2000 Club Car Carryall Turf Plus I II VI Illustrated Parts List

CARRYALL I, CARRYALL II, CARRYALL TURF II, CARRYALL II PLUS, AND CARRYALL VI VEHICLES MANUAL NUMBER 102067402 EDITION CODE 0899D0704B 2000 ILLUSTRATED PARTS LIST

This manual covers all 2000 Carryall ® vehicles. The manual is divided into 16 sections. Sections 1 through 5 pertain to both gasoline and electric vehicles, sections 6 through 11 pertain to gasoline vehicles only, sections 12 through 15 pertain to electric vehicles only, and section 16 pertains to tools that are used on all Club Car products. 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 either the letter G or E, signifying that the page pertains to either the gasoline or electric vehicle only, or to both the gasoline and electric vehicles. 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 titles and numbers, and under them, the individual page titles and numbers to be found in that section. Unless a page title specifies a particular vehicle(s), the page applies to all Carryall vehicles. Typically, there is a two-page spread for each individual page title in the Table of Contents (however, some titles require several spreads). On the left-hand page is an illustration showing the parts in their relative posi- tions; 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. Some item numbers have more than one part number because several models and/or configurations of a component are represented together on one spread. Note that a part description may be indented. This indention corresponds to a parts assembly level indi- cated 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. P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 www.clubcar.com © 1999, CLUB CAR, INC. All rights reserved. This manual effective July 26, 1999 • 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. WARNING USING THE ILLUSTRATED PARTS LIST

2000 Carryall Vehicle Illustrated Parts List CONTENTS FRONT BODY AND TRIM ..................................................................................................................................... 1-3 SEATS AND SUPPORT STRUCTURE– CARRYALL I, II, TURF II AND II PLUS ................................................ 1- 5 SEATS AND SUPPORT STRUCTURE– CARRYALL VI ...................................................................................... 1- 7 TILT BED, HINGE, AND LATCH–CARRYALL I ................................................................................................... 1- 9 LATCH PLATE–CARRYALL I, II, TURF II AND II PLUS; PROP ROD–CARRYALL II, TURF II, AND II PLUS ..... 1- 11 TILT BED, HINGE AND LATCH– CARRYALL II, TURF II AND II PLUS .............................................................. 1- 13 CARGO BOX–CARRYALL TURF II ...................................................................................................................... 1-15 ACCESS DOOR AND SIDE DOORS–CARRYALL VI .......................................................................................... 1-17 FLAT BED ASSEMBLY–CARRYALL VI ............................................................................................................... 1-19 FLAT BED TRIM–CARRYALL VI .......................................................................................................................... 1-21 REAR BODY TRIM–CARRYALL I, II, TURF II AND II PLUS ................................................................................. 1-23 REAR BODY TRIM–CARRYALL VI ...................................................................................................................... 1-25 WHEELS AND TIRES ........................................................................................................................................... 2-3 DECALS– CARRYALL I, II, TURF II, AND II PLUS ............................................................................................... 3-3 DECALS– CARRYALL I, II, TURF II, AND II PLUS, CONTINUED ....................................................................... 3-5 DECALS–CARRYALL VI ...................................................................................................................................... 3-7 DECALS–CARRYALL VI, CONTINUED ............................................................................................................... 3-9 REAR BRAKE ASSEMBLY, SELF-ADJUSTING– CARRYALL I ........................................................................... 4-3 REAR BRAKE ASSEMBLY, MANUALLY ADJUSTED– CARRYALL II, TURF II, II PLUS AND VI ....................... 4-5 BRAKE PEDAL AND CABLE ASSEMBLY– VEHICLE WITH TWO-WHEEL BRAKING ........................................ 4-7 BRAKE PEDAL AND CABLE ASSEMBLY– VEHICLE WITH FOUR-WHEEL BRAKING ..................................... 4-9 FRONT BRAKE ASSEMBLY– VEHICLE WITH FOUR-WHEEL BRAKING .......................................................... 4-11 ACCELERATOR PEDAL ASSEMBLY– ELECTRIC CARRYALL I AND ALL GASOLINE VEHICLES .................. 4-13 ACCELERATOR PEDAL ASSEMBLY– ELECTRIC CARRYALL II AND VI ......................................................... 4-15 STEERING COLUMN ........................................................................................................................................... 5-3 STEERING GEAR ASSEMBLY ............................................................................................................................ 5-5 FRONT SUSPENSION, UPPER– VEHICLE WITH TWO-WHEEL BRAKING........................................................ 5-7 FRONT SUSPENSION, LOWER– VEHICLE WITH TWO-WHEEL BRAKING ....................................................... 5-9 FRONT SUSPENSION, UPPER– VEHICLE WITH FOUR-WHEEL BRAKING .................................................... 5-11 FRONT SUSPENSION, LOWER– VEHICLE WITH FOUR-WHEEL BRAKING..................................................... 5-13 REAR SUSPENSION–CARRYALL I .................................................................................................................... 5-15 REAR SUSPENSION– CARRYALL II, TURF II, II PLUS, AND VI ........................................................................ 5-17 STABILIZER BAR, GASOLINE VEHICLE– CARRYALL II, TURF II, II PLUS, AND VI ........................................... 5-19 BODY AND TRIM SECTION 1 WHEELS AND TIRES SECTION 2 DECALS SECTION 3 BRAKES, PEDAL, AND CABLE ASSEMBLIES SECTION 4 STEERING, FRONT AND REAR SUSPENSION SECTION 5 CONTENTS

