Tracker Off-Road EViS 2020 User manual

REPAIR AND SERVICE MANUAL
TRACKER EViS
10002660-C
Revised Dec 2019
Issued Aug 2019

SAFETY
For any questions about material in this manual, contact an authorized representative.
Read and understand all labels on the vehicle. Always replace any damaged or missing labels.
Steep hills allow the vehicles to move at faster speeds than speeds on a flat surface. To prevent the loss of vehicle control and possible
injury, speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the
brake to control the speed.
If you operate the vehicle above the maximum specified speed, you can damage the drivetrain components. The damage caused by
speeds more than the maximum specified can cause a loss of vehicle control, is abuse, and will not be covered under the warranty.
Refer to the TRANSPORTING VEHICLE section to learn how to tow or move the vehicle from one location to another location.
If the vehicle is used in a commercial environment, signs must be in position to inform of possible conditions that can be dangerous.
Examples shown below.
NOTICES, CAUTIONS, WARNINGS AND DANGERS
Read the NOTICES, CAUTIONS, WARNINGS and DANGERS. The person who services a vehicle needs the mechanical
skill and experience to see possible hazardous conditions. Incorrect service or repairs can cause damage to the vehicle or
make the vehicle dangerous to operate.
NOTICE: A NOTICE indicates and describes information not related to personal injury.
A CAUTION indicates a dangerous condition that can cause injury that is not life threatening.
A WARNING indicates a dangerous condition that can cause death or serious injury.
A DANGER indicates a dangerous condition that will cause death or serious injury.
The battery posts, terminals and all related accessories contain lead and lead compounds.
Wash your hands after contacting any of these components.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed
beyond the factory specifications. Such modifications can cause serious personal injury or death. The manufacturer prohibits and dis-
claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
The manufacturer reserves the right to incorporate engineering and design changes to products in this manual, without obligation to
include these changes on units sold previously.
The information contained in this manual may be revised periodically by the manufacturer, and therefore is subject to change without
notice.
THE MANUFACTURER DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDEN-
TAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
These are the original instructions as defined by 2006/42/EC.
Dealer: 800-296-4804
Consumer: 877-394-6727
www.trackeroffroad.com
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Repair and Service Manual
10002660
REPAIR AND SERVICE MANUAL
72V ELECTRIC POWERED VEHICLE
TRACKER EViS
MODEL YEAR 2020

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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.
The use of non-Original Equipment Manufacturer (OEM) approved parts can void the warranty.
BATTERY PROLONGED STORAGE
Batteries self-discharge over time. The rate of self-discharge varies depending on the
ambient temperature, the age and condition of the batteries.
Fully charged batteries will not freeze in winter temperatures unless the temperature falls
below -75°F (- 60°C).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain.
The battery charger can be left connected to the vehicle to maintain a full charge on the bat-
teries, provided the charger is plugged into an active electrical source. If power to the elec-
trical source is disconnected or interrupted, the battery charger will continue to check the
charge on the battery pack. This will draw power from the battery pack and eventually drain
the batteries if power is not restored in a timely manner.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
Check and maintain the proper fluid level in all battery cells during the storage period.
Proper fluid level is required for maximum battery performance.
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead
smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absor-
bent material, sand or earth and dispose of in accordance with local, state and federal regulations
for acid and lead compounds. Contact local and/or state environmental officials regarding disposal
information.
Operating, servicing and maintaining a passenger vehicle or off-road vehicle
can expose you to chemicals including phthalates and lead, which are known to
the State of California to cause cancer and birth defects or other reproductive
harm. To minimize exposure, wear gloves and wash your hands frequently
when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
WARNING
California Proposition 65

