Manual Number 102397503
Edition Code 0805U0112T
Villager 4, Villager 6, Villager 8,
TransPorter 4, and TransPorter 6
Gasoline and Electric Vehicles
2004-2005
Transportation Vehicles
Illustrated Parts List
P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone 706-863-3000
Service Parts Fax 706-855-7413
www.clubcar.com
USING THE ILLUSTRATED PARTS LIST
ý WARNING
• This manual is to be used only for identification and ordering of service parts. Be sure to read and use
the maintenance and service manual before attempting any vehicle repairs.
This manual covers all DS Villager 4, Villager 6, Villager 8, TransPorter 4, and TransPorter 6 vehicles built during the
2004 and 2005 model years.
The manual is divided into sections. Note that there are two or three flags on the outside edge of each page. The
first flag contains the section number of which that page is a part. The other flag (or flags) contains the letter G or E,
signifying that the page pertains to the electric or gasoline vehicles only.
Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table
of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that
section. The index can be used to find specific parts and assemblies. The index is divided into numerical and
alphabetical listings with the page numbers in italic text.
There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an
illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon.
The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding
to the numbers on the illustration), part descriptions, and quantity of parts used.
Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the
numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented
to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level
2 part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part
quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A
part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of
the vehicle illustrated on that particular spread.
HOW TO ORDER PARTS
Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You
can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our
web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and
Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887.
2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List
NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. is
continually working to further improve its vehicles and other products. These improvements may affect the
parts used to service the vehicle. Any modification and/or significant change in specifications will be for-
warded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of
this illustrated parts list.
Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without
the obligation of making changes to units previously sold.
Copyright © 2005 Club Car, Inc.
Club Car and ArmorFlex
are registered trademarks of Club Car, Inc.
This manual effective July 28, 2003.
2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List Page 1
CONTENTS
SECTION 1 – BODY AND TRIM
Front Body and Trim ..................................................................................................................................................................... 1-3
Dash Components ......................................................................................................................................................................... 1-5
Beverage Holder – Villager Vehicles ........................................................................................................................................ 1-7
Front Seat Bottom and Armrests – DS Villager 4 ................................................................................................................ 1-9
Front Seat Bottom – TransPorter 4 and 6 .............................................................................................................................. 1-11
Front Seat Back and Support Structure – TransPorter 4 .................................................................................................. 1-13
Rear Seat Back and Support Structure – TransPorter 4 .................................................................................................... 1-15
Handrail, Front Seat Back Cover, and Rear Floormat – Transporter 4 ......................................................................... 1-17
Front and Center Seat Bottoms – Villager 6 and 8 ............................................................................................................. 1-19
Seat Backs and Armrests – Villager 6 and 8 .......................................................................................................................... 1-21
Front Center Body and Floormat – Villager 6 and 8 .......................................................................................................... 1-23
Second Center Body and Floormat – Villager 8 .................................................................................................................. 1-25
Rear Forward-Facing Seat Bottom – Villager 6 and 8 ........................................................................................................ 1-27
Rear Forward-Facing Seat Bottom – Villager 6 and 8, Continued ................................................................................ 1-29
Rear-Facing Seat Bottom – Villager Vehicles ........................................................................................................................ 1-31
Rear-Facing Seat Bottom – TransPorter 6 ............................................................................................................................. 1-33
Rear-Facing Seat Bottom – TransPorter 6, Continued ...................................................................................................... 1-35
Rear-Facing Seat Backs and Supports – DS Villager 4 ....................................................................................................... 1-37
Center Seat Back and Support Structure – TransPorter 6 ................................................................................................ 1-39
Rear-Facing Seat Back and Support Structure – TransPorter 6 ..................................................................................... 1-41
Rear Seat Backs and Forward-Facing Armrests – Villager 6 and 8 ................................................................................ 1-43
Rear-Facing Seat Backs and Supports – Villager 6 and Villager 8 ................................................................................. 1-45
Rear Body and Fenders – Gasoline DS Villager 4 ................................................................................................................ 1-47
Rear Access Door ............................................................................................................................................................................ 1-49
