Club Car Golf Cart Illustrated Parts Manual Both Gas and Ele

ILLUSTRATED PARTS LIST DS GOLF CARS GASOLINE/ELECTRIC

The manual is divided into 15 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. Note that there are two or three flags on the outside edge of each page. The first flag will contain the section number of which that page is a part. The other flag (or flags) will contain 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 DS vehicles. You will also find vehicle models and serial numbers specified within the listings for individual page titles. These model and serial number specifications identify the vehicles on which parts usage as described on a particular page either began or ended. Have the serial number(s) of your vehicle(s) at hand and read the listings carefully when using the table of contents. Typically, there is a two-page spread for each individual page title in the Table of Contents (however, some titles required several spreads). 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 models and/or configurations of a component are represent- ed 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 USING THE ILLUSTRATED PARTS LIST 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.

MAINTENANCE AND SERVICE TOOLS SECTION THIS SECTION OF THIS MANUAL CONTAINS A LIST OF MAINTENANCE AND SERVICE TOOLS AVAILABLE FROM CLUB CAR. BODY AND TRIM SECTION BODY TRIM ........................................................................................................................................... 2-3 FRONT BODY ........................................................................................................................................ 2-5 REAR BODY AND FENDER - GASOLINE VEHICLE ............................................................................... 2-7 REAR BODY AND FENDER - ELECTRIC VEHICLE ................................................................................ 2-9 SEAT BOTTOM AND ARMREST ............................................................................................................ 2-11 SEAT BACK AND BAG HOOP ................................................................................................................ 2-13 WHEELS AND TIRES ............................................................................................................................. 2-15 SAFETY DECALS SECTION SAFETY DECALS - GASOLINE VEHICLE .............................................................................................. 3-3 SAFETY DECALS - ELECTRIC VEHICLE ............................................................................................... 3-5 BRAKES, PEDAL, AND CABLE ASSEMBLIES SECTION BRAKE ASSEMBLY ............................................................................................................................... 4-3 BRAKE PEDAL AND CABLE ASSEMBLY ............................................................................................... 4-5 ACCELERATOR PEDAL ASSEMBLY - GASOLINE AND V-GLIDE 36 VOLT VEHICLES ................................... 4-7 ACCELERATOR PEDAL ASSEMBLY - POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ...................... 4-9 STEERING, FRONT AND REAR SUSPENSION SECTION STEERING COLUMN ............................................................................................................................. 5-3 STEERING GEAR ASSEMBLY ............................................................................................................... 5-5 FRONT SUSPENSION, UPPER ............................................................................................................. 5-7 FRONT SUSPENSION, LOWER ............................................................................................................. 5-9 REAR SUSPENSION .............................................................................................................................. 5-11 ELECTRICAL SYSTEM - GASOLINE VEHICLE SECTION WIRING - GASOLINE VEHICLE .............................................................................................................. 6-3 FORWARD AND REVERSE SHIFTER ASSEMBLY - GASOLINE VEHICLE ............................................. 6-5 ELECTRICAL COMPONENT BOX - GASOLINE VEHICLE ...................................................................... 6-7 ELECTRICAL COMPONENTS - GASOLINE VEHICLE ............................................................................ 6-9 STARTER/GENERATOR ASSEMBLY ..................................................................................................... 6-11 STARTER/GENERATOR MOUNTING .................................................................................................... 6-13 BATTERY MOUNTING - GASOLINE VEHICLE ....................................................................................... 6-15 ENGINE SECTION FE 290 ENGINE ............................................................................................................................ 7-3 - 7-13 ENGINE MOUNTING .............................................................................................................................. 7-15 FUEL, INTAKE, AND GOVERNOR SYSTEMS SECTION FUEL SYSTEM ....................................................................................................................................... 8-3 CARBURETOR ASSEMBLY ................................................................................................................... 8-5 CARBURETOR INSTALLATION ............................................................................................................. 8-7 GOVERNOR AND ACCELERATOR CABLES .......................................................................................... 8-9 EXPANSION CHAMBER, CHOKE, AND FILTER ..................................................................................... 8-11 CONTENTS 1 2 3 4 5 6 7 8