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SAFETY INFORMATION
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SAFETY INFORMATION
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures
developed by the manufacturer. Adherence to these procedures and fault testing tips will ensure the best possible ser-
vice from the product. To reduce the chance of personal injury and/or property damage, the following instructions must
be carefully observed:
GENERAL
Many vehicles are used for a variety of tasks beyond their original intended use; therefore it is impossible to anticipate
and warn against every possible combination of circumstances that may occur. Warnings cannot replace good common
sense and prudent driving practices. Common sense and prudent driving practices do more to prevent accidents and
injury than warnings and instructions can provide.
The manufacturer strongly suggests anyone operating the vehicle read the entire owner’s guide provided with the pur-
chase of the vehicle, paying particular attention to the CAUTIONS, WARNINGS and DANGERS within.
For any questions or concerns, contact the closest representative, or write to the address on the back cover of this pub-
lication, Attention: Customer Care Department.
The manufacturer reserves the right to make design changes without obligation to make these changes on units previ-
ously sold and the information contained in this manual is subject to change without notice.
The manufacturer 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.
This vehicle conforms to the current applicable standard for safety and performance requirements.
This vehicle is designed and manufactured for off-road use. It does not conform to Federal Motor Vehicle Safety Stan-
dards and is not equipped for operation on public streets. Some communities may permit these types of vehicles to be
operated on their streets on a limited basis and in accordance with local ordinances.
Ensure all electrical accessories are grounded directly to the battery (-) post. Never use the chassis or body as a
ground connection.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity. Do not exceed number of occupants indicated.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle,
decrease its stability, increase the speed or extend the stopping distance beyond the fac-
tory specification. Such modifications can result in serious personal injury or death.
Modifications that increase the speed and/or weight of the vehicle will extend the braking distance and may reduce the
stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and disclaims
responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
Speed should be moderated by the environmental conditions, terrain and common sense.
GENERAL OPERATION
ALWAYS:
• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control speed on steep grades.
• Reduce speed in damp or wet areas.
• Reduce speed and use caution when approaching sharp or blind turns.
• Reduce speed and use caution when driving over loose terrain.
• Reduce speed and use caution when driving in areas where pedestrians are present.

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SAFETY INFORMATION
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MAINTENANCE
ALWAYS:
• Replace damaged or missing warning, caution or information labels.
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by trained and qualified persons.
• Follow the manufacturer’s maintenance procedures.
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion.
• Check the polarity of each battery terminal and be sure to rewire the batteries correctly.
• Use specified replacement parts. Never use replacement parts of lesser quality.
• Use recommended tools.
• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the
safety of personnel, nor jeopardize the safe operation of the vehicle.
• Support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a jack.
Lift the vehicle in accordance with the manufacturer’s instructions.
• Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
• Test drive vehicle after repairs or maintenance in a safe area free of vehicular and pedestrian traffic.
• Keep complete records of the maintenance history of the vehicle.
VENTILATION
ALWAYS:
• Charge vehicle in a well ventilated area.
• Charge in an area free of flammable liquids and items.
• Charge a vehicle in an area that is free from flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
• Use a dedicated circuit for battery charger. Do not permit other appliances to be plugged into the receptacle
when the charger is in operation.
• Operate charger in accordance with manufacturers recommendations or applicable electrical code.

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TABLE OF CONTENTS
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SAFETY INFORMATION
GENERAL ........................................................................................................................ III
GENERAL OPERATION.................................................................................................. III
MAINTENANCE ............................................................................................................... IV
VENTILATION.................................................................................................................. IV
GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER AND PIN PLATE LOCATION ............................................................. 1
SERVICING THE VEHICLE.............................................................................................. 1
ROUTINE MAINTENANCE............................................................................................... 2
POWERTRAIN MAINTENANCE....................................................................................... 2
BRAKES............................................................................................................................ 2
TIRES................................................................................................................................ 2
VEHICLE CLEANING AND CARE.................................................................................... 2
VEHICLE CARE PRODUCTS........................................................................................... 3
OPS, CANOPY TOP AND WINDSHIELD......................................................................... 3
TRANSPORTING VEHICLE ............................................................................................. 3
EMERGENCY ELECTRIC PARK BRAKE RELEASE....................................................... 3
TOWING A TRAILER........................................................................................................ 4
PROLONGED STORAGE................................................................................................. 4
HARDWARE ..................................................................................................................... 4
TORQUE SPECIFICATIONS............................................................................................ 5
CAPACITIES AND REPLACEMENT PARTS ................................................................... 5
SAFETY
NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................... 7
IMPORTANT SAFETY WARNING.................................................................................... 7
MODIFICATIONS TO VEHICLE ....................................................................................... 7
GENERAL MAINTENANCE.............................................................................................. 7
BEFORE SERVICING VEHICLE ...................................................................................... 7
LIFTING THE VEHICLE.................................................................................................... 8
How to Lift the Vehicle ......................................................................................... 8
Lift Front of Vehicle .............................................................................................. 9
Lift Rear of Vehicle ............................................................................................... 9
Lower Vehicle ....................................................................................................... 9

