102491601
102493301
102714001
103418701
103418801
Caliper, Brake, Hydro-Mechanical, LH .................................................................................................
Caliper, Brake, Hydro-Mechanical, RH ................................................................................................
Bolt, Banjo, M10x1x19 ..............................................................................................................................
Washer, Copper, M10 Crush ...................................................................................................................
Bolt Flange Head, 3/8-24x.750 with Loctite .....................................................................................
Service Kit, Brake Pad (4 Pads) ...............................................................................................................
Spring, Brake Caliper, Return .................................................................................................................
Pin, Slide, 7/16 .............................................................................................................................................
1
1
2
4
4
1
1
2
Page 5-5
5
G
E
D
5
6
G
5
7
E
2
D
10
11
8
4
3
9
1
8
000069-002
Page 5-6
MASTER CYLINDER WITH REMOTE RESERVOIR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
101082903
1014306
102176901
102402801
102402901
102051401
N/A
102618401
102618601
103218213
103293201
Clevis Pin, 5/16 X 1 .....................................................................................................................................
Washer, 1/4" Type B Flat ..........................................................................................................................
Pin, Rue ..........................................................................................................................................................
Cylinder, Master, Tandem ........................................................................................................................
Assembly, Reservoir, Remote (includes items 6 and 7) ................................................................
Filler Cap Asm ........................................................................................................................................
Reservoir, Brake Fluid, Without Cap ...............................................................................................
Screw, #10x3.50 Ab Thd, Hex Hd ..........................................................................................................
Hose, Reservoir, Brake Fluid ...................................................................................................................
1
1
1
1
1
1
1
2
2
1
2
Page 5-7
5
G
E
D
5
G
E
D
6
2
5
1
3
4
000792-001
Page 5-8
MASTER CYLINDER WITH INTEGRAL RESERVOIR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
101082903
102176901
102298401
102618401
103376101
103380701
Clevis Pin, 5/16 X 1 .....................................................................................................................................
Pin, Rue ..........................................................................................................................................................
Nut,m8,all Metal Lock ...............................................................................................................................
Cylinder, Master, Integral Res .................................................................................................................
Filler Cap Asm Integral Res .....................................................................................................................
1
1
2
2
1
1
Page 5-9
5
G
E
D
5
G
E
2
D
8
3
1
12
9
11
6
3
5
3
4
7
10
000015-003
Page 5-10
HYDRAULIC BRAKE LINES AND CLIPS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
101887601
102296140
102296716
102376601
N/A
102475801
102407801
102474301
102475701
102689001
103174301
8639
Bolt, Flanged Head, M6x1.0x40 ............................................................................................................
Screw, M6 X 16 Tt Hx Fl Hd .....................................................................................................................
Assy, Rotor, Brake, Front (includes items 5 and 6) ..........................................................................
Rotor, Brake, Front ................................................................................................................................
Stud, Wheel Lug ....................................................................................................................................
Assembly, Brake Line, Rear .....................................................................................................................
Bracket, Tee, Brakeline ..............................................................................................................................
Clip, Brake Line ............................................................................................................................................
Bracket, Line, Hydraulic ...........................................................................................................................
Brakeline, Front, Assembly .....................................................................................................................
Tie Wrap, 11" Nylon ...................................................................................................................................
2
1
8
1
1
4
1
1
6
2
1
1
Page 5-11
5
G
E
D
5
G
E
D
4
3
8
2
1
6
5
7
000088-001
Page 5-12
BRAKE PEDAL ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
102380601
102618101
102618301
102618601
N/A
102442901
102626201
103273101
Bracket, Pedal, Brake .................................................................................................................................
Nut M6x1 Mech Def Center ....................................................................................................................
Asm, Pedal, Brake, Hung (includes items 6 and 7) .........................................................................
Bushing, Greaseless .............................................................................................................................
Weldment, Pedal, Brake, Hung ........................................................................................................
Bolt, Shoulder, M8 X 70, Hc ....................................................................................................................
1
1
2
2
1
2
1
1
Page 5-13
5
G
E
D
5
G
E
9
D
3
13
13
15
7
18
10
6
8
16
17
4
12
14
11
2
5
9
000533-001
Page 5-14
PARK BRAKE SYSTEM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
N/A
101082903
1011779
1013531
101953101
102292801
102298401
102551901
102552001
102618301
102763301
102763401
103500901
103505301
103505401
103535001
1242
8639
Instl, Brake, Park, AWD (includes items 2 through 18) ..................................................................
Clevis Pin, 5/16 X 1 ...............................................................................................................................
E-Clip, 1/2 ................................................................................................................................................
Spring, Brake Return ............................................................................................................................
Rod, Equalizer, 8.91" ............................................................................................................................
Washer, 5/16, Self Comp, Cup ..........................................................................................................
Washer, 5/16, Self Comp, Cone ........................................................................................................
Cable, Noncoated, Pbrake, Left .......................................................................................................
Cable, Noncoated, Pbrake, Rght .....................................................................................................
Brkt, Cable, Park Brake ........................................................................................................................
Cable, Main, Park Brake ......................................................................................................................
Asm, Pedal, Park Brake ........................................................................................................................
Bracket, Equalizer, Prec Awd .............................................................................................................
Nut, 5/16-18 Hex ...................................................................................................................................
Tie Wrap, 11" Nylon .............................................................................................................................
1
2
2
1
1
2
4
1
1
4
1
1
1
1
1
1
2
2
Page 5-15
5
G
E
D
5
10
7
G
E
D
8
6
10
5
9
11
13
1
12
4
2
000086-002
Page 5-16
PARK BRAKE PEDAL ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102618301
102618601
102751501
102323501
102716001
102741501
102741601
102751301
102751401
103305001
103305101
1035
103505401
Asm, Sub, Bracket, Park Brake (includes items 4 through 12) ....................................................
Washer, Flat, 3/8, Blk Fin .....................................................................................................................
Cable, Crank, Bell ..................................................................................................................................
Bolt Flg, M8x1.25 X 35, Gr10.9 .........................................................................................................
Nut Flg M8 X 1.25 Gr 10 ......................................................................................................................
Asm, Bellcrank, Upper .........................................................................................................................
Asm, Bellcrank, Lower .........................................................................................................................
Brkt, Bellcrank, Prk Brk, Awd .............................................................................................................
Spacer, Pivot, Park Brk, Awd ..............................................................................................................
Cotter Pin, 3/32 x 1 ...............................................................................................................................
Asm, Pedal, Park Brake .............................................................................................................................
3
3
1
2
1
2
2
1
1
1
2
2
1
Page 5-17
5
G
E
D
5
G
E
D
STEERING AND SUSPENSION
6
G
E
D
6
G
E
D
5
2
4
6
3
9
11
8
7
10
000070-002
Page 6-2
STEERING COLUMN
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
N/A
102290120
102298130
102363802
102367101
102618601
102989801
102298130
102571301
102616801
102977101
Instl, Steering System (includes items 2 through 7) ......................................................................
Bolt, M10 X 20 Hex Washer Hd ........................................................................................................
Steering Wheel, Viper, Hex Hub ......................................................................................................
Cap, Steering Wheel, Viper ................................................................................................................
Steering Column (includes items 8 through 11) .......................................................................
Bolt, Flange Head, M8 X 30.0 .....................................................................................................
Shroud, Steering Column ............................................................................................................
Bolt, M4 X .7 X 60 ............................................................................................................................
Handle, Steering, Tilt .....................................................................................................................
1
1
1
1
1
3
1
1
1
1
1
Page 6-3
6
G
E
D
6
G
E
2
18
3
4
11
6
7
8
13
15
16
9
10
5
14
12
D
21
17
22
1
19
20
000071-001
Page 6-4
STEERING GEAR ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1013042
102010102
1013035
1013042
1013044
1013051
1013052
101879401
101879701
101879801
101879901
101880201
N/A
N/A
N/A
N/A
N/A
8990
102022601
102022901
102687801
102816801
Nut, 12mm Hex ...........................................................................................................................................
Steering Rack (includes items 3 through 18) ...................................................................................
Bellows, Long .........................................................................................................................................
Nut, 12mm Hex .....................................................................................................................................
Rack Screw Locknut .............................................................................................................................
Snap Ring ................................................................................................................................................
Seal, Steering Pinion Dust .................................................................................................................
Bearing, Ball ............................................................................................................................................
Support Yoke .........................................................................................................................................
Rack Guide Pressure Spring ..............................................................................................................
Ring, Stop, C-Type ................................................................................................................................
Inner Ball Joint Asm .............................................................................................................................
Pinion, Steering .....................................................................................................................................
Bearing, Lower Pinion .........................................................................................................................
Screw, Rack Guide ................................................................................................................................
Housing, Steering Gear ......................................................................................................................
Rack, Steering ........................................................................................................................................
Tie Wrap, 8" Nylon ................................................................................................................................
End, Tie Rod M12 X 1.25 Rh ....................................................................................................................
Locknut, M12-1.25 Nylon ........................................................................................................................
Bolt, Flange Head, M10x 1.5 X 40 with Loctite ................................................................................
Link, Drag, Wt ..............................................................................................................................................
2
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
2
2
2
4
2
Page 6-5
6
G
E
D
6
4
G
E
5
D
39
40
11
7
11
7
36
37
32
39
34
35
33
30
41
31
38
11
43
11
38
8
10
3
8
22
2
2
24
15
25
6
9
42
9
6
17
18
27
28
13
20
29
26
3
10
21
12
16
19
000534-001
Page 6-6
FRONT SUSPENSION – A-ARMS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
38
39
40
41
42
43
N/A
102022901
102274101
102408401
102437001
102490801
102616301
102617501
102617701
102617801
102620501
102791701
102022901
102376605
102464301
102874301
102361901
102722301
N/A
103277001
102791702
102022901
102376605
102464301
102874301
102361901
102722301
N/A
103277002
102792001
102361901
102722301
102927101
102792002
102361901
102722301
102927102
102874501
103148501
103256401
103256701
103762201
103345801
Suspension, AWD, Wide (includes items 2 through 42) ...............................................................
Locknut, M12-1.25 Nylon ..................................................................................................................
Center Cap, Rubber ..............................................................................................................................
Bushing, A-Arm .....................................................................................................................................
Sleeve, Upper .........................................................................................................................................
Bolt, Flange Head, M12x 1.75x 30 with Loctite ..........................................................................
Bolt, Flange Head, M12 X 1.75 X 70 ...............................................................................................
Nut Flg, M22 X 1.5 Mech Def ............................................................................................................
Nut, Square, M12x 1.75 ......................................................................................................................
Washer Hard, M22 ................................................................................................................................
Nut Flg, M12x1.75, Nylon Gr 10 .......................................................................................................
Upright, Left-Hand (includes items 13 through 20) .................................................................
Locknut, M12-1.25 Nylon ............................................................................................................
Assy, Rotor, Brake, Front, Gr ........................................................................................................
Bearing ...............................................................................................................................................
Asm, Adjuster, Slide (includes items 17 through 19) .........................................................
Joint, Ball .....................................................................................................................................
Ring, Retaining, Ext, 1-1/4" ...................................................................................................
Slide, Adjuster ............................................................................................................................
Upright, Finished, Lh .....................................................................................................................
Upright, Right-Hand (includes items 22 through 29) ..............................................................
Locknut, M12-1.25 Nylon ............................................................................................................
Assy, Rotor, Brake, Front, Gr ........................................................................................................
Bearing ...............................................................................................................................................
Asm, Adjuster, Slide (includes items 26 through 28) .........................................................
Joint, Ball .....................................................................................................................................
Ring, Retaining, Ext, 1-1/4" ...................................................................................................
Slide, Adjuster ............................................................................................................................
Upright, Finished, Rh ....................................................................................................................
Asm, A-Arm, Upper, Left (includes items 31 through 33) ......................................................
Joint, Ball ...........................................................................................................................................
Ring, Retaining, Ext, 1-1/4" .........................................................................................................
Arm, Upper, Wide, Machined, Lh ..............................................................................................
Asm, A-arm, Upper, Right (includes items 35 through 37) ....................................................
Joint, Ball ...........................................................................................................................................
Ring, Retaining, Ext, 1-1/4" .........................................................................................................
Arm, Upper, Wide, Machined,rh ................................................................................................
A-Arm, Lower .........................................................................................................................................
Bushing, A-arm Front ..........................................................................................................................
Sleeve, Lower Arm ................................................................................................................................
Bolt Flg, M12 X 1.75 X 200 10. ..........................................................................................................
Front Halfshaft, Awd ............................................................................................................................
Ring, Hog, Half Shaft .................................................................................................................................
1
2
2
8
4
4
4
2
4
2
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
Page 6-7
6
G
E
D
6
G
E
D
3
2
4
1
7
6
8
5
000791-001
Page 6-8
CV BOOT REPAIR KITS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
AM11807
N/A
AM11808
N/A
AM1241201
N/A
AM1241301
N/A
Boxed Outboard Boot Kit (includes item 2) ......................................................................................
Half Shaft Boot Instl. Instr. .................................................................................................................
Boxed Inboard Boot Kit (includes item 4) .........................................................................................
Half Shaft Boot Instl. Instr. .................................................................................................................
Kit, Outer Boot, Gen 2 (includes item 6) ............................................................................................
Instructions, Boot Replacement ......................................................................................................
Kit, Inner Boot, Gen 2 (includes item 8) .............................................................................................
Instructions, Boot Replacement ......................................................................................................
1
1
1
1
1
1
1
1
Page 6-9
6
G
E
D
6
G
3
E
3
D
4
7
7
8
8
4
4
2
3
3
2
3
5
4
6
3
4
000530-003
Page 6-10
SHOCK ABSORBERS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
N/A
102365601
102616301
102620501
102689101
102689102
102786301
102788701
Inst, Shock, Awd, Bt (includes items 2 through 8) ..........................................................................
Shock, Coil Over Rear ..........................................................................................................................
Bolt, Flange Head, M12 X 1.75 X 70 ...............................................................................................
Brkt, Line, Hyd, Shk Mnt, Drv ............................................................................................................
Brkt, Line, Hyd, Shk Mnt, Pass ...........................................................................................................
Shock, Coil Over, 330 Lb/in ...............................................................................................................
Bolt Flg, M12x1.75x100, Patch .........................................................................................................
1
2
6
6
1
1
2
2
Page 6-11
6
G
E
D
6
G
E
D
13
12
2
7
15
8
9
10
9
11
6
13
4
5
3
14
000031-002
Page 6-12
REAR SUSPENSION – STANDARD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
N/A
1015597
102274101
102393501
102619801
102620401
102620501
N/A
102398901
102477001
103282301
102682901
102684501
102685601
102737101
Instl, Rear Suspension (includes items 2 through 15) ...................................................................
Fitting, 1/4-28 Thread-Forming Grease ........................................................................................
Center Cap, Rubber ..............................................................................................................................
Weldment, Receiver, Rear ..................................................................................................................
Washer, Strip, Swingarm ....................................................................................................................
Bolt Flanged Head, M12 X 1.75 X 50 ..............................................................................................
Sub Asm Swingarm (includes items 9 through 11) ..................................................................
Bushing, Pivot, Urethane .............................................................................................................
Bushing, Teflon ................................................................................................................................
Swingarm, Rear, Awd ....................................................................................................................
Pin, Swingarm, Weldment .................................................................................................................
Washer, M12 Hard Regular ................................................................................................................
Nut Flg M12 X 1.75 Cl10 .....................................................................................................................
Cotter, Rue Ring, 1/2" ..........................................................................................................................
1
2
2
1
2
8
2
2
2
2
1
2
10
8
2
Page 6-13
6
G
E
D
6
G
E
D
ELECTRICAL SYSTEM
7
G
E
D
7
G
DIESEL VEHICLE
E
D
REVERSE
BUZZER
OPTIONAL
000662-002
Page 7-2
7
G
E
D
000662-002
Page 7-3
7
G
E
D
See previous two pages for illustration.
Page 7-4
WIRING – DIESEL VEHICLE, SINGLE PIECE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
102538501
103277501
103327201
Diode, General Purpose, 6.0a ................................................................................................................
Harness, Diesel AWD .................................................................................................................................
Asm, Switch, Limit, Awd ..........................................................................................................................
1
1
1
7
G
E
D
Page 7-5
7
G
CONTROL PANEL HARNESS
E
D
000535-003
Page 7-6
7
G
E
D
000535-003
Page 7-7
7
G
E
D
See previous two pages for illustration.
Page 7-8
WIRING – CONTROL PANEL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
102786401
102936801
103245801
Wire Harness, Powerunit .........................................................................................................................
Breaker, Circuit, 150-Amp .......................................................................................................................
Wire Harness, Control Panel ...................................................................................................................
1
1
1
7
G
E
D
Page 7-9
7
G
E
D
000535-005
Page 7-10
WIRING – SEAT BELT REMINDER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
103213401
Harness, Seatbelt Light ............................................................................................................................
1
7
G
E
D
Page 7-11
7
G
E
D
7
10
11
1
8
3
5
9
12
4
8
13
2
6
000076-002
Page 7-12
ELECTRICAL COMPONENT BOX, DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
1012295
1015521
1015741
102420201
****
102420401
102420501
102447901
102448001
102492201
102492301
1108
332
Fuse, 10-Amp ...............................................................................................................................................
Screw, 1/4-20 X .88 Hex Hd Cap ............................................................................................................
Fuse Block .....................................................................................................................................................
Relay, Mini ISO, SPDT ................................................................................................................................
Connector, Relay ........................................................................................................................................
Plate, Electrical ............................................................................................................................................
Cover, Electrical ..........................................................................................................................................
Fastener, Push-in ........................................................................................................................................
Rivet, Drive ...................................................................................................................................................
Fuse, 25-Amp ...............................................................................................................................................
Fuse, 30-Amp ...............................................................................................................................................
Locknut, 1/4-20 Dimpled ........................................................................................................................
1
1
1
3
4
1
1
8
2
1
2
2
1
**** Special order item available upon request.
Page 7-13
7
G
E
D
7
G
E
D
13
5
2
3
4
11
9
10
12
8
15
7
14
6
000543-005
Page 7-14
ELECTRICAL COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
N/A
1012986
1016630
101802601
101991101
102051601
102051701
102198001
102375401
102869401
102977501
103180101
103193401
103208801
103234401
Instl, Elec Sys, 2300 Restyle (includes items 2 through 15) .........................................................
Lockwasher, M4 .....................................................................................................................................
Light, Oil ...................................................................................................................................................
Plug, Hole ................................................................................................................................................
Nut, M4-0.7 .............................................................................................................................................
Spacer, Keyswitch .................................................................................................................................
Nut, Key Switch .....................................................................................................................................
Receptacle, Accessory .........................................................................................................................
Light, Indicator, Coolant Temp ........................................................................................................
Switch, Rocker, Light ...........................................................................................................................
Light, Indicator, Seat Belt ...................................................................................................................
Cover, Hole, Switch, Rocker ...............................................................................................................
Gauge, Fuel,hr,seatbelt Timer ..........................................................................................................
Keyswitch, 12v, Diesel .........................................................................................................................
Keys (set of 2) .........................................................................................................................................
