ILLUSTRATED PARTS LIST DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER PRINT CODE 0897B0101A

Transcription

1 998 ILLUSTRATD PARTS LIST DS OLF CARS ASOLIN/LCTRIC MANUAL NUMBR PRINT COD 0897B00A

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3 USIN TH ILLUSTRATD PARTS LIST WARNIN THIS MANUAL IS TO B USD ONLY FOR IDNTIFICATION AND ORDRIN OF SRVIC PARTS. B SUR TO RAD AND US TH MAINTNANC AND SRVIC MANUAL BFOR ATTMPTIN ANY VHICL RPAIRS. This manual covers all 998 Club Car DS Tranquility, V-lide 36 volt, DS PowerDrive System 48 and DS PowerDrive Plus vehicles. The manual is divided into 6 sections. Sections through 6 pertain to both gasoline and electric vehicles, sections 7 through pertain to gasoline vehicles only, and sections 3 through 6 pertain to electric vehicles only. 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 or, 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. Typically, there is a two-page spread for each individual page title in the Table of Contents (however, some titles require 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 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,, 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 is a component of the level part (assembly) that it is listed under. A level 3 part is a component of the level 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, 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 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 Augusta, eorgia USA Telephone Service Parts Fax , CLUB CAR, INC. All rights reserved. This manual effective August 8, 997 Manual print code: 0897B00A

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5 CONTNTS MAINTNANC AND SRVIC TOOLS SCTION MAINTNANC AND SRVIC TOOLS BODY AND TRIM SCTION BODY TRIM FRONT BODY RAR BODY AND FNDR - ASOLIN VHICL RAR BODY AND FNDR - LCTRIC VHICL SAT BOTTOM AND ARMRST... - SAT BACK AND BA HOOP WHLS AND TIRS SCTION 3 WHLS AND TIRS SAFTY DCALS SCTION 4 SAFTY DCALS - ASOLIN VHICL SAFTY DCALS - LCTRIC VHICL BRAKS, PDAL, AND CABL ASSMBLIS SCTION 5 BRAK ASSMBLY BRAK PDAL AND CABL ASSMBLY ACCLRATOR PDAL ASSMBLY STRIN, FRONT AND RAR SUSPNSION SCTION 6 STRIN COLUMN STRIN AR ASSMBLY FRONT SUSPNSION, UPPR FRONT SUSPNSION, LOWR RAR SUSPNSION LCTRICAL SYSTM - ASOLIN VHICL SCTION 7 WIRIN - ASOLIN VHICL FORWARD AND RVRS SHIFTR ASSMBLY - ASOLIN VHICL LCTRICAL COMPONNT BOX - ASOLIN VHICL LCTRICAL COMPONNTS - ASOLIN VHICL STARTR/NRATOR ASSMBLY STARTR/NRATOR MOUNTIN BATTRY - ASOLIN VHICL F 90 NIN SCTION 8 F 90 NIN NIN MOUNTIN