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ACCELERATOR
ACCELERATOR PEDAL ................................................................................................. 11
Pedal Replacement .............................................................................................11
BATTERIES AND BATTERY CHARGER
SAFETY........................................................................................................................... 13
BATTERY ........................................................................................................................ 13
Batteries Removal ...............................................................................................14
Battery Installation ..............................................................................................15
BATTERY MAINTENANCE ............................................................................................. 15
At Each Charging Cycle ......................................................................................15
Monthly ...............................................................................................................16
Temperature Affects Battery Capacity ................................................................16
............................................................................................................................16
Electrolyte Level and Water ................................................................................16
Cleaning Batteries ...............................................................................................17
Prolonged Storage ..............................................................................................17
Battery Charging .................................................................................................18
AC Voltage ..........................................................................................................18
FAULT TESTING ............................................................................................................. 18
Hydrometer .........................................................................................................19
Using Hydrometer ...............................................................................................19
BATTERY CHARGER ..................................................................................................... 20
Charger Description ............................................................................................20
Portable Charger Installation ..............................................................................20
BODY
GENERAL........................................................................................................................ 23
BODY COMPONENT REPLACEMENT .......................................................................... 23
Rocker Panel Replacement ................................................................................24
Gauge Panel Replacement .................................................................................24
Cowl Replacement ..............................................................................................25
Removal of Headlight Grille Assembly ................................................................25
Instrument Panel Replacement ...........................................................................26
Rear Fender Replacement ..................................................................................28
Seat Wrap and Closeout Replacement ...............................................................29
Rear Closeout Panel Replacement .....................................................................30

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PAINTING ....................................................................................................................... 32
Minor Scratches ................................................................................................. 32
Larger Scratches ................................................................................................ 32
Complete Panel Repair ...................................................................................... 32
BRAKES
MAINTENANCE .............................................................................................................. 35
Daily Brake Performance Test ........................................................................... 35
Brake System Inspection ................................................................................... 35
MASTER CYLINDER ...................................................................................................... 36
Master Cylinder Replacement ............................................................................ 36
Brake Fluid ......................................................................................................... 37
REPLACEMENT OF WEAR ITEMS ............................................................................... 37
Brake Pads Replacement .................................................................................. 37
Rotor Replacement ............................................................................................ 38
BLEEDING AND FLUSHING .......................................................................................... 38
Bleeding ............................................................................................................. 38
Bleeding Sequence ............................................................................................ 39
Flushing .............................................................................................................. 39
BRAKE PEDAL REMOVAL AND INSTALLATION ......................................................... 40
ELECTRICAL
VOLTAGE TESTING FOR BATTERIES ......................................................................... 47
MAIN HARNESS............................................................................................................. 47
Power Supply ..................................................................................................... 47
Accessory Wiring ............................................................................................... 48
Faulty Wire Replacement ................................................................................... 48
Headlight Bulb Replacement (LED) ................................................................... 48
Tail light Replacement ........................................................................................ 48
ELECTRONIC SPEED CONTROL ................................................................................. 49
Speed Sensor .................................................................................................... 49
Rotary Position Sensor ...................................................................................... 49
Controller ............................................................................................................ 49
Controller Replacement ..................................................................................... 50
Solenoid Replacement ....................................................................................... 51
DC to DC Converter ........................................................................................... 51
FAULT TESTING ............................................................................................................ 52

