Ezgo YEAR 2006+ Guide

19
17
18
13
6
5
9
15
16
78
10
4
3
11
1-INCLUDESITEMS3 - 16
ELECTRIC POWERED COASTAL FLEET
GOLF CARS
ISSUED APRIL 2006 REVISED MAY 2008
SERVICE PARTS MANUAL
604972
R
ef Fcv 17

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC POWERED
COASTAL FLEET GOLF CARS
COASTAL FLEET SERIES GOLF CAR
COASTAL FLEET PDS GOLF CAR
STARTING MODEL YEAR 2006+
DISCLAIMER: The E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obliga-
tion 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 Divi-
sion DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON-
SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone] FAX: [phone]
OUTSIDE USA PHONE: [phone], FAX: [phone]
TEXTRON GOLF, TURF & SPECIALTY PRODUCTS, P.O.BOX 388, AUGUSTA, GEORGIA USA 30903-0388

Page ii
GENERAL INFORMATION
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 vehicle serial number and
manufacture date code.
The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.

Page iii
TABLE OF CONTENTS
Service Parts Manual
SECTION Page No.
HOW TO USE THE SERVICE PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
BATTERY CHARGER - PORTABLE 36 VOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
BODY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
BODY - MID SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
BODY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
BODY - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
BODY - ACCESSORIES CONTINUED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
BODY - ACCESSORIES CONTINUED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
DIRECTION SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
ELECTRICAL SYSTEM - COMMON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
ELECTRICAL SYSTEM - PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
ELECTRICAL SYSTEM - SERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
ELECTRONIC SPEED CONTROL - SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
ELECTRONIC SPEED CONTROL - PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
ELECTRIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
FRONT SUSPENSION/STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1
SEATING AND BAG HOLDER - GOLF CAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
TOW BAR - PERMANENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1
TOW BAR - CASUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-5
WEATHER PROTECTION - GOLF CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1
SPECIALTY PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX A-1
OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX B-1

Page iv
TABLE OF CONTENTS
Service Parts Manual
Notes:

Page v
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
APPENDIX
•Contains a listing of specialty products and options/accessories
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 plate (see BODY located in the Illustrated Parts Breakdown section of this manual
for its location) and note the complete number shown on the plate. It is important that the serial number of your vehicle
and its model number be supplied to Service Parts when ordering any replacement components.
Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual for its loca-
tion) and note the complete number shown on the plate.
HOW TO USE THE SERVICE PARTS MANUAL

Page vi
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 INDEX OF MAJOR COMPONENTS 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.
2. IF YOU KNOW THE PART NUMBER
•Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on.
•Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying
description for specific information regarding the part.
•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.
Title Title
Left hand illustration page
(continued on right hand page
if required)
Parts list (continued on
rear of page if required)
Front of Vehicle
123
101
100
99
98
120
74
70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,86
84,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70- Includes Items 71 - 74
81 - Includes Items 82 - 84
86 - Includes Items 87 - 89
94 - Includes Items 95, 96
111 - Includes Items 112 - 114
118 - Includes Items 119 - 121
126 - Includes Items 127 - 131
103
*See Body Section for
decal information
127
128129
130
131
126

Page vii
Service Parts Manual
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN

Page A-1 Service Parts Manual
16
15
14
11
12
13
17
To Harness
from
Direction
Selector
7
45
3
26
3
23
24
29
28
21
19
20
23
24
1 - Includes Items 3 - 19, 21, 23, 26 - 43
2 - Includes Items 3 - 17, 20, 21, 24 - 43
31 - Includes Items 32 - 35
33 - Includes Items 34, 35
Ref Acl 1-1
A
A
ACCELERATOR

Page A-2
Service Parts Manual
ACCELERATOR
To Harness
from
Direction
Selector
34
37
32
42
37
41
43
39
38
45
46 35
Ref Acl 1-2