6 CONTNTS FUL, INTAK, AND OVRNOR SYSTMS SCTION 9 FUL SYSTM CARBURTOR ASSMBLY CARBURTOR INSTALLATION OVRNOR AND ACCLRATOR CABLS INTAK DUCT, CHOK, AND AIR BOX ASSMBLY XHAUST SYSTM SCTION 0 XHAUST SYSTM TORQU CONVRTR SCTION DRIV CLUTCH DRIVN CLUTCH UNITIZD TRANSAXL - ASOLIN VHICL SCTION UNITIZD TRANSAXL - ASOLIN VHICL LCTRICAL SYSTM - LCTRIC VHICL SCTION 3 LCTRICAL COMPONNTS, FRONT BODY - LCTRIC VHICL WIRIN - V-LID 36 VOLT VHICL FORWARD AND RVRS SWITCH - V-LID 36 VOLT VHICL WIPR SWITCH - V-LID 36 VOLT VHICL RSISTOR AND BOARD ASSMBLY - V-LID 36 VOLT VHICL BATTRIS, CHARR RCPTACL, SOLNOID - V-LID 36 VOLT VHICL WIRIN - POWRDRIV SYSTM 48 VHICL FORWARD AND RVRS SWITCH - POWRDRIV SYSTM 48 VHICL BATTRIS, CHARR RCPTACL - POWRDRIV SYSTM 48 VHICL COMPUTR, CONTROLLR, AND SOLNOID - POWRDRIV SYSTM 48 VHICL MULTI-STP POTNTIOMTR - POWRDRIV SYSTM 48 AND POWRDRIV PLUS WIRIN - POWRDRIV PLUS VHICL FORWARD AND RVRS SWITCH, TOW SWITCH - POWRDRIV PLUS VHICL BATTRIS, CHARR RCPTACL - POWRDRIV PLUS VHICL SOLNOIDS, NRY DISPLACMNT MODUL - POWRDRIV PLUS VHICL CONTROLLR, ON-BOARD COMPUTR - POWRDRIV PLUS VHICL BATTRY CHARR SCTION 4 ACCU-POWR CHARR, DOMSTIC - V-LID 36 VOLT VHICL ACCU-POWR CHARR, XPORT - V-LID 36 VOLT VHICL ACCU-POWR CHARR, XPORT, 00 VOLT - V-LID 36 VOLT VHICL POWRDRIV CHARR, DOMSTIC - POWRDRIV SYSTM 48 AND POWRDRIV PLUS POWRDRIV CHARR, XPORT - POWRDRIV SYSTM 48 AND POWRDRIV PLUS POWRDRIV CHARR, UROPAN - POWRDRIV SYSTM 48 AND POWRDRIV PLUS LCTRIC MOTOR SCTION 5 MOTOR - V-LID 36 VOLT VHICL MOTOR - POWRDRIV SYSTM 48 VHICL MOTOR - POWRDRIV PLUS VHICL

7 CONTNTS TRANSAXL - LCTRIC VHICL SCTION 6 TRANSAXL - LCTRIC VHICL

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9 MAINTNANC AND SRVIC TOOLS

10 ST POWR SWITCH TO "ON". POT CALIBRATION: ST MOD SWITCH TO "POT". CHCK INTRNAL 4.30±.03 VOLT SINAL BY PRSSIN "TST" BUTTON. CONNCT TST SOCKT TO POT PLU, CONNCT RN LAD TO RN/ WHIT POT LIMIT SWITCH LAD, CONNCT BLU LAD TO BATTRY POSITIV. ILLUMINATION OF TH L..D. INDICATS A CLOSD PDAL LIMIT SWITCH, RAD TH POTNTIOMTR ST VOLTA FROM TH L.C.D. DISPLAY. S SRVIC MANUAL FOR ADJUSTMNT PROCDUR. SPD SNSOR TST: ST MOD SWITCH TO "SSAM", CONNCT TST SOCKT TO MOTOR SPD SNSOR PLU, ROTAT MOTOR. L..D. SHOULD PULS ON AND OFF INDICATIN SPD SNSOR IS FUNCTIONAL. S OPRATIN INSTRUCTIONS FOR MOR DTAIL R WARNIN R ACCLRATOR PDAL HIHT CALIBRATION & TST MODUL INSTRUCTIONS SPD CONTROL TST PDAL CIRCUIT POWR ON OFF Club Car MOD SSAM POT COMMUNICATION DISPLAY MODUL DISPLAY FUNCTIONS: PRSS AND HOLD BUTTON TO SHOW FUNCTION NUMBR. RLAS BUTTON TO SHOW FUNCTION VALU. Func - Battery voltage. Func - nergy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Func4 - Last charge termination type ( = Incomplete, = DVDT, 4 = Normal, 8 = Max. timer). POWR ON OFF Club Car PART # Page -

