2003 Club Car Models Turf 272 Carryall 272 Carryall 472 Gasoline Golf Carts Illustrated Parts List

MANUAL NUMBER 102318703 EDITION CODE 0103B0904A TURF 272, CARRYALL 272, AND CARRYALL 472 GASOLINE VEHICLES 2003 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 ∆ 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 2003 Turf 272, Carryall 272™, and Carryall 472 vehicles. The manual is divided into 13 sections. Sections 1 through 12 pertain to the 272 and 472 vehicles, and Section 13 pertains to tools that are used on all Club Car products. Note that there are two 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 contains the letter G, signifying that the page pertains to the gasoline vehicle 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. Some item numbers have more than one part number because several configurations of a component are represented together on one spread. There are some wiring diagrams in this manual that cover two pages. For these diagrams the parts list page will be on the next two-page spread. 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 Club Car contact 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 3281 or 3854. USING THE ILLUSTRATED PARTS LIST

2003 Turf/Carryall 272 and Carryall 472 Gasoline Vehicles 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 forwarded 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 incurring the obligation of making changes to units previously sold. Copyright © 2003 Club Car, Inc. Club Car and Carryall are registered trademarks of Club Car, Inc. This manual effective July 22, 2002.

2003 Turf/Carryall 272 and Carryall 472 Gasoline Vehicles Illustrated Parts List CONTENTS SECTION 1 – BODY AND TRIM Front Body Trim ................................................................................................................................ 1-3 Front Seats ....................................................................................................................................... 1-5 Rear Seat and Support Structure – Carryall 472 Vehicles ............................................................... 1-7 Latch Plate and Prop Rod – Turf 272 and Carryall 272 Vehicles ..................................................... 1-9 Tilt Bed, Hinge and Latch – Turf 272 and Carryall 272 Vehicles ...................................................... 1-11 Cargo Box – Turf 272 and Carryall 272 Vehicles ............................................................................. 1-13 Tilt Bed, Hinge and Latch – Carryall 472 Vehicles ........................................................................... 1-15 Cargo Box – Carryall 472 Vehicles ................................................................................................... 1-17 Rear Body Trim – Carryall 272 Vehicles ........................................................................................... 1-19 Rear Body Trim – Carryall 472 Vehicles ........................................................................................... 1-21 SECTION 2 – WHEELS AND TIRES Wheels and Tires .............................................................................................................................. 2-3 SECTION 3 – DECALS Decals – Turf 272 Vehicles ............................................................................................................... 3-3 Decals – Carryall 272 Vehicles ......................................................................................................... 3-5 Decals, Continued – Turf 272 and Carryall 272 Vehicles ................................................................. 3-7 Decals, Continued – Carryall 472 Vehicles ...................................................................................... 3-9 Decals, Continued – Carryall 472 Vehicles ...................................................................................... 3-11 SECTION 4 – BRAKE SYSTEMS Front Brake Assembly ...................................................................................................................... 4-3 Rear Brake Assembly ....................................................................................................................... 4-5 Master Cylinder ................................................................................................................................. 4-7 Hydraulic Brake System – Turf 272 and Carryall 272 Vehicles ........................................................ 4-9 Hydraulic Brake System – Carryall 472 Vehicles ............................................................................. 4-11 Hand Park Brake Assembly .............................................................................................................. 4-13 SECTION 5 – PEDAL GROUP Brake Pedal Assembly ..................................................................................................................... 5-3 Accelerator Pedal Assembly ............................................................................................................. 5-5 SECTION 6 – STEERING, FRONT AND REAR SUSPENSION Steering Column ............................................................................................................................... 6-3 Steering Gear Assembly ................................................................................................................... 6-5 Front Suspension ............................................................................................................................. 6-7

