Textron EZGO EXPRESS S4 Service & Parts Manual
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Textron EZGO EXPRESS S4 Service & Parts Manual

Textron EZGO EXPRESS S4 Service & Parts Manual

72v electric powered vehicle
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Express S4, 72V
Service Parts Manual
699361 - B
REVISED SEPTEMBER 2019
ISSUED JUNE 2019

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  • Page 1 Express S4, 72V Service Parts Manual 699361 - B REVISED SEPTEMBER 2019 ISSUED JUNE 2019...
  • Page 3 Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed be- yond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles prohibits and dis-claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
  • Page 4 GENERAL INFORMATION To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
  • Page 5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL ..........V ACCELERATOR .
  • Page 6 NOTES Page iv Service Parts Manual Service Parts Manual...
  • Page 7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: • GENERAL INFORMATION • ILLUSTRATED PARTS BREAKDOWN The first section, GENERAL INFORMATION, contains the following information: • WARRANTY INFORMATION • TABLE OF CONTENT • HOW TO USE THE SERVICE PARTS MANUAL The second section, ILLUSTRATED PARTS BREAKDOWN, contains illustrations and parts lists for all systems of your vehicle.
  • Page 8 HOW TO USE THE SERVICE PARTS MANUAL Title Title *See Body Section for decal information 102,104 Front of Vehicle 83,88 81,86 84,89 82,87 128 129 Left hand illustration page Parts list (continued on rear of page if required) 1. WHEN THE PART NUMBER IS NOT KNOWN •...
  • Page 9 HOW TO USE THE SERVICE PARTS MANUAL 3. COLOR CODE FOR BODY COMPONENTS The last two digits of the part number for the body part will denote the color code, locate the part number for the cowl, rear body, seat pod, side panel or seat wrap then locate your color in the list below, replace the last ** or XX with the two digit color code.
  • Page 10 ACCELERATOR To harness from direction selector Part of Frame Pedal Box Assembly includes items 2 - 34 Accelerator Pedal Assembly includes items 28 - 30 Pedal Harness includes items 33 - 34 699361 Service Parts Manual Page A-1...
  • Page 11 ACCELERATOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 12 ACCELERATOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 13 ACCELERATOR Notes: 699361 Service Parts Manual Page A-4...
  • Page 14 BATTERY CHARGER 699361 Service Parts Manual Page B-1...
  • Page 15 BATTERY CHARGER THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 16 BATTERY CHARGER Notes: 699361 Service Parts Manual Page B-3...
  • Page 17 BATTERY CHARGER Notes: 699361 Service Parts Manual Page B-4...
  • Page 18 BODY Front of Vehicle Front of Vehicle 699361 Service Parts Manual Page C-1...
  • Page 19 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 20 BODY Front of Vehicle Instrument Panel Assembly includes items 8 - 16 Instrument Panel Assembly with Ball Deflector includes items 9 - 13 699361 Service Parts Manual Page C-3...
  • Page 21 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 22 BODY Front of Vehicle Front of Vehicle 699361 Service Parts Manual Page C-5...
  • Page 23 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 24 BODY Front of Vehicle Front of Vehicle Rear Bumper Installation Front of Vehicle 699361 Service Parts Manual Page C-7...
  • Page 25 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 26 BODY Front of Vehicle FLOOR MOUNT GUN HOLDER Front of Vehicle 699361 Service Parts Manual Page C-9...
  • Page 27 BODY THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 28 BODY Notes: 699361 Service Parts Manual Page C-11...
  • Page 29 BODY Notes: 699361 Service Parts Manual Page C-12...
  • Page 30 BRAKES Brake Pedal Assembly (with Brake Lights) includes items 2 - 28 WHITE BLACK 699361 Service Parts Manual Page D-1...
  • Page 31 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 32 BRAKES Compensator Assembly includes items 37 - 49 Front of Vehicle Part of Frame Accelerator Pedal 699361 Service Parts Manual Page D-3...
  • Page 33 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 34 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 35 BRAKES Notes: 699361 Service Parts Manual Page D-6...