11 ITM PART NO. DSCRIPTION 3 4 MAINTNANC AND SRVIC TOOLS ACCLRATOR PDAL ADJUSTMNT TOOL ADHSION PROMOTR - ARMORFLX ADHSIV, UID RIN, 3 RAM TUB ARMORFLX RPAIR KIT BATTRY DISCHAR MACHIN, 36/48 VOLT BATTRY TRMINAL PROTCTOR SPRAY BATTRY THRMOMTR BARIN AND OIL SAL RMOVR ASSMBLY BARIN DRIVR ST BARIN PULLR BARIN PULLR WD ATTACHMNT CALIBRATION TST MODUL CAM INSTALLATION TOOL CLUTCH TOOL KIT (INCLUDS ITMS 4-0 ) CLUTCH ALINMNT TOOL DRIV CLUTCH PULLR CLUTCH DRIV HUB PULLR DRIVN CLUTCH CAM PULLR DRIVN CLUTCH PULLR PLU DRIV CLUTCH HOLDR TOOL ASSMBLY PRSS WLDMNT COMMUNICATION DISPLAY MODUL COMPRSSION AU AND ADAPTR CONTINUITY TSTR DRY MOLY LUBRICANT FLY WHL PULLR KIT AR YOK... QTY AS QTY LC PLAS RFR TO TH MAINTNANC AND SRVIC MANUAL FOR PROPR TOOL APPLICATION. Page -3

12 00 n k 00k MAX V 000 0k k 00 FUSD n n 0n PULS NIN TACHOMTR PT-000 Club Car POSTION RST WAVTK DM5-XL V OFF V Ω A V Ω! COM! 00nA Page -4

13 ITM PART NO. DSCRIPTION 3 4 MAINTNANC AND SRVIC TOOLS OVRNOR SHAFT INSTALLATION TOOL HYDROMTR INTRNAL RTAININ RIN PLIRS LIQUID ASKT (TRANSAXL CAS) PISTON RIN COMPRSSOR KIT PISTON RIN PLIRS RTAININ RIN PLIRS - 45 XTRNAL RTAININ RIN PLIRS - 90 INTRNAL SAFTY FIRST CARD (50 PR PACK) SAL PULLR STARTR/NRATOR BLT TNSION TOOL STRIN COLUMN BARIN PRSS TOOL STRIN COLUMN RTAININ RIN TOOL TACHOMTR... 4 N/A TOUCH-UP PAINT, LACQUR - BI... 4 N/A TOUCH-UP PAINT, LACQUR - WHIT... 4 N/A TOUCH-UP PAINT, LACQUR - RY... 4 N/A TOUCH-UP PAINT, LACQUR - RD... 4 N/A TOUCH-UP PAINT, LACQUR - DARK BLU... 4 N/A TOUCH-UP PAINT, LACQUR - DARK RN TRANSMISSION TOOL KIT TRANSAXL PINION SAL TOOL TRANSAXL AXL SAL TOOL VALV CLARANC ADJUSTR SCRW HOLDR VALV UID RAMR (INCLUDS ITM 48) ARBOR VALV SAT CUTTR T-WRNCH VALV SAT CUTTR UID VALV SAT CUTTR, 45 (3MM DIAMTR) VALV SAT CUTTR, 3 AND 45 (35MM DIAMTR) VALV SPRIN COMPRSSOR VOLT OHM MTR TUN-UP KIT (F 90) (INCLUDS AIR FILTR, SPARK PLU, OIL FILTR, FUL FILTRS) (NOT SHOWN)... QTY AS QTY LC PLAS RFR TO TH MAINTNANC AND SRVIC MANUAL FOR PROPR TOOL APPLICATION. Page -5