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General .............................................................................................................. 52
Testing Battery Voltage ...................................................................................... 52
Continuity Check ................................................................................................ 52
Testing A Switch for Continuity .......................................................................... 52
Testing A Solenoid for Continuity ....................................................................... 53
ACCESORIES................................................................................................................. 53
Key Switch ......................................................................................................... 53
State of Charge (SOC) Meter ............................................................................. 53
Rocker Switches ................................................................................................ 54
Winch Contactor Connections ............................................................................ 55
FRONT CV SHAFT, SUSPENSION, AND STEERING
FRONT SUSPENSION ................................................................................................... 57
Front Strut Assembly Replacement ................................................................... 57
Control Arm Assembly Replacement ................................................................. 58
Lower Ball Joint Replacement ............................................................................ 58
Wheel Bearing Replacement ............................................................................. 59
Strut Replacement ............................................................................................. 60
FRONT AXLE.................................................................................................................. 61
CV Shaft Replacement ....................................................................................... 61
CV Joint Boot Replacement ............................................................................... 62
Front Differential Replacement .......................................................................... 62
STEERING...................................................................................................................... 63
Steering Wheel Replacement ............................................................................ 63
Steering Column Replacement .......................................................................... 64
Steering Rack Replacement .............................................................................. 65
Tie Rod Removal ............................................................................................... 66
Tie Rod Installation ............................................................................................ 66
MAINTENANCE .............................................................................................................. 66
Wheel Alignment ................................................................................................ 66
MOTOR
GENERAL ....................................................................................................................... 69
Motor Brake Removal ........................................................................................ 69
Motor Brake Installation ..................................................................................... 69
Front Motor Removal ......................................................................................... 70
Front Motor Installation ...................................................................................... 71

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Rear Motor Removal .......................................................................................... 72
Rear Motor Installation ....................................................................................... 73
MOTOR TESTS .............................................................................................................. 73
SEATING AND OPS
SEATING ........................................................................................................................ 75
Front Seat Removal and Installation .................................................................. 75
Front Seat Back and Support ............................................................................. 75
Rear Seat Removal and Installation ................................................................... 75
Seat Cushion Disassembly ................................................................................ 77
Footrest Removal and Installation ...................................................................... 77
Seat Belt Removal and Installation .................................................................... 77
Front Seat Belt Buckle Replacement ................................................................. 78
Rear Seat Belt Buckle Replacement .................................................................. 78
UPPER OPERATOR PROTECTION SYSTEM .............................................................. 80
Upper OPS Frame Removal and Installation ..................................................... 80
LOWER OPERATOR PROTECTION SYSTEM ............................................................. 81
Brush Guard Removal and Installation .............................................................. 81
OPS Lower Weldment Removal and Installation ............................................... 82
REAR AXLE AND SUSPENSION
REAR AXLE .................................................................................................................... 85
Maintenance ....................................................................................................... 85
Checking the Lubricant Level ............................................................................. 85
Rear CV Axle Removal ...................................................................................... 85
Differential Removal ........................................................................................... 86
REAR SUSPENSION...................................................................................................... 87
Strut Assembly Removal .................................................................................... 87
Strut Assembly Maintenance Items .................................................................... 88
FAULT TESTING
SUSPENSION AND STEERING..................................................................................... 91
CURTIS CONTROLLER ................................................................................................. 92
General .............................................................................................................. 92
Navigation .......................................................................................................... 92
Changing Data Value ......................................................................................... 92
Favorites ............................................................................................................ 92

