Ezgo RXV Electric 611105 Guide

RXV ELECTRIC
SERVICE PARTS MANUAL
ISSUED FEBRUARY 2009 REVISED NOVEMBER 2015
611105

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC POWERED
FLEET & PERSONAL GOLF CARS
RXV GOLF CAR
RXV FREEDOM™
RXV SHUTTLE 2 + 2
STARTING MID-MODEL YEAR 2009
(MANUFACTURED BEGINNING FEBRUARY 23, 2009)
E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include
these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically by the E-Z-GO Division, and therefore is subject to change without notice.
The E-Z-GO Division DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI-
DENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL:
SALES PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii
NOTES
Service Parts Manual
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 the vehicle serial number
and the manufacturer code.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling batteries may void the warranty.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.

Page iii
TABLE OF CONTENTS
Service Parts Manual
SECTION Page No.
HOW TO USE THE SERVICE PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vii
ACCELERATOR PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
• Accelerator Pedal Pad
• Accelerator Pedal Assembly
• Switches
BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
• Charger
• Charger Cords
• Cover
• Handle
BODY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
• Front Bumper
• Front Splash Shield
• Cowl
• Nameplate
• Instrument Panel
• Instrument Panel Trim
• Cup Holder
BODY - MID SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
• Pedal Cover
• Floorboard
• Floormat
• Rocker Panels
BODY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
• Rear Body
• Rear Splash Shields
• Seat Support
• Bagwell Liner
• Access Panel
• Scuff Guards
• Rear Bumper
BODY - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
• Side Baskets
• Sand Bottle
• Cooler
• Soft Swipe
• Divot Repair
• Club & Ball Washer
• Four Bag Attachment
BRAKES - PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
• Brake Pedal Pad
• Brake Pedal Assembly
• Brake Pedal Return Spring
• Switches
BRAKES - MOTOR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 3
• Motor Brake Assembly
• Brake Handle
• Handle Return Spring

Page iv
TABLE OF CONTENTS
SECTION Page No.
Service Parts Manual
ELECTRICAL SYSTEM - MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
• Main Harness
• Solenoid
• Reverse Warning Indicator
• Run / Tow Switch
• Run Plug
• Controller Splash Shield
• Key Switch
• Charger Receptacle
• Solenoid Wires
ELECTRICAL SYSTEM - BATTERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 5
• Batteries
• Battery Tray
• Battery Hold Down
• Battery Strap
• Wires
ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
• Horn Assembly
• Horn Button
• State of Charge Meter
• Headlights
• Tail Lights
• Turn Signal Switch
• Headlight Switch
ELECTRONIC SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1
• Controller Assembly
• Resistor Assembly
• Resistor Mounting Bracket
• Sensor
FRONT SUSPENSION - STRUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
• Strut Assemblies
• Spindles
• A-Arm
• Front Hub
• Wheel Bolt
FRONT SUSPENSION - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G - 5
• Steering Rack Assembly
• Steering Column
• Steering Wheel
• Score Card Holder
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
• AC Motor
• Flexloom Sleeve
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J - 1
• Axle Assembly
• Rear Hub
• Wheel Bolt
• Axle Shaft

Page v
TABLE OF CONTENTS
Service Parts Manual
SECTION Page No.
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
• Shocks
• Leaf Spring
• Shackles
• Bushings
SEATING & BASKET- FRONT SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
• Front Seat Bottom
• Front Seat Back
• Hip Restraints
• Seat Back Support
• Sweater Basket
• Bag Strap
• Bag Strap Clamp
SEATING - REAR SEAT 2 + 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 4
• Rear Seat Bottom
• Rear Seat Back
• Seat Back Support
• Seat Hinge
• Arm Rest
• Rear Seat Floor Board Assembly
• Seat Belt
REAR FACING SEAT - EXCEED MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 9
• Rear Facing Floor Board Assembly
• Rear Facing Seat Bottom Assembly
• Seat Back Assembly
TOW BAR - PERMANENT TOWING VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 1
• Tow Bar
• Latch
• Retainer
TOW BAR - PERMANENT TOWED VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M - 3
• Steering Link
• Front Casting
• Spacer
• Rod Ends
WEATHER PROTECTION - GOLF CAR SUN TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 1
• Sun Top
• Top Struts
WEATHER PROTECTION - SHUTTLE 2+2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 3
• Sun Top
• Top Struts
WEATHER PROTECTION - WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N - 5
• Windshield
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P - 1
• Tires
• Wheels
• Lug Nuts
• Dust Cap
• Wheel Cover

