2006 Club Car DS Golf Cart Illustrated Parts List

Manual Number 102907601 Edition Code 0306P0112N Gasoline and Electric Vehicles 2006 DS Golf Car 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 2006 DS golf cars. 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. 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.

2006 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 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 © 2006 Club Car, Inc. Club Car and ArmorFlex are registered trademarks of Club Car, Inc. This manual effective July 25, 2005.

2006 DS Golf Cars Illustrated Parts List Page 1 CONTENTS SECTION 1 – BODY AND TRIM Front Body ........................................................................................................................................................................................ 1-3 Rear Body Trim ................................................................................................................................................................................ 1-5 Dash Components ......................................................................................................................................................................... 1-7 Beverage Holder ............................................................................................................................................................................. 1-9 Front Seat Bottom and Armrests .............................................................................................................................................. 1-11 Rear Body and Fender – Gasoline Vehicle ............................................................................................................................. 1-13 Rear Body and Fender – Electric Vehicle ................................................................................................................................ 1-15 Seat Back and Bag Hoop .............................................................................................................................................................. 1-17 Canopy ............................................................................................................................................................................................... 1-19 Rear Access Door ............................................................................................................................................................................ 1-21 Scuff Guard and Bagwell Protector Kits ................................................................................................................................. 1-23 Rear Body and Fender – Electric Vehicle (Style B) .............................................................................................................. 1-25 Rear Body and Fender – Gasoline Vehicle (Style B) ............................................................................................................ 1-27 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 Rear Brake Assembly, Self-Adjusting ...................................................................................................................................... 4-3 Brake Pedal Assembly ................................................................................................................................................................... 4-5 Brake Cable, Equalizer, and Equalizer Rod ............................................................................................................................ 4-7 Accelerator Pedal Assembly – Gasoline Vehicle ................................................................................................................. 4-9 Accelerator Pedal Assembly – Electric Vehicles with MCOR ........................................................................................... 4-11 Accelerator Rod – Gasoline Vehicles ....................................................................................................................................... 4-13 SECTION 5 – STEERING, FRONT AND REAR SUSPENSION Steering Column ............................................................................................................................................................................. 5-3 Steering Wheel ................................................................................................................................................................................ 5-5 Front Suspension, Upper ............................................................................................................................................................. 5-7 Front Suspension, Lower ............................................................................................................................................................. 5-9 Front Spindles and Hubs ............................................................................................................................................................. 5-11 Rear Suspension – Gasoline Vehicle ........................................................................................................................................ 5-13 Rear Suspension – Electric Vehicle ........................................................................................................................................... 5-15

2006 DS Golf Cars Illustrated Parts List CONTENTS Steering Gear Assembly ............................................................................................................................................................... 5-17 SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLE Wiring .................................................................................................................................................................................................. 6-5 Electrical Component Box ........................................................................................................................................................... 6-7 Electrical Components, Front Body .......................................................................................................................................... 6-9 Starter/Generator Assembly Model G425419 – Gasoline Vehicles ............................................................................... 6-11 FE290 Starter/Generator Mounting ......................................................................................................................................... 6-13 Battery – Gasoline Vehicle ........................................................................................................................................................... 6-15 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 FE290 Engine Mounting ............................................................................................................................................................... 7-15 SECTION 8 – FUEL, INTAKE, AND GOVERNOR SYSTEMS Fuel System ....................................................................................................................................................................................... 8-3 Carburetor Assembly – FE290 .................................................................................................................................................... 8-5 Carburetor Installation – FE290 ................................................................................................................................................. 8-7 Governor and Accelerator Cables ............................................................................................................................................. 8-9 Air Box and Intake Hose ................................................................................................................................................................ 8-11 Intake System ................................................................................................................................................................................... 8-13 SECTION 9 – EXHAUST SYSTEM Exhaust System – FE290 Engine ................................................................................................................................................ 9-3 SECTION 10 – TORQUE CONVERTER Drive Clutch ...................................................................................................................................................................................... 10-3 Drive Belt – FE290 ........................................................................................................................................................................... 10-5 Driven Clutch .................................................................................................................................................................................... 10-7 SECTION 11 – TRANSAXLE – GASOLINE VEHICLE Transaxle – Gasoline Vehicles, Gear Cases and Brackets .................................................................................................. 11-3

2006 DS Golf Cars Illustrated Parts List Page 3 CONTENTS Transaxle – Gasoline Vehicles, Transmission and Gear Reduction ............................................................................... 11-5 Transaxle – Gasoline Vehicles, Differential and Axles ....................................................................................................... 11-7 Forward/Reverse Shifter Assembly – Gasoline Vehicles .................................................................................................. 11-9 Forward/Reverse Shifter Cable – Gasoline Vehicles .......................................................................................................... 11-11 SECTION 12 – ELECTRICAL SYSTEM – ELECTRIC VEHICLE Wiring ................................................................................................................................................................................................. 12-5 Instrument Panel Components ................................................................................................................................................. 12-7 Motor Controller Output Regulator (MCOR) ........................................................................................................................ 12-9 Forward/Reverse Switch, Tow/Run Switch ........................................................................................................................... 12-11 Battery Charger Receptacle ........................................................................................................................................................ 12-13 Batteries, Electric Vehicle ............................................................................................................................................................. 12-15 Computer, Controller, and Solenoid – Electric Vehicle .................................................................................................... 12-17 SECTION 13 – ELECTRIC MOTOR Motor (Model 5BC59JBS6365) – Electric Vehicle ................................................................................................................ 13-3 Motor (Model 5BC59JBS6390) – Electric Vehicle ................................................................................................................ 13-5 Motor (Model EJ4-4001) – Electric Vehicle ............................................................................................................................ 13-7 Motor (Model EJ8-4001A) – Electric Vehicle ......................................................................................................................... 13-9 SECTION 14 – TRANSAXLE – ELECTRIC VEHICLE Transaxle – Earlier Version .......................................................................................................................................................... 14-3 Transaxle – Electric Vehicles (Later Style) .............................................................................................................................. 14-5 SECTION 15 – BATTERY CHARGER PowerDrive 3 Battery Charger, Domestic .............................................................................................................................. 15-3 PowerDrive 2 Battery Charger (Model 22110), Domestic ................................................................................................ 15-5 PowerDrive Battery Charger (Model 17930), Domestic ................................................................................................... 15-7 PowerDrive Battery Charger (Model 18780), Export ......................................................................................................... 15-9 PowerDrive Battery Charger (Model 20310), European ................................................................................................... 15-11 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

2006 DS Golf Cars Illustrated Parts List CONTENTS SECTION i – INDEX

G E 1 D BODY AND TRIM

2 2006 DS Golf Cars Illustrated Parts List G E 1 D 1 33 35 3 4 29 34 2 30 31 32 6 - 27 28 000249-002 5

2006 Club Car DS Golf Cart Illustrated Parts List

You're Reading a Preview

Recently Viewed