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Main Menu Definitions ........................................................................................93
Fault Code Chart .................................................................................................97
Curtis Handheld Diagnostic Tool Function ........................................................105
ELECTRICAL FAULT TESTING.................................................................................... 117
Front - Slave and Rear - Master .......................................................................117
Controller Location and Mounting Configuration ...............................................118
COMPONENT TESTING ............................................................................................... 118
Voltmeter ...........................................................................................................118
Fuses - Testing .................................................................................................119
Key Switch - Testing .........................................................................................119
State of Charge (SOC) Meter - Testing ............................................................120
Electronic Speed Controller Solenoid - Testing ................................................120
Temperature Sensor - Testing ..........................................................................121
Electronic Speed Sensor - Testing ...................................................................121
AC Motor Bench Test ........................................................................................122
WEATHER PROTECTION
GENERAL...................................................................................................................... 125
Transporting Vehicle .........................................................................................125
CANOPY TOP ............................................................................................................... 125
Canopy Top Removal .......................................................................................125
WHEELS AND TIRES.................................................................................................... 127
WHEEL AND TIRE SERVICE........................................................................................ 128
Tire Repair ........................................................................................................128
Wheel Installation ..............................................................................................128
VEHICLE SPECIFICATIONS......................................................................................... 131
Tracker EViS .....................................................................................................131
PERIODIC SERVICE SCHEDULE
PSS................................................................................................................................ 133
APPENDIX A
BATTERY CHARGER USER’S GUIDE......................................................................... 135

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GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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GENERAL INFORMATION AND ROUTINE MAINTENANCE
SERIAL NUMBER AND PIN PLATE
LOCATION
The PIN plate is attached to the frame below the seat
wrap panel (Ref. Fig. 3).
Two serial number labels, PART A and PART B, and a
PIN label are attached to the frame below the flip seat
(Ref. Fig. 2).
Design changes occur continuously. When you order ser-
vice parts, the PIN number, manufacture date code, or
serial number must be available.
Fig. 1 SN Label
Fig. 2 Serial Number and PIN Labels
Fig. 3 PIN Plate
SERVICING THE VEHICLE
To prevent severe injury or death,
resulting from improper servicing
techniques, observe the following
warnings:
Do not attempt any type of servicing operations
before reading and understanding all notes, cau-
tions, and warnings in this manual.
Any service that requires adjustments to be made to
the powertrain while the motor is in operation must
be made with all four wheels raised.
Wear eye protection when working on the vehicle. In
particular, use care when working around batteries
or using solvents or compressed air.
To reduce the possibility of causing an electrical
arc, which could cause a battery explosion, disable
all electrical loads from the batteries before remov-
ing any heavy gauge battery wires.
To prevent the possibility of motor disintegration in
the electric powertrain, never operate vehicle at full
throttle for more than 4 - 5 seconds while vehicle is
in a “no load” condition (all 4 wheels off of the
ground).
It is in the best interest of both vehicle owner and servic-
ing dealer to carefully follow the procedures recom-
mended in this manual. Adequate preventative
maintenance, applied at regular intervals, is the best
guarantee for keeping the vehicle both dependable and
economical.
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear, or abuse.
It is impossible to anticipate all possible component fail-
ures or the manner in which each component can fail.
A vehicle requiring repair indicates that the vehicle is no
longer functioning as designed and should be considered
potentially hazardous. Use caution when working on a
vehicle. When diagnosing, removing or replacing any
components that are not operating properly, consider the
safety of yourself and those around you should the com-
ponent move unexpectedly.
Some components are heavy, spring loaded, highly corro-
sive, explosive, or can produce amperage or reach high
temperatures. Carbon monoxide, battery acid and hydro-
gen gas could cause serious bodily injury to the techni-
cian/mechanic and bystanders if not treated with the
utmost caution. Be careful not to place hands, face, feet,
or body in a location that could expose them to injury
should an unforeseen dangerous situation occur.
Always use the appropriate tools listed in the tool list and
wear approved safety equipment.
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART should be per-
formed (Ref. Fig. 4).
PA R T CPA R T B
PA R T A
PIN Label
Serial Number
Part A
Serial Number
Part B
PIN Plate
Front of Vehicle

