Bad Boy OFF ROAD AMBUSH iS Service & Parts Manual

Bad Boy OFF ROAD AMBUSH iS Service & Parts Manual

4 x 4 hybrid utility vehicle

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SERVICE PARTS MANUAL
640770-AB
ISSUED OCTOBER 2014
REVISED JUL Y 2017

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Table of Contents
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Summary of Contents for Bad Boy OFF ROAD AMBUSH iS

  • Page 1 & SERVICE PARTS MANUAL 640770-AB ISSUED OCTOBER 2014 REVISED JUL Y 2017...
  • Page 3 SERVICE PARTS MANUAL 4 X 4 HYBRID UTILITY VEHICLE AMBUSH iS STARTING MODEL YEAR 2015 THROUGH MODEL YEAR 2017 CALIFORNIA Proposition 65 Warning WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects and other reproductive harm.
  • Page 4 NOTES This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of america Federal and State emission certification applicable at the time of manufacture.
  • Page 5 TABLE OF CONTENTS SECTION Page No. HOW TO USE THE SERVICE PARTS MANUAL ......................v ACCELERATOR ..............................A - 1 BATTERY SYSTEM.............................B - 1 BODY ...................................C - 1 BRAKES ................................D - 1 CLUTCH ................................E - 1 DIRECTION SELECTOR ............................. F - 1 DIFFERENTIAL LOCK............................
  • Page 6 NOTES Notes: Page iv 640770 Service Parts Manual...
  • Page 7 HOW TO USE THE SERVICE PARTS MANUAL This manual is divided into several sections: • GENERAL INFORMATION • ILLUSTRATED PARTS BREAKDOWN • APPENDIX The first section, GENERAL INFORMATION, contains the following information: • WARRANTY INFORMATION • GENERAL INDEX • 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 ACCELERATOR PEDAL ASSEMBLY includes items 2 - 14 Service Parts Manual Page A-1 640770 Service Parts Manual...
  • 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 Engine Shown For Reference Front of Vehicle GOVERNOR ASSEMBLY includes items 2 - 21 GOVERNOR BRACKET ASSEMBLY includes items 6 - 13 Front of Vehicle Service Parts Manual Page A-3 640770 Service Parts Manual...
  • Page 13 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 14 ACCELERATOR Notes: Service Parts Manual Page A-5 640770 Service Parts Manual...
  • Page 15 ACCELERATOR Notes: Service Parts Manual Page A-6 Service Parts Manual 640770 Service Parts Manual...
  • Page 16 BATTERY SYSTEM Service Parts Manual 640770 Service Parts Manual Page B-1...
  • Page 17 BATTERY SYSTEM 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 18 BATTERY SYSTEM 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 19 BATTERY SYSTEM Notes: Service Parts Manual Service Parts Manual 640770 Service Parts Manual Page B-4...
  • Page 20 BATTERY SYSTEM To Controller To Solenoid Service Parts Manual 640770 Service Parts Manual Page B-5...
  • Page 21 BATTERY SYSTEM 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 BATTERY SYSTEM Notes: Service Parts Manual 640770 Service Parts Manual Page B-7...
  • Page 23 BATTERY SYSTEM Notes: Service Parts Manual Service Parts Manual 640770 Service Parts Manual Page B-8...
  • Page 24 BODY - FRONT INSTRUMENT PANEL ASSEMBLY includes items 15 - 17 Front of Vehicle MIN 150 www.badboybuggies.com 638040 DASH ASSEMBLY, STEERING COLUMN includes items 26 - 30 Service Parts Manual Page C-1 640770 Service Parts Manual...
  • Page 25 BODY - FRONT 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 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 27 BODY Notes: Service Parts Manual Page C-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 28 BODY - MID Front of Vehicle Front of Vehicle Service Parts Manual Page C-5 640770 Service Parts Manual...
  • Page 29 BODY - MID 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 30 BODY - MID Front of Vehicle Front of Vehicle Service Parts Manual Page C-7 640770 Service Parts Manual...