1
2
1
3
2
1
1
1
1
1
1
3
1
1
1
Page 7-15
7
G
E
D
7
G
2
4
E
1
D
5
3
9
6
10
7
11
8
000077-002
Page 7-16
BATTERY – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
1010934
1014375
101898001
102355301
102442201
102448401
102448501
102498201
N/A
1241
7473
Screw, 5/16-18 X 1.00 Hex Cap ..............................................................................................................
Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ...............................................................................
Clamp, Battery .............................................................................................................................................
Lockwasher, #10 Split Ss ..........................................................................................................................
Asm, #6 Red Wire .......................................................................................................................................
Wire Asm, #6 Blk, Awd, 350 ....................................................................................................................
Wire Asm, #6 Blk, Awd, 325 ....................................................................................................................
Bolt, M10 X 1.25 X 25 Loctite .................................................................................................................
Battery, Start, 12v .......................................................................................................................................
Washer, 5/16 Type A Flat .........................................................................................................................
Locknut, 5/16-18 Nylon Insert ...............................................................................................................
1
2
1
2
1
1
1
1
1
1
1
Page 7-17
7
G
E
D
7
G
E
D
DIESEL ENGINE – CLOSED BREATHER
8
G
E
D
8
G
E
D
12
28
20
9
24
17
30
4
19
22
30
23
19
30
8
18
27
1
7
11
29
30
16
15
6
14
10
25
3
29
4
16
30
26
21
5
13
2
4
000025-002
Page 8-2
KUBOTA D722 DIESEL ENGINE MOUNTING
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
1012769
101833101
101833201
102298401
102370101
102370501
102370601
102382401
102410603
102414701
102414801
102462301
102462501
102465901
102490101
102490201
102490501
102494401
102498201
102618601
102621301
102621501
102670701
102934601
96701412
96704622
96704721
96718978
96741038
96741046
Screw, M6-1.00 X 25mm Hex Cap ........................................................................................................
Stud, M8-1.25 X 50 mm Two-Ended ....................................................................................................
Stud, M8-1.25 X 60mm Two-Ended .....................................................................................................
Spacer, Engine, Diesel ..............................................................................................................................
Isolator Ring and Bushing .......................................................................................................................
Washer, Snubbing, Ring N Bush ...........................................................................................................
Bracket, FNR Trans Cable .........................................................................................................................
P-Clamp, Insulated .312 In ......................................................................................................................
Plate, Engine Mounting, Weld, Left-Hand .........................................................................................
Plate, Engine Mounting, Weld, Right-Hand ......................................................................................
Hose, Vent, Transmission .........................................................................................................................
Cover, CVT Inner, Diesel ...........................................................................................................................
Shaft, CVT Adapter ....................................................................................................................................
Bolt, M10 X 1.5 X 20 Loctite ....................................................................................................................
Bolt, M8 X 1.25 X 25 Loctite ....................................................................................................................
Bolt, M10 X 1.5 X 100 Loctite .................................................................................................................
Bracket, Transmission Mounting ..........................................................................................................
Bolt, M10 X 1.25 X 25 Loctite .................................................................................................................
Bolt, M8 X 1.25 X 40 with Loctite ..........................................................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Nut Flg M10 X 1.5 Nylon ..........................................................................................................................
Engine, Kubota, D722, with Closed Breather, 60a ..........................................................................
Washer, M12 Hard ......................................................................................................................................
Locknut, M12x1.75 Nylon Insert ...........................................................................................................
Bolt, M12 X 1.75 X 90 ................................................................................................................................
Bolt, M8 X 1.25 X 80 ...................................................................................................................................
Washer, M8 Hard ........................................................................................................................................
Washer, M10 Hard ......................................................................................................................................
3
1
1
7
1
4
4
1
1
1
1
1
1
1
4
7
1
2
8
1
3
3
1
1
4
4
4
1
10
12
Page 8-3
8
G
E
D
8
G
15
E
4
D
16
13
12
11
11
14
3
2
5
21
19
6
18
17
11
10
9
20
12
6
7
8
2
2
-
15
1
000039-001
Page 8-4
CRANKCASE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
102600001
102600101
102600201
102600401
102600601
102600701
102600801
102601001
102601301
102726201
102726301
102726401
102726501
102726601
N/A
102600301
102601401
102631601
N/A
102730801
102732601
Engine Block (includes items 2 through 15) ....................................................................................
Pin, Pipe, Dia 8 X 14 ..............................................................................................................................
Pin, Straight, Dia 5 X 10 ......................................................................................................................
Pin, Pipe, Dia 7 X 14 ..............................................................................................................................
Pin, Straight, Dia 8 X 16 ......................................................................................................................
Plug, 1/8" .................................................................................................................................................
Plug, 3/32" ...............................................................................................................................................
Plug, 1/4" .................................................................................................................................................
Pin, Pipe, Dia 8 X 11 ..............................................................................................................................
Cap, Sealing, Small ...............................................................................................................................
Cap, Sealing, Med .................................................................................................................................
Cap, Sealing, Large ...............................................................................................................................
Cover, Fuel Camshaft ...........................................................................................................................
Plug, Expansion .....................................................................................................................................
Block, Engine ..........................................................................................................................................
O Ring, 8 X 7 .................................................................................................................................................
Cock, Drain ...................................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Plate, Engine Block ....................................................................................................................................
Switch, Oil Pressure ...................................................................................................................................
Gasket, Fuel Pump, D722 ........................................................................................................................
1
2
2
1
2
3
5
1
2
3
5
2
1
1
1
1
1
2
1
1
1
Page 8-5
8
G
E
D
8
G
E
D
7
2
6
1
5
4
3
000040-001
Page 8-6
OIL PAN
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102605101
102606901
102607001
102607201
102607301
102607401
102654601
Bolt, M6 X 1 X 14 .........................................................................................................................................
Bolt, M8 X 1.25 X 15 ...................................................................................................................................
Oil Pan ............................................................................................................................................................
Plug, Drain, M12 X 14 ...............................................................................................................................
Gasket, 20 X 13 ............................................................................................................................................
Filter, Oil, Pick Up ........................................................................................................................................
O Ring, 20 X 17 ............................................................................................................................................
22
1
1
1
1
1
1
Page 8-7
8
G
E
D
8
G
E
D
10
11
2
12
7
3
13
6
4
5
9
1
9
-
13
8
000041-002
Page 8-8
CYLINDER HEAD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102600301
102652801
102653901
102654101
102701001
102726701
102727101
102798001
102600801
102653401
102653501
102726901
102727001
O Ring, 8 X 7 .................................................................................................................................................
Bolt, Cylinder Head ....................................................................................................................................
Hook, Engine ...............................................................................................................................................
Gasket, Cylinder Head ..............................................................................................................................
Spring, Start .................................................................................................................................................
Bolt, Engine Hook ......................................................................................................................................
Stay, Cylinder Head ...................................................................................................................................
Head, Cylinder, Complete (includes items 9 through 13) ............................................................
Plug, 3/32" ...............................................................................................................................................
Guide, Exhaust Valve ...........................................................................................................................
Guide, Inlet Valve ..................................................................................................................................
Cap, Sealing, Head ...............................................................................................................................
Cap, Sealing, Head, Top ......................................................................................................................
1
14
2
1
1
2
1
1
1
3
3
1
2
Page 8-9
8
G
E
D
8
G
E
D
17
18
19
14
10
12
9
1
2
3
8
4
7
6
7
5
11
13
9
16
000042-002
Page 8-10
GEAR CASE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102601801
102601901
102602001
102602101
102602301
102602401
102602601
102602701
102602801
102654301
102703301
102727401
102727501
102729301
N/A
102601001
102727601
N/A
102798201
O Ring, 18 X 13 ............................................................................................................................................
Spring, Valve ................................................................................................................................................
Ball, Valve ......................................................................................................................................................
Seat, Valve .....................................................................................................................................................
Joint, Pipe .....................................................................................................................................................
Washer, Plain, Special ...............................................................................................................................
Bolt, M6 X 1 X 60 .........................................................................................................................................
Seal, Oil ..........................................................................................................................................................
Bolt, D722, Front Case ..............................................................................................................................
Bolt, D722 Intake Manfld Lower ...........................................................................................................
Filter, Engine Oil, D722 .............................................................................................................................
Bolt, Gearcase, Top ....................................................................................................................................
Bolt, Gearcase, Lower ...............................................................................................................................
Gasket, Gearcase, D722 ...........................................................................................................................
Case, Gear (includes items 16 through 19) .......................................................................................
Plug, 1/4" .................................................................................................................................................
Screw, Breather .....................................................................................................................................
Case, Gear ................................................................................................................................................
Stay, Spring .............................................................................................................................................
3
1
1
1
1
1
2
1
9
1
1
2
1
1
1
2
2
1
1
Page 8-11
8
G
E
D
8
G
E
D
9
12
8
7
11
13
4
2
1
10
6
5
000181-001
Page 8-12
HEAD COVER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102644001
102644101
102798401
102633301
102798501
102798601
102799001
102799101
102799201
N/A
102798701
102798801
102798901
O Ring, 30 X 36 ............................................................................................................................................
Plug, Oil Filler ...............................................................................................................................................
Assembly, Cylinder Head Cover (includes items 4 through 10) ................................................
Pipe, Water Return, D722 ...................................................................................................................
Gasket, Cylinder Head Cover ............................................................................................................
Shield, Breather .....................................................................................................................................
Valve, Breather .......................................................................................................................................
Cover, Breather ......................................................................................................................................
Screw, Breather .....................................................................................................................................
Cover, Cylinder Head ...........................................................................................................................
Bolt, Cylinder Head Cover .......................................................................................................................
Tube, Breather .............................................................................................................................................
Clamp, Breather Tube ...............................................................................................................................
1
1
1
1
1
1
1
1
4
1
4
1
2
Page 8-13
8
G
E
D
8
G
E
D
1
2
000044-002
Page 8-14
DIPSTICK AND GUIDE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
102606701
102727701
Gauge, Oil .....................................................................................................................................................
Guide, Oil Gauge ........................................................................................................................................
1
1
8
G
E
D
Page 8-15
8
G
E
D
5
4
3
2
1
6
000045-001
Page 8-16
OIL PUMP
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102606201
102606301
102606401
102606501
102606601
102727901
Nut, Flange, D722 Oil Pump ...................................................................................................................
Gear, Oil Pump Drive .................................................................................................................................
Key, Feather, 8x4 .........................................................................................................................................
Assy, Pump, Oil ............................................................................................................................................
Gasket, Oil Pump ........................................................................................................................................
Bolt, Oil Pump .............................................................................................................................................
1
1
1
1
1
3
Page 8-17
8
G
E
D
8
G
E
D
10
12
11
3
2
1
4
5
5
5
6
7
9
8
8
000046-001
Page 8-18
MAIN BEARING CASE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
102608201
102608301
102608601
102608701
102608901
102609101
102609301
102609401
102609601
102728001
102608401
102608501
Gasket, Bearing Case ................................................................................................................................
Gasket, Cover ...............................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Bolt, M6 X 1 X 22 .........................................................................................................................................
Bolt, Bearing Case, Top .............................................................................................................................
Assy Case, Main Brg, First ........................................................................................................................
Assy Case, Main Brg, Sec ..........................................................................................................................
Bolt, Bearing Case, Bottom .....................................................................................................................
Assy Case, Main Brg, Third ......................................................................................................................
Assy, Cover, Bearing Case (includes items 11 and 12) ..................................................................
Cover, Bearing Case .............................................................................................................................
Seal, Oil .....................................................................................................................................................
1
1
8
8
6
1
1
2
1
1
1
1
Page 8-19
8
G
E
D
8
G
E
D
6
5
2
3
4
8
16
9
7
15
1
14
11
10
13
12
000047-002
Page 8-20
CAMSHAFT AND IDLE GEAR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
102604201
102604901
102603201
N/A
102605001
102605101
102605301
102605401
102605501
102605801
102605601
102605901
102606001
N/A
102799401
102654401
Bolt, D722, Cam End .................................................................................................................................
Gear, Idle (includes items 3 and 4) .......................................................................................................
Bushing, D722 Idle Gear .....................................................................................................................
Gear, Idle ..................................................................................................................................................
Shaft, Idle Gear ............................................................................................................................................
Bolt, M6 X 1 X 14 .........................................................................................................................................
Ring, Snap .....................................................................................................................................................
Push Rod .......................................................................................................................................................
Tappet ............................................................................................................................................................
Assy Camshaft, Long (includes items 11 through 15) ..................................................................
Key, Feather, Long Camshaft ............................................................................................................
Gear, Cam ................................................................................................................................................
Stopper, Camshaft ................................................................................................................................
Camshaft .................................................................................................................................................
Ball, Check ...............................................................................................................................................
Collar, Idle Gear ...........................................................................................................................................
2
1
1
1
1
3
1
6
6
1
1
1
1
1
1
1
Page 8-21
8
G
E
D
8
G
E
D
2
3
11
36 37
24
26
35
25
34
9
4
12 13 14
10
6
7
8
5
15 16 17
1
18 19 20
30
31
32
33
21 22 23
27 28 29
000048-002
Page 8-22
PISTON AND CRANKSHAFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
102604401
102607601
102607602
102607801
102607901
102630701
N/A
102630703
102732201
N/A
102608101
102608801
N/A
102608803
102608804
N/A
102608806
102609001
N/A
102609003
102609801
N/A
102609803
102610001
102608001
N/A
102630001
N/A
102630003
102630101
102630201
102630301
102630401
102630901
102631001
102728101
102728102
Key, Feather, Short Camshaft .................................................................................................................
Assy Piston Ring, D722 Std .....................................................................................................................
Assy Piston Ring, D722 +.025 ................................................................................................................
Assy, Connecting Rod (includes items 5 through 10) ...................................................................
Bolt, Connecting Rod ..........................................................................................................................
Metal, Crank, Rod, D722, Std ............................................................................................................
Metal, Crank, Rod, D722, .020 ..........................................................................................................
Metal, Crank, Rod, D722, .040 ..........................................................................................................
Bushing, Piston Pin, D722 ..................................................................................................................
Rod, Connecting ...................................................................................................................................
Sleeve, Crankshaft .....................................................................................................................................
Metal,crank, O Side, Std ...........................................................................................................................
Metal,crank, O Side, +.020 ......................................................................................................................
Metal,crank, O Side, +.040 ......................................................................................................................
Metal,crank, I Side, Std .............................................................................................................................
Metal,crank, I Side, +.020 ........................................................................................................................
Metal,crank, I Side, +.040 ........................................................................................................................
Metal, Crank, Main, Rear Std ..................................................................................................................
Metal, Crank, Main, Rear -.020 ...............................................................................................................
Metal, Crank, Main, Rear -.040 ...............................................................................................................
Metal, Crank, Main, Mid Std ...................................................................................................................
Metal, Crank, Main, Mid +.020 ...............................................................................................................
Metal, Crank, Main, Mid +.040 ...............................................................................................................
Crankshaft (includes items 25 and 26) ...............................................................................................
Ball, Crankshaft ......................................................................................................................................
Crankshaft ...............................................................................................................................................
Metal, Crank, D722, Frnt, Std .................................................................................................................
Metal, Crank, 722, Frnt, -.020 .................................................................................................................
Metal, Crank, 722, Frnt, -.040 .................................................................................................................
Gear, Crank ...................................................................................................................................................
Slinger, Oil .....................................................................................................................................................
O Ring, 23 X 26 ............................................................................................................................................
Collar, Crankshaft .......................................................................................................................................
Circlip, Piston Pin ........................................................................................................................................
Pin, Piston .....................................................................................................................................................
Piston, D722, Std ........................................................................................................................................
Piston, D722, +0.25 ....................................................................................................................................
1
3
3
3
6
3
3
3
3
1
1
2
2
2
2
2
2
1
1
1
4
2
2
1
3
1
1
1
1
1
1
1
1
6
3
3
3
Page 8-23
8
G
E
D
8
G
E
D
5
1
6
4
3
2
000049-001
Page 8-24
FLYWHEEL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102647501
102647801
102647901
N/A
102648001
102728301
Plate, Rear End ............................................................................................................................................
Flywheel (includes items 3 and 4) ........................................................................................................
Gear, Ring, D722 ....................................................................................................................................
Flywheel ...................................................................................................................................................
Bolt, Flange Head, M10 X 1.5 X 25 .......................................................................................................
Bolt, End Plate .............................................................................................................................................
1
1
1
1
5
10
Page 8-25
8
G
E
D
8
G
E
D
14
1
3
2
13
12
11
10
9
8
7
4
6
5
000050-001
Page 8-26
SHAFT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
102604201
102604701
N/A
102728401
102603601
102603701
102603801
102603901
102604001
102604101
102604301
102604401
102604501
102728501
Bolt, D722, Cam End .................................................................................................................................
Circlip, External ...........................................................................................................................................
Stopper, Fuel, C/shaft ...............................................................................................................................
Assy, Fuel Camshaft (includes items 5 through 13) .......................................................................
Gear, Injection Pump ...........................................................................................................................
Ball, Injection Pump .............................................................................................................................
Sleeve, Governor ...................................................................................................................................
Ball, Governor ........................................................................................................................................
Case, Governor Ball ..............................................................................................................................
Circlip ........................................................................................................................................................
Bearing, Ball ............................................................................................................................................
Key, Feather, Short Camshaft ...........................................................................................................
Camshaft, Fuel, Short ..........................................................................................................................
Bearing, Ball .................................................................................................................................................
2
1
1
1
1
8
1
32
1
1
1
1
1
1
Page 8-27
8
G
E
D
8
G
7
E
11
5
6
D
11
2
8
10
9
12
1
13
3
4
000051-002
Page 8-28
IDLE APPARATUS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102635301
102635701
102637001
102637101
102728601
102635501
102635801
102635901
102728701
N/A
102728801
102728901
102799501
Gasket, 6 X 10 ..............................................................................................................................................
Cap, Bolt Assy ..............................................................................................................................................
Nut, Lock, Special .......................................................................................................................................
Nut, Special ..................................................................................................................................................
Assy, Idle Apparatus (includes items 6 through 11) ......................................................................
Nut, M8, D722 Idle App, Specl .........................................................................................................
Nut, M8, D722 Idle App ......................................................................................................................
Assy, Bolt, Adjusting (includes items 9 and 10) .........................................................................
Spring, Idle Apparatus ..................................................................................................................
Stud, Idle Adjustment ...................................................................................................................
Gasket, Idle Apparatus, Rear .............................................................................................................
Gasket, Idle Apparatus, Front ................................................................................................................
Bolt, Idle Adjusting ....................................................................................................................................
1
1
1
1
1
1
1
1
1
1
2
1
1
Page 8-29
8
G
E
D
8
G
E
D
2
4
5
3
1
6
000182-001
Page 8-30
STOP SOLENOID
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102640601
102729101
102799601
102799701
102799801
N/A
Washer, Spring, M6, D722 .......................................................................................................................
Bolt, Solenoid, Stop, D722 ......................................................................................................................
Solenoid, Stop .............................................................................................................................................
Stay, Stop Solenoid ...................................................................................................................................
O-Ring, Stop Solenoid ..............................................................................................................................
Bolt, Stop Solenoid ....................................................................................................................................