Page A-3 Service Parts Manual
Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
ACCELERATOR
1 73333-G09 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3 - 19, 21, 23, 26 - 43)............... 1
2 73333-G10 PEDAL BOX ASSEMBLY, PDS MODEL ONLY
(INCLUDES ITEMS 3 - 17, 20, 21, 24 - 43) ........................................................ 1
3 25853-G01 PEDAL BOX AND COVER (SEAL AND BEARING)..................................... 1
4 25854-G01 INDUCTIVE THROTTLE SENSOR .............................................................. 1
5 00983-G01 SELF THREADING NUT, 3/16" .................................................................... 2
6
7 602484 PLUNGER..................................................................................................... 1
8
9
10
11 73332-G01 ACCELERATOR ROD .................................................................................. 1
12 00532-G4 NUT, 5/16 - 24............................................................................................... 1
13 10385-G4 CLEVIS YOKE (ADJUSTABLE).................................................................... 1
14 17677-G2 SPRING RETAINER, 3/8"............................................................................. 1
15 73046-G01 COMPRESSION SPRING............................................................................ 1
16 17979-G1 ACCELERATOR ROD BUSHING................................................................. 1
17 17677-G1 SPRING RETAINER, 1/2"............................................................................. 1
18
19 25861-G01 MICRO SWITCH........................................................................................... 1
20 25861-G02 MICRO SWITCH (PDS MODEL ONLY)........................................................ 1
21 01050-G01 SCREW, #4 - 14 X 5/8" LG........................................................................... 2
22
23 25879-G03 WIRING HARNESS (PEDAL BOX ASSEMBLY) .......................................... 1
24 25879-G05 WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY)....... 1
25
26 00684-G6 SCREW, #8 - 32 X 3/4" LG (STAINLESS STEEL)........................................ 2
27
28 70116-G02 ACCELERATOR PEDAL BRACKET............................................................. 1
29 01051-G01 SCREW, #8 - 16 X 1/2" LG........................................................................... 4

Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page A-4
Service Parts Manual
ACCELERATOR
30
31 25799-G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 32 - 35)............. 1
32 * ACCELERATOR PEDAL........................................................................ 1
33 27844-G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 34, 35)............. 1
34 27512-G01 ACCELERATOR PEDAL PAD ......................................................... 1
35 15766-G1 OVAL RIVET 3/16" X 7/16" LG ........................................................ 6
36
37 17838-G1 NYLON BUSHING........................................................................................ 3
38 74432-G01 PEDAL PIVOT PIN ....................................................................................... 1
39 12064-G6 PUSHNUT, 9/32" I.D..................................................................................... 1
40
41 10386-G3 CLEVIS PIN, 5/16" X 13/16" LG ................................................................... 1
42 17255-G1 TEFLON WASHER, 5/16"............................................................................. 1
43 10387-G3 COTTER PIN, 3/32" X 3/4" LG ..................................................................... 1
44
45 00715-G2 BOLT, 5/16 - 18 X 4/5" LG................................................................................... 4
46 70135-G01 PEDAL PIVOT COVER....................................................................................... 1

Page B-1 Service Parts Manual
76
71
3 6
7
1 - Includes Items 3 - 63
2 - Includes Items 3 - 13, 18 - 63, 70 - 76
10
8
9
9
Transformer
Wire
11
13
10 9
9
11
8
12
POWERWISE™
POWERWISE™ +
R
ef Bcp 1-1
74 75
70
15
4
5
B
BATTERY CHARGER - PORTABLE 36 VOLT

Page B-2
Service Parts Manual
BATTERY CHARGER - PORTABLE 36 VOLT
25
24
D
E
31
29
30
20
20
WHT from
Transformer
19
18 21
22
33, 66
A
20
C
To grounding
To Black/
Control Board
To Amp Fuse
To
Transformer
To Power
Input Board
R
ef Bcp 1-2
26

