2004-2005 Club Car DS Gasoline and Electric Vehicle Illustarted Parts List

Club Car MANUAL NUMBER 102397501 EDITION CODE 1004C1205B DS GOLF CARS GASOLINE/ELECTRIC 2004-2005 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 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 2004 and 2005 Club Car ® DS Tranquility ® , DS V-Glide 36-Volt, DS PowerDrive ® System 48™, and IQ System™ 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, E, or D signifying that the page pertains to either the gasoline, electric, or diesel vehicle only, or to all gasoline, electric and diesel 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 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. 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

2004-2005 DS Golf Cars 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 improve- ments 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 the obligation of making changes to units previously sold. Copyright © 2004 Club Car, Inc. Club Car , ArmorFlex, PowerDrive and Tranquility are registered trademarks of Club Car, inc. This manual effective July 22, 2003.

2004-2005 DS Golf Cars Illustrated Parts List CONTENTS SECTION 1 – BODY AND TRIM Body Trim ......................................................................................................................................... 1-3 Front Body ........................................................................................................................................ 1-5 Rear Body and Fender – Gasoline Vehicle ...................................................................................... 1-7 Rear Body and Fender – Electric Vehicle ......................................................................................... 1-9 Seat Bottom and Armrest ................................................................................................................. 1-11 Seat Back and Bag Hoop ................................................................................................................. 1-13 Canopy ............................................................................................................................................. 1-15 SECTION 2 – WHEELS AND TIRES Wheels and Tires .............................................................................................................................. 2-3 SECTION 3 – DECALS Decals – Gasoline Vehicle ................................................................................................................ 3-3 Decals – Electric Vehicle .................................................................................................................. 3-5 SECTION 4 – BRAKES, PEDAL, AND CABLE ASSEMBLIES Brake Assembly ................................................................................................................................ 4-3 Brake Pedal and Cable Assembly .................................................................................................... 4-5 Accelerator Pedal Assembly ............................................................................................................. 4-7 SECTION 5 – STEERING, FRONT AND REAR SUSPENSION Steering Column ............................................................................................................................... 5-3 Steering Gear Assembly ................................................................................................................... 5-5 Front Suspension, Upper .................................................................................................................. 5-7 Front Suspension, Lower .................................................................................................................. 5-9 Rear Suspension .............................................................................................................................. 5-11 SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLE Wiring – Gasoline Vehicle ................................................................................................................. 6-3 Forward/Reverse Shifter Assembly – Gasoline Vehicle ................................................................... 6-5 Electrical Component Box – Gasoline Vehicle ................................................................................. 6-7 Electrical Components, Front Body – Gasoline Vehicle ................................................................... 6-9 Starter/Generator Assembly ............................................................................................................. 6-11 Starter/Generator Mounting .............................................................................................................. 6-13 Battery – Gasoline Vehicle ............................................................................................................... 6-15

2004-2005 DS Golf Cars Illustrated Parts List CONTENTS SECTION 7 – FE290 ENGINE 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 Engine Mounting .............................................................................................................................. 7-15 SECTION 8 – FUEL, INTAKE, AND GOVERNOR SYSTEMS Fuel System ..................................................................................................................................... 8-3 Carburetor Assembly ....................................................................................................................... 8-5 Carburetor Installation ...................................................................................................................... 8-7 Governor and Accelerator Cables .................................................................................................... 8-9 Intake Duct, Choke, and Air Box Assembly ..................................................................................... 8-11 SECTION 9 – EXHAUST SYSTEM Exhaust System ............................................................................................................................... 9-3 SECTION 10 – TORQUE CONVERTER Drive Clutch ...................................................................................................................................... 10-3 Driven Clutch .................................................................................................................................... 10-5 SECTION 11 – UNITIZED TRANSAXLE MC008C-ES00 Prior To Serial Number MC008C3H1264 – Gear Cases and Brackets .................. 11-3 MC008C-ES00 Prior To Serial Number MC008C3H1264 – Transmission and Gear Reduction ..... 11-5 MC008C-ES00 Prior To Serial Number MC008C3H1264 – Differential and Axles ......................... 11-7 MC008C-ES00 After Serial Number MC008C3H1264 – Gear Cases and Brackets ....................... 11-9 MC008C-ES00 After Serial Number MC008C3H1264 – Transmission and Gear Reduction .......... 11-11 MC008C-ES00 After Serial Number MC008C3H1264 – Differential and Axles ............................... 11-13 SECTION 12 – ELECTRICAL SYSTEM – ELECTRIC VEHICLE Electrical Components, Front Body – Electric Vehicle ..................................................................... 12-3 Wiring – V-Glide 36-Volt Vehicle ..................................................................................................... 12-5 Forward/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 Batteries, Charger Receptacle, Solenoid – V-Glide 36-Volt Vehicle ................................................ 12-13