2
2
1
1
1
2
Page 8-31
8
G
E
D
8
G
E
D
4
8
13
2
9
3
14
5
11
7
12
1
11
15
6
10
000057-003
Page 8-32
60-AMP ALTERNATOR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
102630601
102631601
102647701
102701201
102730201
102730401
102730601
102731301
102732501
102800701
102801001
102934701
102934801
102934901
103239901
Pulley, Fan Drive .........................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Nut, M8, Plate ..............................................................................................................................................
Pulley, Water Pump ...................................................................................................................................
Collar, Alternator Assy, D722 ..................................................................................................................
Bolt, Alt, D722, Adjuster ...........................................................................................................................
Bolt, Alt, D722, Drive Pulley ....................................................................................................................
Bolt, D722, Drive Pulley ...........................................................................................................................
Washer, Spring, D722, Starter ................................................................................................................
Bolt, Alternator, Lower .............................................................................................................................
Washer, Alternator, Upper ......................................................................................................................
Alternator, 60 Amp ....................................................................................................................................
Brkt, Alt, D722, 60 Amp ............................................................................................................................
Belt, Acc Drive, D722, 60 Amp ...............................................................................................................
Guard, Acc Belt ............................................................................................................................................
1
2
1
1
1
1
1
4
1
1
2
1
1
1
1
Page 8-33
8
G
E
D
8
G
9
E
10
D
8
1
11
2
3
2
4
5
6
7
000053-002
Page 8-34
INJECTION PUMP
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
102640501
102640601
102640701
102640901
102641001
102641101
102641201
102800101
102637701
102640401
N/A
Bolt, Hex-Head, M5 X 0.75 X ...................................................................................................................
Washer, Spring, M6, D722 .......................................................................................................................
Nut, Special ..................................................................................................................................................
Shim, Injection Pump, 0.20 mm ............................................................................................................
Stud, M5 X 25 ...............................................................................................................................................
Assembly, Fuel Injection Pump (includes items 9 through 11) .................................................
Screw, Hollow, D722, Inj Pump ........................................................................................................
Joint, Eye ..................................................................................................................................................
Pump, Injection .....................................................................................................................................
2
4
2
1
1
1
2
1
1
1
1
Page 8-35
8
G
E
D
8
G
6
E
15
14
D
7
13
8
12
5
9
10
16
17
1
18
11
19
4
2
3
000054-002
Page 8-36
SPEED CONTROL PLATE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102634501
102635201
102635301
102654301
102800401
102633701
102633801
102633901
102634001
102634101
102634401
102634601
102634701
102729401
102729501
N/A
N/A
102800501
102800601
Gasket, Control Plate ................................................................................................................................
Bolt, M6 X 1 X 30 .........................................................................................................................................
Gasket, 6 X 10 ..............................................................................................................................................
Assembly, Speed Plate (includes items 6 through 19) .................................................................
Lever, Engine Stop ................................................................................................................................
Nut, Speed Control ..............................................................................................................................
Lever, Speed Control ...........................................................................................................................
O Ring, 19 X 16 ......................................................................................................................................
Plate, Speed Control ............................................................................................................................
O Ring, 9 X 7 ...........................................................................................................................................
Collar, Lever ............................................................................................................................................
Spring, Return ........................................................................................................................................
Cap, Speed Cntrl Plate Rtrn ...............................................................................................................
Pin, Spring, Speed Plate .....................................................................................................................
Nut, Speed Control ..............................................................................................................................
Bolt, Speed Control ..............................................................................................................................
Lever, Governor .....................................................................................................................................
Shaft, Governor Lever .........................................................................................................................
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
Page 8-37
8
G
E
D
8
G
E
4
D
3
5
6
7
8
9
1
10
17
19
16
11
18
14
12
13
15
2
000055-001
Page 8-38
NOZZLE HOLDERS AND GLOW PLUGS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102605701
102635301
102642401
102642501
102642601
102642801
102642901
102643001
102643101
102643201
102643301
102643401
102729601
N/A
102643701
102729701
102641501
102642701
102643601
Assy Pipe, D722 Fuel Over Flow ............................................................................................................
Gasket, 6 X 10 ..............................................................................................................................................
Cord, Glow Plug ..........................................................................................................................................
Nut, Flange,m4 ............................................................................................................................................
Glow Plug .....................................................................................................................................................
Screw, Washer .............................................................................................................................................
Clamp, Pipe, Top .........................................................................................................................................
Pipe, Injection, Left ....................................................................................................................................
Pipe, Injection, Right .................................................................................................................................
Pipe, Injection, Middle .............................................................................................................................
Clamp, Pipe, Bottom .................................................................................................................................
Assy Pipe, Over Flow (includes items 13 and 14) ...........................................................................
Clip, Pipe, Return ..................................................................................................................................
Hose, Overflow ......................................................................................................................................
Screw, Air Bleeder ......................................................................................................................................
Kit, Holder, Nozzle (includes items 17 through 19) .......................................................................
Assembly, Nozzle Holder ...................................................................................................................
Seal, Heat .................................................................................................................................................
Gasket, Nozzle .......................................................................................................................................
1
1
1
3
3
2
2
1
1
1
2
1
2
1
1
3
3
3
3
Page 8-39
8
G
E
D
8
G
E
D
1
3
10
11
12
9
2
8
5
4
7
6
000056-002
Page 8-40
GOVERNOR COMPONENTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
102635101
102636301
102800201
102800301
102636201
102636401
102636501
N/A
N/A
102633601
102636601
N/A
Spring, Governor ........................................................................................................................................
Bolt, M5 X 0.75 X 25 ...................................................................................................................................
Spring, Start .................................................................................................................................................
Assembly, Governor Fork (includes items 5 through 9) ...............................................................
Holder, Fork Lever ................................................................................................................................
Bolt, M5 X 0.75 X 11 .............................................................................................................................
Washer, Spring, M5 ..............................................................................................................................
Lever, Fork, Middle, D722 CB ............................................................................................................
Assembly, Governor Fork Level, Lower, D722 CB (includes items 10 through 12) ........
Pin, Spring .........................................................................................................................................
Shaft, Fork Lever .............................................................................................................................
Lever, Fork, End, D722 CB ............................................................................................................
1
2
1
1
1
1
1
1
1
1
1
1
Page 8-41
8
G
E
D
8
G
E
D
2
5
3
4
5
1
3
000058-001
Page 8-42
STARTER
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
102645501
102647701
102648401
102648501
102732501
Nut, D722, Starter ......................................................................................................................................
Nut, M8, Plate ..............................................................................................................................................
Bolt, M8 X 1.25 X 28 ...................................................................................................................................
Motor, Starter ..............................................................................................................................................
Washer, Spring, D722, Starter ................................................................................................................
2
2
2
1
4
Page 8-43
8
G
E
D
8
G
E
10
9
D
12
19
5
11
7
6
14
8
18
2
13
15
4
3
1
16
17
000062-002
Page 8-44
VALVES AND ROCKER ARMS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102646401
102651301
102651601
102651801
102652001
102651501
102651701
N/A
102652601
102652701
102652901
102653001
102653101
102653201
102653301
102653601
102653701
102801101
102801201
Bolt, M6 X 1 X 8 ...........................................................................................................................................
Washer, D722, Plain, Rocker ...................................................................................................................
Washer, Rocker Arm ..................................................................................................................................
Pin, Spring, D722, Rocker ........................................................................................................................
Assy Rocker Arm (includes items 6 through 8) ...............................................................................
Nut, M6 .....................................................................................................................................................
Screw-Adjusting ....................................................................................................................................
Arm, Rocker ............................................................................................................................................
Shaft, Rocker Arm ......................................................................................................................................
Spring, Rocker Arm ...................................................................................................................................
Collet, Valve Spring, Set ...........................................................................................................................
Cap, Valve, D722 .........................................................................................................................................
Spring, Valve ................................................................................................................................................
Retainer, Spring ..........................................................................................................................................
Seal, Valve Stem ..........................................................................................................................................
Valve, Exhaust ..............................................................................................................................................
Valve, Inlet ....................................................................................................................................................
Bracket, Rocker Arm, D722 Closed-Breather ....................................................................................
Bolt, Rocker Arm .........................................................................................................................................
2
2
2
1
6
6
6
1
1
2
6
6
6
6
6
3
3
3
3
Page 8-45
8
G
E
D
8
G
E
D
3
1
5
6
4
2
000063-002
Page 8-46
DIESEL INLET MANIFOLD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102646101
102654301
102801301
102646001
102801401
102801501
Bolt, M6 X 1 X 45 .........................................................................................................................................
Assembly, Intake Manifold (includes items 4 through 6) ............................................................
Gasket, Intake Manifold .....................................................................................................................
Pipe, Breather .........................................................................................................................................
Manifold, Intake ....................................................................................................................................
3
2
1
1
1
1
Page 8-47
8
G
E
D
8
G
E
D
3
2
7
1
6
5
4
7
000064-001
Page 8-48
EXHAUST MANIFOLD
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102646301
102646501
102646601
102647101
102647201
102731501
102731601
Cover, Heat Proof .......................................................................................................................................
Stud, M6 X 26 ...............................................................................................................................................
Gasket, Ex-manifold ..................................................................................................................................
Nut, Flange, M6, Ubs .................................................................................................................................
Bolt, Flange Head, M6 X 1 X 16 .............................................................................................................
Manifold, Exhaust, D722 ..........................................................................................................................
Bolt, D722, Exhst Manfld Cover .............................................................................................................
1
3
1
3
3
1
2
Page 8-49
8
G
E
D
8
G
11
E
12
9
D
4
2
1
10
5
6
3
7
13
8
20
26
27
25
22
21
15
14
24
19
23
17
18
16
000065-001
Page 8-50
GASKET KITS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
102731801
102422301
102600301
102633401
102635301
102644001
102644501
102646001
102646601
102653301
102654101
102654701
102798501
102731901
102601801
102606601
102608201
102608301
102630301
102632701
102634001
102634401
102634501
102654601
102728801
102729301
102732601
Kit, Gasket Upper, D722 (includes items 2 through 13) ...............................................................
Gasket, Exhaust Diesel ........................................................................................................................
O Ring, 8 X 7 ...........................................................................................................................................
Gasket, Thermostat ..............................................................................................................................
Gasket, 6 X 10 .........................................................................................................................................
O Ring, 30 X 36 ......................................................................................................................................
Gasket, Head Cover ..............................................................................................................................
Gasket, Intake Manifold .....................................................................................................................
Gasket, Ex-manifold .............................................................................................................................
Seal, Valve Stem ....................................................................................................................................
Gasket, Cylinder Head .........................................................................................................................
Gasket, Water Flange ..........................................................................................................................
Gasket, Cylinder Head Cover ............................................................................................................
Kit, Gasket Lower, D722 (includes items 15 through 27) .............................................................
O Ring, 18 X 13 ......................................................................................................................................
Gasket, Oil Pump ..................................................................................................................................
Gasket, Bearing Case ...........................................................................................................................
Gasket, Cover .........................................................................................................................................
O Ring, 23 X 26 ......................................................................................................................................
Gasket, Water Pump, D722 ...............................................................................................................
O Ring, 19 X 16 ......................................................................................................................................
O Ring, 9 X 7 ...........................................................................................................................................
Gasket, Control Plate ...........................................................................................................................
O Ring, 20 X 17 ......................................................................................................................................
Gasket, Idle Apparatus, Rear .............................................................................................................
Gasket, Gearcase, D722 ......................................................................................................................
Gasket, Fuel Pump, D722 ...................................................................................................................
1
1
1
1
3
1
1
1
1
6
1
1
1
1
3
1
1
1
1
1
1
1
1
1
2
1
1
Page 8-51
8
G
E
D
8
G
E
D
2
1
5
3
4
3
6
000066-001
Page 8-52
PISTON KIT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102732001
102607601
102630901
102631001
102728101
102732201
Kit, Piston Rebuild, D722 (includes items 2 through 6) ................................................................
Assy Piston Ring, D722 Std ................................................................................................................
Circlip, Piston Pin ..................................................................................................................................
Pin, Piston ................................................................................................................................................
Piston, D722, Std ...................................................................................................................................
Bushing, Piston Pin, D722 ..................................................................................................................
1
1
2
1
1
1
Page 8-53
8
G
E
D
8
G
E
D
FUEL, INTAKE, & GOVERNOR SYSTEM
9
G
E
D
9
G
E
D
15
10
11
9
20
3
19
7
9
1
17
13
8
22
4
5
21
18
16
23
9
4
9
6
12
14
000081-003
Page 9-2
FUEL SYSTEM – DIESEL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
102410801
N/A
101313402
1013746
101587703
101824401
102289001
102410602
102411203
102426301
102430001
102430101
102430201
102430301
102430401
102434601
102434701
102434801
102466201
102618601
102670801
102710301
96705587
Pump, Diesel Fuel Electric .......................................................................................................................
Asm, Fuel System, Kubota (includes items 3 through 23) ...........................................................
Clamp, Green Hose ..............................................................................................................................
Clamp, 0.301 ID Hose ..........................................................................................................................
Hose, Fuel, Vent, 22" Long .................................................................................................................
Vent Barb .................................................................................................................................................
Screw, M8X1.25X30, Hex ....................................................................................................................
P-Clamp, Insulated 1.75 In .................................................................................................................
Clamp, Hose, Ctb 14mm ....................................................................................................................
Strap, Tank, Fuel ....................................................................................................................................
Hose, Tank To Prefilter Diesel ...........................................................................................................
Hose, Fuel Prefilter To Pump .............................................................................................................
Hose, Fuel Pump To Filter ..................................................................................................................
Hose, Fuel Filter To Eng ......................................................................................................................
Hose, Fuel Return .................................................................................................................................
Filter Assy, Fuel ......................................................................................................................................
Filter, Fuel ................................................................................................................................................
Adapter, 90, 5/16 Tube .......................................................................................................................
Bezel, Fuel Fill .........................................................................................................................................
Screw, M6 X 1 X 25 Thd Form ...........................................................................................................
Plate, Fuel/Oil System .........................................................................................................................
Bolt, M8 X 1.25 X 30 .............................................................................................................................
1
1
1
2
1
1
5
1
6
1
1
1
1
1
1
1
1
2
1
3
1
1
2
Page 9-3
9
G
E
D
9
G
E
16
D
6
15
2
7
8
3
11
5
12
4
13
10
9
14
000082-005
Page 9-4
FUEL TANK – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
102952101
1013461
1013462
1015139
1015143
1016
N/A
N/A
102406701
102406801
102478501
102494701
102522001
N/A
183
8797
Asm, Tank, Fuel, Diesel, 4x4 (includes items 2 through 16) ........................................................
Screw, #10-16 Hex-Head Hi-Lo ........................................................................................................
Sending Unit, Fuel Level * .................................................................................................................
Insulation Grommet ............................................................................................................................
Vent, Fuel Tank ......................................................................................................................................
Lockwasher, #10 Split ..........................................................................................................................
Wire Asm, Blk, 170mm ........................................................................................................................
Wire Asm, Org, 170mm .......................................................................................................................
Bushing, Line, Return ..........................................................................................................................
Elbow, 90 Barbed ..................................................................................................................................
Pickup Tube, Fuel ..................................................................................................................................
Cap, Fuel (Diesel) ..................................................................................................................................
Gasket, Rubber ......................................................................................................................................
Tank, Fuel, Diesel, 4x4 .........................................................................................................................
Washer, #10 Type A Flat ......................................................................................................................
Nut, #10-32 Brass Hex .........................................................................................................................
1
5
1
1
1
1
1
1
2
1
1
1
1
1
1
1
* Note: Must replace fuel sending unit gasket when servicing this
component.
Page 9-5
9
G
E
D
9
G
3
5
1
E
D
6
4
5
1
2
000536-002
Page 9-6
CABLES – DIESEL VEHICLE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
1011084
102475701
102495801
102498801
102615801
8990
Nut, 1/4-28 Hex Jam .................................................................................................................................
Clip, Brake Line ............................................................................................................................................
Cable, Transmission Shift ........................................................................................................................
Cable, Accelerator, Diesel ........................................................................................................................
Joint, Ball, .346 Dia .....................................................................................................................................
Tie Wrap, 8" Nylon .....................................................................................................................................
2
3
1
1
2
1
Page 9-7
9
G
E
D
9
G
E
D
2
6
2
7
18
18
5
11
19
12
9
16
3
17
8
4
10
15
4
19
13
14
000026-001
Page 9-8
ACCELERATOR PEDAL ASSEMBLY – STYLE B
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
102489901
102296401
N/A
102442901
102445201
N/A
N/A
N/A
102469401
N/A
102476301
102476401
102479301
N/A
102618101
103273101
96706825
102618301
102618601
Asm, Pedal, Accelerator (includes items 2 through 17) ................................................................
Nut-m6x1.0 Flng All Mtl Lock ...........................................................................................................
Pullrod, Spring, Compression ...........................................................................................................
Bushing, Greaseless .............................................................................................................................
Spring, Comp, Pedal, Pullrod ............................................................................................................
Washer, Retaining Spring, 7mm ......................................................................................................
Guide, Cable, Accelerator ..................................................................................................................
Weldment, Bracket, Pedal ..................................................................................................................
Weldment, Lever, Motion, Lost ........................................................................................................
Spring, Torsion .......................................................................................................................................
Spring, Stop, Pedal ...............................................................................................................................
Bolt, Stop, Pedal ....................................................................................................................................
Pad, Grip Tape, Accelerator ...............................................................................................................
Weldment, Pedal, Accel ......................................................................................................................
Nut M6x1 Mech Def Center ..............................................................................................................
Bolt, Shoulder, M8 X 70, Hc ...............................................................................................................
Bolt, M6 X 1 X 70 ...................................................................................................................................
1
3
1
4
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
Page 9-9
9
G
E
D
9
G
E
1
D
3
10
13
11
8
9
12
4
5
5
7
6
3
2
000090-002
Page 9-10
INTAKE DUCT AND AIR BOX ASSEMBLY – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102379001
102395601
102411209
102541465
102621201
102621501
N/A
102810701
102498601
102725501
102725601
N/A
103441401
Hose, Intake, D722 .....................................................................................................................................
Hose, Intake, Primary ................................................................................................................................
Clamp, Hose, Ctb 55mm ..........................................................................................................................
Bolt, M 6 X 1.0 X 65 Hex, Flange, Head, Black ...................................................................................
Bolt Flanged Head, M8 X1.25x 16 with Loctite ...............................................................................
Nut Flg, M6 X 1.0 Nylon ...........................................................................................................................
Weldment, Support, Air Cleaner ..........................................................................................................
Filter, Air, Canister, W/labe (includes items 9 through 12) ..........................................................
Element, Filter, Air, 5 In .......................................................................................................................
Valve, Evacuator, Filter Air .................................................................................................................
Cap, Latch Lock, Filter, Air ..................................................................................................................
Body, Canister, Filter, Air .....................................................................................................................
Clamp, Worm Screw, Hose, 2" ................................................................................................................
1
1
3
2
2
2
1
1
1
1
1
1
1
Page 9-11
9
G
E
D
9
G
E
D
EXHAUST SYSTEM
10
G
E
D
10
G
5
E
D
10
8
7
9
6
4
4
11
2
3
000538-001
Page 10-2
EXHAUST SYSTEM
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
N/A
101887601
102298720
102409501
102621201
102786201
102812801
102409501
N/A
N/A
102930901
Instl, Exhaust, AWD (includes items 2 through 11) ........................................................................
Locknut, M6-1.00 Nylon Insert ........................................................................................................