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15 BODY AND TRIM

16 Dash Frame Front Body Of Car Frame Dash Center Dash 3 PLACS PLACS PLACS PLACS PLACS 0 9 PLACS 8 Page -

17 ITM PART NO. DSCRIPTION 3 4 BODY TRIM COMPONNT, LFT DASH, BLACK PANL, CNTR DASH, BLACK PLU, HOL (V-LID 36 VOLT VHICL ONLY) COMPONNT, RIHT DASH, BLACK MAT, FLOOR KIT, SNAP WASHR, BLACK (INCLUDS ITMS 7-0)... 7 N/A NUT, SPD... 8 N/A WASHR, # N/A SCRW, #0 SHT MTAL... 0 N/A COVR, SCRW HAD SCRW, FLAN LOCK RIVT, ALUMINUM POP, 3/ KIT, DRINK HOLDR (INCLUDS ITMS 4 AND 5) BOLT, HX HAD, /4-0 x 3/ NUT, U, / KIT, BAWLL PROTCTOR (INCLUDS ITM 7) FASTNR, PLASTIC BARRL KIT, RAR BUMPR (INCLUDS ITMS 9-3) BUMPR, RAR PLAT, MOUNTIN, LON NUT, NYLON LOCK, 5/ WASHR, SPCIAL, 5/ BOLT, PHILLIPS TRUSS HAD SHOULDR, 3/8-8 x KIT, SCUFF UARD (INCLUDS ITM 5) FASTNR, PLASTIC BARRL... QTY AS QTY LC Page -3

18 PLACS PLACS PLACS Club Car PLACS PLACS 8 PLACS 5 Page -4

19 ITM PART NO. DSCRIPTION 3 4 FRONT BODY KIT, FRONT BUMPR (INCLUDS ITMS - 5) BUMPR, FRONT SCRW, PHILLIPS TRUSS HAD, 5/6-8 x NUT, NYLON LOCK, 5/ RIVT, PUSH TYP BLIND NAMPLAT - OLD BODY, FRONT - BI BODY, FRONT - WHIT BODY, FRONT - RAY BODY, FRONT - RD BODY, FRONT - DARK BLU BODY, FRONT - DARK RN BODY, FRONT WITH HADLIHT OPNIN - BI BODY, FRONT WITH HADLIHT OPNIN - WHIT BODY, FRONT WITH HADLIHT OPNIN - RAY BODY, FRONT WITH HADLIHT OPNIN - RD BODY, FRONT WITH HADLIHT OPNIN - DARK BLU BODY, FRONT WITH HADLIHT OPNIN - DARK RN TRIM, FRONT BODY BOLT, CARRIA, 5/6-8 x WASHR, FLAT, 5/ SCRW, FLAN LOCK NUT, SLAB BAS T (PACKA OF 4) BUMPR, SID UARD TRIM SCRW, SLF-TAPPIN, #8-3 x 3/ SCRW, PHILLIPS TRUSS HAD, 5/6-8 x NUT, NYLON LOCK, 5/ QTY AS QTY LC Page -5

20 FRONT SAT SUPPORT VRTICAL STRUT 3 4 PLACS PLACS 9 PLACS ;; yy 8 ACH SID OF VHICL ACH SID OF VHICL PLACS PLACS ACH SID OF VHICL 0 5 PLACS Page -6

21 RAR BODY AND FNDR - ASOLIN VHICL ITM PART NO. DSCRIPTION SCRW, PHILLIPS HAD, /4-0 x PLAT, BODY KICK U-NUT, / PLAT, BODY HIN WASHR, FLAT, / NUT, NYLON LOCK, / ASSMBLY, ACCSS DOOR - BLACK ASSMBLY, ACCSS DOOR - BI NUT, BLIND, / N/A INSULATION, SOUND, FRONT... 0 N/A INSULATION, SOUND, LFT SID BODY... N/A INSULATION, SOUND, BODY LFT / RIHT FNDR BODY - BI BODY - WHIT BODY - RAY BODY - RD BODY - DARK BLU BODY - DARK RN BODY WITH TAILLIHT OPNIN - BI BODY WITH TAILLIHT OPNIN - WHIT BODY WITH TAILLIHT OPNIN - RAY BODY WITH TAILLIHT OPNIN - RD BODY WITH TAILLIHT OPNIN - DARK BLU BODY WITH TAILLIHT OPNIN - DARK RN... 3 N/A INSULATION, SOUND, RIHT SID FNDR - SHORT... 4 N/A INSULATION, SOUND, LFT SID FNDR - LON SUPPORT, FRONT BODY KIT, FORWARD AND RVRS SWITCH COVR (INCLUDS OF ITM 7) FASTNR, PLASTIC BARRL CLIP, BODY KPR SCRW, SLF-TAPPIN, #8-3 x 3/ SCRW, HX HAD CAP, /4-0 x BARRL, PLASTIC FNDR, INNR WASHR, FLAT, TYP B, /4... QTY AS QTY LC Page -7