2000 Carryall Vehicle Illustrated Parts List CONTENTS FORWARD/REVERSE SHIFTER ASSEMBLY– GASOLINE VEHICLE ................................................................ 6-3 WIRING–GASOLINE CARRYALL I ...................................................................................................................... 6-5 WIRING–GASOLINE CARRYALL II ..................................................................................................................... 6-7 ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE– CARRYALL I, II, AND TURF II ................................ 6-9 ELECTRICAL COMPONENTS, FRONT BODY– GASOLINE CARRYALL I, II, TURF II, AND II PLUS ................ 6-11 HEADLIGHTS– GASOLINE CARRYALL TURF II ................................................................................................. 6-13 WIRING– GASOLINE CARRYALL TURF II ........................................................................................................... 6-15 WIRING–GASOLINE CARRYALL II PLUS ........................................................................................................... 6-17 WIRING–GASOLINE CARRYALL VI .................................................................................................................... 6-21 ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE– CARRYALL II PLUS AND VI ................................... 6-23 ELECTRICAL COMPONENTS, FRONT BODY– GASOLINE CARRYALL VI ...................................................... 6-25 CONTROLS AND GAUGES–GASOLINE CARRYALL VI ..................................................................................... 6-27 ELECTRICAL COMPONENTS, REAR BODY– GASOLINE CARRYALL VI ......................................................... 6-29 STARTER/GENERATOR ASSEMBLY ................................................................................................................. 6-31 STARTER/GENERATOR MOUNTING ................................................................................................................. 6-33 BATTERY–GASOLINE VEHICLE ......................................................................................................................... 6-35 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 FE350 ENGINE– SHROUDS AND BRACKETS ................................................................................................... 7-15 FE350 ENGINE– IGNITION COMPONENTS AND FLYWHEEL .......................................................................... 7-17 FE350 ENGINE– OIL CIRCULATION ................................................................................................................... 7-19 FE350 ENGINE– CYLINDER HEAD ..................................................................................................................... 7-21 FE350 ENGINE– CRANKCASE, CAMSHAFT AND OIL SENSOR ...................................................................... 7-23 FE350 ENGINE– CRANKCASE AND CRANKSHAFT .......................................................................................... 7-25 ENGINE MOUNTING ............................................................................................................................................ 7-27 FUEL SYSTEM ..................................................................................................................................................... 8-3 CARBURETOR ASSEMBLY, FE290 ENGINE– CARRYALL I AND II .................................................................. 8-5 CARBURETOR ASSEMBLY, FE350 ENGINE– CARRYALL TURF II, II PLUS, AND VI ....................................... 8-7 CARBURETOR INSTALLATION ........................................................................................................................... 8-9 GOVERNOR AND ACCELERATOR CABLES ...................................................................................................... 8-11 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY– CARRYALL I .................................................................. 8-13 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY– CARRYALL II, TURF II, AND II PLUS ............................ 8-15 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY– CARRYALL VI ................................................................ 8-17 EXHAUST SYSTEM, FE290– CARRYALL I AND II ............................................................................................. 9-3 EXHAUST SYSTEM, FE350– CARRYALL TURF II, II PLUS, AND VI .................................................................. 9-5 ELECTRICAL SYSTEM– GASOLINE VEHICLE SECTION 6 ENGINE SECTION 7 FUEL, INTAKE, AND GOVERNOR SYSTEMS SECTION 8 EXHAUST SYSTEM SECTION 9