M8-1.25x20 Taptite ..............................................................................................................................
Spring, Exhaust ......................................................................................................................................
Bolt Flanged Head, M8 X1.25x 16 with Loctite ..........................................................................
Pipe, Exhaust, Int, Offset ....................................................................................................................
Asm, Muffler, AWD Homologation (includes items 8 through 10) .....................................
Spring, Exhaust ...............................................................................................................................
Muffler ................................................................................................................................................
Bracket, Muffler ...............................................................................................................................
Shield, Exhaust, Clearance ................................................................................................................
1
1
2
4
2
1
1
4
1
1
1
Page 10-3
10
G
E
D
10
G
E
D
6
5
1
4
3
2
000538-003
Page 10-4
EXHAUST PIPES – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102298401
102409301
102422301
102621301
102628101
102731601
Pipe, Exhaust Diesel Main .......................................................................................................................
Gasket, Exhaust Diesel .............................................................................................................................
Bolt, M8 X 1.25 X 40 with Loctite ..........................................................................................................
Shield, Diesel Exhaust ..............................................................................................................................
Bolt, D722, Exhst Manfld Cover .............................................................................................................
3
1
1
3
1
1
Page 10-5
10
G
E
D
10
G
E
D
CLUTCHES
11
G
E
D
11
G
E
D
1
2
4
3
000008-002
Page 11-2
CLUTCH COVER (STANDARD)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
102296716
102411210
N/A
103320601
Screw, M6 X 16 Tt Hx Fl Hd .....................................................................................................................
Clamp, Hose, Ctb 64mm ..........................................................................................................................
Cover, Cvt, Open .........................................................................................................................................
Hose, Outlet, Cvt ........................................................................................................................................
7
1
1
1
Page 11-3
11
G
E
D
11
G
E
D
8
3
10
9
2
4
4
11
6
7
4
5
2
1
Page 11-4
11
000008-001
CLUTCH COVER (SEALED)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
102616003
101856102
102296716
102411210
102414501
102481001
102481201
102481301
102616101
102628001
103320601
Kit, Sealed CVT Cover (includes items 2 through 11) ....................................................................
Screw, 1/4-15 X 1.50 Hi-lo Hex .........................................................................................................
Screw, M6 X 16 Tt Hx Fl Hd ................................................................................................................
Clamp, Hose, Ctb 64mm ....................................................................................................................
Cover, CVT Outer ..................................................................................................................................
Hose, Inlet, Cover, CVT ........................................................................................................................
Bracket, Inlet, Cover, CVT ...................................................................................................................
Gasket, Cover, CVT ...............................................................................................................................
Cap, Inlet, Cover, CVT ..........................................................................................................................
Filter, Inlet, Cover, CVT ........................................................................................................................
Hose, Outlet, Cvt ...................................................................................................................................
1
3
7
2
1
1
1
1
1
1
1
Page 11-5
11
G
E
D
11
G
E
1
D
000084-001
Page 11-6
DRIVE BELT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
102374901
Belt, Drive ......................................................................................................................................................
1
11
G
E
D
Page 11-7
11
G
11
6
E
D
12
4
10
5
14
18
22
19
23
13
15
8
16
7
9
17
20
1
21
4
-
23
2
3
000007-004
Page 11-8
DRIVE CLUTCH – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
102385601
102616501
103185501
102690501
102690701
102690801
102691401
102691601
102691701
102691801
N/A
N/A
N/A
102690201
102690301
102690401
102690501
102690701
N/A
102839401
N/A
103185801
103185901
Washer, Stepped ........................................................................................................................................
Bolt, M10 X 1.5 X 160 ................................................................................................................................
Clutch, 4x4, Diesel, W/cover (includes items 4 through 23) .......................................................
Screw, Shlder Hex, .312 X 1.75 .........................................................................................................
Nut, Lock Hex, 1/14-20, Flexlc ..........................................................................................................
Sub Assy, Wt Clutch, Diesel ...............................................................................................................
Spring, Compression, Primary .........................................................................................................
Washer, Lock, H-Spring, 1/4 ..............................................................................................................
Screw, Cap, Hex Hd, 1/4 X 1.25 ........................................................................................................
Shim, 1.63 X 1.33 ...................................................................................................................................
Subassembly, Drive Clutch ...............................................................................................................
Subassembly, Moveable, Drive Clutch ..........................................................................................
Subassembly, Spider Utility, Diesel (includes items 14 through 20) ..................................
Pin, Spring Slotted,1.25 X 1.0 .....................................................................................................
Pin, Dowel, .375 X 1.50 .................................................................................................................
Roller, Torque, Diesel .....................................................................................................................
Screw, Shlder Hex, .312 X 1.75 ...................................................................................................
Nut, Lock Hex, 1/14-20, Flexlc ....................................................................................................
Spider, Drive Clutch .......................................................................................................................
Sub Assy, Roller Weight ................................................................................................................
Cover, Drive Clutch ..............................................................................................................................
Cover, Clutch, 4x4 .................................................................................................................................
Gasket, Cover, Clutch, 4x4 .................................................................................................................
1
1
1
2
2
2
1
4
4
1
1
1
1
2
2
4
2
2
1
2
1
1
1
Page 11-9
11
G
E
D
11
G
E
9
D
10
8
3
2
4
6
7
5
2
-
8
1
Page 11-10
000003-001
DRIVEN CLUTCH
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
102369901
102695401
N/A
102695601
102695701
102695801
102695901
N/A
102385701
102719301
CVT, Secondary (includes items 2 through 8) ..................................................................................
Washer, Thrust, 1.53 X 1.92 ...............................................................................................................
Sheave, Driven Clutch .........................................................................................................................
Retainer, Spring, Inner ........................................................................................................................
Spring, Compression, Secondary ....................................................................................................
Retainer, Spring, Outer .......................................................................................................................
Ring, Retaining, External ....................................................................................................................
Driven Clutch Base Sheave ...............................................................................................................
Washer, Stepped ........................................................................................................................................
Bolt, M10 X 1.50 X 90, Loctite ................................................................................................................
1
1
1
1
1
1
1
1
1
1
Page 11-11
11
G
E
D
11
G
E
D
DRIVETRAIN COMPONENTS
12
G
E
D
12
G
4
E
6
D
12
3
11
9
10
7
9
8
2
8
5
2
000030-003
Page 12-2
FORWARD/REVERSE SHIFTER ASSEMBLY
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
N/A
102298401
102375901
102376001
N/A
102615701
102616701
102618301
102684501
102684601
103187501
8717
8990
Instl, Fnr, Shifter, Dom (includes items 2 through 13) ...................................................................
Bushing, Fnr ............................................................................................................................................
Knob, Fnr .................................................................................................................................................
Weldment, FNR Shifter Bracket .......................................................................................................
Stud, Ball, .346 Dia ................................................................................................................................
Locknut, M10x1.5 Nylon Insert ........................................................................................................
Washer, M12 Hard Regular ................................................................................................................
Shoulder Bolt,m12 X 20 M10 Thd ...................................................................................................
Weldment, FNR Shifter .......................................................................................................................
Tie Wrap, 8" Nylon ................................................................................................................................
1
3
1
1
1
1
1
3
2
1
1
1
2
Page 12-3
12
G
E
D
12
G
E
D
2
1
6
5
3
4
000012-003
Page 12-4
FRONT DIFFERENTIAL MOUNTING PLATE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102381701
102462401
102491001
102491101
102711601
103244701
Spacer Block, Diff .......................................................................................................................................
Hose, Vent, Front Diff ................................................................................................................................
Bolt Flanged Head, 3/8-16x1.0 with Loctite .....................................................................................
Bolt, Flange Head, M10 X 1.5 X 25 .......................................................................................................
Asm, Mount, Diff Plate .............................................................................................................................
1
1
2
2
4
1
Page 12-5
12
G
E
D
12
2
G
8
E
6
7
9
3
10
11
12
13
4
5
D
33
34
32
35
26
28
29
27
31
30
20
21
22
23
24
25
35
17
15
18
16
14
19
40
38
36
39
37
000010-001
Page 12-6
FRONT DIFFERENTIAL (OUTPUT COMPONENTS)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
34
35
36
37
38
39
40
102371801
102438201
102439001
102439101
102439201
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
102438301
102439401
102439501
N/A
N/A
N/A
102438401
102439601
102439801
102439901
102439701
N/A
102438501
102438601
N/A
N/A
N/A
N/A
102438701
102438801
102438901
102439301
102440101
N/A
N/A
102440301
N/A
Differential, Front * (includes items 2 through 40) ........................................................................
Kit, Assy, Output Cover Plate (includes items 3 through 13) ................................................
Set Screw, #10-24 UNC-3A with Patch ....................................................................................
Thrust Button ...................................................................................................................................
Thrust Plate ......................................................................................................................................
Mate-N-Lock Pin .............................................................................................................................
Mate-N-Lock Housing ...................................................................................................................
Oil Seal ...............................................................................................................................................
Grommet ...........................................................................................................................................
Plate, Output Cover .......................................................................................................................
O-Ring ................................................................................................................................................
Coil, Pocket Insert ...........................................................................................................................
Coil with Press-Fit Bobbin ...........................................................................................................
Kit, Assy, Race Output Hub (includes items 15 through 19) .................................................
Pin, Dowel .........................................................................................................................................
Bearing, Needle ..............................................................................................................................
Race/Output Hub, Male ...............................................................................................................
Bushing, PermiGlide ......................................................................................................................
Race/Output Hub, Female ..........................................................................................................
Kit, Assy, Clutch (includes items 21 through 23) .......................................................................
Clutch Hsg/Ring Gear, Machined .............................................................................................
Kit, Roller (contains 14 rollers) ...................................................................................................
Kit, Assy, Roll Cage (includes items 24 and 25) ....................................................................
Kit, H-Clip Spring (contains 14 clips) .................................................................................
Roll Cage, Plastic .......................................................................................................................
Kit, Bolt (contains 7 bolts) ..................................................................................................................
Kit, Minor Repair (includes items 28 through 31) .....................................................................
Oil Seal ...............................................................................................................................................
O-Ring ................................................................................................................................................
O-Ring ................................................................................................................................................
Oil Seal, Triple-Lipped ..................................................................................................................
Retaining, Ring Internal ......................................................................................................................
Plate, Armature .....................................................................................................................................
Shim, Armature, Plate .........................................................................................................................
Bearing, Ball ............................................................................................................................................
Kit, Assy, Drain Plug (includes items 37 and 38) ........................................................................
Plug, Oil Drain ..................................................................................................................................
Washer, Nylon, 0.625 x 0.382 x 0.06 .........................................................................................
Plug, Oil Fill .............................................................................................................................................
Bushing, Self-Lubricating, 80 x 85 x 20 .........................................................................................
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
1
1
1
1
1
* Note: This assembly also contains components listed on the following two
pages.
Page 12-7
12
G
E
D
12
G
E
D
4
1
2
3
5
6
7
000010-002
Page 12-8
FRONT DIFFERENTIAL (INPUT COMPONENTS)
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
102440201
102440601
N/A
N/A
102440401
102440501
N/A
Kit, Assy, Input Cover Plate (includes items 2 through 4) ............................................................
Cover, Input, Machined ......................................................................................................................
O-Ring .......................................................................................................................................................
Oil Seal, Triple-Lipped .........................................................................................................................
Shaft, Pinion, Machined ...........................................................................................................................
Bearing, Ball .................................................................................................................................................
Bushing, Plain 16 Id X 15 Wide ..............................................................................................................
1
1
1
1
1
1
1
Note: This page contains a list of components internal to the front
differential. See the previous pages for other front differential components.
Page 12-9
12
G
E
D
12
G
E
D
4
2
3
000091-001
Page 12-10
PROP SHAFTS
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
N/A
102371701
102372101
95293643
Inst, Prop Shafts, Awd (includes items 2 through 4) .....................................................................
Prop Shaft, Front ...................................................................................................................................
Prop Shaft, Rear .....................................................................................................................................
Pin, Spring, 5/16 X 1-1/2 Hd ..............................................................................................................
1
1
1
2
Page 12-11
12
G
E
D
12
G
19
E
9
20
2
D
10
8
11
3
7
13
17
6
18
12
5
4
16
14
15
9
19
7
10
8
3
11
20
2
Page 12-12
000004-001
REAR DIFFERENTIAL
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
102831501
102276001
102376602
102449101
102463501
102463601
102463801
102672101
102672201
102672301
102672401
N/A
102693301
102693401
102693501
102694201
102694301
102694401
102694701
102694801
Axle, Rear, Guard Mounts (Complete Assembly) (includes items 2 through 20) ................
Locking Cap, Nut ..................................................................................................................................
Assy, Rotor, Brake, Rear .......................................................................................................................
Gearcase, Lower, Machined ..............................................................................................................
Axle, Right-hand ...................................................................................................................................
Axle, Left-Hand ......................................................................................................................................
Ring, Retaining, Internal .....................................................................................................................
Washer,counterbored 51 X 30 .........................................................................................................
Washer, Bellevle, 1.063 X .043 ..........................................................................................................
Washer, Belleville, 49 X 4 ....................................................................................................................
Nut, Hex, M20 X 1.5 , Modified ........................................................................................................
Screw, M10 X 25 ....................................................................................................................................
Screw,hex Flange, M8 X 35 ................................................................................................................
Plug,3/8-16, Hex Flange .....................................................................................................................
Washer, .625 X .382 X .60 ...................................................................................................................
Plug, Square Skt, 1/12-14, Ptf ...........................................................................................................
Bellows, Vent, Upper Housing .........................................................................................................
Clamp, Hose, Dw-9.5 ...........................................................................................................................
Screw, Hex Fl, M12 X 1.75 X 30 .........................................................................................................
Pin, Cotter, 5/32 X 1.25 ........................................................................................................................
1
2
2
1
1
1
2
2
12
2
2
8
9
1
1
1
1
1
12
2
Page 12-13
12
G
E
D
12
G
8
E
10
11
9
D
27
30
29
24
1
3
28
2
25
15
27
13
26
16
12
15
17
18
22
14
21
20
23
19
4
5
7
6
000004-002
Page 12-14
REAR DIFFERENTIAL, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
102765301
102449201
102694001
102765401
102463401
102463801
102464301
102765501
102463301
102463801
102464301
102765801
102464201
102464401
102464501
102762601
102765701
102463101
102463901
102464001
102464101
102693601
102694502
102961501
102464201
102464401
102464501
102961301
102961401
102961601
Asm, Gearcase, Upper (includes items 2 and 3) ..............................................................................
Gearcase, Upper, Machined ..............................................................................................................
Vent, Top, Upper Housing .................................................................................................................
Asm, Axle Tube, RH (includes items 5 through 7) ..........................................................................
Weldment, Axle Tube Rh ...................................................................................................................
Bearing .....................................................................................................................................................
Asm, Axle Tube, LH (includes items 9 through 11) ........................................................................
Weldment, Axle Tube Lh ....................................................................................................................
Bearing .....................................................................................................................................................
Kit, Rear Axle Gear Repair (includes items 13 through 17) .........................................................
Bearing, Ball ............................................................................................................................................
Seal, Dual-Lip 25x 62x 7tc ..................................................................................................................
Gear, Ring, 33-Tooth ............................................................................................................................
Asm, Pinion W/ Bearings (includes items 18 through 23) .....................................................
Pinion, I0t Machined .....................................................................................................................
Ring, Retaining, External .............................................................................................................
Bearing, Ball ......................................................................................................................................
Bearing, Needle, Drawn Shell ....................................................................................................
Washer, 2.625 X 2.367 X .06 ........................................................................................................
Shim, 1.50 X 1.189 X .008 .............................................................................................................
Asm, Differential & Carrier (includes items 25 through 30) ........................................................
Bearing, Ball ............................................................................................................................................
Housing, Differential, Mach ..............................................................................................................
Pin, Dowel, 4 X 35 .................................................................................................................................
Asm, Locker, Nongrease/Spacers ....................................................................................................
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
Page 12-15
12
G
E
D
12
G
24
E
27
22
28
26
D
25
23
29
9
4
6
8
5
3
7
10
17
18
14
21
19
13
20
12
11
15
21
2
16
000016-006
Page 12-16
TRANSMISSION – DIESEL VEHICLES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
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
102943201
102693301
102697801
102764201
102694201
102696301
102697401
102698301
102698901
102699401
102765201
102696201
102696501
102696701
102696801
102696901
102697101
102697601
102697701
102699201
102699701
103250301
102693501
102694201
102696101
102697301
102699401
102721501
103250401
Transmission, Diesel, Parallel Shaft (includes items 2 through 22) ..........................................
Screw,hex Flange, M8 X 35 ................................................................................................................
Fork, Transmission ................................................................................................................................
Asm, Gear Case, Rear (includes items 5 through 10) ...............................................................
Plug, Square Skt, 1/12-14, Ptf .....................................................................................................
Oil, Deflector ....................................................................................................................................
Gearcase, Rear .................................................................................................................................
Vent, Trans ........................................................................................................................................
Screw, Tapping # 10-24 X .375 ...................................................................................................
Seal, Triple, 25 X 35 X 7.8 .............................................................................................................
Kit, Reverse Gear Repair (includes items 12 through 21) .......................................................
Ring, Retaining, Basic External ..................................................................................................
Washer, Thrust, 1.007 X .062 .......................................................................................................
Washer, 26.231 X 39.167 X 1.57 .................................................................................................
Bearing, Ball ......................................................................................................................................
Bearing, Ball ......................................................................................................................................
Bearing, Needle ..............................................................................................................................
Sprocket, 19-Tooth .........................................................................................................................
Sprocket, 51-Tooth .........................................................................................................................
Chain, .375p, .75 Wide, 60ptch ..................................................................................................
Ring, Retaining, E-Ring .................................................................................................................
Asm, Case, Gear, Front (includes items 23 through 29) ..........................................................
Washer, .625 X .382 X .60 .............................................................................................................
Plug, Square Skt, 1/12-14, Ptf .....................................................................................................
Pin, Dowel, 6 X 20 ...........................................................................................................................
Gearcase, Front ...............................................................................................................................
Seal, Triple, 25 X 35 X 7.8 .............................................................................................................
Seal, Dual-Lip ...................................................................................................................................
Plug, 3/4-16 ......................................................................................................................................
1
11
1
1
1
1
1
1
1
2
1
2
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
Page 12-17
12
G
E
D
12
G
11
E
13
14
12
15
D
18
17
16
21
22
20
18
19
23
1
2
7
8
6
4
5
3
10
9
000016-008
Page 12-18
TRANSMISSION – DIESEL VEHICLES, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
102697501
102698701
102764901
102696201
102696501
102696801
102696901
102697101
102697901
102698001
102765101
102697201
N/A
102698601
102699301
103721801
102696201
102696901
102697001
102698101
102698401
102699001
102699701
Dog, Engagement ......................................................................................................................................
Shaft, Intermediate ...................................................................................................................................
Kit, Forward Gear Repair (includes items 4 through 10) ..............................................................
Ring, Retaining, Basic External .........................................................................................................
Washer, Thrust, 1.007 X .062 .............................................................................................................
Bearing, Ball ............................................................................................................................................
Bearing, Ball ............................................................................................................................................
Bearing, Needle .....................................................................................................................................
Gear, Helical 58-Tooth .........................................................................................................................