Rear Body and Fenders – Electric DS Villager 4 ................................................................................................................... 1-51
Rear Body Trim – Transporter 4 and 6 .................................................................................................................................... 1-53
Rear Body and Fender – Villager 6 and 8 ............................................................................................................................... 1-55
Heat Shield – Gasoline Villager 6 and 8 .................................................................................................................................. 1-57
Battery Insulator – Electric Villager 6 and 8 .......................................................................................................................... 1-59
Battery Insulator – Electric TransPorter Vehicles ................................................................................................................ 1-61
Rear Cargo Bed – TransPorter 4 ................................................................................................................................................ 1-63
Stake Side – TransPorter 4 ........................................................................................................................................................... 1-65
Rear Footrest and Handrails – DS Villager 4, Villager 6, and Villager 8 ....................................................................... 1-67
Rear Footrest and Handrails – TransPorter 6 ........................................................................................................................ 1-69
SECTION 2 – WHEELS AND TIRES
Wheels and Tires (White Rims) – Villager 4 ........................................................................................................................... 2-3
Wheels and Tires (Beige Rims) – Villager 4 ............................................................................................................................ 2-5
Page 2 2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List
CONTENTS
Wheels and Tires – Turf/Carryall 6 ............................................................................................................................................ 2-7
Wheels and Tires – Villager 6 and 8 (Front Only) ................................................................................................................. 2-9
SECTION 3 – DECALS
Decals – DS Villager 4 Gasoline Vehicles ................................................................................................................................ 3-3
Decals – DS Villager 4 Electric Vehicles ................................................................................................................................... 3-5
Decals – DS Villager 4 Electric Vehicles ................................................................................................................................... 3-7
Decals – DS Villager 4 Gasoline Vehicles ................................................................................................................................ 3-9
Decals – Villager 6 Gasoline and Electric Vehicles ............................................................................................................... 3-11
Decals – Villager 6 PowerDrive Vehicles ................................................................................................................................. 3-13
Decals – Villager 6 Gasoline Vehicles ....................................................................................................................................... 3-15
Decals – Villager 8 Gasoline and Electric Vehicles ............................................................................................................... 3-17
Decals – Villager 8 Electric Vehicles .......................................................................................................................................... 3-19
Decals – Villager 8 Gasoline Vehicles ....................................................................................................................................... 3-21
Logo Decals – Villager 4, 6, and 8 Gasoline and Electric Vehicles ................................................................................. 3-23
Decals – TransPorter 4 Gasoline and Electric Vehicles ...................................................................................................... 3-25
Decals – TransPorter 4 and 6 Gasoline and Electric Vehicles .......................................................................................... 3-27
Decals – TransPorter 4 and 6 Electric Vehicles ..................................................................................................................... 3-29
Decals – TransPorter 4 and 6 Gasoline Vehicles .................................................................................................................. 3-31
Logo Decals – TransPorter 4 and 6 Gasoline and Electric Vehicles ............................................................................... 3-33
SECTION 4 – BRAKES, PEDAL, AND CABLE ASSEMBLIES
Brake Assembly, Self-Adjusting – DS Villager 4 ................................................................................................................... 4-3
Rear Brake Assembly, Manually-Adjusted – Vehicles with 4-Wheel Brakes ............................................................... 4-5
Brake Pedal Assembly – DS Villager 4 ...................................................................................................................................... 4-7
Brake Pedal Assembly – Vehicles with Four-Wheel Brakes .............................................................................................. 4-9
Front Brake Assembly – Vehicles with Four-Wheel Brakes .............................................................................................. 4-11
Front Brake Cables and Equalizer – Vehicles with Four-Wheel Brakes ........................................................................ 4-13
Front Brake Cable Clips and Hardware – Vehicles with Front-Wheel Brakes ............................................................ 4-15
Brake Cable, Equalizer, and Equalizer Rod – DS Villager 4 ............................................................................................... 4-17
Rear Brake Cables and Equalizer – Villager 6, and TransPorter 4 and 6 ...................................................................... 4-19
Rear Brake Cables, Equalizer, and Equalizer Rod – Villager 8 Vehicles ........................................................................ 4-21
Accelerator Pedal – Gasoline Vehicles ..................................................................................................................................... 4-23