Page vi
TABLE OF CONTENTS
SECTION Page No.
Service Parts Manual
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R - 1
• Frames
• Seat Frames

Page vii
HOW TO USE THE SERVICE PARTS MANUAL
Service Parts Manual
This manual is divided into several sections:
GENERAL INFORMATION
•TABLE OF CONTENTS
•HOW TO USE THE SERVICE PARTS MANUAL
ILLUSTRATED PARTS BREAKDOWN
•Contains illustrations and parts lists for all systems of the vehicle.
USE OF THE MANUAL
To use this manual, consult the TABLE OF CONTENTS (page iii) to locate the information or illustration required.
Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of
components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your
situation. Locate the serial number. It is important that the serial number of your vehicle and its model number be sup-
plied to Service Parts when ordering any replacement components.
SERIAL NUMBER LOCATION
Three serial number and manufacture date code labels are on the vehicle. One is placed on the steering column, the
second is located on the frame member under the front splash shield on the driver side and the third is located on the
passenger side frame rail at the rear of the vehicle.
In order to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must
be provided when ordering service parts.
Serial Number
Serial Number
Serial Number

Page viii
HOW TO USE THE SERVICE PARTS MANUAL
Service Parts Manual
1. WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the TABLE OF CONTENTS and select the
most appropriate component description.
•Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying
description for specific information regarding the part that was not shown in the index.
•From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying
it with the pictorial representation on the illustrated page.
Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is
found. The part number is the lowest assembly sold by Service Parts. The asterisk (*) indicates that the part depicted is
not available for purchase.
NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.
To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.
37
28
46
39
40
21
22
23
71
24
2627
25
38
43
4849
57 60
58
61
54
54
68 64
67
65
41
42
70
63
44
59
Front of Vehicle
55
55
52
53
45
2
34
33
32
31
30
5
3
4
12
13
14 15
16 17 18
11
10
8
9
6
47
Title Title
Left hand illustration page
(continued on right hand page
if required) Parts list (continued on
rear of page if required)

Page ix
Service Parts Manual
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN

Page A-1 Service Parts Manual
ACCELERATOR
5
4
1
6
Accelerator Pedal Assembly includes items 2 - 6
3
2
9
10
7

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. 1 2 3 4 5 DESCRIPTION QTY.
Page A-2
Service Parts Manual
ACCELERATOR
1 626138 ACCELERATOR PEDAL ASSEMBLY, BLACK (INCLUDES ITEMS 2 - 6) .... 1
2 612889 ACCELERATOR PEDAL MOLEX SWITCH ............................................. 1
3 620030 SOCKET HEAD CAP SCREW, M5 - 0.8 X 10.......................................... 2
4 600019 ROTARY POSITION SENSOR................................................................. 1
5 600543 BUTTON HEAD TORX BOLT, M4 - 0.75 X 12 ......................................... 2
6 610529 ACCELERATOR PEDAL PAD .................................................................. 1
7 614393 ACCELERATOR PEDAL BOOT ..................................................................... 1
8
9 615747 JUMPER HARNESS, ACCELERATOR PEDAL SWITCH .............................. 1
10 606277 BOSS SCREW, M6 - 1.0 X 25 ........................................................................ 3

Page B-1 Service Parts Manual
BATTERY CHARGER
1
2

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 PARTNO. 12345 DESCRIPTION QTY.
Page B-2
Service Parts Manual
BATTERY CHARGER
1 635671 CHARGER, 3 METER CORD......................................................................... 1
2 635672 CHARGER, 5.5 METER CORD...................................................................... 1
3 611781 5M GFI CHARGER CORD KIT (NOT ILLUSTRATED)................................... 1

Page C-1 Service Parts Manual
BODY
19
18
17
11
28
25
26
14
39
27
34
35
7
1
23
38
30
24
31
8
13
4
9
10
6
5
2
17
21
20
22