Kit, Neutral Switch Repair (includes items 12 through 15) .........................................................
Spring, .484 X .340 X 1.076 ................................................................................................................
Guide, Detent Bullet ............................................................................................................................
Bullet, Detent .........................................................................................................................................
Switch, Indicator, Pollak .....................................................................................................................
Kit, Input Shaft Repair (includes items 17 through 23) ................................................................
Ring, Retaining, Basic External .........................................................................................................
Bearing, Ball ............................................................................................................................................
Bearing, Ball ............................................................................................................................................
Shaft, Input .............................................................................................................................................
Gear, Helical, 31-tooth ........................................................................................................................
Ring, Retaining, E-Ring .......................................................................................................................
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
Page 12-19
12
G
E
D
12
G
E
D
6
4
3
2
5
1
000016-010
Page 12-20
TRANSMISSION – DIESEL VEHICLES, SHIFT SHAFT AND BELL
CRANK
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102696001
102696401
102696601
102699601
103239501
103239801
Nut, Lock Hex, Nylon, 5/16-24 ...............................................................................................................
Ring, Retaining, External 9/16 ...............................................................................................................
Washer, Flat, .58 X 1.08 X .05 ..................................................................................................................
Seal, Dul Lip, .88 X .56 X .19 ....................................................................................................................
Bellcrank, Alum ...........................................................................................................................................
Shaft, Shift ....................................................................................................................................................
1
1
1
1
1
1
Page 12-21
12
G
E
D
12
G
E
D
RADIATOR AND COOLANT SYSTEM –
DIESEL VEHICLES
13
G
E
D
13
G
E
14
D
7
6
15
13
11
8
2
10
16
11
11
12
11
13
3
9
4
5
9
13
000541-001
Page 13-2
RADIATOR
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
N/A
1014471
102377801
102377901
102380301
102410301
102737301
102737401
102411207
102411208
102411301
102436701
102490301
102685001
102855501
96705199
Asm, Radiator (includes items 2 through 16) ..................................................................................
Tape, Vinyl Foam 1/8" x 3/4" * ..........................................................................................................
Hose, Coolant Lower Pipe .................................................................................................................
Hose, Coolant Lower Rad ...................................................................................................................
Tee, Coolant Fill .....................................................................................................................................
Exchanger, Engine Coolant (includes items 7 and 8) ..............................................................
Cap, Radiator ....................................................................................................................................
Drain Cock, Radiator .....................................................................................................................
Clamp, Hose, Ctb 35mm ....................................................................................................................
Clamp, Hose, Ctb 38mm ....................................................................................................................
Nut, Self Retaining ...............................................................................................................................
Fan, Cooling 12 In Elect ......................................................................................................................
Bolt, M6 X 1 X 16 Loctite ....................................................................................................................
Isolator, Twin-Stud ...............................................................................................................................
Shroud, Radiator Fan ...........................................................................................................................
Washer, M6 ..............................................................................................................................................
1
1
1
1
1
1
1
1
2
1
4
1
8
2
1
4
* Note: Item not shown.
Page 13-3
13
G
E
D
13
G
E
D
4
2
7
5
8
3
6
000540-001
Page 13-4
COOLANT EXPANSION TANK
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
N/A
102411204
N/A
102427501
102973201
N/A
N/A
N/A
Asm, Coolant Bottle (includes items 2 through 8) .........................................................................
Clamp, Hose, CTB 15mm ...................................................................................................................
Clamp, Hose, Ctb 25mm ....................................................................................................................
Cap, Radiator ..........................................................................................................................................
Bottle, Coolant .......................................................................................................................................
Hose, Cut, 5/8, 445 ...............................................................................................................................
Hose, Cut, Coolant, 700 ......................................................................................................................
Hose, Cut, Coolant, 1100 ....................................................................................................................
1
2
1
1
1
1
1
1
Page 13-5
13
G
E
D
13
G
E
D
3
2
4
5
6
000539-001
Page 13-6
COOLANT PIPES AND HOSES
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
102628701
102377401
102377701
N/A
N/A
N/A
Weldment, Group, Coolant Pipe (includes items 2 through 6) ..................................................
Pipe, Coolant Upper ............................................................................................................................
Pipe, Coolant Lower .............................................................................................................................
Tab, Rear Mntg, Coolant Pipe ...........................................................................................................
Pipe, Vent, Coolant ...............................................................................................................................
Tab, Cooling Pipe Mount ...................................................................................................................
1
1
1
2
1
1
Page 13-7
13
G
E
D
13
9
G
E
D
22
5
2
19
6
18
4
14
2
6
20
21
2
7
3
17
13
16
12
9
9
10
11
12
15
8
9
000542-001
Page 13-8
COOLING SYSTEM CLAMPS, HOSES, AND HARDWARE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
N/A
1011578
1015457
102288901
102289001
102298720
102377501
102377601
102411204
102411205
102411206
102411207
102411208
102427601
102435001
102480501
102618601
102684901
102946701
103423701
96704176
96704416
Instl, System, Cooling, Diesel (includes items 2 through 22) .....................................................
Spacer, 0.720" .........................................................................................................................................
Bolt - Hex, M8x1.25 X 135 ..................................................................................................................
Screw, M8X1.25X30, Hex ....................................................................................................................
M8-1.25x20 Taptite ..............................................................................................................................
Hose, Coolant Upper Rad ..................................................................................................................
Hose, Coolant Lower Eng ...................................................................................................................
Clamp, Hose, CTB 15mm ...................................................................................................................
Clamp, Hose, CTB 22mm ...................................................................................................................
Clamp, Hose, Ctb 30mm ....................................................................................................................
Clamp, Hose, Ctb 35mm ....................................................................................................................
Clamp, Hose, Ctb 38mm ....................................................................................................................
Clamp, Bar ...............................................................................................................................................
Hose, Vent Tube To Eng, Coolnt ......................................................................................................
Hose, Coolant, Return, Engine .........................................................................................................
Bumper, 19mm Stud ...........................................................................................................................
Bracket, Radiator Support .................................................................................................................
Bolt, M8 X 1.25 X 110 ...........................................................................................................................
Nut Flg, M6 X 1 Serrated ....................................................................................................................
Nut Flg, M8 X 1.25 Serrated ..............................................................................................................
1
3
1
1
4
2
1
1
4
1
1
5
1
1
1
1
3
2
2
1
2
2
Page 13-9
13
G
E
D
13
G
E
D
12
13
2
3
9
5
7
8
6
11
10
4
1
000059-001
Page 13-10
WATER FLANGE AND THERMOSTAT
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
6
7
8
9
10
11
12
13
102410001
102631301
102631401
102631601
102633001
102633201
102633301
N/A
102633401
102654701
102730901
102731001
102731101
Sensor, Coolant Temp ...............................................................................................................................
Cover, Thermostat .....................................................................................................................................
Assy, Thermostat ........................................................................................................................................
Bolt, M6 X 1 X 20 .........................................................................................................................................
Band, Pipe .....................................................................................................................................................
Flange, Water (includes items 7 and 8) ..............................................................................................
Pipe, Water Return, D722 ...................................................................................................................
Flange, Water .........................................................................................................................................
Gasket, Thermostat ...................................................................................................................................
Gasket, Water Flange ................................................................................................................................
Bolt, Alt, D722, Stay Lower ......................................................................................................................
Pipe, Water Return, D722 ........................................................................................................................
Bolt, D722, Thermostat Cover ...............................................................................................................
1
1
1
2
2
1
1
1
1
1
1
1
2
Page 13-11
13
G
E
D
13
G
E
D
2
3
1
000060-001
Page 13-12
WATER PUMP
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
102608701
102632701
102731201
Bolt, M6 X 1 X 22 .........................................................................................................................................
Gasket, Water Pump, D722 .....................................................................................................................
Water Pump Assembly .............................................................................................................................
4
1
1
13
G
E
D
Page 13-13
13
G
E
D
1
5
3
2
1
4
000061-001
Page 13-14
BLOCK COOLANT PIPE
ITEM
PART NO.
DESCRIPTION
QTY
1 2 3 4
1
2
3
4
5
102631701
102631801
102632001
102632101
102632201
Band, Pipe, with Nut .................................................................................................................................
Pipe, Water, Bent ........................................................................................................................................
Nut, Flange, M6 ...........................................................................................................................................
Pipe, Water, Bent ........................................................................................................................................
Stud, M6 X 15 ...............................................................................................................................................
2
1
1
1
1
Page 13-15
13
G
E
D
13
G
E
D
MAINTENANCE AND SERVICE TOOLS
14
G
E
D
14
G
E
D
1
2
4
3
7
6
5
8
9
15
14
10
16
Page 14-2
11
12
17
13
18
19
MAINTENANCE AND SERVICE TOOLS
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
The following tool list includes all tools available from Club Car for
maintenance and service procedures for gasoline, electric, and/or
diesel vehicles, both past and present models. Be sure to carefully
examine the tool list for applicability to your vehicle before ordering.
1
2
3
4
5
6
7
8
9
10
11
101871001
101813202
101641202
101831901
1014305
1011767
1016417
1016416
1012811
1012812
1013582
12
13
102555501
102249901
14
15
16
17
18
19
****
****
101887101
101808401
102562401
102686101
Accelerator Pedal Adjustment Tool .......................................................................
Adhesive, Guide Ring, 3-Gram Tube .....................................................................
Arbor ................................................................................................................................
Battery Discharge Machine, 36/48 Volt ................................................................
Battery Terminal Protector Spray ...........................................................................
Battery Thermometer .................................................................................................
Bearing and Oil Seal Remover Assembly ............................................................
Bearing Driver Set ........................................................................................................
Bearing Puller ................................................................................................................
Bearing Puller Wedge Attachment ........................................................................
Brake Adjustment Tool (used only on vehicles with
manually adjusted mechanical brakes) ...............................................................
Brake Cable Release Tool ...........................................................................................
Brake Pedal Adjustment Tool Kit (used for the Carryall Electric
Industrial Truck only) (includes items 14 and 15)..............................................
Brake Pedal Adjustment Tool .............................................................................
Brake Pedal Tension Tool .....................................................................................
Calibration Test Module ............................................................................................
Cam Installation Tool ..................................................................................................
Charger Bezel Tool .......................................................................................................
Clutch Removal Tool (for 4x4 vehicles) .................................................................
E
D
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Please refer to the maintenance and service manual
for proper tool application.
****
14
Special order item available upon request
Page 14-3
14
G
G
IN
N
R
A
W
E
D
21
24
23
22
27
26
25
20
28
30
29
32
31
COMMUNICATION
DISPLAY MODULE
DISPLAY FUNCTIONS:
PRESS AND HOLD
BUTTON TO SHOW
FUNCTION NUMBER.
RELEASE BUTTON TO
SHOW FUNCTION VALUE.
Func1 - Battery voltage.
Func2 - Energy units removed since last charge cycle.
Func3 - Total accumulated energy units removed.
Func4 - Last charge termination type (1 = Incomplete,
2 = DVDT, 4 = Normal, 8 = Max. timer).
POWER
ON
OFF
R
Club Car
PART #17075
33
38
Page 14-4
39
36
35
34
40
41
42
37
43
MAINTENANCE AND SERVICE TOOLS, CONTINUED
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
20
21
1014510
1014498
22
23
24
25
26
27
28
1014496
1014497
1014508
1014507
1015524
101809101
102601501
29
102603501
30
102605201
31
102606101
32
102607501
33
34
35
36
37
38
39
40
101831801
101641002
1011273
102773801
102773901
102774101
102774101
102675401
41
42
43
102774201
102774301
102774401
Clutch Tool Kit (includes items 21 - 27) ................................................................
Clutch Alignment Tool (for pre-unitized transaxle
vehicles built prior to 1997 model year) ........................................................
Drive Clutch Puller (for Kawasaki engines only) ..........................................
Drive Clutch Hub Puller (for Kawasaki engines only) ................................
Driven Clutch Cam Puller (for Kawasaki engines only) .............................
Driven Clutch Puller Plug (for Kawasaki engines only) .............................
Drive Clutch Holder Tool Assembly (for Kawasaki engines only) ..........
Press Weldment (for Kawasaki engines only) ...............................................
Drive ClutchFixed Sheave Tool
(for 4x4 vehicles) ...........................................................................................................
Driven Clutch Spring Compression Base (for use with items 30
and 31) (for 4x4 vehicles) ...........................................................................................
Driven Clutch Spring Compression Collar (for use with items 29
Driven Clutch Spring Compression Nut (for use with items 29
Drive Clutch Spider Removal Tool
(for 4x4 vehicles) ...........................................................................................................
Communication Display Module ...........................................................................
Compression Gauge and Adapter .........................................................................
Continuity Tester ..........................................................................................................
Cutter, Valve Seat, #122 ..............................................................................................
Cutter, Valve Seat #115 ...............................................................................................
Wrench, T, #505..............................................................................................................
Adapter, T-Wrench........................................................................................................
Cutter, Valve Seat, 60 Degree (requires item 51)
(for Honda GX620 Gasoline Engines) ...................................................................
Pilot, 6.6 MM ...................................................................................................................
Pilot, 6.62 MM.................................................................................................................
Pilot, 6.65 MM.................................................................................................................
1
E
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
D
1
1
1
1
1
1
1
1
1
1
1
1
14
Page 14-5
14
G
E
D
44
45
46
47
48
49
50
51
2
56
57
3
54
52 53
58
Page 14-6
59 60
61
Liquid
Gasket
55
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
1
1
1
1 2 3 4
44
45
46
1012151
1016627
102669901
47
48
49
1016418
101933101
102169401
50
51
52
1011478
1013593
102248803
53
102248804
54
55
56
57
58
59
59
59
59
59
59
59
59
59
59
60
61
102251501
102241502
102241501
101928701
102243402
101997201
101997207
101997212
101997211
101997205
101997209
101997204
101997203
101997206
101997202
102562301
102587201
Dry Moly Lubricant ......................................................................................................
Flywheel Puller Kit (for Kawasaki Engines) .........................................................
Gauge, Carburetor Float Level
Gear Yoke ........................................................................................................................
Governor Shaft Installation Tool (for Kawasaki Engine Vehicles) ...............
Hydraulic Brake Adjuster (for Turf/CA 272/472, Pioneer/XRT 1200,
Bobcat 2100, HUV 4213) ............................................................................................
Hydrometer ....................................................................................................................
Internal Retaining Ring Pliers ..................................................................................
IQ Display Module (IQDM) Kit (IQ System and IQ Plus vehicles) .................
(includes items 54 and 55)
IQ Display Module (IQDM-P) Kit (IQ System and IQ Plus vehicles)..............
(includes items 54 and 55)
Adaptor, Cable .........................................................................................................
IQDM Series 2 Cable ..............................................................................................
IQDM Series 1 Cable (replacement) ......................................................................
Liquid Gasket (transaxle case) .................................................................................
Moly-Teflon Lubricant (4-oz. (113-gram) tube) .................................................
Paint, Touch-Up – Beige* ..........................................................................................
Paint, Touch-Up – Black* ...........................................................................................
Paint, Touch-Up – Burgundy* ..................................................................................
Paint, Touch-Up – Classic Blue (Navy)* .................................................................
Paint, Touch-Up – Dark Gray* ..................................................................................
Paint, Touch-Up – Dark Green* ...............................................................................
Paint, Touch-Up – Gray* .............................................................................................
Paint, Touch-Up – Red* ..............................................................................................
Paint, Touch-Up – Royal Blue (Pacific Blue)* .......................................................
Paint, Touch-Up – White* ..........................................................................................
Paint, Precedent Underbody – Gray.......................................................................
Paint Pen, Touch-Up, Precedent Underbody – Black .......................................
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* Item 59 is not for use on Surlyn® body material, which is used
on Precedent vehicles.
G
E
1
1
14
Page 14-7
D
14
G
E
D
63
62
66
65
64
Safety First
Never use a vehicle that is unsafe.
Inspect each day.
Inspect
GOOD
NEED(S)
ATTENTION
• Brakes
• Park Brake
• Steering
• Accelerator
• F & R Selector
• Reverse Buzzer
• Key Switch
• Speeds
• Tires
• Bag Straps and Buckles
Other Mechanical Problems
• Unusual Noise
• Will Not Run
• Stopped on Course
• Other:
•
•
•
Damage
• Right Side
• Left Side
• Front
• Rear
• Other: ______________
No Damage
NEED(S)
ATTENTION
Cleanliness
• Seats
• Floor Mat
• Dash Compartments
• Bag Well
• Beverage Holders
• Overall Appearance: ___________________
Date: _____________ Inspected By: _________________
Car No. ___________
(Over)
CCI 1018231
69
68
67
71
70
72
AM10753
ON
OFF
STR
SPK
MAX
MIN
GAS
DSL
GAS/DIESEL
TACHOMETER
73
77
Page 14-8
83
76
75
74
84
85
86
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
62
63
64
65
66
67
68
69
1016414
1016415
102668801
1012549
1012560
101823101
1012809
102330901
70
71
72
73
74
75
76
77
78
1014264
1014259
102061201
AM10753
AM10771
1014162
1014161
1014115
101611003
79
AM11804
80
AM11805
81
AM1220301
82
AM1232401
83
84
1016413
102674601
85
86
101641201
102674401
Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) .................
Piston Ring Pliers (for Kawasaki Engines) ............................................................
Puller, Special Use (for Kubota D722 Diesel Engines) .....................................
Retaining Ring Pliers, 45° External .........................................................................
Retaining Ring Pliers, 90° Internal ..........................................................................
Safety First Card (50 per pack) .................................................................................
Seal Puller .......................................................................................................................
Spanner Wrench (for coil over shock front
suspension vehicles only) .........................................................................................
Steering Column Bearing Press Tool .....................................................................
Steering Column Retaining Ring Tool ..................................................................
Steering Wheel Puller Tool .......................................................................................
Tachometer (includes gasoline engine pick up lead only) ...........................
Tachometer Diesel Probe (for use with item 73) ..............................................
Transaxle Axle Seal Tool .............................................................................................
Transaxle Pinion Seal Tool .........................................................................................
Transmission Tool Kit ..................................................................................................
Tune-Up Kit, All OHV (for FE290, FE350, FE400 only) (includes
air filter, spark plug, oil filter, fuel filters) (not shown) ....................................
Tune-Up Kit, Gx620 (for Honda Engines) (includes air filter,
spark plug, oil filter, fuel filters) (not shown) ......................................................
Tune-Up Kit, D722 (for Kubota Engines) (includes air filter,
oil filter, fuel filters, water separator filter) (not shown) .................................
Tune-Up Kit, Precedent (for FE290/350 Engines) (includes air
filter, spark plug, oil filter, fuel filters) (not shown) ...........................................
Tune-Up Kit, FH680D (for Kawasaki V-Twin Engines) (includes oil
filter, fuel filter, air filter, and spark plugs) (not shown)...................................
Valve Clearance Adjuster Screw Holder (for FE290 engines only) .............
Valve Guide Driver
Valve Guide Reamer (FE290, FE350, and FE400 only) ......................................
Valve Guide Reamer, 6.6 mm
1
1
1
1
1
1
1
1
1
1
1
E
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14
1
1
1
1
1
1
Page 14-9
D
14
G
E
D
87
88
-
45
45
89
90
+
WAVETEK
V
5XL
1000
V
OFF
500
200
200
20
200
2m
2
200
m
20
m
200
m
2000
k
200k
20k
V
!