Accelerator Pedal Assembly – Electric Vehicles with MCOR ........................................................................................... 4-25
Accelerator Rod – Gasoline DS Villager 4 ............................................................................................................................... 4-27
Accelerator Rod – Gasoline Villager 6, and TransPorter 4 and 6 .................................................................................... 4-29
Accelerator Rod – Gasoline Villager 8 ...................................................................................................................................... 4-31
2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List Page 3
CONTENTS
SECTION 5 – STEERING, FRONT AND REAR SUSPENSION
Steering Column – Villager 6 and 8 ......................................................................................................................................... 5-3
Steering Column – All Vehicles Except Villager 6 and 8 ................................................................................................... 5-5
Steering Wheel ................................................................................................................................................................................ 5-7
Steering Wheel – All Vehicles Except DS Villager 4 ............................................................................................................ 5-9
Steering Gear Assembly ............................................................................................................................................................... 5-11
Front Suspension, Upper ............................................................................................................................................................. 5-13
Front Suspension, Lower ............................................................................................................................................................. 5-15
Front Suspension, Upper – Villager 6, and TransPorter 4 and 6 .................................................................................... 5-17
Front Suspension, Lower – Villager 6, and TransPorter 4 and 6 .................................................................................... 5-19
Front Suspension, Upper – Villager 8 ...................................................................................................................................... 5-21
Front Suspension, Lower – Villager 8 ...................................................................................................................................... 5-23
Front Spindles and Hubs – DS Villager 4 Vehicles .............................................................................................................. 5-25
Front Spindles and Hubs – All Vehicles Except DS Villager 4 ......................................................................................... 5-27
Rear Suspension Components – DS Villager 4 Electric Vehicles ................................................................................... 5-29
Rear Suspension Components – DS Villager 4 Gasoline Vehicles ................................................................................ 5-31
Rear Suspension Components – Villager 6 and 8, and TransPorter 4 and 6 Gasoline Vehicles ......................... 5-33
Rear Suspension – Villager 6 and 8 and TransPorter 4 and 6 Electric Vehicles ........................................................ 5-35
Stabilizer Bar – Villager 6 and 8, and TransPorter 4 and 6 Gasoline Vehicles ........................................................... 5-37
SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLES
Wiring – Gasoline Villager 6 and TransPorter 4 and 6 ....................................................................................................... 6-5
Front Body Electrical Components – Villager 6 and 8, and TransPorter 4 and 6 ..................................................... 6-7
Wiring – Gasoline Villager 8 ........................................................................................................................................................ 6-11
Wiring – Gasoline DS Villager 4 ................................................................................................................................................. 6-15
Headlights ......................................................................................................................................................................................... 6-17
Electrical Component Box – Gasoline DS Villager 4 .......................................................................................................... 6-19
Electrical Component Box – Gasoline TransPorter 4 and 6, and Villager 6 ............................................................... 6-21
Electrical Component Box – Gasoline Villager 8 ................................................................................................................. 6-23
Controls and Indicators – DS Villager 4 .................................................................................................................................. 6-25
Controls and Indicators – Villager 6 and 8, and TransPorter 4 and 6 ........................................................................... 6-27
Starter/Generator Assembly Model G425419 – Gasoline Vehicles .............................................................................. 6-29
FE290 Starter/Generator Mounting – Gasoline DS Villager 4 ......................................................................................... 6-31
FE350 Starter/Generator Mounting – Gasoline Vehicles ................................................................................................. 6-33
Battery – Gasoline Vehicle ........................................................................................................................................................... 6-35
Electrical Components, Rear Body – Gasoline TransPorter 4 and 6 ............................................................................. 6-37
Electrical Components, Rear Body – Villager 6 and 8 ........................................................................................................ 6-39
Page 4 2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List
CONTENTS
SECTION 7 – FE290 ENGINE (PEDAL-START VEHICLES)
FE290 Engine – Shrouds and Brackets .................................................................................................................................... 7-3
FE290 Engine – Ignition Components and Flywheel ......................................................................................................... 7-5
FE290 Engine – Oil Circulation ................................................................................................................................................... 7-7