2000 Carryall Vehicle Illustrated Parts List CONTENTS DRIVE CLUTCH ................................................................................................................................................... 10-3 DRIVEN CLUTCH ................................................................................................................................................. 10-5 UNITIZED TRANSAXLE, GASOLINE VEHICLE– GEAR CASES AND BRACKETS ............................................ 11-3 UNITIZED TRANSAXLE, GASOLINE VEHICLE– F&R TRANSMISSION AND GEAR REDUCTION ................... 11-5 UNITIZED TRANSAXLE, GASOLINE VEHICLE– DIFFERENTIAL AND AXLES .................................................. 11-7 FORWARD/REVERSE SWITCH– POWERDRIVE VEHICLE ................................................................................ 12-3 MULTISTEP POTENTIOMETER– POWERDRIVE CARRYALL I ......................................................................... 12-5 WIRING– CARRYALL I POWERDRIVE VEHICLE ............................................................................................... 12-7 ELECTRICAL COMPONENTS, FRONT BODY– CARRYALL I AND II POWERDRIVE VEHICLES .................... 12-9 BATTERIES, CHARGER RECEPTACLE– CARRYALL I POWERDRIVE VEHICLE ............................................ 12-11 COMPUTER, CONTROLLER, AND SOLENOID– CARRYALL I POWERDRIVE VEHICLE ................................. 12-13 CONTINUOUSLY VARIABLE POTENTIOMETER– CARRYALL II AND VI POWERDRIVE VEHICLES .............. 12-15 WIRING– CARRYALL II POWERDRIVE VEHICLE .............................................................................................. 12-17 COMPUTER, CONTROLLER, AND SOLENOID – CARRYALL II POWERDRIVE VEHICLE ............................... 12-19 BATTERIES, CHARGER RECEPTACLE– CARRYALL II POWERDRIVE VEHICLE ........................................... 12-21 WIRING– CARRYALL VI POWERDRIVE VEHICLE ............................................................................................. 12-25 ELECTRICAL COMPONENTS, FRONT BODY– CARRYALL VI POWERDRIVE VEHICLE ................................ 12-27 CONTROLS AND GAUGES– CARRYALL VI POWERDRIVE VEHICLE .............................................................. 12-29 ELECTRICAL COMPONENTS, CENTER BODY– CARRYALL VI POWERDRIVE VEHICLE .............................. 12-31 ELECTRICAL COMPONENTS, CENTER BODY, CONTINUED– CARRYALL VI POWERDRIVE VEHICLE ....... 12-33 ELECTRICAL COMPONENTS, REAR BODY– CARRYALL VI POWERDRIVE VEHICLE .................................. 12-35 POWERDRIVE BATTERY CHARGER, DOMESTIC–CARRYALL I AND II .......................................................... 13-3 POWERDRIVE BATTERY CHARGER, EXPORT–CARRYALL I AND II .............................................................. 13-5 POWERDRIVE BATTERY CHARGER, EUROPEAN–CARRYALL I AND II ......................................................... 13-7 ONBOARD POWERDRIVE BATTERY CHARGER, DOMESTIC–CARRYALL VI ................................................ 13-9 ONBOARD POWERDRIVE BATTERY CHARGER, EXPORT–CARRYALL VI .................................................... 13-11 MOTOR–POWERDRIVE ELECTRIC VEHICLE .................................................................................................... 14-3 TRANSAXLE, TYPE G– POWERDRIVE ELECTRIC VEHICLE ............................................................................. 15-3 MAINTENANCE AND SERVICE TOOLS .............................................................................................................. 16-3 MAINTENANCE AND SERVICE TOOLS, CONTINUED ...................................................................................... 16-5 TORQUE CONVERTER SECTION 10 UNITIZED TRANSAXLE– GASOLINE VEHICLE SECTION 11 ELECTRICAL SYSTEM– ELECTRIC VEHICLE SECTION 12 BATTERY CHARGER SECTION 13 ELECTRIC MOTOR SECTION 14 TRANSAXLE– ELECTRIC VEHICLE SECTION 15 MAINTENANCE AND SERVICE TOOLS SECTION 16 INDEX SECTION i

1 E G BODY AND TRIM

2 2000 Carryall Vehicle Illustrated Parts List 1 1 1 G 1 E GO STOP CLUB CAR TYPICAL 2 PLACES TYPICAL 2 PLACES CARRYALL I ONLY CARRYALL II, TURF II, II PLUS, AND VI TYPICAL 2 PLACES 15 16 17 TYPICAL 6 PLACES 18 19 TYPICAL 2 PLACES 6 7 12 14 13 1 TYPICAL 2 PLACES 20 29 31 30 10 9 8 3 9 8 2 TYPICAL 2 PLACES 3 4 5 TYPICAL: 3 PLACES PASSENGER SIDE DASH 2 PLACES DRIVER SIDE DASH FRAME DASH BOTTOM 27 TYPICAL 2 PLACES FRAME FRONT BODY 23 24 25 26 22 DASH CENTER DASH CARRYALL TURF II ONLY 32 33 34 28 21 TYPICAL 8 PLACES 11 TYPICAL 2 PLACES REF. TYPICAL 12 PLACES 12 35 36

2000 Club Car Carryall Turf Plus I II VI Illustrated Parts List

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