MAX
1000 --750V
Page 14-10
200
A
2k
!
COM
200nA
FUSED
91
92
95
96
93
94
ITEM
PART NO.
DESCRIPTION
QTY
DIESEL
QTY
GAS
QTY
ELEC
G
1 2 3 4
87
88
89
90
91
92
93
94
95
96
1016552
1016551
1016553
1016554
101641101
1011480
102570401
103601401
103601701
103600501
Valve Seat Cutter Guide .............................................................................................
Valve Seat Cutter T-Wrench ......................................................................................
Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) ...........
Valve Seat Cutter, 45°/30° (35 mm diameter) ....................................................
Valve Spring Compressor ..........................................................................................
Volt Ohm Meter ............................................................................................................
Tool, Tensioning, Starter Generator (For Precedent vehicles) ......................
Puller, Drive Clutch, XRT 950*...................................................................................
Tool, Disassembly, Driven Clutch, XRT 950 ..........................................................
Screw, Driven Clutch Disassembly, M6, XRT 950 ...............................................
1
1
1
1
1
1
1
1
1
1
1
E
D
1
*Note: The XRT 950 Drive Clutch Puller requires the use of Screw,
Driven Clutch Disassembly, CCI Part Number 103600501.
14
Page 14-11
INDEX
Part Number and Page
AM10753 14-9
AM10771 14-9
AM11807 6-9
AM11808 6-9
AM1241201 6-9
AM1241301 6-9
AM1245401 1-23
183 9-5
332 2-23, 2-25, 2-39, 2-43, 7-13
334 2-33
357 2-37
403 2-35
451 2-23, 2-25
808 2-3
1016 9-5
1017 1-21
1032 2-39
1035 5-17
1108 7-13
1231 2-39
1241 7-17
1242 5-15
1308 1-29, 1-31
1631 1-21
7049 2-39
7173 1-21
7174 1-21
7310 3-3
7473 2-35, 2-43, 7-17
7973 2-39
8233 2-13, 2-39, 2-43
8251 2-41
8639 5-11, 5-15
8717 1-21, 12-3
8754 2-35, 2-37
8755 2-35, 2-37
8797 9-5
8990 1-21, 2-37, 6-5, 9-7, 12-3
1010200 2-37
1010434 2-39
1010435 2-35, 2-39, 2-43
1010436 2-43
101082903 5-7, 5-9, 5-15
1010934 2-39, 7-17
1011084 9-7
1011273 14-5
1011478 14-7
1011480 14-11
1011553
1011578
1011652
1011767
1011779
1011931
4-3
2-3, 2-21, 13-9
2-23, 2-25
14-3
5-15
1-21
1011990 2-39
1012151 14-7
1012295 7-13
1012303 2-35
1012438 1-21
1012549 14-9
1012560 14-9
1012769 8-3
1012809 14-9
1012811 14-3
1012812 14-3
1012830 2-23, 2-25
1012986 7-15
1013035 6-5
1013042 6-5
1013044 6-5
1013051 6-5
1013052 6-5
101313402 9-3
1013317 2-39
1013366 2-43
1013461 9-5
1013462 9-5
1013531 5-15
1013582 14-3
1013593 14-7
1013734 2-23, 2-25
1013746 9-3
1014063 1-21
1014115 14-9
1014161 14-9
1014162 14-9
1014259 14-9
1014264 14-9
1014305 14-3
1014306 2-41, 2-43, 5-7
1014321 2-39
1014375 7-17
1014387 2-39
1014415 2-39, 2-43
1014471 2-35, 13-3
1014496 14-5
1014497 14-5
1014498 14-5
1014507 14-5
1014508 14-5
1014510 14-5
1014537 2-39, 2-43
1015139 9-5
1015143 9-5
1015245 2-39
1015246 2-39
1015258 2-35
1015277 2-33
1015313 2-39
1015363 2-39
1015390
1015392
1015399
1015400
1015457
1015521
1015524
1015583
1015597
1015720
2-39
2-19
2-35, 2-39, 2-43
2-35, 2-39
13-9
7-13
14-5
2-35
6-13
1-21
1015741 7-13
101587703 9-3
1016078 2-33
101609401 4-3
1016103 1-21
101611003 14-9
101641002 14-5
101641101 14-11
101641201 14-9
101641202 14-3
1016413 14-9
1016414 14-9
1016415 14-9
1016416 14-3
1016417 14-3
1016418 14-7
1016551 14-11
1016552 14-11
1016553 14-11
1016554 14-11
1016603 2-37
1016627 14-7
1016630 7-15
1016916 2-13
1016967 2-11
1017162 2-37
1017167 2-37
1017774 2-37
101802601 7-15
101804301 2-13
101808401
101809101
101813202
14-3
14-5
14-3
101823101
101824401
101831801
14-9
9-3
14-5
101831901
101833101
101833201
101835601
101856102
101871001
101879401
101879701
101879801
101879901
14-3
8-3
8-3
2-33, 2-35
11-5
14-3
6-5
6-5
6-5
6-5
Page i-1
INDEX
101880201
101887101
101887601
101894302
101894304
101898001
101928701
101932201
101933101
101953101
101958602
101963401
101972001
101972002
101972003
101972004
101972005
101972006
101972007
101972009
101972011
101972012
101991101
102010102
102022601
102022901
102023703
102025401
102025801
102030101
102030201
102045001
102047001
102048401
102051401
102051601
102051701
102059001
102059401
102061101
102061201
102065901
102066001
102169401
102171503
102176901
102198001
102221301
102221401
102221501
102221701
102221801
102222001
102222101
102222201
102224001
Page i-2
6-5
14-3
2-23, 2-25, 5-11, 10-3
2-39
2-43
7-17
14-7
1-21
14-7
5-15
2-33
2-39, 2-43
14-7
14-7
14-7
14-7
14-7
14-7
14-7
14-7
14-7
14-7
7-15
6-5
6-5
6-5, 6-7
2-23, 2-25
1-33
2-19
2-39
2-39
2-13
2-23, 2-25
2-13
5-7
7-15
7-15
2-23, 2-25
2-23, 2-25
2-23, 2-25
14-9
2-35
2-37
14-7
2-35
5-7, 5-9
7-15
2-43
2-43
2-43
2-43
2-43
2-43
2-43
2-43
4-3
102239901
102241501
102241502
102243402
102248803
102249901
102251501
102274101
102276001
102288901
102289001
102290120
102292356
102292701
102292801
102296140
102296401
102296716
102297230
102298130
102298401
12-3
102298580
102298720
102301401
102323101
102323501
102324401
102330901
102355301
102361901
102363802
102365601
102367101
102367601
102369901
102370101
102370501
102370601
102371701
102371801
102372101
102374901
102375401
102375901
102376001
102376601
102376602
102376605
102377401
102377501
102377601
102377701
102377801
102377901
102379001
2-43
14-7
14-7
14-7
14-7
14-3
14-7
6-7, 6-13
12-13
13-9
2-3, 2-13, 9-3, 13-9
6-3
2-3
2-5, 2-7, 2-9
2-5, 2-7, 2-9, 5-15
5-11
9-9
5-11, 11-3, 11-5
2-3, 2-5, 2-7, 2-9, 2-13
2-23, 2-25, 6-3
2-11, 2-23, 2-25, 5-9, 5-15, 8-3, 10-5,
2-13
2-11, 10-3, 13-9
2-33
2-33
2-11, 5-17
2-29
14-9
7-17
6-7
6-3
6-11
6-3
5-3
11-11
8-3
8-3
8-3
12-11
12-7
12-11
11-7
7-15
12-3
12-3
5-11
12-13
6-7
13-7
13-9
13-9
13-7
13-3
13-3
9-11
102380301
102380601
102381701
102382401
102385601
102385701
102393501
102395601
102398901
102399201
102399202
102402801
102402901
102406701
102406801
102407801
102408401
102409301
102409501
102410001
102410301
102410602
102410603
102410801
102411203
102426901
102427501
102427601
13-3
5-13
12-5
8-3
11-9
11-11
6-13
9-11
6-13
5-5
5-5
5-7
5-7
9-5
9-5
5-11
6-7
10-5
10-3
13-11
13-3
9-3
8-3
9-3
9-3
13-5, 13-9
13-9
13-9
13-3, 13-9
13-3, 13-9
9-11
11-3, 11-5
13-3
11-5
8-3
8-3
2-33
1-21, 7-13
7-13
7-13
8-51, 10-5
9-3
2-33, 2-37
2-35
13-5
13-9
102430001
102430101
102430201
9-3
9-3
9-3
102430301
102430401
102434601
102434701
102434801
102435001
102436701
9-3
9-3
9-3
9-3
9-3
13-9
13-3
102411204
102411205
102411206
102411207
102411208
102411209
102411210
102411301
102414501
102414701
102414801
102418101
102420201
102420401
102420501
102422301
102426301
102426601
INDEX
102437001
102438201
102438301
102438401
102438501
102438601
102438701
102438801
102438901
102439001
102439101
102439201
102439301
102439401
102439501
102439601
102439701
102439801
102439901
102440101
102440201
102440301
102440401
102440501
102440601
102442001
102442201
102442901
102445201
102447901
102448001
102448401
102448501
102449101
102449201
102456001
102458901
102459001
102459101
102459201
102459301
102459401
102459501
102460201
102462301
102462401
102462501
102463101
102463301
102463401
102463501
102463601
102463801
102463901
102464001
102464101
6-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-7
12-9
12-7
12-9
12-9
12-9
1-21, 2-23, 2-25
7-17
5-13, 9-9
9-9
7-13
7-13
7-17
7-17
12-13
12-15
2-23, 2-25
2-23, 2-25, 4-5
4-5
4-5
4-5
4-3
4-3
4-5
4-5
8-3
12-5
8-3
12-15
12-15
12-15
12-13
12-13
12-13, 12-15
12-15
12-15
12-15
102464201
102464301
102464401
102464501
102465701
102465901
102466201
102469401
102473501
102473601
102473701
102474301
102475701
102475801
102475901
102476301
102476401
102477001
102478501
102479301
102480501
102481001
102481201
102481301
102488001
102489901
102490101
102490201
102490301
102490501
102490801
102491001
102491101
102491301
102491302
102491501
102491601
102491701
102492201
102492301
102493301
102493801
102494401
102494701
102495801
102498201
102498601
102498801
102522001
102538501
102541465
102551901
102552001
102555501
102562401
102570401
12-15
6-7, 12-15
12-15
12-15
2-37
8-3
9-3
9-9
2-23, 2-25
2-23, 2-25
2-23
5-11
5-11, 9-7
5-11
2-23, 2-25
9-9
9-9
6-13
9-5
9-9
13-9
11-5
11-5
11-5
5-3, 5-5
9-9
2-31, 8-3
8-3
13-3
8-3
6-7
1-23, 1-25, 12-5
12-5
2-11, 2-27
2-11
1-15, 2-11, 2-13, 2-27
5-3, 5-5
2-17, 2-41
7-13
7-13
5-3, 5-5
2-33
8-3
9-5
9-7
7-17, 8-3
9-11
9-7
9-5
7-5
9-11
5-15
5-15
14-3
14-3
14-11
102571301
102600001
102600101
102600201
102600301
6-3
8-5
8-5
8-5
8-5, 8-9, 8-51
102600401
102600601
102600701
102600801
102601001
102601301
102601401
102601501
102601801
102601901
102602001
102602101
102602301
102602401
102602601
102602701
102602801
102603201
102603501
102603601
102603701
102603801
102603901
102604001
102604101
102604201
8-5
8-5
8-5
8-5, 8-9
8-5, 8-11
8-5
8-5
14-5
8-11, 8-51
8-11
8-11
8-11
8-11
8-11
8-11
8-11
8-11
8-21
14-5
8-27
8-27
8-27
8-27
8-27
8-27
8-21, 8-27
8-27
8-23, 8-27
8-27
8-27
8-21
8-21
8-7, 8-21
14-5
8-21
8-21
8-21
8-21
8-39
8-21
8-21
8-21
14-5
8-17
8-17
8-17
8-17
8-17, 8-51
8-15
8-7
8-7
102604301
102604401
102604501
102604701
102604901
102605001
102605101
102605201
102605301
102605401
102605501
102605601
102605701
102605801
102605901
102606001
102606101
102606201
102606301
102606401
102606501
102606601
102606701
102606901
102607001
Page i-3
INDEX
102607201
102607301
102607401
102607501
102607601
8-7
8-7
8-7
14-5
8-23, 8-53
102607602
102607801
102607901
102608001
102608101
102608201
102608301
102608401
102608501
102608601
102608701
8-23
8-23
8-23
8-23
8-23
8-19, 8-51
8-19, 8-51
8-19
8-19
8-19
8-19, 13-13
102608801 8-23
102608803 8-23
102608804 8-23
102608806 8-23
102608901 8-19
102609001 8-23
102609003 8-23
102609101 8-19
102609301 8-19
102609401 8-19
102609601 8-19
102609801 8-23
102609803 8-23
102610001 8-23
102614101 2-35, 2-37
102614401 2-43
102615701 12-3
102615801 9-7
102616003 11-5
102616101 11-5
102616301 6-7, 6-11
102616501 11-9
102616701 12-3
102616801 6-3
102617001 1-19
102617201 1-23, 1-25, 2-11, 2-27
102617501 6-7
102617701 6-7
102617801 6-7
102618101 5-13, 9-9
102618301 1-23, 1-25, 2-11, 2-33, 5-13, 5-15,
5-17, 9-9, 12-3
102618401 5-7, 5-9
102618601 1-23, 1-25, 2-13, 2-21, 2-33, 2-37,
5-7, 5-13, 5-17, 6-3, 8-3, 9-3, 9-9, 13-9
102619801 6-13
102620401
102620501
102621201
102621301
Page i-4
6-13
6-7, 6-11, 6-13
9-11, 10-3
8-3, 10-5
102635501
102635701
102635801
8-3, 9-11
5-13
11-5
10-5
13-7
2-37
8-23
8-23
8-23
8-23
8-23, 8-51
8-23
8-33
8-23
8-23
8-23, 8-53
8-23, 8-53
13-11
13-11
8-5, 8-33, 13-11
13-15
13-15
13-15
13-15
13-15
8-51, 13-13
13-11
13-11
8-13, 13-11
8-51, 13-11
8-41
8-37
8-37
8-37
8-37, 8-51
8-37
8-37, 8-51
8-37, 8-51
8-37
8-37
8-41
8-37
8-29, 8-37, 8-39, 8-51
8-29
8-29
8-29
102635901
102636201
102636301
8-29
8-41
8-41
102636401
102636501
102636601
102637001
102637101
102637701
102640401
8-41
8-41
8-41
8-29
8-29
8-35
8-35
102621501
102626201
102628001
102628101
102628701
102629001
102630001
102630003
102630101
102630201
102630301
102630401
102630601
102630701
102630703
102630901
102631001
102631301
102631401
102631601
102631701
102631801
102632001
102632101
102632201
102632701
102633001
102633201
102633301
102633401
102633601
102633701
102633801
102633901
102634001
102634101
102634401
102634501
102634601
102634701
102635101
102635201
102635301
102640501
102640601
8-35
8-31, 8-35
102640701
102640901
102641001
102641101
102641201
102641501
102642401
102642501
102642601
102642701
102642801
102642901
102643001
102643101
102643201
102643301
102643401
8-35
8-35
8-35
8-35
8-35
8-39
8-39
8-39
8-39
8-39
8-39
8-39
8-39
8-39
8-39
8-39
8-39
102643601
102643701
102644001
8-39
8-39
8-13, 8-51
102644101
102644501
102645501
8-13
8-51
8-43
102646001
102646101
102646301
102646401
102646501
102646601
102647101
102647201
102647501
102647701
102647801
102647901
102648001
102648401
102648501
8-47, 8-51
8-47
8-49
8-45
8-49
8-49, 8-51
8-49
8-49
8-25
8-33, 8-43
8-25
8-25
8-25
8-43
8-43
102651301
102651501
102651601
8-45
8-45
8-45
102651701
102651801
102652001
8-45
8-45
8-45
102652601
102652701
102652801
102652901
102653001
102653101
102653201
102653301
102653401
8-45
8-45
8-9
8-45
8-45
8-45
8-45
8-45, 8-51
8-9
102653501
8-9
INDEX
102653601
102653701
102653901
102654101
102654301
102654401
102654601
102654701
102668801
102669901
102670601
102670701
102670801
102671201
102672101
102672201
102672301
102672401
102673201
102674001
102674101
102674201
102674401
102674601
102675001
102675101
102675201
102675301
102675401
102682901
102684501
102684601
102684901
102685001
102685601
102686101
102687801
102689001
102689101
102689102
102690201
102690301
102690401
102690501
102690701
102690801
102691401
102691601
102691701
102691801
102693301
102693401
102693501
102693601
102694001
102694201
8-45
8-45
8-9
8-9, 8-51
8-11, 8-37, 8-47
8-21
8-7, 8-51
8-51, 13-11
14-9
14-7
2-23, 2-25
1-15, 8-3
9-3
2-29
12-13
12-13
12-13
12-13
2-43
14-5
14-5
14-5
14-9
14-9
14-5
14-5
14-5
14-5
14-5
6-13
6-13, 12-3
12-3
13-9
13-3
6-13
14-3
6-5
5-11
6-11
6-11
11-9
11-9
11-9
11-9
11-9
11-9
11-9
11-9
11-9
11-9
12-13, 12-17
12-13
12-13, 12-17
12-15
12-15
12-13, 12-17
102694301
102694401
102694502
102694701
102694801
102695401
102695601
102695701
102695801
102695901
102696001
102696101
102696201
12-13
12-13
12-15
12-13
12-13
11-11
11-11
11-11
11-11
11-11
12-21
12-17
12-17, 12-19
102696301
102696401
102696501
12-17
12-21
12-17, 12-19
102696601
102696701
102696801
12-21
12-17
12-17, 12-19
102696901
102697001
102697101
102697201
102697301
102697401
12-17, 12-19
12-19
12-17, 12-19
12-19
12-17
12-17
102697501
102697601
102697701
102697801
102697901
102698001
102698101
102698301
102698401
102698601
102698701
102698901
102699001
102699201
102699301
102699401
102699601
102699701
12-19
12-17
12-17
12-17
12-19
12-19
12-19
12-17
12-19
12-19
12-19
12-17
12-19
12-17
12-19
12-17
12-21
12-17, 12-19
102701001
102701201
102703301
8-9
8-33
8-11
102710301
102711601
102714001
9-3
12-5
5-3, 5-5
102716001
102718101
102719301
102721501
102722301
102725501
102725601
5-17
2-23, 2-25, 2-27
11-11
12-17
6-7
9-11
9-11
102726201
102726301
102726401
102726501
102726601
102726701
102726901
102727001
102727101
102727401
102727501
102727601
102727701
102727901
102728001
102728101
8-5
8-5
8-5
8-5
8-5
8-9
8-9
8-9
8-9
8-11
8-11
8-11
8-15
8-17
8-19
8-23, 8-53
102728102
102728301
102728401
102728501
102728601
102728701
102728801
102728901
102729101
102729301
102729401
102729501