FE290 Engine – Cylinder Head ................................................................................................................................................... 7-9
FE290 Engine – Crankcase, Camshaft, and Oil Sensor ....................................................................................................... 7-11
FE290 Engine – Crankcase and Crankshaft ............................................................................................................................ 7-13
FE290 Engine Mounting ............................................................................................................................................................... 7-15
SECTION 8 – FE350 ENGINE WITH ACR (KEY-START VEHICLES)
FE350 Engine with ACR (Automatic Compression Release) – Shrouds and Brackets ............................................ 8-3
AS11 FE350 Engine – Ignition Components and Flywheel ............................................................................................. 8-5
FE350 Engine – Oil Circulation ................................................................................................................................................... 8-7
AS11 FE350 Engine – Cylinder Head ........................................................................................................................................ 8-9
FE350 Engine with ACR – Crankcase, Camshaft, and Oil Sensor .................................................................................... 8-11
AS11 FE350 Engine – Crankcase and Crankshaft ................................................................................................................ 8-13
FE350 Engine Mounting ............................................................................................................................................................... 8-15
SECTION 9 – FUEL, INTAKE, AND GOVERNOR SYSTEMS
Fuel System – TransPorter 4 and 6 ........................................................................................................................................... 9-3
Fuel System – DS Villager 4, Villager 6, and Villager 8 ....................................................................................................... 9-5
Fuel Tank with Fuel Level Sending Unit ................................................................................................................................. 9-7
Carburetor Assembly, FE290 Engine – DS Villager 4 .......................................................................................................... 9-9
Carburetor Assembly, FE350 Engine – Villager 6 and 8, and Transporter 4 and 6 .................................................. 9-11
Carburetor Installation, FE290 Engine – DS Villager 4 ....................................................................................................... 9-13
Carburetor Installation, FE350 Engine – Villager 6 and 8, and Transporter 4 and 6 ............................................... 9-15
Governor and Accelerator Cables ............................................................................................................................................. 9-17
Air Box and Intake Hose ................................................................................................................................................................ 9-19
Intake System – DS Villager 4 ..................................................................................................................................................... 9-21
Intake System – TransPorter 4 and 6 ........................................................................................................................................ 9-23
Intake System – Villager 6 ............................................................................................................................................................ 9-25
Intake System – Villager 8 ............................................................................................................................................................ 9-27
SECTION 10 – EXHAUST SYSTEM
Exhaust System – FE290 Engine ................................................................................................................................................ 10-3
Exhaust System – FE350 Engine ................................................................................................................................................ 10-5
2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List Page 5
CONTENTS
SECTION 11 – TORQUE CONVERTER
Drive Clutch – DS Villager 4 ........................................................................................................................................................ 11-3
Drive Clutch – Villager 6 and 8, and Transporter 4 and 6 ................................................................................................ 11-5
Drive Belt – DS Villager 4 ............................................................................................................................................................. 11-7
Drive Belt – Villager 6 and 8, and Transporter 4 and 6 ...................................................................................................... 11-9
Driven Clutch ................................................................................................................................................................................... 11-11
SECTION 12 – UNITIZED TRANSAXLE
Transaxle – Gasoline Vehicles, Gear Cases and Brackets ................................................................................................. 12-3
Transaxle – Gasoline Vehicles, Transmission and Gear Reduction ............................................................................... 12-5
Transaxle – Gasoline Vehicles, Differential and Axles ....................................................................................................... 12-7
Forward/Reverse Shifter Assembly – Gasoline Vehicles .................................................................................................. 12-9
Forward/Reverse Shifter Cable – DS Villager 4 Vehicles .................................................................................................. 12-11
Forward/Reverse Shifter Cable – Villager 6 and TransPorter 4 and 6 Vehicles ........................................................ 12-13
Forward/Reverse Shifter Cable – Villager 8 ........................................................................................................................... 12-15
SECTION 13 – ELECTRICAL SYSTEM – ELECTRIC VEHICLES
Wiring – DS Villager 4 IQ System Vehicle with Six 8-Volt Batteries .............................................................................. 13-5
Headlights ......................................................................................................................................................................................... 13-7