22 5 FRONT SAT SUPPORT VRTICAL STRUT PLACS PLACS PLACS PLACS ACH SID OF VHICL 0 4 ACH SID OF VHICL ACH SID OF VHICL Page -8

23 ITM PART NO. DSCRIPTION RAR BODY AND FNDR - LCTRIC VHICL NUT, U, / PLAT, BODY HIN PLAT, BODY KICK WASHR, FLAT, / SCRW, PHILLIPS HAD, /4-0 x NUT, NYLON LOCK, / FNDR, INNR FASTNR, PLASTIC BARRL SPACR, 7/ BOLT, HX HAD, /4-0 x 3/ BOLT, HX HAD, /4-0 x / SPACR, / CLIP, BODY KPR SCRW, SLF-TAPPIN, # BODY - BI BODY - WHIT BODY - RAY BODY - RD BODY - DARK BLU BODY - DARK RN BODY WITH TAILLIHT OPNIN - BI BODY WITH TAILLIHT OPNIN - WHIT BODY WITH TAILLIHT OPNIN - RAY BODY WITH TAILLIHT OPNIN - RD BODY WITH TAILLIHT OPNIN - DARK BLU BODY WITH TAILLIHT OPNIN - DARK RN DOOR, ACCSS - BLACK DOOR, ACCSS - BI NUT, BLIND, / KIT, FORWARD AND RVRS SWITCH COVR (INCLUDS OF ITM 9) FASTNR, PLASTIC BARRL SUPPORT, FRONT BODY WASHR, FLAT, TYP B, /4... QTY AS QTY LC Page -9

24 PLACS 9 8 PLACS PLACS 4 PLACS PLACS PLACS 6 7 RFRNC RAR BODY AND FNDR 8 4 PLACS Page -0

25 ITM PART NO. DSCRIPTION 3 4 SAT BOTTOM AND ARMRST ASSMBLY, SAT BOTTOM - BUFF (INCLUDS ITMS AND 3) ASSMBLY, SAT BOTTOM - WHIT (INCLUDS ITMS AND 3) ASSMBLY, SAT BOTTOM - RAY (INCLUDS ITMS AND 3) ASSMBLY, SAT BOTTOM - BLACK (INCLUDS ITMS AND 3) COVR, VINYL SAT BOTTOM - BUFF COVR, VINYL SAT BOTTOM - WHIT COVR, VINYL SAT BOTTOM - BLACK COVR, VINYL SAT BOTTOM - RAY INSRT, WOOD ASSMBLY, SAT BOTTOM AND ARMRST (INCLUDS ITMS 5-9) BRACKT, SAT SUPPORT KIT, ARMRST (INCLUDS ITMS 7-9) RIVT, MATIN, 3/ N/A ASSMBLY, ARMRST, LFT... 9 N/A ASSMBLY, ARMRST, RIHT BUMPR, SAT SCRW, WASHR HAD TAP, # ASKT, SAT, SHORT (ASOLIN VHICL ONLY) ASKT, SAT, LON (ASOLIN VHICL ONLY)... 4 N/A INSULATION, SOUND (ASOLIN VHICL ONLY) WASHR, FLAT, STAINLSS STL, # SCRW, HX HAD CAP, /4-0 x PLAT, SAT HIN, STAINLSS STL RIVT, POP, STAINLSS STL, 3/ QTY AS QTY LC Page -