  • Page 36 BRAKES Brake Assembly (Driver Side) includes items 3 - 9 Brake Assembly (Passenger Side) includes items 3 - 8, 10 Brake Drum Assembly includes items 17, 18 Adjuster Assembly Front of Vehicle Tension Pin 699361 Service Parts Manual Page D-7...
  • Page 37 BRAKES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 38 BRAKES Notes: 699361 Service Parts Manual Page D-9...
  • Page 39 BRAKES Notes: 699361 Service Parts Manual Page D-10...
  • Page 40 ELECTRICAL Note: FRAME SHOWN PARTIALLY 699361 Service Parts Manual Page E-1...
  • Page 41 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 42 ELECTRICAL Front of Vehicle 699361 Service Parts Manual Page E-3...
  • Page 43 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 44 ELECTRICAL Battery Installation Front of Vehicle Charger Receptacle Assembly includes items 15 - 23 To Battery Positive Solenoid Front of Vehicle Fuse Block Installation Fender Liner Instrument Front of Vehicle Panel 699361 Service Parts Manual Page E-5...
  • Page 45 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 46 ELECTRICAL Control Panel Assembly includes items 3 - 9 Headlight Assembly Front of Vehicle Taillight Assembly Rear Body Inside of Cowl Front of Vehicle LED Headlight Assembly, (Driver Side) includes item 17 LED Headlight Assembly, (Passenger Side) includes item 17 Taillight Assembly, (Driver Side) Light Assembly To Bezel includes items 31, 33 - 35...
  • Page 47 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 48 ELECTRICAL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 49 ELECTRICAL Notes: 699361 Service Parts Manual Page E-10...
  • Page 50 ELECTRONIC SPEED CONTROL Electronic Speed Control Assembly includes items 2 - 8 Battery Tray Front of Vehicle 699361 Service Parts Manual Page F-1...
  • Page 51 ELECTRONIC SPEED CONTROL THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 52 ELECTRONIC SPEED CONTROL Notes: 699361 Service Parts Manual Page F-3...
  • Page 53 ELECTRONIC SPEED CONTROL Notes: 699361 Service Parts Manual Page F-4...
  • Page 54 FRONT SUSPENSION AND STEERING Front of Vehicle Part of Frame *NOTE: Tie Rod Not Shown for Clarity Spindle and Hub Assembly (Passenger Side) includes items 3 - 12 Spindle and Hub Assembly (Driver Side) includes items 4 - 12, 14 699361 Service Parts Manual Page G-1...
  • Page 55 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 56 FRONT SUSPENSION AND STEERING Steering Column Assembly includes items 6 - 16 Tie Rod Assembly includes items 20 - 24 Front of Vehicle 699361 Service Parts Manual Page G-3...
  • Page 57 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 58 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 59 FRONT SUSPENSION AND STEERING Notes: 699361 Service Parts Manual Page G-6...
  • Page 60 FRONT SUSPENSION AND STEERING Rack and Pinion Unit includes items 2 - 23 Tie Rod End (Outer) includes items 24 - 25 699361 Service Parts Manual Page G-7...
  • Page 61 FRONT SUSPENSION AND STEERING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information.
  • Page 62 FRONT SUSPENSION AND STEERING Notes: 699361 Service Parts Manual Page G-9...
  • Page 63 FRONT SUSPENSION AND STEERING Notes: 699361 Service Parts Manual Page G-10...
  • Page 64 MOTOR Part of Motor Rear Axle Front of Vehicle Front of Vehicle 699631 Service Parts Manual Page H-1...
  • Page 65 MOTOR THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 66 MOTOR Notes: 699631 Service Parts Manual Page H-3...
  • Page 67 MOTOR Notes: 699631 Service Parts Manual Page H-4...
  • Page 68 REAR AXLE Front of Vehicle Rear Axle with Limited Slip Differential, 16.99:1 includes items 5 - 42 Rear Axle, 16.99:1 includes items 4 - 42 699631 Service Parts Manual Page J-1...
  • Page 69 REAR AXLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 70 REAR AXLE THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 71 REAR AXLE Notes: 699631 Service Parts Manual Page J-4...
  • Page 72 REAR SUSPENSION Front of Vehicle 699361 Service Parts Manual Page K-1...