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 PARTNO. 12345 DESCRIPTION QTY.
Page C-2
Service Parts Manual
BODY
1 6XXXXX*** FRONT COWL, WITHOUT HEADLIGHT OPENING (see colors below)........ 1
606953 .... IVORY
606954 .... FOREST GREEN
606955 .... PATRIOT BLUE
606956 .... BLACK
606957 .... BURGANDY
606958 .... BRIGHT WHITE
606959 .... FLAME RED
606960 .... STEEL BLUE
608476 .... PLATINUM
608477 .... ALMOND
608493 .... ELECTRIC BLUE
608494 .... INFERNO RED
617580 .... SUN BURST ORNAGE
617578 .... BRITISH RACING GREEN
630161 .... BARLEY GOLD
630163 .... OASIS GREEN
630165 .... JAVA BROWN
630167 .... METALLIC CHARCOAL
2 6XXXXX*** FRONT COWL, WITH HEADLIGHT OPENING (see colors below) ............... 1
620227 .... IVORY
620228 .... FOREST GREEN
620229 .... PATRIOT BLUE
620230 .... BLACK
620231 .... BURGANDY
620232 .... BRIGHT WHITE
620233 .... FLAME RED
620234 .... STEEL BLUE
608478 .... PLATINUM
608479 .... ALMOND
608516 .... ELECTRIC BLUE
608517 .... INFERNO RED
617581 .... SUN BURST ORNAGE
617579 .... BRITISH RACING GREEN
630169 .... BARLEY GOLD
630171 .... OASIS GREEN
630173 .... JAVA BROWN
630175 .... METALLIC CHARCOAL

Page C-3 Service Parts Manual
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 PARTNO. 12345 DESCRIPTION QTY.
BODY
3
4 600242 INSTRUMENT PANEL TRIM, OPENING FOR KEY SWITCH ONLY.............. 1
5 608808 INSTRUMENT PANEL TRIM, OPENING FOR KEY SWITCH & SOC............ 1
6 608864 INSTRUMENT PANEL TRIM, OPENING FOR KEY SW, SOC & LIGHT SW. 1
7 600243 BALL HOLDER INSERT, DRIVER SIDE......................................................... 1
8 600241 BALL HOLDER INSERT, PASSENGER SIDE................................................. 1
9 602388 ACCESS COVER ASSEMBLY (includes item 10) .......................................... 1
10 602100 U - CLIP .................................................................................................... 3
11 606277 BOSS SCREW, M6 ......................................................................................... 4
12
13 602387 INSTRUMENT PANEL (includes item 14)....................................................... 1
14 602184 SPRING CLIP ........................................................................................... 4
15
16
17 605935 FRONT BUMPER............................................................................................ 1
18 604066 FLAT WASHER, M10 (O.D. 30, I.D. 10.5, THK. 1.75)..................................... 2
19 600525 FLANGED HEX NUT WITH PLASTIC INSERT, M10 - 1.5.............................. 2
20 602572 PAN HEAD TORX BOLT, M10 - 15 X 25mm ................................................... 4
21 70200G01 TRUSS HEAD TORX 3 BOLT, 3/8" - 16 X 3/4" LG.......................................... 2
22 604066 FLAT WASHER, M10, 10.5 X 30mm............................................................... 4
23 601634 FRONT SPLASH GUARD............................................................................... 1
24 16816G2 CHRISTMAS TREE RIVET (.25" x .88") ......................................................... 3
25 635612 CUPHOLDER ASSEMBLY WITH USB CUTOUT (includes item 27).............. 1
26 602101 CUPHOLDER ASSEMBLY (includes item 27) ................................................ 1
27 608522 WARNING AND INSTRUCTION DECAL.................................................. 1
28 71597G01 SELF THREADING NUT................................................................................. 3
29
30 606405 E - Z - GO NAMEPLATE ................................................................................. 1
31 608991 YELLOW REFLECTOR, FRONT .................................................................... 2
32
33

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 PARTNO. 12345 DESCRIPTION QTY.
Page C-4
Service Parts Manual
BODY
34 608528 WARNING AND INSTRUCTION DECAL (Freedom vehicles)........................ 1
35 608701 WARNING AND INSTRUCTION DECAL, PICTOGRAMS (CE vehicles)....... 1
36
37
38 607131 GLOVE BOX, PASSENGER SIDE.................................................................. 1
39 607533 GLOVE BOX, DRIVER SIDE.......................................................................... 1

Page C-5 Service Parts Manual
BODY
6
3
1
2
21
20
21
20
12 13
19
14
15
15
16
17
5
7
7