Ezgo SHUTTLE 4 User manual

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ELECTRIC & PRECISION DRIVE SYSTEM™
PERSONNEL CARRIERS AND
5 PASSENGER GOLF CAR
STARTING MODEL YEAR: 2002
SERVICE PARTS MANUAL
28736-G01
REVISED: 12/2002

Page i
Service Parts Manual
SERVICE PARTS MANUAL
ELECTRIC AND
PRECISION DRIVE SYSTEM™
PERSONNEL CARRIERS AND
5 PASSENGER GOLF CAR
VEHICLES
SHUTTLE™ 4
SHUTTLE™ 6
TE5
TE5 PDS
Textron Golf, Turf & Specialty Products reserves the right to make design changes without obligation to make these changes on units previously sold and the
information contained in this manual is subject to change without notice.
Textron Golf, Turf & Specialty Products is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material 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
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 vehicle serial number and
manufacturer code.
The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.
Overfilling of 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ILLUSTRATED PARTS BREAKDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
BATTERY CHARGER (PORTABLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
BATTERY CHARGER (ON BOARD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
BRAKES - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
DIRECTION SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
ELECTRONIC SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
ELECTRONIC SPEED CONTROL - PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
FRONT SUSPENSION/STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
ELECTRIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
REAR AXLE - HYDRAULIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1
SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
SPECIALTY PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX A-1
OPTIONS/ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX B-1
INDEX OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX-1

Page iv
TABLE OF CONTENTS
Service Parts Manual
N
otes:

Page vii
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
INDEX OF MAJOR COMPONENTS
•Contains a listing of parts (excluding hardware) grouped by part number and description and indicates on which
page(s) they can be found
USE OF THE MANUAL
To use this manual, consult the TABLE OF CONTENTS (page iii) or the INDEX OF MAJOR COMPONENTS (located at
rear of this manual) 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 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 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 descrip-
tion 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
L
eft hand illustration page
(
continued on right hand page
i
f 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
81,8684,89
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 ix
Service Parts Manual
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN

Page x
HOW TO USE THE SERVICE PARTS MANUAL
Service Parts Manual

Page xi
Service Parts Manual

Page A-1 Service Parts Manual
1 - Includes Items 3 - 43
31 - Includes Items 32 - 35
33 - Includes Items 34, 35
16
15
14
11
12
13
17
To Direction
Selector
Harness
3
29
28
97
8
4
5
45
3
26
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ef Acl 7-1
ACCELERATOR

Page A-2
Service Parts Manual
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ef Acl 7-2
ACCELERATOR

Page A-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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
1 73333-G08 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 3 - 19, 21, 23, 26 - 43)............... 1
2 73333-G07 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 25857-G01 PLUNGER SLEEVE...................................................................................... 1
8 28443-G01 PLUNGER..................................................................................................... 1
9 28444-G01 PLUNGER CAM............................................................................................ 1
10
11 73332-G01 ACCELERATOR ROD .................................................................................. 1
12 00532-G4 LOCK NUT, 5/16 - 24.................................................................................... 1
13 10385-G4 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 - 20 X 5/8" LG........................................................................... 2
22
23 25879-G07 WIRING HARNESS (PEDAL BOX ASSEMBLY) .......................................... 1
24 25879-G06 WIRING HARNESS (PEDAL BOX ASSEMBLY) (PDS MODEL ONLY)....... 1
25
26 00684-G6 SCREW, #8 - 32 X 3/4" LG........................................................................... 4
27
28 70116-G01 ACCELERATOR PEDAL BRACKET............................................................. 1
29 01051-G01 SCREW, #8 - 16 X 1/2" LG........................................................................... 4
ACCELERATOR

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
30
31 25799-G01 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 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 13/16" LG. .............................................................................. 4
46 70135-G01 PEDAL PIVOT COVER....................................................................................... 1
ACCELERATOR

Page B-1 Service Parts Manual
1
3
2
R
ef Bcp 7
BATTERY CHARGER (PORTABLE)

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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-2
Service Parts Manual
1 28435-G03 48V LESTER BATTERY CHARGER................................................................... 1
2 28435-G01 48V LESTER BATTERY CHARGER WITH SWITCHABLE INPUT .................... 1
3 28435-G05 48V LESTER BATTERY CHARGER CE APPROVED........................................ 1
For service or replacement parts, contact:
Lester Electrical
625 West “A” Street
Lincoln, NE 68522
Phone: [phone], FAX: [phone]
Always provide the following information when requesting information
or ordering replacement parts:
Model Number:
Serial Number: (stamped into housing)
BATTERY CHARGER (PORTABLE)

Page B-3 Service Parts Manual
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6
7
8
14
43
R
ef Bco 7
1
BATTERY CHARGER (ON BOARD)

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.
G** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page B-4
Service Parts Manual
1 28435-G07 48V LESTER BATTERY CHARGER................................................................... 1
2
3 73173-G01 CHARGER RECEPTACLE COVER PLATE........................................................ 1
4 14601-G10 RIVET, 1/8" X 7/16" LG (ALUMINUM)................................................................. 4
5
6 73371-G01 COVER................................................................................................................ 1
7 00740-G4 SCREW, #10 - 32 X 1/2" LG................................................................................ 4
8 00565-G5 LOCK WASHER, #10.......................................................................................... 4
9
10 73368-G01 CORD REEL ....................................................................................................... 1
11 00438-G6 BOLT, 5/16 - 18 X 3/4" LG................................................................................... 2
12 11027-G1 LOCK NUT, 5/16 - 18 .......................................................................................... 2
13
14 11027-G2 LOCK NUT, 1/4 - 20 ............................................................................................ 4
For charger service or replacement parts, contact:
Lester Electrical
625 West “A” Street
Lincoln, NE 68522
Phone: [phone], FAX: [phone]
Always provide the following information when requesting information
or ordering replacement parts:
Model Number:
Serial Number: (stamped into housing)
BATTERY CHARGER (ON BOARD)

Page C-1 Service Parts Manual
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18
37
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5
1
1 - Includes Items 2 - 5
22
21
24
25
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43
45
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46
38
42
4
2
3
8
9
41
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ef Bod 7-1
BODY

Page C-2
Service Parts Manual
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111
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ef Bod 7-2
BODY