  • Page 73 REAR SUSPENSION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 74 REAR SUSPENSION Notes: 699361 Service Parts Manual Page K-3...
  • Page 75 REAR SUSPENSION Notes: 699361 Service Parts Manual Page K-4...
  • Page 76 SEATING Seat Back Assembly includes items 2 - 9 Seat Back Assembly includes items 5 - 9 Front of Vehicle Seat Bottom Assembly includes items 17 - 26 Front of Vehicle Flip Seat Bottom Assembly includes items 31 - 38 Seat Bottom Assembly includes items 33 - 35 Front of Vehicle 699361 Service Parts Manual...
  • Page 77 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 78 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 79 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 80 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 81 SEATING Notes: 699361 Service Parts Manual Page L-6...
  • Page 82 SEATING Front of Vehicle Rear Flip Seat Handrail Kit includes items 32 - 37 Flip Seat Bottom Assembly Seat Back Support 699361 Service Parts Manual Page L-7...
  • Page 83 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 84 SEATING THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 85 SEATING Notes: 699361 Service Parts Manual Page L-10...
  • Page 86 WEATHER PROTECTION Front of Vehicle DETAIL D (REAR) Sun Top Kit (Black) includes items 2 - 29 Sun Top Kit (White) includes items 3 - 29, 33 (Passenger Side Shown) Sun Top Kit (Tan) includes items 3 - 29, 36 Front of Vehicle DETAIL A DETAIL B...
  • Page 87 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 88 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 89 WEATHER PROTECTION Notes: 699361 Service Parts Manual Page M-4...
  • Page 90 WEATHER PROTECTION Strut Full Windshield Kit includes items 2 - 7 Front of Vehicle Windshield Retainer Rubber Latch Strut Front of Vehicle Split Windshield Kit (Clear) includes items 12, 13 Hardware Kit includes items 3 - 6, 14 Split Windshield Kit (Tinted) includes items 16, 17 Hardware Kit includes items 3 - 6, 14 21 22 23 24 25 26 27 28 29 30 WEATHER ENCLOSURE...
  • Page 91 WEATHER PROTECTION THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 92 WEATHER PROTECTION Notes: 699361 Service Parts Manual Page M-7...
  • Page 93 WEATHER PROTECTION Notes: 699361 Service Parts Manual Page M-8...
  • Page 94 WHEELS AND TIRES Wheel and Tire Assembly, Kenda includes items 2 - 4 Wheel and Tire Assembly, Kenda includes items 7 - 9 Wheel and Tire Assembly, Left Side includes item 16 Wheel and Tire Assembly, Right Side includes item 16 Wheel design may vary by Part Number Tire design may vary by Part Number...
  • Page 95 WHEELS AND TIRES THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 96 WHEELS AND TIRES Notes: 699361 Service Parts Manual Page N-3...
  • Page 97 WHEELS AND TIRES Notes: 699361 Service Parts Manual Page N-4...
  • Page 98 DECALS AND LABELS WARNING Failure to follow these instructions can result in SERIOUS INJURY or DEATH The vehicle is not a toy; always drive responsibly. Driver must possess valid driver’s license. Never drive on public roads except where allowed by law. Never drive vehicle under influence of drugs or alcohol. Do not start moving until all occupants are seated and holding on. Keep entire body inside the moving vehicle.
  • Page 99 DECALS AND LABELS THE USE OF NON U.L. PARTS WILL VOID ANY U.L. LISTING. When ordering parts, please specify the model and serial number of the product. * Indicates a component that is not available as an individual part. *** Indicates consult Customer Service Department for additional information. ITEM PART NO.
  • Page 100 DECALS AND LABELS Notes: 699361 Service Parts Manual Page P-3...
  • Page 101 DECALS AND LABELS Notes: 699361 Service Parts Manual Page P-4...
  • Page 102 Textron Specialized Vehicles, Inc., 1451 Marvin Griffin Road Augusta, Georgia 30906 - 3852 USA CONTACT INFORMATION Owner’s Guides and Repair Manuals are available from a local Distributor, an authorized Branch, Parts & Accessories Department or at www.shop.txtsv.com/shop-ezgo Copyrighted Material This manual may not be reproduced in whole or...

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