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GENERAL INFORMATION AND ROUTINE MAINTENANCE
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10002660
Fig. 4 Initial Service Chart
ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service, pro-
vided it receives regular maintenance (See PERIODIC
SERVICE SCHEDULE on page 133).
Verify appropriate lubrication locations (See Checking the
Lubricant Level on page 85).
NOTICE: To prolong vehicle life, some maintenance
items must be serviced more frequently on vehicles
used under severe driving conditions such as
extreme temperatures, extreme dust/debris condi-
tions, or frequent use with maximum load.
POWERTRAIN MAINTENANCE
The powertrain is most easily accessed from the under-
side of the vehicle (See LIFTING THE VEHICLE on
page 8). Remove the cowl for full access to the front pow-
ertrain (See Cowl Replacement on page 25). Remove the
rear seat for full access to the rear powertrain (See Rear
Seat Removal and Installation on page 75).
Use insulated wrenches to prevent
the possibility of a dropped wrench
causing a short-circuit in a battery,
which can cause an explosion and severe personal
injury or death.
To prevent accidental starting, disconnect the main
negative battery cable before servicing.
BRAKES
This vehicle is equipped with four wheel hydraulic disc
brakes. Check the fluid level at intervals specified (See
PERIODIC SERVICE SCHEDULE on page 133). If fluid
leaks are noticed or the brake pedal seems soft, check
the fluid level immediately. If the brake pedal is soft, the
brake system should be bled to remove air from the brake
lines (See Bleeding on page 38).
The parking brake is an electric motor brake and is
engaged any time that the vehicle comes to a complete
stop. The parking brake is released when the vehicle is in
F (forward) or R (reverse) and the accelerator pedal is
pressed.
After the vehicle has been put into service, it is recom-
mended that the brakes be checked periodically (See
Daily Brake Performance Test on page 35).
To prevent severe injury or death
caused from driving a vehicle with
an improperly operating brake sys-
tem, the braking system must be properly main-
tained. All driving brake tests must be done in a safe
location with regard for the safety of all personnel.
TIRES
Tire condition should be inspected and inflation pressures
checked periodically while tires are cool (See PERIODIC
SERVICE SCHEDULE on page 133). Be sure to install
the valve dust cap after checking or inflating tire.
VEHICLE CLEANING AND CARE
Read and understand all instruc-
tions supplied by the manufacturer
of the pressure washer before use.
When pressure washing the exterior
of the vehicle, do not use pressure
in excess of 700 psi. Maintain a 12”
minimum distance from spray nozzle to painted sur-
face. To reduce the possibility of cosmetic damage,
do not use any abrasive or reactive solvents to
clean plastic parts.
Proper techniques and cleaning materials must be used
to prevent damage to the exterior of the vehicle. Using
excessive water pressure can cause severe injury to
operator or bystander. Excessive pressure can also
cause damage to seals, plastics, seat material, body fin-
ish, or the electrical system. Do not use pressure in
excess of 700 psi to wash exterior of vehicle.
Clean the windshield with water and clean cloth. Minor
scratches can be removed using a commercial plastic
polish or Plexus®plastic cleaner. Both are available from
the service parts department.
Normal cleaning of vinyl seats and plastic or rubber trim
requires the use of a mild soap solution applied with a
sponge or soft brush followed by and wiping with a damp
cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
INITIAL SERVICE CHART
Item Service Operation
Battery Charger Remove from vehicle and read operat-
ing instructions.
Batteries Charge. Batteries must be fully
charged before initial use.
Seats Remove protective plastic covering.
Brakes Check operation; adjust if necessary.
Check hydraulic fluid level; add if nec-
essary.
Tires Check air pressure; adjust if necessary.
Refer to WHEELS AND TIRES section
for inflation recommendations.
Vehicle Inspection Visually inspect for leaks or damage
that may have occurred during ship-
ment from the factory.
Inspect for loose hardware; tighten if
necessary.

