2010 Club Car Villager 2+2 LSV Electric Factory Service & Work Shop Manual

Manual Number 103373105 Edition Code 1007C1211B DS Villager 4, Villager 6, Villager 8, Transporter 4, and Transporter 6 Gasoline and Electric Vehicles 2008-2011 Transportation Maintenance and Service Manual

2008-2011 Transportation Vehicle Maintenance and Service Manual Page i FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation. This manual provides detailed information for the maintenance and repair of Villager and TransPorter vehicles and should be used in conjunction with the appropriate maintenance and service supplement. If you do not have the appropriate maintenance and service supplement, you may order one from your Club Car representative. Maintenance and service supplements available include the following: This manual and corresponding maintenance and service supplement should be thoroughly reviewed prior to servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded. This manual was written for the trained technician who already has knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained technician. It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support. This manual, used in conjunction with the appropriate maintenance and service supplement, covers all aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at: Club Car, LLC; P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical Service Representative at (706) 863-3000, extension 3580. 2009-2011 IQ System Vehicle Maintenance and Service Supplement Publication Part No. 103373106 2009-2011 FE290 Gasoline Vehicle Maintenance and Service Supplement Publication Part No. 103373108 2009-2011 FE350 Gasoline Vehicle Maintenance and Service Supplement Publication Part No. 103373109 2009-2011 IQ Plus System Vehicle Maintenance and Service Supplement Publication Part No. 103373107 Copyright © 2007, 2009, 2011 Club Car, LLC Club Car is a registered trademarks of Club Car, LLC. This manual effective August 1, 2007.

Page ii 2008-2011 Transportation Vehicle Maintenance and Service Manual ý WARNING • Read Section 1 – Safety before attempting any service on the vehicle. • Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed. NOTE: This manual represents the most current information at the time of publication. Club Car, LLC is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures. Any modification and/or signif- icant change in specifications or procedures will be forwarded to all Club Car distributors and dealers and will, when applicable, appear in future editions of this manual. Club Car, LLC reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle owner’s manual or write to: Club Car, LLC, P.O. Box 204658, Augusta, GA 30917-4658, USA, Attention: Warranty Administration.

2008-2011 Transportation Vehicle Maintenance and Service Manual Page iii CONTENTS SECTION 1 – SAFETY General Warning ............................................................................................................................... 1-1 Disabling The Vehicle ................................................................................................................... 1-4 Disconnecting The Battery – Gasoline Vehicles ........................................................................... 1-4 Connecting The Battery – Gasoline Vehicles ............................................................................... 1-4 Disconnecting The Batteries – Electric Vehicles .......................................................................... 1-4 Connecting The Batteries – Electric Vehicles ............................................................................... 1-5 SECTION 2 – VEHICLE SPECIFICATIONS Vehicle Specifications – Electric Vehicles ........................................................................................ 2-1 Vehicle Specifications – Gasoline Vehicles ..................................................................................... 2-3 .......................................................................................................................................................... 2-4 SECTION 3 – GENERAL INFORMATION General Information .......................................................................................................................... 3-1 Serial Number Identification .............................................................................................................. 3-1 Storage – Gasoline Vehicle .............................................................................................................. 3-2 Preparing the Gasoline Vehicle for Extended Storage ................................................................. 3-2 Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-4 Storage – Electric Vehicle ................................................................................................................. 3-5 Preparing the Electric Vehicle for Extended Storage .................................................................... 3-5 Returning the Stored Electric Vehicle to Service .......................................................................... 3-7 SECTION 4 – BODY AND TRIM Cleaning the Vehicle ......................................................................................................................... 4-1 Front Body ........................................................................................................................................ 4-2 Center Body – Villager 6 and 8 ......................................................................................................... 4-3 Rear Body – Villager 4, 6, and 8 ....................................................................................................... 4-7 Front and Rear Body Repair ............................................................................................................. 4-12 Stress Lines or Streaks ................................................................................................................. 4-12 Minor Impact Damage/Deformations ............................................................................................ 4-13 Minor Scratches and Surface Blemishes ...................................................................................... 4-13 Small Scratches That Cannot Be Buffed Out ............................................................................... 4-13 Touch-up Paint Color Chart .......................................................................................................... 4-14 Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-14 Center Body Repair – Villager 6 and 8 ............................................................................................. 4-14

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2010 Club Car Villager 2+2 LSV Electric Factory Service & Work Shop Manual

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