2003 Turf/Carryall 272 and Carryall 472 Gasoline Vehicles Illustrated Parts List CONTENTS Rear Suspension .............................................................................................................................. 6-9 SECTION 7 – ELECTRICAL SYSTEM Wiring – Turf 272, Pedal-Start Vehicle ............................................................................................. 7-5 Wiring – Carryall 272, Key-Start Vehicle .......................................................................................... 7-9 Wiring – Carryall 472, Key-Start Vehicle .......................................................................................... 7-13 Forward/Reverse Shifter Assembly .................................................................................................. 7-15 Electrical Component Box, Pedal-Start Vehicles ............................................................................. 7-17 Electrical Component Box, Key-Start Vehicles ................................................................................ 7-19 Electrical Components, Front Body .................................................................................................. 7-21 Electrical Components, Dash Panel ................................................................................................. 7-23 Starter/Generator Assembly ............................................................................................................. 7-25 Starter/Generator Mounting ............................................................................................................. 7-27 Battery .............................................................................................................................................. 7-29 SECTION 8 – ENGINE FE350 Engine (Pedal-Start) – Shrouds and Brackets ...................................................................... 8-3 FE350 Engine (Pedal-Start) – Ignition Components and Flywheel .................................................. 8-5 FE350 Engine (Pedal-Start) – Oil Circulation ................................................................................... 8-7 FE350 Engine (Pedal-Start) – Cylinder Head .................................................................................. 8-9 FE350 Engine (Pedal-Start) – Crankcase, Camshaft and Oil Sensor .............................................. 8-11 FE350 Engine (Pedal-Start) – Crankcase and Crankshaft .............................................................. 8-13 FE400 Engine (Key-Start) – Shrouds and Brackets ......................................................................... 8-15 FE400 Engine (Key-Start) – Ignition Components and Flywheel ..................................................... 8-17 FE400 Engine (Key-Start) – Oil Circulation ...................................................................................... 8-19 FE400 Engine (Key-Start) – Cylinder Head ..................................................................................... 8-21 FE400 Engine (Key-Start) – Crankcase, Camshaft and Oil Sensor ................................................. 8-23 FE400 Engine (Key-Start) – Crankcase and Crankshaft ................................................................. 8-25 Engine Mounting .............................................................................................................................. 8-27 SECTION 9 – FUEL, INTAKE, AND GOVERNOR SYSTEMS Fuel System – Turf 272 and Carryall 272 Vehicles .......................................................................... 9-3 Fuel System – Carryall 472 Vehicles ............................................................................................... 9-5 Carburetor Assembly, FE350 engine ............................................................................................... 9-7 Carburetor Assembly, FE400 engine ............................................................................................... 9-9 Carburetor Installation ...................................................................................................................... 9-11 Governor and Accelerator Cables .................................................................................................... 9-13 Intake Duct, Choke, and Air Box Assembly – Turf 272 and Carryall 272 Vehicles .......................... 9-15 Intake Duct, Choke, and Air Box Assembly – Carryall 472 Vehicles ............................................... 9-17

2003 Turf/Carryall 272 and Carryall 472 Gasoline Vehicles Illustrated Parts List CONTENTS SECTION 10 – EXHAUST SYSTEM Exhaust System, FE350 engine ....................................................................................................... 10-3 Exhaust System, FE400 engine ....................................................................................................... 10-5 SECTION 11 – TORQUE CONVERTER Drive Clutch ...................................................................................................................................... 11-3 Driven Clutch .................................................................................................................................... 11-5 SECTION 12 – UNITIZED TRANSAXLE Unitized Transaxle, MC012C – Gear Cases, Brackets and Guard ................................................... 12-3 Unitized Transaxle, MC012C – F&R Transmission and Gear Reduction ......................................... 12-5 Unitized Transaxle, MC012C – Differential Lock and Axles ............................................................. 12-7 Unitized Transaxle – Differential Lock Cable Assembly and Shifter ................................................. 12-9 SECTION 13 – MAINTENANCE AND SERVICE TOOLS Maintenance and Service Tools ....................................................................................................... 13-3 Maintenance and Service Tools, Continued ..................................................................................... 13-5 Maintenance and Service Tools, Continued ..................................................................................... 13-7 SECTION i – INDEX

G E 1 BODY AND TRIM

2 2003 Turf/Carryall 272 and Carryall 472 Gasoline Vehicles Illustrated Parts List G E 1 24 26 TYPICAL 2 PLACES 25 16 TYPICAL 4 PLACES 19 TYPICAL 4 PLACES 13 14 9 TYPICAL 5 PLACES 2 TYPICAL 2 PLACES 21 20 1 3 4 12 5 11 10 17 15 2 7 6 8 22 TYPICAL 2 PLACES TYPICAL 2 PLACES 18 29 23 TYPICAL 2 PLACES 2 TYPICAL 6 PLACES TYPICAL 5 PLACES TYPICAL 7 PLACES 14 TYPICAL 4 PLACES 20 TYPICAL 2 PLACES TYPICAL 4 PLACES 18 TYPICAL 2 PLACES 23 27 23 TYPICAL 2 PLACES 20

2003 Club Car Models Turf 272 Carryall 272 Carryall 472 Gasoline Golf Carts Illustrated Parts List

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