Page B-3 Service Parts Manual
BATTERY CHARGER - PORTABLE 36 VOLT
DC
DC
AMPERES
AMPERES
10
10
20
20
30
30
0
WHT from DC Cord
AMMETER INSTALLATION
47
48 49 50 48 5152
54
53
51
53
51
Heat
Sink
48
53
46
B
50
45
Chassis
55
GRN
XF
WHT
BRN from Control Board
ORN from Control Board
BLK from Transformer
BLK from Transformer
BLK from AC Cord
WHT from
AC Cord
GRN to
Ground
BRNORN YEL
72
POWER INPUT BOARD
INSTALLATION
58
A
POWERWISE™ +
CONTROL / POWER INPUT
BOARD INSTALLATION
BLK from
Transformer
BLK from
Transformer
BLK from
AC Cord
WHT from
AC Cord
GRN to
Ground
16
57
A
GRN
XF
WHT
RED to
Heat Sink
BLACK from
DC Plug
POWERWISE™
R
ef Bcp 1-3
63
62
60
61
AC
Cord
Port
Front of
Charger
GRN to
Power
Input
Board
GRN to
AC Cord
D
GROUNDING DETAIL
43
67
36 38 39 35
42
40
33 - Includes Items 34 - 43
66 - Includes Items 34 - 42, 67
37
41
41 34 DC CABLE ASSEMBLY
E
C
To
Capacitor
To XF on Power Input Board
To Norm. Open
on Power
Input Board
To Diodes
56
54
53
To
DC
Cord
TRANSFORMER
DETAIL
55
28
27

Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-4
Service Parts Manual
BATTERY CHARGER - PORTABLE 36 VOLT
1 28115-G01 POWERWISE™ CHARGER (10' CORD) (INCLUDES ITEMS 3 - 63)................ 1
2 28115-G02 POWERWISE™ + CHARGER (PORTABLE, 10' CORD) (INCLUDES ITEMS
3 - 13, 18 - 63, 70 - 76)....................................................................................... 1
3 * CHASSIS ...................................................................................................... 1
4 00513-G6 SCREW, #8 - 18 X 1 3/4" LG ........................................................................ 2
5 00559-G4 WASHER, #8 ................................................................................................ 2
6 11572-G3 EXPANSION NUT......................................................................................... 2
7 28104-G01 HEAT SINK ................................................................................................... 1
8 00372-G4 SCREW, #8 - 32 X 1/2" LG ........................................................................... 4
9 00559-G4 WASHER, #8 ................................................................................................ 4
10 00565-G4 LOCK WASHER, #8 ..................................................................................... 4
11 00526-G1 NUT, #8 - 32 ................................................................................................. 4
12 28548-G01 DIODE........................................................................................................... 1
13 28110-G01 ELECTRICAL CLIP....................................................................................... 1
14
15 * LABEL (POWERWISE™) ............................................................................ 1
16 28667-G01 CONTROL / POWER INPUT BOARD .......................................................... 1
17
18 * COVER ......................................................................................................... 1
19 28102-G01 HANDLE ....................................................................................................... 1
20 00614-G4 SCREW, #8 - 18 X 1/2" LG ........................................................................... 6
21 28136-G01 LABEL (VENTILATION)................................................................................ 1
22 28136-G02 LABEL (CORD CONDITION)........................................................................ 1
23
24 26979-G01 CAPACITOR BRACKET ............................................................................... 1
25 28109-G01 CAPACITOR ................................................................................................. 1
26 00969-G01 SCREW, #8 - 32 X 3/8" LG ........................................................................... 3
27 00414-G5 BOLT, 1/4 - 20 X 5/8" LG .............................................................................. 3
28 11027-G2 LOCK NUT, 1/4 - 20...................................................................................... 3
29 19388-G4 AC CORD ..................................................................................................... 1