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The painted surfaces of the vehicle provide attractive
appearance as well as durable protection. Frequent
washing with lukewarm or cold water and mild detergent
is required to preserve the painted surfaces.
Occasional cleaning and waxing with non-abrasive prod-
ucts designed for ‘clear coat’ automotive finishes will
enhance the appearance and durability of the painted
surfaces.
Corrosive materials used as fertilizers or dust control can
collect on the underside of the vehicle. These materials
will cause corrosion of components, unless flushed occa-
sionally with plain water. Clean any areas where mud or
other debris can collect. Loosen sediment packed in
closed areas to ease its removal. Always use caution not
to chip or otherwise damage paint.
VEHICLE CARE PRODUCTS
There are several products, available through a local dis-
tributor, an authorized Branch, or the Service Parts
Department, to help maintain the vehicle. Among them
are:
• Touch-up paint specially formulated to match
vehicle colors for use on both metal and TPE
(plastic) bodies. (P/N 28140G**, 28432G** and
75831G01)
• Multi-purpose battery protectant (P/N 27619G01)
formulated to form a long-term, flexible, non-
tacky, dry coating that will not crack, peel or flake
over a wide temperature range.
• Use windshield and plastic protectant (P/N
606314) to remove minor scratches from wind-
shield.
OPS, CANOPY TOP AND WINDSHIELD
The Operator Protection System
(OPS) and optional canopy top do
not provide protection from roll
over or falling objects.
The optional windshield does not provide protection
from tree limbs or flying objects.
Remove the optional windshield and store securely
before transporting the vehicle on a trailer. The
optional windshield is not designed to withstand
highway speeds.
The vehicle is equipped with an OPS (Operator Protec-
tion System), and may be equipped with an optional can-
opy top, and/or an optional windshield.
The OPS and optional canopy top provide some protec-
tion from smaller falling objects, but will not protect
against large falling objects such as trees or heavy limbs.
The optional windshield deflects oncoming wind from
occupants, but will not protect against flying objects and
tree limbs.
The optional canopy top and optional windshield provide
some protection from the elements; however, they will not
keep occupants dry in a downpour.
The optional canopy top and optional windshield are
designed for weather protection only (See WEATHER
PROTECTION on page 125).
TRANSPORTING VEHICLE
To prevent personal injury to occu-
pants of other highway vehicles,
make sure the vehicle and contents
are adequately secured to trailer.
Do not ride on a vehicle being transported.
Remove the windshield before transporting the
vehicle.
Maximum speed with canopy top installed is 50 mph
(80 kph).
Do not tow the vehicle. It is not designed to be
towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flat bed truck or other suit-
able transport.
If the vehicle is to be transported on a trailer at highway
speeds, the windshield and canopy top must be removed
(if equipped) and the seat bottoms secured. Always
check that the vehicle and its contents are adequately
secured before transporting the vehicle. The rated capac-
ity of the trailer must be more than the weight of the vehi-
cle and load (See VEHICLE SPECIFICATIONS on
page 131). Engage the park brake and secure the vehicle
to the trailer using ratchet tie downs.
EMERGENCY ELECTRIC PARK
BRAKE RELEASE
If the park brake release switch does not deactivate the
electric park brake, or if the vehicle experiences a power
failure, you can release the park brake using the proce-
dure below. This method is intended for emergency pro-
cedures only and should only be used if necessary.
NOTICE: Leaving the key switch in the ON position
while the park brake is released for long periods of
time will result in a complete discharge of the bat-
tery pack.
Tool List Qty.
Wheel Chocks..............................................................4
1. Chock the wheels so that the vehicle cannot roll.
2. Turn the key switch to the OFF position and remove
the key.
3. Remove the seat bottom.
4. Locate the connectors labeled 1,2,3, and 4. They are
zip tied to the main wiring harness between the pas-
senger side battery and the row of three batteries in
the middle.
5. Disconnect both sets of connectors and connect 1 to
3 and 2 to 4.
6. Insert the key and turn the key switch to the N posi-
tion. This will release the park brake.