26 3 PLACS 6 7 PLACS PLACS PLACS PLACS PLACS PLACS 6 4 PLACS Page -

27 ITM PART NO. DSCRIPTION 3 4 SAT BACK AND BA HOOP ASSMBLY, SAT BACK - WHIT (INCLUDS ITMS AND 3) ASSMBLY, SAT BACK - BUFF (INCLUDS ITMS AND 3) ASSMBLY, SAT BACK - RAY (INCLUDS ITMS AND 3) ASSMBLY, SAT BACK - BLACK (INCLUDS ITMS AND 3) CAP, SAT BACK - BLACK COVR, VINYL, SAT BACK - BUFF COVR, VINYL, SAT BACK - WHIT COVR, VINYL, SAT BACK - BLACK COVR, VINYL, SAT BACK - RAY MOUNT, SAT BACK WASHR, XTRNAL TOOTH LOCK, / SCRW, PHILLIPS TRUSS HAD, /4-0 x 3/ NUT, NYLON LOCK, / SCRW, HX HAD, /4-0 x 3/ WASHR, FLAT, / SCRW, CAP HX HAD, 5/6-8 x / WASHR, FLAT, 5/ NUT, NYLON LOCK, 5/ SPACR, BA HOOP ASSMBLY, BA HOOP (INCLUDS ITMS 5-7) FASTNR, PLASTIC BARRL STRAP, BA BUCKL, BA STRAP SUPPORT, SAT BACK, MAIN ASSMBLY, KN BRAC WLDMNT FASTNR, PLASTIC BARRL - RAY PAD, MOUNTIN, SAT BACK SUPPORT KIT, SWATR BASKT (INCLUDS ITMS 3-7) SCRW, PHILLIPS TRUSS HAD, /4-0 x / WASHR, FLAT, 5/ SPACR, NYLON NUT, NYLON LOCK, / BOLT, HX HAD, /4-0 x WASHR, FLAT, 5/ BOLT, CARRIA, 5/6-8 x / SCRW, SLF-TAPPIN, 5/6-8 x / SPACR, BODY QTY AS QTY LC Page -3

28 Page -4

29 WHLS AND TIRS 3

30 STANDARD TRAD PRMIUM TRAD XTRA TRACTION Page 3-

31 ITM PART NO. DSCRIPTION 3 4 WHLS AND TIRS NUT, LU ASSMBLY, BI WHL AND STANDARD TRAD TIR (8 x 8.5-8) ASSMBLY, BI WHL AND PRMIUM TRAD TIR (8 x 8.5-8) N/A ASSMBLY, BI WHL AND PRMIUM TRAD TIR, WHIT WALL (8 x 8.5-8) ASSMBLY, BI WHL AND XTRA TRACTION TIR, 6 PLY (8 x 8.5-8) ASSMBLY, WHIT WHL AND STANDARD TRAD TIR (8 x 8.5-8) ASSMBLY, WHIT WHL AND PRMIUM TRAD TIR (8 x 8.5-8) N/A ASSMBLY, WHIT WHL AND PRMIUM TRAD TIR, WHIT WALL (8 x 8.5-8) ASSMBLY, WHIT WHL AND XTRA TRACTION TIR, 6 PLY (8 x 8.5-8) WHL RIM, BI WHL RIM, WHIT TIR, UNMOUNTD, STANDARD TRAD (8 x 8.5-8) TIR, UNMOUNTD, PRMIUM TRAD (8 x 8.5-8) TIR, UNMOUNTD, XTRA TRACTION, 6 PLY (8 x 8.5-8) STM, VALV QTY AS QTY LC 3 Page 3-3

32 3 Page 3-4

33 SAFTY DCALS 4

34 4 DRIVR / PASSNR WARNIN DCAL KY SWITCH OFF ON 3 OPRATIN INSTRUCTIONS DCAL FRAM ROUND AND OVRNOR WARNIN DCAL (ON VHICL FRAM NAR BATTRY) 6 ASOLIN WARNIN DCAL (ON VHICL FRAM NAR FUL TANK) 4 MOVIN PARTS AND HOT MANIFOLD DCAL (ON STARTR/NRATOR AND NIN) 5 PRIODIC SRVIC DCAL (ON AIR INTAK BOX) 7 8 INRSOLL-RAND DCAL (ON BODY PANL) Page 4-