EXHAUST SYSTEM SECTION EXHAUST SYSTEM ............................................................................................................................... 9-3 TORQUE CONVERTER SECTION DRIVE CLUTCH ..................................................................................................................................... 10-3 DRIVEN CLUTCH ................................................................................................................................... 10-5 UNITIZED TRANSAXLE - GASOLINE VEHICLE SECTION UNITIZED TRANSAXLE - GASOLINE VEHICLE ............................................................................. 11-3 - 11-5 ELECTRICAL SYSTEM - ELECTRIC VEHICLE SECTION ELECTRICAL COMPONENTS, FRONT BODY - ELECTRIC VEHICLE ............................................................... 12-3 WIRING - V-GLIDE 36 VOLT VEHICLE ................................................................................................... 12-5 FORWARD AND REVERSE SWITCH - V-GLIDE 36 VOLT VEHICLE ...................................................... 12-7 WIPER SWITCH - V-GLIDE 36 VOLT VEHICLE ...................................................................................... 12-9 RESISTOR AND BOARD ASSEMBLY - V-GLIDE 36 VOLT VEHICLE ...................................................... 12-11 ELECTRICAL COMPONENTS, REAR BODY - V-GLIDE 36 VOLT VEHICLE ........................................... 12-13 WIRING - POWERDRIVE SYSTEM 48 VEHICLE .................................................................................... 12-15 FORWARD AND REVERSE SWITCH - POWERDRIVE SYSTEM 48 VEHICLE ........................................ 12-17 ELECTRICAL COMPONENTS, REAR BODY - POWERDRIVE SYSTEM 48 VEHICLE ......................... 12-19 - 12-21 ON-BOARD COMPUTER - POWERDRIVE SYSTEM 48 VEHICLE .......................................................... 12-23 CONTINUOUSLY VARIABLE POTENTIOMETER - POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ............................................................................................................................ 12-25 WIRING - POWERDRIVE PLUS VEHICLE ................................................................................................. 12-27 ON-BOARD COMPUTER - POWERDRIVE PLUS VEHICLE .................................................................... 12-29 FORWARD AND REVERSE SWITCH - POWERDRIVE PLUS VEHICLE ................................................. 12-31 ENERGY DISPLACEMENT MODULE - POWERDRIVE PLUS VEHICLE ............................................................ 12-33 ELECTRICAL COMPONENTS, REAR BODY - POWERDRIVE PLUS VEHICLE ................................... 12-35 - 12-37 BATTERY CHARGER SECTION ACCU-POWER ® CHARGER, DOMESTIC - V-GLIDE 36 VOLT VEHICLE ................................................ 13-3 ACCU-POWER CHARGER, EXPORT - V-GLIDE 36 VOLT VEHICLE ...................................................... 13-5 ACCU-POWER CHARGER, EXPORT, 100 VOLT - V-GLIDE 36 VOLT VEHICLE ..................................... 13-7 POWERDRIVE CHARGER, DOMESTIC - POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ......... 13-9 POWERDRIVE CHARGER, EXPORT - POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ............. 13-11 ELECTRIC MOTOR SECTION MOTOR - V-GLIDE 36 VOLT VEHICLE ................................................................................................... 14-3 MOTOR - POWERDRIVE SYSTEM 48 VEHICLE .................................................................................... 14-5 MOTOR - POWERDRIVE PLUS VEHICLE .............................................................................................. 14-7 TRANSAXLE - ELECTRIC VEHICLE SECTION TRANSAXLE - ELECTRIC VEHICLE ....................................................................................................... 15-3 CONTENTS 10 11 13 14 15 12 9