  • Page 31 BODY - MID 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 BODY - REAR Body Trim for 2 Passenger Vehicle Front of Vehicle Rear Fender Flare (Driver Side) Front of Vehicle Service Parts Manual Page C-9 640770 Service Parts Manual...
  • Page 33 BODY - REAR 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 BODY - REAR Body Trim for 4 Passenger Vehicle Front of Vehicle Service Parts Manual Page C-11 640770 Service Parts Manual...
  • Page 35 BODY - REAR 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 36 BODY Notes: Service Parts Manual Page C-13 640770 Service Parts Manual...
  • Page 37 BODY Notes: Service Parts Manual Page C-14 Service Parts Manual 640770 Service Parts Manual...
  • Page 38 BRAKES DISC BRAKE ASSEMBLY includes items 24 - 30 Front of Vehicle Caliper Front of Vehicle Front of Vehicle Service Parts Manual Page D-1 640770 Service Parts Manual...
  • Page 39 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 40 BRAKES PARK BRAKE LEVER WITH CABLES includes items 3 - 4 Front of Vehicle Service Parts Manual Page D-3 640770 Service Parts Manual...
  • Page 41 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 42 BRAKES Notes: Service Parts Manual Page D-5 640770 Service Parts Manual...
  • Page 43 BRAKES Notes: Service Parts Manual Page D-6 Service Parts Manual 640770 Service Parts Manual...
  • Page 44 CLUTCH SECONDARY CLUTCH ASSEMBLY includes items 3 - 4 Service Parts Manual Page E-1 640770 Service Parts Manual...
  • Page 45 CLUTCH 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 CLUTCH Notes: Service Parts Manual Page E-3 640770 Service Parts Manual...
  • Page 47 CLUTCH Notes: Service Parts Manual Page E-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 48 DIRECTION SELECTOR NEUTRAL BRACKET WITH BUSHING ASSEMBLY includes items 14 & 15 ELECTRIC DIRECTION SELECTOR SHIFT ASSEMBLY includes items 9 - 15 Service Parts Manual Page F-1 640770 Service Parts Manual...
  • Page 49 DIRECTION SELECTOR 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 50 DIRECTION SELECTOR Notes: Service Parts Manual Page F-3 640770 Service Parts Manual...
  • Page 51 DIRECTION SELECTOR Notes: Service Parts Manual Page F-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 52 DIFFERENTIAL LOCK Differential Lock Pod Front Cable Details Rear Cable Details Service Parts Manual Page G-1 640770 Service Parts Manual...
  • Page 53 DIFFERENTIAL LOCK 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 54 DIFFERENTIAL LOCK Notes: Service Parts Manual Page G-3 640770 Service Parts Manual...
  • Page 55 DIFFERENTIAL LOCK Notes: Service Parts Manual Page G-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 56 ELECTRICAL SYSTEM FUSE BOX Service Parts Manual Page H-1 640770 Service Parts Manual...
  • Page 57 ELECTRICAL SYSTEM 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 58 ELECTRICAL SYSTEM CONTROLLER BRACKET FUSE BLOCK Service Parts Manual Page H-3 640770 Service Parts Manual...
  • Page 59 ELECTRICAL SYSTEM 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 60 ELECTRICAL SYSTEM To Battery To Battery +ve Terminal -ve Terminal MOTOR CONTROLLER Service Parts Manual Page H-5 640770 Service Parts Manual...
  • Page 61 ELECTRICAL SYSTEM 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 62 ELECTRICAL SYSTEM Front of Vehicle 3-Pin To Main Harness Inside of Cowl LED HEADLIGHT ASSEMBLY (PASSENGER SIDE) includes item 12 LED HEADLIGHT ASSEMBLY (DRIVER SIDE) includes item 12 Rear Fender 2 PASSENGER 4 PASSENGER Service Parts Manual Page H-7 640770 Service Parts Manual...
  • Page 63 ELECTRICAL SYSTEM 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 64 ELECTRICAL SYSTEM Front of Vehicle 10Amp Dash Panel Service Parts Manual Page H-9 640770 Service Parts Manual...