102729601
102729701
102730201
102730401
102730601
102730801
102730901
102731001
102731101
102731201
102731301
102731501
102731601
102731801
102731901
102732001
102732201
102732401
102732501
102732601
102736901
102737101
102737301
102737401
102741501
102741601
102751301
8-23
8-25
8-27
8-27
8-29
8-29
8-29, 8-51
8-29
8-31
8-11, 8-51
8-37
8-37
8-39
8-39
8-33
8-33
8-33
8-5
13-11
13-11
13-11
13-13
8-33
8-49
8-49, 10-5
8-51
8-51
8-53
8-23, 8-53
2-23, 2-25
8-33, 8-43
8-5, 8-51
3-3
6-13
13-3
13-3
5-17
1-25, 1-33, 5-17
5-17
102751401
5-17
Page i-5
INDEX
102751501
102762601
102763301
102763401
102763701
102798701
102798801
102798901
102799001
102799101
102799201
102799401
102799501
102799601
102799701
102799801
102800101
102800201
102800301
102800401
102800501
102800601
102800701
102801001
102801101
102801201
102801301
102801401
102801501
102810701
8-13
8-13
8-13
8-13
8-13
8-13
8-21
8-29
8-31
8-31
8-31
8-35
8-41
8-41
8-37
8-37
8-37
8-33
8-33
8-45
8-45
8-47
8-47
8-47
9-11
102866901
102867001
102867101
102867202
102867301
102867602
102869401
102874301
102874501
102882401
102882501
102883401
102885001
102895101
102895401
102895701
102896401
102896501
102913801
102913901
102914001
102914101
102914102
102918501
102921601
102787501
102787601
102787602
102787701
102788701
102789001
102789101
102789201
102789301
5-17
12-15
5-15
5-15
2-23, 2-25
12-17
12-19
12-19
12-17
12-15
12-15
12-15
12-15
12-15
1-29
1-33
1-23, 1-25
1-23, 1-25
1-23, 1-25
1-23, 1-25
1-23, 1-25
1-25, 1-33
1-25, 1-33
1-33
1-23, 1-25
1-15, 1-17, 1-19, 1-23, 1-25
10-3
6-11
7-9
1-23, 1-25
1-23, 1-25
1-23, 1-25
1-23
1-25
1-23, 1-25
6-11
1-19
1-19
1-19
1-19
102812801
102816801
102831501
102839401
102849801
102850501
102854401
102854501
102854601
102854801
102854901
102855501
102859101
102866510
102866514
10-3
6-5
12-13
11-9
1-21
1-21
1-21
1-21
1-21
1-21
1-21
13-3
1-23, 1-25
2-5, 2-9
2-5
102921701
102922601
102922701
102923001
102923101
102923201
102923301
102923401
102923801
102790001
102790801
102790901
1-19
1-19
1-19
102866515
102866518
102866610
102791001
102791301
102791701
1-19
1-19
6-7
102866614
102866615
102866618
102791702
102792001
102792002
102794801
102794901
102798001
102798201
102798401
102798501
6-7
6-7
6-7
1-25, 1-33
1-25, 1-33
8-9
8-11
8-13
8-13, 8-51
8-13
102866710
102866714
102866715
102866718
102866719
102866810
2-9
2-5, 2-7, 2-9
2-5, 2-9
2-5
2-9
2-5, 2-7, 2-9
2-5, 2-9
2-5
2-9
2-5, 2-9
2-7
2-5, 2-9
2-5
2-9
2-5, 2-9
2-7
102926701
102926801
102927101
102927102
102927201
102927301
102927401
102928001
102928101
102764201
102764901
102765101
102765201
102765301
102765401
102765501
102765701
102765801
102784001
102784003
102784201
102784601
102784701
102784801
102784901
102785001
102785101
102785401
102785501
102786101
102786201
102786301
102786401
102787101
102787201
102798601
Page i-6
102866814
102866815
102866818
102866819
102925201
102925601
102926301
102926401
102926501
102926601
2-3
2-3
2-13
2-15
2-13
2-3
7-15
6-7
6-7
2-3
2-37
2-13
2-3
2-3
2-3
2-19
2-5, 2-7, 2-9
2-5, 2-7, 2-9
2-41
2-41
2-41
2-41
2-41
1-21
1-15, 1-17, 1-19, 1-23, 1-25
1-23, 1-25
1-25, 1-33
1-25, 1-33
1-23, 1-25
1-23, 1-25
1-17
1-19
1-17
1-25, 1-33
1-15
4-11
1-27
1-27
1-27
1-9, 1-11, 1-27
1-27
1-27
6-7
6-7
1-5
1-5
1-5, 1-9, 1-11
1-29, 1-31
1-29, 1-31
102928501
102928601
102928701
1-29, 1-31
1-21, 1-29, 1-31
1-29, 1-31
1-29, 1-31
1-29, 1-31
1-31
102928901
1-29, 1-31
102928201
102928301
102928401
INDEX
102929501
102929601
102929701
102929801
102930001
102930101
102930201
102930301
102930401
102930501
1-11
1-9, 1-11
1-11
1-9, 1-11
1-5
1-7
1-9
1-11
1-13
1-27
102930801
102930901
102934601
4-3
10-3
8-3
102934701
102934801
102934901
102935501
102936801
102937401
102937501
102937601
102943101
102943201
102943807
102945701
102946701
102950601
102952101
102961201
102961301
102961401
102961501
102961601
102967901
8-33
8-33
8-33
2-11
1-21, 7-9
1-21
1-21
1-21
3-3
12-17
3-3
3-3
13-9
4-3
9-5
4-3
12-15
12-15
12-15
12-15
1-21, 2-5, 2-7, 2-9, 2-23, 2-25
13-5
1-25, 1-33
1-25, 1-33
6-3
2-11
7-15
2-3
2-3
2-11
2-11
2-27, 2-29, 2-31
6-3
6-7
5-11
2-13
2-13
7-15
2-15
2-15
2-15
11-9
11-9
102973201
102973501
102973601
102977101
102977201
102977501
102978801
102978901
102983201
102983601
102988701
102989801
103148501
103174301
103179901
103180001
103180101
103182701
103182702
103182801
103185501
103185801
103185901
103187501
103188601
103188701
103191201
103191301
103191401
103191501
103192101
103193401
103200501
103208801
103210801
103210802
103210901
103211101
103213201
103213401
103213501
103215201
103215901
103216401
11-9
12-3
4-3
4-5
2-39
2-39
2-39
2-39
2-29
7-15
2-41
7-15
2-29
2-29
2-29
2-29
2-3
7-11
2-3
1-21
2-29
2-23, 2-25, 2-27, 2-29, 2-31
103218107
103218213
103218901
2-3
5-7
2-25
103225801
103227001
103233001
103233410
103233415
103233417
103233510
103233515
103233517
103233614
103233617
103233714
103233717
103234201
103234401
2-29
2-37
2-13
4-9
4-9
4-9
4-9
4-9
4-9
4-7
4-7
4-7
4-7
4-7, 4-9
7-15
103234503
103237501
103237701
103239501
103239801
103239901
103243001
103243101
103243201
103243501
103243601
103243701
103243801
103243901
103244001
3-3
1-3
1-3
12-21
12-21
8-33
1-9
1-9
1-9
1-9, 1-11
1-9
1-9
1-9
1-9, 1-11
1-9, 1-11
12-5
103244701
103245801
103250301
103250401
103253801
103256401
103256701
103267001
103267002
103268001
103273101
103274502
103274602
103277001
103277002
103277501
103282301
103283801
103289001
103289002
103289101
103289102
103289103
103289104
103293201
103296001
103305001
103305101
103319601
103319701
103319901
103320601
103327201
103331201
103345801
103355401
103361701
103376101
103377501
103379401
103380701
103400001
103409001
103418701
103418801
103423701
103441401
103485501
103487501
103500901
103505301
103505401
103535001
103538701
103538901
103721801
103762201
7-9
12-17
12-17
2-13
6-7
6-7
2-23
2-25
2-13
5-13, 9-9
2-31
2-31
6-7
6-7
7-5
6-13
2-31
2-41
2-41
2-41
2-41
2-41
2-41
5-7
2-11
5-17
5-17
2-21
2-21
4-5
11-3, 11-5
7-5
2-41
6-7
1-15
2-27
5-9
2-27
2-39
5-9
2-21
1-33
5-5
5-3, 5-5
2-21, 13-9
9-11
2-17
2-17
5-15
5-15
5-15, 5-17
5-15
2-35
2-35
12-19
6-7
Page i-7
INDEX
95293643
96701412
96704176
96704416
96704622
96704721
96705199
96705587
96706825
96715552
96718978
96727003
96741038
96741046
96742515
cylinder head cover 8-13
drain cock 8-5
filler cap 5-7
fuel camshaft 8-27
fuel cap 9-5
fuel filter 9-3
fuel injection pump 8-35
fuel pump 9-3
fuel tank vent 9-5
gear case 12-15, 12-17
governor fork 8-41
governor fork lever 8-41
idle apparatus 8-29
inner ball joint 6-5
intake manifold 8-47
latch, tilt bed 2-35
muffler 12-5
nozzle holder 8-39
oil pump 8-17
overflow pipe 8-39
pinion 12-15
piston ring 8-23, 8-53
reservoir, remote 5-7
rocker arm 8-45
speed plate 8-37
12-11
8-3
13-9
13-9
8-3
8-3
13-3
9-3
9-9
2-11
8-3
1-15
8-3
1-23, 1-25, 2-31, 8-3
2-23, 2-25
A
A-arm 6-7
accelerator cable 9-7
accelerator pedal 9-9
accelerator pedal adjustment tool
accessory receptacle 7-15
actuator 2-37
adapter
actuator 2-37
cable (IQDM) 14-7
tube 9-3
adhesive, guide ring 14-3
adjuster
hydraulic brake 14-7
adjuster, forward/aft 2-23, 2-25
adjuster, slide 6-7
adjuster, slider 2-23, 2-25
air clean support 9-11
air filter 9-11
air filter canister 9-11
air filter evacuator 9-11
alternator 8-33
alternator belt 8-33
arbor 14-3
arm
A- 6-7
rocker 8-45
arm attachment 1-17
arm, swing 6-13
assembly
accelerator pedal 9-9
adjusting bolt 8-29
bearing case cover 8-19
brake line 5-11
brake pedal 5-13
brake rotor 5-11, 12-13
bucket seat 2-23
camshaft 8-21
case, main bearing 8-19
connecting rod 8-23
Page i-8
14-3
tailgate 2-43
tether 2-43
thermostat 13-11
tilt bed 2-35
tire 3-3
water pump 13-13
wire 7-17, 9-5
assembly, subgear case 12-17
moveable drive clutch 11-9
spider 11-9
stationary 11-9
swingarm 6-13
weight clutch 11-9
attachment
bucket 1-7
mower 1-13
pallet fork 1-5
push broom 1-11
snow blade 1-9
attachment arm 1-17
axle 12-13
axle tube 12-15
axle, rear, guard mounts 12-13
B
ball
check
8-21
crankshaft 8-23
governor 8-27
injection pump 8-27
valve
ball joint
8-11
6-7, 9-7
ball stud 12-3
band, pipe 13-11, 13-15
banjo bolt 5-3, 5-5
bar clamp 13-9
barb, vent 9-3
barrel, plastic 2-39
barrier, heat 1-23, 1-25
base, seat holder 2-23, 2-25
battery 7-17
battery clamp 7-17
battery discharge machine 14-3
battery terminal protector spray 14-3
battery thermometer 14-3
bearing 6-7, 12-15
ball (steering pinion) 6-5
lower pinion 6-5
needle 12-7, 12-15, 12-17, 12-19
bearing and oil seal remover 14-3
bearing case cover 8-19
bearing case, main 8-19
bearing driver set 14-3
bearing puller 14-3
bearing puller wedge 14-3
bed floor plate 2-35
bed latch 2-39
bed latch spring 2-39
bed, tilt 2-35
bellcrank 5-17, 12-21
bellows 6-5, 12-13
belt guard 8-33
belt, alternator 8-33
belt, drive 11-7
bezel, fuel fill 9-3
blade, snow 1-9
block, differential spacer 12-5
block, engine 8-5
block, fuse 7-13
bobbin, coil with press fit 12-7
bolt
adjusting 8-29
banjo 5-3, 5-5
boot kit, boxed 6-9
boot replacement kit 6-9
boot, half shaft 6-9
bottle, coolant 13-5
box
cargo 2-43
box, hydraulic control
bracket
actuator 2-37
bed latch 2-33
brake line 5-11
brake pedal 5-13
cover inlet 11-5
1-21
INDEX
draw latch 2-3
hood support 2-13
hydraulic line 5-11, 6-11
muffler 10-3
park brake 5-17
radiator support 13-9
rocker arm 8-45
seatbelt 2-23, 2-25
steering column 2-11
transmission cable 8-3
transmission mounting 8-3
brake adjustment tool 14-3
brake cable 5-15
brake cable release tool 14-3
brake caliper 5-3, 5-5
brake caliper return spring 5-5
brake fluid reservoir 5-7
brake line 5-11
brake line, front 5-11
brake pad service kit 5-3, 5-5
brake pedal 5-13
brake pedal adjustment tool 14-3
brake pedal tension tool 14-3
brake return spring 5-15
brake rotor 5-11, 12-13
breaker, circuit 1-21, 7-9
breather cover 8-13
breather shield 8-13
breather tube 8-13
breather valve 8-13
broom weldment 1-11
broom, push 1-11
brush, FNR 2-13
bucket attachment 1-7
bucket seat 2-23, 2-25
bullet, detent 12-19
bumper 13-9
bed 2-33, 2-37
rubber 2-43
bushing 2-37
A-arm 6-7
flanged bronze 8-21
forward/reverse 12-3
greaseless 5-13, 9-9
nylon 2-39
Permiglide 12-7
piston pin 8-23, 8-53
pivot, urethane 6-13
plain 12-9
return line 9-5
self-lubricating 12-7
snap-in 2-39
steel 2-35
teflon 6-13
urethane 2-35
button, thrust 12-7
C
cable
accelerator 9-7
bell crank 5-17
brake 5-15
IQDM 14-7
transmission 9-7
cage, roll 12-7
calibration test module 14-3
caliper, brake 5-3, 5-5
cam installation tool 14-3
camshaft 8-21
camshaft, fuel 8-27
canister, air filter 9-11
cap
air filter 9-11
bolt assembly 8-29
corner 2-39
filler 5-7
fuel 9-5
inlet 11-5
pressure 13-5
radiator 13-3
rubber 6-7, 6-13
sealing 8-5, 8-9
speed control plate 8-37
steering wheel 6-3
valve 8-45
cap, filler 5-9
cap, front corner 2-43
carburetor air vent tube 9-3
carburetor float level tool 14-7
card, safety first 14-9
cargo box 2-43
case
gear 8-11, 12-13, 12-15, 12-17
governor ball 8-27
main bearing 8-19
case cover, bearing 8-19
center console 1-21
center console cover 2-23, 2-25
chain, transmission 12-17
charger bezel tool 14-3
circuit breaker 1-21, 7-9
clamp
bar 13-9
battery 7-17
breather tube 8-13
hose 9-3
p- (fuel filter) 8-3, 9-3
pipe 8-39
clevis pin 5-7, 5-9, 5-15
clip
hair pin 2-43
clip, body trim 2-5, 2-7, 2-9
clip, brake line 5-11, 9-7
clip, return pipe 8-39
closeout 2-41
clutch 11-11
clutch alignment tool 14-5
clutch cover 11-9
clutch housing 12-7
clutch removal tool 14-3
clutch tool kit 14-5
clutch, diesel 11-9
coil
pocket insert 12-7
coil over shock 6-11
coil with press-fit bobbin 12-7
collar, alternator assembly 8-33
collar, crankshaft 8-23
collar, idle gear 8-21
collar, lever 8-37
collet 8-45
column, steering 6-3
communication display module 14-5
compression gauge 14-5
compressor, piston ring 14-9
compressor, valve spring 14-11
connecting rod 8-23
connector, relay 7-13
console, center 1-21
continuity tester 14-5
Control assembly, hydraulic 1-21
control box, hydraulic 1-21
coolant bottle 13-5
coolant exchanger 13-3
coolant fill tee 13-3
coolant lamp sensor 13-11
coolant pipe 13-7
coolant pipe mounting tab 13-7
coolant temperature indicator light 7-15
cooling fan 13-3
cord, glow plug 8-39
corner cap 2-43
cotter, rue ring 6-13
coupling 1-25, 1-27, 1-33
cover
bearing case 8-19
breather 8-13
CCI dash storage 2-15
clutch 11-9
CVT 8-3, 11-3, 11-5, 11-9
cylinder head 8-13
electrical 7-13
fuel camshaft 8-5
heat proof 8-49
input 12-9
rocker switch hole 7-15
thermostat 13-11
cover plate, output 12-7
Page i-9
INDEX
drive clutch fixed sheave tool 14-5
drive clutch holder tool 14-5
drive clutch hub puller 14-5
drive clutch puller 14-5
drive clutch spider removal tool 14-5
drive clutch, moveable 11-9
drive shaft 12-11
driven clutch base sheave 11-11
driven clutch cam puller 14-5
driven clutch puller plug 14-5
cover, joystick 1-21
cover, steering column 6-3
cowl panel 2-5, 2-7, 2-9
cowl panel, driver-side 2-5, 2-9
cowl panel, passenger-side 2-5, 2-9
crank 8-23
crankshaft 8-23
C-type stop ring 6-5
cup holder 2-13
cup holder, seat 2-23, 2-25
cutter, valve seat 14-5, 14-11
CVT 11-11
CVT cover 11-3
CVT cover kit, sealed 11-5
CVT cover kit, unsealed 11-5
cylinder head 8-9
cylinder head cover 8-13
cylinder, master 5-7, 5-9
driven clutch spring compression base tool
14-5
driven clutch spring compression collar tool
14-5
driven clutch spring compression nut tool
14-5
dry moly lubricant 14-7
E
D
dash 2-13
decal
4x4 4-7, 4-9
bed 4-9
bed warning 4-3
CA 295 4-7
Club Car tailgate 2-43
crush area warning 4-3
driver/passenger 4-5
ground warning 4-5
hot manifold warning 4-5
hot surface warning 2-23, 2-25, 4-5
hydraulic controls 1-21
hydraulic pump 4-3
IntelliTach 4-11
joystick on/off 4-5
lock lever 1-19, 4-3
on/off 4-5
operating instructions 4-5
rollover warning 4-3
ROPS warning 4-3
rotating parts 4-3
rotating parts and hot manifold
rotating parts warning 4-5
tailgate 2-39
trailer hitch 4-3
under 16 warning 4-3
deflector oil 12-17
diesel tachometer probe 14-9
differential housing 12-15
differential, front 12-7
diode 7-5
dowel pin 12-7
drag link 6-5
drain cock 8-5
drive belt 11-7
Page i-10
4-5
E-clip 5-15
elbow 9-5
electric motor 1-29, 1-31
end, tie rod 6-5
engine block 8-5
engine, diesel, Kubota D722 with closed
breather 8-3
equalizer rod 5-15
exchanger, engine coolant 13-3
exhaust installation 10-3
exhaust pipe 10-3
exhaust valve 8-45
extension, spring latch 2-35
G
gasket
bearing case 8-19, 8-51
clutch cover 11-9