MAINTENANCE AND SERVICE TOOLS 1 G E

DESCRIPTION PART NUMBER 1-2 G E 1 ACCELERATOR PEDAL ADJUSTMENT TOOL ........................................................................................ 1018710-01 ADAPTER PLUG ASSEMBLY .................................................................................................................. 1018945-01 ADHESION PROMOTER - ARMORFLEX ® .................................................................................................... 1016985 ADHESIVE, GUIDE RING, 3 GRAM TUBE .............................................................................................. 1018132-02 ARMORFLEX REPAIR KIT ............................................................................................................................ 1017295 BATTERY DISCHARGE MACHINE 36/48 VOLT ...................................................................................... 1018319-01 BATTERY TERMINAL PROTECTOR SPRAY ................................................................................................ 1014305 BATTERY THERMOMETER .......................................................................................................................... 1011767 BEARING AND OIL SEAL REMOVER ASSEMBLY ........................................................................................ 1016417 BEARING DRIVER SET ................................................................................................................................ 1016416 BEARING PULLER ...................................................................................................................................... 1012811 BEARING PULLER WEDGE ATTACHMENT ................................................................................................ 1012812 CALIBRATION TEST MODULE ................................................................................................................ 1018871-01 CAM INSTALLATION TOOL .................................................................................................................... 1018084-01 CLUTCH TOOL KIT ...................................................................................................................................... 1014510 CLUTCH ALIGNMENT TOOL (USED ON VEHICLES PRIOR TO SERIAL NUMBER 9701) ........................ 1014498 DRIVE CLUTCH PULLER ........................................................................................................................ 1014496 CLUTCH DRIVE HUB PULLER ................................................................................................................ 1014497 DRIVEN CLUTCH CAM PULLER .............................................................................................................. 1014508 DRIVEN CLUTCH PULLER PLUG ............................................................................................................ 1014507 DRIVEN CLUTCH HOLDER TOOL ASSEMBLY ........................................................................................ 1015524 PRESS WELDMENT .......................................................................................................................... 1018091-01 COMMUNICATION DISPLAY MODULE .................................................................................................. 1018318-01 COMPRESSION GAUGE ........................................................................................................................ 1016410-01 ADAPTER .......................................................................................................................................... 1016410-02 CONTINUITY TESTER .................................................................................................................................. 1011273 DRY MOLY LUBRICANT .............................................................................................................................. 1012151 FLY WHEEL PULLER KIT ............................................................................................................................ 1016627 GEAR YOKE ................................................................................................................................................ 1016418 HYDROMETER ............................................................................................................................................ 1011478 INTERNAL RETAINING RING PLIERS .......................................................................................................... 1013593 LIQUID GASKET (TRANSAXLE CASE) .................................................................................................... 1019287-01 PISTON RING COMPRESSOR KIT .............................................................................................................. 1016414 PISTON RING PLIERS .................................................................................................................................. 1016415 RETAINING RING PLIERS - 45° EXTERNAL ................................................................................................ 1012549 RETAINING RING PLIERS - 90° INTERNAL .................................................................................................. 1012560 SAFETY FIRST CARD (50 PER PACK) .................................................................................................... 1018231-01 SEAL PULLER .............................................................................................................................................. 1012809 STARTER/GENERATOR BELT TENSION TOOL .......................................................................................... 1016867 STEERING COLUMN BEARING PRESS TOOL ............................................................................................ 1014264 STEERING COLUMN RETAINING RING TOOL ............................................................................................ 1014259 TACHOMETER ............................................................................................................................................ 1016112 MAINTENANCE AND SERVICE TOOLS

MAINTENANCE AND SERVICE TOOLS 1-3 G E 1 DESCRIPTION PART NUMBER TOUCH-UP PAINT, LACQUER - BEIGE .................................................................................................. 1017097-01 TOUCH-UP PAINT, LACQUER - WHITE .................................................................................................. 1017097-02 TOUCH-UP PAINT, LACQUER - GRAY .................................................................................................... 1017097-04 TOUCH-UP PAINT, LACQUER - RED ...................................................................................................... 1017097-06 TOUCH-UP PAINT, LACQUER - DARK BLUE ........................................................................................... 1017097-08 TOUCH-UP PAINT, LACQUER - DARK GREEN ........................................................................................ 1017097-09 TRANSMISSION TOOL KIT .......................................................................................................................... 1014115 TRANSAXLE PINION SEAL TOOL ................................................................................................................ 1014161 TRANSAXLE AXLE SEAL TOOL .................................................................................................................. 1014162 TUNE-UP KIT (FE 290) ............................................................................................................................ 1016110-02 VALVE CLEARANCE ADJUSTER SCREW HOLDER .................................................................................... 1016413 VALVE GUIDE REAMER .......................................................................................................................... 1016412-01 ARBOR .............................................................................................................................................. 1016412-02 VALVE SEAT CUTTER HOLDER BAR .......................................................................................................... 1016551 VALVE SEAT CUTTER HOLDER .................................................................................................................. 1016552 VALVE SEAT CUTTER 45° (32MM DIAMETER) ............................................................................................ 1016553 VALVE SEAT CUTTER 45° (35MM DIAMETER) ............................................................................................ 1016554 VALVE SEAT CUTTER 32° (35MM DIAMETER) ............................................................................................ 1016555 VALVE SPRING COMPRESSOR ............................................................................................................ 1016411-01 VOLT OHM METER ...................................................................................................................................... 1011480 PLEASE REFER TO THE MAINTENANCE AND SERVICE MANUAL FOR PROPER TOOL APPLICATION.

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Club Car Golf Cart Illustrated Parts Manual Both Gas and Ele

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