  • Page 65 ELECTRICAL SYSTEM 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 ELECTRICAL SYSTEM Notes: Service Parts Manual Page H-11 640770 Service Parts Manual...
  • Page 67 ELECTRICAL SYSTEM Notes: Service Parts Manual Page H-12 Service Parts Manual 640770 Service Parts Manual...
  • Page 68 ENGINE SUBARU ENGINE-EH722 includes items 2 - 18 Front of Vehicle Service Parts Manual Page J-1 640770 Service Parts Manual...
  • Page 69 ENGINE 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 ENGINE Front of Vehicle Service Parts Manual Page J-3 640770 Service Parts Manual...
  • Page 71 ENGINE 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 72 ENGINE 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 73 ENGINE Notes: Service Parts Manual Page J-6 Service Parts Manual 640770 Service Parts Manual...
  • Page 74 ENGINE MUFFLER Front of Vehicle Service Parts Manual Page K-1 640770 Service Parts Manual...
  • Page 75 ENGINE MUFFLER 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 76 ENGINE MUFFLER Notes: Service Parts Manual Page K-3 640770 Service Parts Manual...
  • Page 77 ENGINE MUFFLER Notes: Service Parts Manual Page K-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 78 FRONT AXLE INDEPENDENT DIFFERENTIAL includes items 2 - 3 Motor Part of Frame Front of Vehicle Service Parts Manual Page L-1 640770 Service Parts Manual...
  • Page 79 FRONT 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 80 FRONT AXLE Notes: Service Parts Manual Page L-3 640770 Service Parts Manual...
  • Page 81 FRONT AXLE Notes: Service Parts Manual Page L-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 82 FRONT SUSPENSION AND STEERING STEERING RACK WITH SPACER includes items 25 - 26 8 28 Service Parts Manual Page M-1 640770 Service Parts Manual...
  • Page 83 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 84 FRONT SUSPENSION AND STEERING FRONT STRUT ASSEMBLY (DRIVER SIDE) includes items 3 - 23 FRONT STRUT ASSEMBLY (PASSENGER SIDE) includes items 3 - 22, 24 Part of Frame A-Arm Assembly STRUT/BEARING ASSEMBLY (DRIVER SIDE) includes items 25 - 27 STRUT/BEARING ASSEMBLY (PASSENGER SIDE) includes items 26 - 28 Service Parts Manual Page M-3...
  • Page 85 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 86 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 87 FRONT SUSPENSION AND STEERING Notes: Service Parts Manual Page M-6 Service Parts Manual 640770 Service Parts Manual...
  • Page 88 FRONT SUSPENSION AND STEERING STEERING COLUMN ASSEMBLY includes items 5 - 9 STEERING COLUMN ASSEMBLY includes items 5 - 9 Service Parts Manual Page M-7 640770 Service Parts Manual...
  • Page 89 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 90 FRONT SUSPENSION AND STEERING Notes: Service Parts Manual Page M-9 640770 Service Parts Manual...
  • Page 91 FRONT SUSPENSION AND STEERING Notes: Service Parts Manual Page M-10 Service Parts Manual 640770 Service Parts Manual...
  • Page 92 FUEL SYSTEM CARB FUEL TANK ASSEMBLY (WITH SWITCH) includes items 4 - 14 Front of Vehicle EARLY PRODUCTION VEHICLES Service Parts Manual Page N-1 640770 Service Parts Manual...
  • Page 93 FUEL SYSTEM 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 94 FUEL SYSTEM To Engine POA of Engine Part of Frame Fuel Filter To Fuel Pump Front of Vehicle Fuel Pump EARLY PRODUCTION VEHICLES Service Parts Manual Page N-3 640770 Service Parts Manual...
  • Page 95 FUEL SYSTEM 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 FUEL SYSTEM Front of Vehicle To Fuel Pump Fuel Pump LATE PRODUCTION VEHICLES Service Parts Manual Page N-5 640770 Service Parts Manual...
  • Page 97 FUEL SYSTEM 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 98 FUEL SYSTEM FUEL TANK ASSEMBLY (WITH SENDER UNIT) includes items 2 - 9 Front of Vehicle LATE PRODUCTION VEHICLES Service Parts Manual Page N-7 640770 Service Parts Manual...