Wiring – PowerDrive Electric Villager 6 and TransPorter 4 and 6 ................................................................................. 13-11
Wiring – PowerDrive Electric Villager 8 .................................................................................................................................. 13-15
Front Body Electrical Components – Villager 6 , and TransPorter 4 and 6 ................................................................ 13-17
Front Body Electrical Components – Villager 8 ................................................................................................................... 13-19
Instrument Panel Components – DS Villager 4 Vehicle ................................................................................................... 13-21
Instrument Panel Components – Villager 6 and 8, and TransPorter 4 and 6 ............................................................ 13-23
Motor Controller Output Regulator (MCOR) ........................................................................................................................ 13-25
Forward/Reverse Switch – PowerDrive .................................................................................................................................. 13-27
Forward/Reverse Switch and Tow/Run Switch – IQ System DS Villager 4 ................................................................ 13-29
Battery Charger Receptacle – Villager Vehicles ................................................................................................................... 13-31
Electrical Components – PowerDrive Villager 6 and 8, and TransPorter 4 and 6 .................................................... 13-33
Electrical Components, Continued – PowerDrive TransPorter 4 and 6 ...................................................................... 13-35
Electrical Components, Continued – PowerDrive Villager 6 .......................................................................................... 13-37
Electrical Components, Continued – Powerdrive Villager 8 ........................................................................................... 13-39
Batteries – DS Villager 4 with Six 8-Volt Batteries ............................................................................................................... 13-41
Computer, Controller, and Solenoid – DS Villager 4 IQ System Vehicle ..................................................................... 13-43
Electrical Components, Rear Body – TransPorter 4 and 6 PowerDrive ....................................................................... 13-45
Rear Reverse Buzzer – TransPorter 4 and 6 ........................................................................................................................... 13-47
Electrical Components, Rear Body – Villager 6 and 8 PowerDrive ............................................................................... 13-49
Page 6 2004-2005 Transportation Gasoline and Electric Vehicle Illustrated Parts List
CONTENTS
Rear Reverse Buzzer – Villager 6 and 8 .................................................................................................................................... 13-51
SECTION 14 – ELECTRIC MOTOR
Motor (Model 5BC59JBS6360) – PowerDrive ........................................................................................................................ 14-3
Motor (Model 5BC59JBS6365) – Electric Vehicle ................................................................................................................. 14-5
Motor (Model 5BC59JBS6390) – Electric Vehicle ................................................................................................................. 14-7
Motor (Model EJ4-4001) – Electric Vehicle ............................................................................................................................ 14-9
Motor (Model EJ8-4001A) – Electric Vehicle ......................................................................................................................... 14-11
SECTION 15 – TRANSAXLE – ELECTRIC VEHICLES
Transaxle – Electric Vehicles ....................................................................................................................................................... 15-3
Transaxle – Electric Vehicles ....................................................................................................................................................... 15-5
SECTION 16 – BATTERY CHARGER
PowerDrive 3 Battery Charger, Domestic .............................................................................................................................. 16-3
PowerDrive 2 Battery Charger (Model 22110), Domestic ................................................................................................ 16-5
PowerDrive Battery Charger (Model 17930), Domestic .................................................................................................... 16-7
PowerDrive Battery Charger (Model 18780), Export .......................................................................................................... 16-9
PowerDrive Battery Charger (Model 20310), European .................................................................................................... 16-11
Onboard PowerDrive Battery Charger (Model 17935), Domestic ................................................................................. 16-13
Onboard PowerDrive Battery Charger (Model 17790), Export ....................................................................................... 16-15
SECTION 17 – MAINTENANCE AND SERVICE TOOLS
Maintenance and Service Tools ................................................................................................................................................. 17-3
Maintenance and Service Tools, Continued ......................................................................................................................... 17-5
Maintenance and Service Tools, Continued ......................................................................................................................... 17-7
Maintenance and Service Tools, Continued ......................................................................................................................... 17-9
Maintenance and Service Tools, Continued ......................................................................................................................... 17-11
SECTION i – INDEX
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2004-2005 Club Car Transporter Villager Gasoline & Electric Transportation Vehicle Parts Catalog
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Description
This manual covers the following machines:
- 2004 2005 Club Car Transporter Villager Gasoline & Electric Transportation Vehicle Parts Catalog
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