2004-2005 DS Golf Cars Illustrated Parts List CONTENTS Forward/Reverse Switch – PowerDrive System 48 Vehicle ............................................................. 12-15 Batteries, Charger Receptacle – PowerDrive System 48 Vehicle .................................................... 12-17 Computer, Controller, and Solenoid – PowerDrive System 48 Vehicle ............................................ 12-19 Motor Controller Output Regulator (MCOR) ..................................................................................... 12-21 Wiring – PowerDrive System 48 Vehicle .......................................................................................... 12-23 Wiring – IQ System Vehicle with Motor Controller Output Regulator (MCOR) ................................. 12-25 Forward/Reverse Switch, Tow/Run Switch – IQ System Vehicle ..................................................... 12-27 Batteries, Charger Receptacle – IQ System Vehicle ........................................................................ 12-29 Computer, Controller, and Solenoid – IQ System Vehicle ................................................................ 12-31 SECTION 13 – ELECTRIC MOTOR Motor – V-Glide 36-Volt Vehicle ....................................................................................................... 13-3 Motor – PowerDrive System 48 Vehicle ........................................................................................... 13-5 Motor (MODEL 5BC59JBS6365) – IQ System Vehicle .................................................................... 13-7 Motor (Model EJ4-4001) – IQ System Vehicle ................................................................................. 13-9 SECTION 14 – TRANSAXLE – ELECTRIC VEHICLE Transaxle, Type G – Electric Vehicle ................................................................................................ 14-3 Transaxle, Type K – Electric Vehicle ................................................................................................ 14-5 SECTION 15 – BATTERY CHARGER Accu-Power Battery Charger, Domestic – V-Glide 36-Volt Vehicle .................................................. 15-3 Accu-Power Battery Charger, Export, 230-Volt – V-Glide 36-Volt Vehicle ....................................... 15-5 Accu-Power Battery Charger, Export, 100-Volt – V-Glide 36-Volt Vehicle ....................................... 15-7 PowerDrive Battery Charger, Domestic ............................................................................................ 15-9 PowerDrive 2 Battery Charger, Domestic ......................................................................................... 15-11 GE PowerDrive Battery Charger, Domestic ...................................................................................... 15-13 PowerDrive Battery Charger, Export ................................................................................................ 15-15 PowerDrive Battery Charger, European ........................................................................................... 15-17 SECTION 16 – MAINTENANCE AND SERVICE TOOLS Maintenance and Service Tools ....................................................................................................... 16-3 Maintenance and Service Tools, Continued ..................................................................................... 16-5 Maintenance and Service Tools, Continued ..................................................................................... 16-7 Maintenance and Service Tools, Continued ..................................................................................... 16-9 Maintenance and Service Tools, Continued ..................................................................................... 16-11

G E 1 BODY AND TRIM

2 2004-2005 DS Golf Cars Illustrated Parts List G E 1 22 23 24 20 21 21 22 TYPICAL 2 PLACES 17 18 TYPICAL 9 PLACES 16 15 12 14 13 TYPICAL 2 PLACES 10 9 8 7 6 1 3 4 2 11 Dash Frame TYPICAL 3 PLACES Front Body Of Car Frame Center Dash Dash TYPICAL 2 PLACES 5 TYPICAL 2 PLACES 21 20 19 25

2004-2005 Club Car DS Gasoline and Electric Vehicle Illustarted Parts List

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