  • Page 99 FUEL SYSTEM 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 FUEL SYSTEM Notes: Service Parts Manual Page N-9 640770 Service Parts Manual...
  • Page 101 FUEL SYSTEM Notes: Service Parts Manual Page N-10 Service Parts Manual 640770 Service Parts Manual...
  • Page 102 MOTOR SPEED SENSOR KIT includes items 8 - 9 Service Parts Manual Page P-1 640770 Service Parts Manual...
  • Page 103 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 104 MOTOR Notes: Service Parts Manual Page P-3 640770 Service Parts Manual...
  • Page 105 MOTOR Notes: Service Parts Manual Page P-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 106 OPERATOR PROTECTION SYSTEM Part of Frame Part of frame Front of Vehicle Service Parts Manual Page Q-1 640770 Service Parts Manual...
  • Page 107 OPERATOR PROTECTION SYSTEM 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 108 OPERATOR PROTECTION SYSTEM OPS UPPER KIT includes items 2 - 7 OPS UPPER HARDWARE KIT includes items 8 - 9 ACCESSORIES OPS KIT includes items 11 - 18 OPS ACCESSORY HARDWARE KIT includes items 22 - 28 Front of Vehicle OPS Bottom (Ref only) Service Parts Manual...
  • Page 109 OPERATOR PROTECTION SYSTEM 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 110 OPERATOR PROTECTION SYSTEM Notes: Service Parts Manual Page Q-5 640770 Service Parts Manual...
  • Page 111 OPERATOR PROTECTION SYSTEM Notes: Service Parts Manual Page Q-6 Service Parts Manual 640770 Service Parts Manual...
  • Page 112 REAR AXLE MANUAL INDEPENDENT DIFFERENTIAL includes items 2 - 4 Part of Frame Front of Vehicle Service Parts Manual Page R-1 640770 Service Parts Manual...
  • Page 113 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 114 REAR AXLE Service Parts Manual Page R-3 640770 Service Parts Manual...
  • Page 115 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 116 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 117 REAR AXLE Notes: Service Parts Manual Page R-6 Service Parts Manual 640770 Service Parts Manual...
  • Page 118 REAR SUSPENSION REAR STRUT ASSEMBLY (DRIVER SIDE) includes items 3 - 23, 25 REAR STRUT ASSEMBLY (PASSENGER SIDE) includes items 3 - 22, 24, 26 STRUT/BEARING ASSEMBLY (DRIVER SIDE) includes items 25 - 27 STRUT/BEARING ASSEMBLY (PASSENGER SIDE) includes items 26 - 28 Part of Frame Service Parts Manual Page S-1...
  • Page 119 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 120 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 121 REAR SUSPENSION Notes: Service Parts Manual Page S-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 122 REAR SUSPENSION Front of Vehicle TIE ROD ASSEMBLY includes items 4 - 8 POA of STRUT Service Parts Manual Page S-5 640770 Service Parts Manual...
  • Page 123 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 124 REAR SUSPENSION Front of Vehicle Service Parts Manual Page S-7 640770 Service Parts Manual...
  • Page 125 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 126 REAR SUSPENSION Notes: Service Parts Manual Page S-9 640770 Service Parts Manual...
  • Page 127 REAR SUSPENSION Notes: Service Parts Manual Page S-10 Service Parts Manual 640770 Service Parts Manual...
  • Page 128 SEATING SEAT BOTTOM ASSEMBLY (BLACK) includes items 2 - 9 SEAT BOTTOM (BLACK) includes items 3, 4 Front of Vehicle SEAT BACK ASSEMBLY (BLACK) includes items 13 - 18 SEAT BACK (BLACK) includes items 14, 15 Front of Vehicle Service Parts Manual Page T-1 640770 Service Parts Manual...
  • Page 129 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 130 SEATING FLIP SEAT BOTTOM ASSEMBLY 4 PASSENGER includes items 3, 4 Seat Backrest Assembly BACKREST ASSEMBLY (BLACK) FLIP SEAT BOTTOM ASSEMBLY (BLACK) includes items 17 - 21 includes items 2 - 8 Service Parts Manual Page T-3 640770 Service Parts Manual...