B
4Repair Manual
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
10002660
7. Carefully remove the wheel chocks in the direction
that the vehicle needs to be moved.
8. Turn the key switch to the OFF position after the car
has been moved.
9. Disconnect both sets of connectors and connect 1 to
2 and 3 to 4. This will return the vehicle to normal
operation.
Fig. 5 Motor Brake Jumper
TOWING A TRAILER
The vehicle is equipped with a 2-inch receiver. The trailer
and its load must not exceed 1000 lbs (454 kg) and no
more than 100 lbs (46 kg) tongue weight can be attached
to the hitch. The overall capacity of the vehicle, operator,
passenger, and accessories must be reduced to compen-
sate for the trailer and load.
The range of motion of the trailer is limited by the ball and
hitch. The trailer should not be used on rough trails or
over objects such as logs, large rocks, holes, etc.
Never install baskets or extensions using the hitch receiv-
ers. Such items will change the performance characteris-
tics of vehicle and cause unsafe handling, possible roll
over, or vehicle damage.
PROLONGED STORAGE
During periods of storage, the batteries must be main-
tained to prevent discharge.
During cold conditions, the batteries must be fully
charged to prevent the possibility of freezing. A fully
charged battery will not freeze in temperatures above
-75° F (-60° C). Although the chemical reaction is slowed
in cold temperatures, the battery must be stored fully
charged, and disconnected from any circuit that could dis-
charge the battery.
Clean the batteries and neutralize all deposits on the bat-
tery cases to prevent self discharge.
The battery charger can remain connected to the vehicle
to maintain a full charge on the batteries provided the
charger is connected to an active electrical source. If
power to the electrical source is disconnected or inter-
rupted, the battery charger will continue to check the
charge on the battery pack. This will pull power from the
battery pack and eventually drain the batteries if power is
not restored in a timely manner.
HARDWARE
Periodically, inspect the vehicle for loose fasteners. Use
care when tightening fasteners, refer to the following table
for torque values (Ref. Fig. 6).
Three classes of standard hardware, and two classes of
metric hardware are used in the vehicle.
Standard:
• Grade 2 hardware is unmarked.
• Grade 5 hardware can be identified by the three
marks on the hex head.
• Grade 8 hardware is identified by six marks on the
head.
The class specification is marked on metric hardware.

B
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
5
Repair and Service Manual
10002660
TORQUE SPECIFICATIONS
Fig. 6 Torque Specifications
CAPACITIES AND REPLACEMENT PARTS
Fig. 7 Capacities and Replacement Parts
CAPACITIES REPLACEMENT PARTS
Front Axle Oil 48 oz. 90 wt. Gear Oil LED Headlight Bulb P/N 619101
Rear Axle Oil 48 oz. 90 wt. Gear Oil Headlight Bulb P/N 619100
Brake Fluid DOT 4 ATC Type Fuse 10 Amp P/N 35212G07
ATC Type Fuse 15 Amp P/N 35212G01
ATC Type Fuse 20 Amp P/N 35212G02
ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)
BOLT SIZE
Grade 2
1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
4
(5)
8
(11)
15
(20)
24
(33)
35
(47)
55
(75)
75
(102)
130
(176)
125
(169)
190
(258)
Grade 5
Grade 8
6
(8)
13
(18)
23
(31)
35
(47)
55
(75)
80
(108)
110
(149)
200
(271)
320
(434)
480
(651)
6
(8)
18
(24)
35
(47)
55
(75)
80
(108)
110
(149)
170
(230)
280
(380)
460
(624)
680
(922)
BOLT SIZE
Class 5.8
(Grade 2)
M4 M5 M6 M8 M10 M12 M14
1
(2)
2
(3)
4
(6)
10
(14)
20
(27)
35
(47)
55
(76.4)
Class 8.8
(Grade 5)
2
(3)
4
(6)
7
(10)
18
(24)
35
(47)
61
(83)
97
(131)
Class 10.9
(Grade 8)
3
(4)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
5.8
8.8
10.9

6Repair and Service Manual
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
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