control plate 8-37, 8-51
cover 8-19, 8-51, 11-5
cylinder head 8-9, 8-51
cylinder head cover 8-13, 8-51
drain plug 8-7
exhaust 8-51, 10-5
ex-manifold 8-49, 8-51
fuel pump 8-5, 8-51
gearcase 8-11, 8-51
head cover 8-51
head cover nut 8-29, 8-37, 8-39, 8-51
idle apparatus 8-29, 8-51
F
fan shroud 13-3
fan, cooling 13-3
fascia 2-3
fastener, push-in 7-13
fender, front 2-3
fender, left rear 2-41
fender, rear 2-41
filler cap 5-7, 5-9
filter
air 9-11
fuel 9-3
inlet cover 11-5
oil 8-7, 8-11
filter, air, canister 9-11
fitting, thread-forming grease
flange, water 13-11
floor mat 2-19
floor plate, bed 2-35
floorboard 2-21
fluid, hydraulic 1-23
flywheel 8-25
flywheel puller 14-7
FNR brush 2-13
FNR brush strip 2-13
FNR shifter bracket 8-3
fork pallet 1-5
fork, pallet 1-5
fork, transmission 12-17
Forward/Reverse shifter 12-3
frame, tilt bed 2-35
front brake line 5-11
front differential 12-7
front gear case 12-17
front panel 2-7, 2-39, 2-41
fuel camshaft 8-27
fuel cap 9-5
fuel filter 9-3
fuel gauge 7-15
fuel gauge sending unit 9-5
fuel injection pump 8-35
fuel pickup tube 9-5
fuel pump 9-3
fuel system 9-3
fuel tank (diesel) 9-5
fuel tank strap 9-3
fuel tank vent 9-5
fuel tank, diesel 9-5
fuse
10-amp 7-13
25-amp 7-13
30-amp 7-13
fuse block 7-13
6-13
intake manifold 8-47, 8-51
liquid 14-7
nozzle 8-39
oil pump 8-17, 8-51
sending unit 9-5
thermostat 8-51, 13-11
water flange 8-51, 13-11
water pump 8-51, 13-13
gauge, compression 14-5
INDEX
gauge, fuel 7-15
gauge, oil 8-15
gear
cam 8-21
case 8-11, 12-13, 12-15, 12-17
crank 8-23
helical 12-19
idle 8-21
injection pump 8-27
oil pump drive 8-17
ring 8-25, 12-7, 12-15
gear case, front 12-17
gear ring engagement 12-19
gear yoke 14-7
glow plug 8-39
glow plug cord 8-39
governor fork lever 8-41
governor lever 8-37
governor shaft installation tool 14-7
governor shield 10-3
grill 2-3
grip tape, accelerator pad 9-9
grip, tilt latch hand 2-35, 2-39
grommet 9-5, 12-7
guard, belt 8-33
guard, splash 2-11
guide
accelerator cable 9-9
detent bullet 12-19
exhaust valve 8-9
inlet valve 8-9
oil gauge 8-15
valve seat cutter 14-11
guide ring adhesive 14-3
FNR strip brush 2-13
fork lever 8-41
holder, cup 2-13
hood 2-5, 2-7, 2-9
hood hinge 2-5, 2-7, 2-9
hood latch 2-3
hood prop 2-5, 2-7, 2-9
hook, engine 8-9
hose 1-23, 1-25, 1-33, 13-5
coolant 13-3, 13-5, 13-9
fuel filter 9-3
fuel pump 9-3
fuel return 9-3
inlet cover 11-5
intake 9-11
overflow 8-39
vent 8-3, 12-5, 13-9
hose, hydraulic 1-23, 1-25, 1-27
hose, outlet 11-3, 11-5
housing
clutch 12-7
differential 12-15
Mate-N-Lock 12-7
steering gear 6-5
hub, race/output 12-7
hydraulic brake adjuster 14-7
hydraulic control box 1-21
hydraulic fluid 1-23
hydraulic hose 1-23, 1-25, 1-27
hydraulic power unit 1-29, 1-31, 1-33
hydraulic power unit harness 7-9
hydraulic tube 1-23, 1-25
hydrometer 14-7
I
H
hair pin clip 2-43
half shaft boot 6-9
handbook, operator 1-3
handle, tilt steering 6-3
harness 2-3, 2-37, 7-5
harness, control panel wire 7-9
harness, headlight 2-3
harness, hydraulic power unit 7-9
harness, seatbelt light 7-11
head restraint 2-31
head restraint kit 2-31
head, cylinder 8-9
headlight 2-3
headlight harness 2-3
heat barrier 1-23, 1-25
heat seal 8-39
helical gear 12-19
hinge plate 2-23, 2-25
hinge, hood 2-5, 2-7, 2-9
holder
idle apparatus 8-29
idle gear 8-21
injection pump gear 8-27
inlet valve 8-45
insulation, heat barrier 1-23, 1-25
intake manifold 8-47
internal retaining ring pliers 14-7
IQ display module (IQDM) 14-7
isolator ring and bushing 8-3
isolator, twin stud 13-3
J
joint
ball 6-7, 9-7
eye 8-35
pipe 8-11
joystick control 1-21
joystick control box 1-21
joystick cover 1-21
K
keeper, push-close latch 2-15
key
feather 8-17, 8-21, 8-23, 8-27
key (pair) 7-15
key switch 7-15
key switch spacer 7-15
keyswitch nut 7-15
kick panel 2-41
kit
bolt 12-7
brake pad service 5-3, 5-5
brake pedal adjustment tool 14-3
clutch 12-7
cover plate, input 12-9
cover plate, output 12-7
drain plug 12-7
forward gear repair 12-19
gasket 8-51
H-clip spring 12-7
head restraint 2-31
IQ display module (IQDM) 14-7
neutral switch repair 12-19
nozzle holder 8-39
piston rebuild 8-53
race output hub 12-7
rear axle gear repair 12-15
repair, minor 12-7
reverse gear repair 12-17
roll cage 12-7
roller 12-7
ROPS 2-29
tune-up 14-9
kit, boot replacement 6-9
knob, forward/reverse
12-3
L
latch 2-15
latch bracket 2-3
latch keeper 2-15
latch plate, tilt bed 2-33
latch, bed 2-39
latch, hood draw 2-3
latch, slam 2-43
latch, spring 2-43
latch, tilt bed 2-35
lever
engine stop 8-37
fork 8-41
governor 8-37
lost motion 9-9
speed control 8-37
light
oil 7-15
light, coolant temperature indicator
7-15
Page i-11
INDEX
light, head 2-3
light, seat belt 7-15
line, brake reservoir 5-7
link, drag 6-5
liquid gasket 14-7
low oil warning light 7-15
lubricant, dry moly 14-7
lubricant, moly-teflon 14-7
M
manifold
exhaust 8-49
intake 8-47
master cyliner 5-9
mat, floor 2-19
Mate-N-Lock housing 12-7
Mate-N-Lock pin 12-7
meter, volt ohm 14-11
module
calibration test 14-3
communication display 14-5
moly-teflon lubricant 14-7
motor 1-29, 1-31
starter 8-43
moveable drive clutch 11-9
mower attachment 1-13
muffler 10-3, 12-5
N
nongrease/spacers locker
nozzle holder 8-39
nut, keyswitch 7-15
12-15
O
oil deflector 12-17
oil filter 8-7, 8-11
oil pan 8-7
oil pressure switch 8-5
oil pump 8-17
oil pump drive gear 8-17
oil seal 8-11, 8-19, 12-7, 12-9
oil slinger 8-23
oil warning light, low 7-15
operator handbook 1-3
O-ring 8-5, 8-7, 8-9, 8-11, 8-13, 8-23, 8-31, 8-37,
8-51, 12-7, 12-9
overflow pipe 8-39
P
paint, touch-up 14-7
pallet fork 1-5
pallett fork 1-5
pan
center 1-21, 2-23, 2-25
oil 8-7
Page i-12
seat 2-23, 2-25
panel
center cowl 2-5, 2-7, 2-9
driver-side 2-41
driver-side cowl 2-5, 2-9
front kick 2-41
left 2-43
passenger-side 2-41
passenger-side cowl 2-5, 2-9
right 2-43
side 2-39
panel, front 2-7, 2-39, 2-41, 2-43
panel, side 2-41
p-clamp (fuel filter) 8-3, 9-3
pedal, accelerator 9-9
pedal, brake 5-13
pin, clevis 5-7, 5-9, 5-15
pin, dowel 12-7
pin, Mate-N-Lock 12-7
pin, piston 8-23, 8-53
pin, slide, caliper slide pin 5-3, 5-5
pinion 12-15
pinion, steering 6-5
pipe
breather 8-47
coolant 13-7
exhaust 10-3, 10-5
injection 8-39
overflow 8-39
water 13-15
water return 8-13, 13-11
pipe band 13-11, 13-15
pipe clamp 8-39
pipe, coolant 13-7
piston 8-23, 8-53
piston pin 8-23, 8-53
piston ring 8-23, 8-53
piston ring compressor 14-9
piston ring pliers 14-9
plate
armature 12-7
back 2-35, 2-37
cover, output 12-7
electrical 7-13
engine block 8-5
engine mounting 8-3
fuel/oil 9-3
hinge 2-23, 2-25
latch 2-33
shroud 8-25
speed 8-37
speed control 8-37
tailgate latch wear 2-39
thrust 12-7
plate, closeout 2-41
pliers
internal retaining ring 14-7
piston ring 14-9
retaining ring 14-9
plug 1-29, 1-31, 12-17
drain 8-7
driven clutch puller 14-5
engine block 8-5, 8-9, 8-11, 12-13
expansion 8-5
gearcase 12-13, 12-17
glow 8-39
hole 7-15
oil drain 12-7
oil fill 12-7
oil filler 8-13
power unit, hydraulic 1-31, 1-33
press weldment 14-5
prop rod 2-33
prop shaft 12-11
prop, hood 2-5, 2-7, 2-9
protector spray, battery terminal 14-3
puller
bearing 14-3
clutch 14-3
drive clutch 14-5
drive clutch hub 14-5
driven clutch cam 14-5
flywheel 14-7
seal 14-9
special use tool 14-9
pulley
fan drive 8-33
water pump 8-33
pullrod, compression spring 9-9
pump
fuel 9-3
fuel injection 8-35
oil 8-17
water 13-13
push broom 1-11
push rod 8-21
R
rack guide pressure spring 6-5
rack, steering 6-5
radiator 13-3
radiator cap 13-3
radiator pipe 13-7
reamer, valve guide 14-9
receiver, rear 6-13
receptacle, accessory 7-15
relay 1-21, 7-13
relay connector 7-13
remover, bearing and oil seal 14-3
reservoir, brake fluid 5-7
reservoir, remote 5-7
restraint, head 2-31
INDEX
retainer
spring (driven clutch) 11-11
valve spring 8-45
retaining ring pliers 14-9
ring
piston 8-23, 8-53
snap 6-5
ring gear 8-25, 12-7, 12-15
ring, C-type stop 6-5
ring, retaining, ext 6-7
rivet, blind push 2-11
rocker arm 8-45
rocker switch 1-21, 2-37
rocker switch (lights) 7-15
rod
connecting 8-23
crank crank rod 8-23
equalizer 5-15
prop 2-33
push 8-21
roll cage 12-7
roller weight 11-9
roller, torque 11-9
ROPS front base weldment 2-11
ROPS kit 2-29
ROPS support tube 2-29
ROPS top 2-29
ROPS warning decal 4-3
rotor, brake 5-11, 12-13
rubber bumper 2-43
S
safety first card 14-9
screw, valve clearance adjuster 14-9
seal
dual lip 12-15, 12-17, 12-21
heat 8-39
oil 8-11, 8-19, 12-7, 12-9
steering pinion dust 6-5
triple lip 12-17
valve stem 8-45, 8-51
seal puller 14-9
seat
bucket 2-23
valve 8-11
seat belt light 7-15
seat holder base 2-23, 2-25
seat, bucket 2-23, 2-25
bucket seat 2-25
seatbelt light harness 7-11
sending unit, fuel gauge 9-5
sensor, coolant lamp 13-11
service kit, brake pad 5-3, 5-5
shaft
CVT adapter 8-3
drive 12-11
fork lever 8-41
governor lever 8-37
idle gear 8-21
input 12-19
intermediate 12-19
output 12-19
pinion 12-9
prop 12-11
rock arm 8-45
shift 12-21
sheave, drive clutch base 11-11
sheave, driven clutch 11-11
shield, breather 8-13
shield, exhaust 10-5
shield, governor 10-3
shim 11-9, 12-15
shim, armature plate 12-7
shim, injection pump 8-35
shim, latch plate 2-33
shock absorber 6-11
shock absorber, coil over 6-11
shoe, skid 1-9
shroud, fan 13-3
side panel 2-41
side panel weldment 2-39
skid shoe 1-9
slam latch 2-43
sleeve
crankshaft 8-23
governor 8-27
lower arm 6-7
upper suspension 6-7
slide adjuster 6-7
slide pin 5-3, 5-5
slide, adjuster 6-7
slinger, oil 8-23
snap ring 6-5
snow blade 1-9
snow blade weldment 1-9
solenoid, stop 8-31
spacer
engine 8-3
key switch 7-15
spacer block, differential 12-5
spanner wrench 14-9
speed plate 8-37
spider 11-9
splash guard 2-11
spray, battery terminal protector 14-3
spring
brake caliper return 5-5
brake return 5-15
compression 11-9, 11-11
detent bullet 12-19
exhaust 10-3
governor 8-41
idle apparatus 8-29
latch tilt 2-39
pedal 9-9
pedal stop 9-9
rack guide pressure 6-5
return 8-37
rocker arm 8-45
start 8-9, 8-41
torsion 9-9
valve 8-11, 8-45
spring latch 2-43
sprocket 12-17
start spring 8-41
starter motor 8-43
stay
cylinder head 8-9
spring 8-11
stop solenoid 8-31
steel bushing 2-35
steering column 6-3
steering column bearing press tool
steering column bracket 2-11
steering column cover 6-3
steering column retaining ring tool
steering gear housing 6-5
steering pinion dust seal 6-5
steering rack 6-5
steering wheel 6-3
steering wheel puller tool 14-9
stem, valve 3-3
stop solenoid stay 8-31
stopper, camshaft 8-21
stopper, fuel camshaft 8-27
strap, fuel tank 9-3
strip, FNR brush 2-13
stud 8-3, 8-35, 8-49, 13-15
idle adjustment 8-29
self-clinching 2-39, 2-43
stud, ball 12-3
support yoke (steering) 6-5
support, structural 2-13
swingarm 6-13
switch 1-21, 1-29, 1-31
indicator (transmission) 12-19
key 7-15
light rocker 7-15
14-9
14-9
oil pressure 8-5
switch, rocker 1-21, 2-37
T
tab, coolant pipe mounting 13-7
tachometer 14-9
tachometer probe, diesel 14-9
tailgate 2-39, 2-43
tailgate angle 2-39, 2-43
tailgate latch wear plate 2-39
Page i-13
INDEX
taligate 2-39
tank, fuel 9-5
tank, fuel (diesel) 9-5
tape, grip, accelerator pad 9-9
tape, vinyl foam 2-35, 13-3
tappet 8-21
tee, coolant fill 13-3
temperature indicator light, coolant 7-15
tester, continuity 14-5
tether 2-43
thermometer, battery 14-3
thermostat 13-11
thread-forming grease fitting 6-13
thrust button 12-7
thrust plate 12-7
tie rod end 6-5
tie wrap 1-21, 2-37, 5-11, 5-15, 6-5, 9-7, 12-3
tilt bed 2-35
tilt bed frame 2-35
tilt latch hand grip 2-35, 2-39
tire 3-3
tire assembly, black 3-3
tire, mud 3-3
tool
accelerator pedal adjustment 14-3
belt tensioning, starter/generator 14-11
brake adjustment 14-3
brake cable release 14-3
brake pedal adjustment 14-3
brake pedal tension 14-3
cam installation 14-3
carburetor float level 14-7
charger bezel 14-3
clutch alignment 14-5
cT-wrench 14-5
drive clutch fixed sheave 14-5
drive clutch holder 14-5
drive clutch spider removal 14-5
driven clutch spring compression base
14-5
driven clutch spring compression collar
14-5
driven clutch spring compression nut 14-5
governor shaft installation 14-7
puller, special use 14-9
steering column bearing press 14-9
steering column retaining ring
steering wheel puller 14-9
transaxle axle seal 14-9
transaxle pinion seal 14-9
transmission 14-9
valve guide driver 14-9
valve seat cutter 14-5
tool kit, clutch 14-5
torque converter 11-11
torque roller 11-9
Page i-14
14-9
touch-up paint 14-7
track, prop rod 2-33
transaxle axle seal tool 14-9
transaxle housing 12-15
transaxle pinion seal tool 14-9
transmission cable 9-7
transmission cable bracket 8-3
transmission chain 12-17
transmission fork 12-17
transmission tool 14-9
transmission, diesel, parallel shaft
tube
axle 12-15
breather 8-13
carburetor air vent 9-3
fuel pickup 9-5
ROPS support 2-29
tube, hydraulic 1-23, 1-25
tune-up kit 14-9
T-wrench tool 14-5
weldment, accelerator pedal bracket 9-9
weldment, actuator bracket 2-37
weldment, air cleaner support 9-11
weldment, brake pedal 5-13
weldment, coolant pipe 13-7
weldment, Forward/Reverse shifter 12-3
weldment, Forward/Reverse shifter bracket
12-3
12-17
U
upright 6-7
urethane bushing
2-35
V
weldment, front dash
dash weldment 2-11
weldment, lever, lost motion 9-9
weldment, receiver 6-13
weldment, tilt bed frame 2-35
wheel 3-3
wheel, steering 6-3
wire assembly 7-17, 9-5
wire harness 2-3, 2-37, 7-5
wire harness, control panel 7-9
wire harness, headlight 2-3
wire harness, hydraulic power unit 7-9
wrap, tie 1-21, 2-37, 5-11, 5-15, 6-5, 9-7, 12-3
wrench, spanner 14-9
Y
yoke, gear 14-7
yoke, support (steering)
valve 1-29, 1-31, 9-11
breather 8-13
exhaust 8-45
inlet 8-45
seat 8-11
valve clearance adjuster screw 14-9
valve guide driver tool 14-9
valve guide reamer 14-9
valve seat cutter 14-5, 14-11
valve seat cutter guide 14-11
valve seat cutter tool 14-5
valve seat t-wrench 14-11
valve spring compressor 14-11
valve stem 3-3
vent barb 9-3
vent, housing, upper 12-15
vent, transmission 12-17
volt ohm meter 14-11
W
warning light, low oil 7-15
water flange 13-11
water pump 13-13
wedge, bearing puller 14-3
weight clutch 11-9
weldment
press 14-5
ROPS base front 2-11
weldment, accelerator pedal 9-9
6-5
Club Car, Inc.
P.O. Box 204658
Augusta, GA 30917-4658
USA
Web www.clubcar.com
Phone 1.706.863.3000
1.800.ClubCar
Int’l
+1 706.863.3000
Fax
1.706.863.5808

Carryall 295 SE et XRT 1550 SE

Transcription

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