  • Page 131 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 132 SEATING Upper OPS Front of Vehicle Lower OPS Service Parts Manual Page T-5 640770 Service Parts Manual...
  • Page 133 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 134 SEATING Front of vehicle 2 10 Front of vehicle Service Parts Manual Page T-7 640770 Service Parts Manual...
  • Page 135 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 136 SEATING Front of Vehicle Front of Vehicle Service Parts Manual Page T-9 640770 Service Parts Manual...
  • Page 137 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 138 SEATING Notes: Service Parts Manual Page T-11 640770 Service Parts Manual...
  • Page 139 SEATING Notes: Service Parts Manual Page T-12 Service Parts Manual 640770 Service Parts Manual...
  • Page 140 TRUCKBED Front of Vehicle PLASTIC BED ASSEMBLY (MANUAL LIFT) includes items 2 - 27 PLASTIC BED ASSEMBLY includes items 3 - 12 PLASTIC BED LATCH includes items 35 - 43 Front of Vehicle Seat support Frame Front of Vehicle Service Parts Manual Page U-1 640770 Service Parts Manual...
  • Page 141 TRUCKBED 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 142 TRUCKBED 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 143 TRUCKBED Notes: Service Parts Manual Page U-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 144 WEATHER PROTECTION Front of Vehicle Vehicle shown for reference only Front of Vehicle WINDSHIELD KIT (FULL) includes items 2 - 14 WINDSHIELD KIT (SPLIT) includes items 19 - 38 Service Parts Manual Page V-1 640770 Service Parts Manual...
  • Page 145 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 146 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 147 WEATHER PROTECTION Notes: Service Parts Manual Page V-4 Service Parts Manual 640770 Service Parts Manual...
  • Page 148 WEATHER PROTECTION Vehicle shown for reference only BAD BOY TOP KIT includes items 2, 3 CANOPY TOP HARDWARE KIT includes items 4 - 9 Service Parts Manual Page V-5 640770 Service Parts Manual...
  • Page 149 *** Indicates consult Customer Service Department for additional information. ITEM PART NO. DESCRIPTION QTY. 628584 BAD BOY TOP KIT, 43" LG (INCLUDES ITEMS 2, 3) ........627077 CANOPY TOP ..................628585 CANOPY TOP HARDWARE KIT (INCLUDES ITEMS 4 - 9) ....RUBBER SPACER................
  • Page 150 WEATHER PROTECTION Notes: Service Parts Manual Page V-7 640770 Service Parts Manual...
  • Page 151 WEATHER PROTECTION Notes: Service Parts Manual Page V-8 Service Parts Manual 640770 Service Parts Manual...
  • Page 152 WHEELS AND TIRES WHEEL AND TIRE ASSEMBLY, FRONT (PASSENGER SIDE) includes items 3, 4 WHEEL AND TIRE ASSEMBLY, FRONT (DRIVER SIDE) includes items 3, 4 WHEEL AND TIRE ASSEMBLY, REAR (PASSENGER SIDE) includes items 7, 8 WHEEL AND TIRE ASSEMBLY, REAR (DRIVER SIDE) includes items 7, 8 WHEEL AND TIRE ASSEMBLY, FRONT (PASSENGER SIDE) includes items 15, 16 WHEEL AND TIRE ASSEMBLY, FRONT (DRIVER SIDE) includes items 15, 16 WHEEL AND TIRE ASSEMBLY, REAR (PASSENGER SIDE) includes items 19, 20...
  • Page 153 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 154 WHEELS AND TIRES Notes: Service Parts Manual Page W-3 640770 Service Parts Manual...
  • Page 156 Textron Specialized Vehicles, Inc. 1451 Marvin Griffin Road Augusta, Georgia 30906-3852 USA CONTACT US: North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-438-3946, FAX: 1-800-752-6175 International: Phone: 001-706-798-4311, FAX: 001-706-771-4609 Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Parts &...

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