Page B-5 Service Parts Manual
Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
BATTERY CHARGER - PORTABLE 36 VOLT
30 13557-G2 STRAIN RELIEF (AC)................................................................................... 1
31 13557-G3 STRAIN RELIEF (DC)................................................................................... 1
32
33 73345-G01 DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34 - 43)........... 1
34 73051-G11 PLUG (TOP HALF)................................................................................. 1
35 73051-G12 PLUG (BOTTOM HALF)......................................................................... 1
36 73051-G27 AUXILARY CONTACT ........................................................................... 1
37 73051-G14 MALE PIN............................................................................................... 2
38 73051-G08 SCREW, #10 - 32 X 1/2" LG (BRASS)................................................... 2
39 73051-G15 MAGNET ................................................................................................ 1
40 73051-G16 SCREW, #6 - 32 X 1/2" LG (STAINLESS STEEL)................................. 2
41 73051-G10 LOCK NUT, #6 - 32 ................................................................................ 4
42 73051-G17 SCREW, #6 - 32 X 1" LG (STAINLESS STEEL).................................... 2
43 73344-G01 DC CORD, 10' LG .................................................................................. 1
44
45 28105-G01 AMMETER .................................................................................................... 1
46 01051-G01 SCREW, #8 - 16 X 1/2" LG ........................................................................... 2
47 00559-G4 WASHER, #8 ................................................................................................ 2
48 01003-G01 WASHER, #10 (BRASS)............................................................................... 4
49 22589-G2 SHOULDER WASHER, #10 ......................................................................... 1
50 00771-G6 NYLON WASHER, 3/8" ................................................................................ 1
51 00528-G4 NUT, #10 - 32 (BRASS)................................................................................ 3
52 28106-G01 50 AMP FUSE............................................................................................... 1
53 00565-G5 LOCK WASHER, #10 ................................................................................... 4
54 00378-G4 SCREW, #10 - 24 X 1/2" LG ......................................................................... 2
55 00526-G3 NUT, #10 - 24 ............................................................................................... 2
56 28103-G01 TRANSFORMER .......................................................................................... 1
57 27877-G01 SPACER SUPPORT..................................................................................... 4
58 17618-G1 WIRE TIE ...................................................................................................... 2
59

Where applicable, THE USE OF NON UL PARTS WILL VOID ANY UL 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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-6
Service Parts Manual
BATTERY CHARGER - PORTABLE 36 VOLT
60 00372-G3 SCREW, #8 - 32 X 3/8" LG ........................................................................... 1
61 25977-G32 16 GA WIRE (GREEN 4")............................................................................. 1
62 00565-G4 LOCK WASHER, #8 ..................................................................................... 1
63 00526-G1 NUT, #8 - 32 ................................................................................................. 1
64
65 28115-G07 POWERWISE™ CHARGER (PORTABLE, 18' CORD) (INCLUDES ITEMS
3 - 31, 45 - 63, 66, 67)......................................................................................... 1
66 73345-G03 DC CORD AND HANDLE ASSEMBLY (INCLUDES ITEMS 34 - 42, 67)..... 1
67 73344-G03 DC CORD, 18' LG .................................................................................. 1
68
69 28115-G08 POWERWISE™ + CHARGER (PORTABLE, 18' CORD) (INCLUDES ITEMS
3 - 13, 18 - 31, 45 - 63, 66, 67, 70 - 76) .............................................................. 1
70 * LABEL (POWERWISE™ +) ......................................................................... 1
71 28667-G02 CONTROL BOARD....................................................................................... 1
72 28667-G03 POWER INPUT BOARD............................................................................... 1
73
74 01005-G01 SCREW, #6 - 19 X 5/16" LG ......................................................................... 3
75 00559-G3 WASHER, #6 ................................................................................................ 3
76 28111-G01 SUPPORT SPACER..................................................................................... 3

Page C-1 Service Parts Manual
34 35
36
37
31
1 - Includes Items 2 - 5
20
29 38
12
25
26
23
24
22
R
ef Bod 17-1
9
8
1
18
4
2
3
30
16
5
13
BODY - FRONT