35 ITM PART NO. DSCRIPTION 3 4 SAFTY DCALS - ASOLIN VHICL DCAL, DRIVR/PASSNR WARNIN DCAL, KY SWITCH DCAL, OPRATIN INSTRUCTIONS DCAL, ASOLIN DANR DCAL, HOT MANIFOLD WARNIN DCAL, NATIV FRAM ROUND WARNIN DCAL, PRIODIC SRVIC SCHDUL DCAL, INRSOLL-RAND... QTY AS QTY LC 4 Page 4-3

36 4 DRIVR / PASSNR WARNIN DCAL KY SWITCH OFF ON 3 OPRATIN INSTRUCTIONS DCAL 4 DANR DCAL (ON BODY UNDR SAT) MOTOR BRAKIN DCAL (POWRDRIV PLUS VHICLS ONLY) WARNIN HOT RSISTORS (COILD WIR) CAN CAUS SVR BURNS. RSISTOR WARNIN DCAL (ON FRAM UNDR SAT ON V-LID 36 VOLT VHICL) (ON MOUNTIN PLAT UNDR ACCSS PANL ON POWRDRIV PLUS VHICL) 5 DANR / POISON! FLUSH YS SULFURIC IMMDIATLY NO ACID WITH WATR SHILD SPARKS CAN CAUS T YS XPLOSIV FLAMS BLINDNSS OR MDICAL ASS SMOKIN SVR BURNS HLP CAN CAUS FAST BLINDNSS OR INJURY KP OUT OF TH RACH OF CHILDRN DO NOT TIP KP VNT CAPS TIHT AND LVL 6 Club Car F N 9 TOW SWITCH WARNIN DCAL (ON TOW SWITCH BRACKT UNDR SAT) 8 7 INRSOLL-RAND DCAL (POWRDRIV PLUS VHICLS ONLY) POTNTIOMTR CAUTION DCAL (ON WIPR SWITCH COVR INSID BATTRY COMPARTMNT) Page 4-4

37 ITM PART NO. DSCRIPTION 3 4 SAFTY DCALS - LCTRIC VHICL DCAL, DRIVR/PASSNR WARNIN DCAL, KY SWITCH DCAL, OPRATIN INSTRUCTIONS DCAL, MOTOR BRAKIN (POWRDRIV PLUS VHICL) DCAL, RSISTOR WARNIN (V-LID 36 VOLT AND POWRDRIV PLUS VHICLS) DCAL, BATTRY DANR/POISON DCAL, INRSOLL-RAND DCAL, POTNTIOMTR CAUTION DCAL, TOW SWITCH (POWRDRIV PLUS VHICL)... QTY AS QTY LC 4 Page 4-5

38 4 Page 4-6

39 BRAKS, PDAL, AND CABL ASSMBLIS 5

40 PLACS 0 4 PLACS PLACS ;; yy ;y ; y 6 7 PLACS LCTRIC VHICL ONLY ASOLIN VHICL ONLY S RAR SUSPNSION - SCTION 6 FOR MOUNTIN Page 5-

41 ITM PART NO. DSCRIPTION 3 4 BRAK ASSMBLY CLUSTR, RIHT BRAK (INCLUDS ITMS - 9) CLUSTR, LFT BRAK (INCLUDS ITMS - 9) ASSMBLY, BACKIN PLAT, RIHT (INCLUDS ITMS, 3 AND 4) ASSMBLY, BACKIN PLAT, LFT (INCLUDS ITMS, 3 AND 4) MCHANISM, ADJUSTIN, RIHT MCHANISM, ADJUSTIN, LFT WASHR WASHR, PLAT COVR, DUST PACKA, BRAK SHO (FOUR PICS) KIT, SHO RTAINR (FOUR PICS) PACKA, BRAK SPRIN (FOUR PICS) ASSMBLY, LVR, RIHT ASSMBLY, LVR, LFT NUT, HX HAD LOCK, RAD 8, 5/ BOLT, BRAK CLUSTR MOUNTIN PIN, CLVIS, 5/ PIN, COTTR, 3/3 x HANR, BRAK CABL (ASOLIN VHICL ONLY) HANR, BRAK CABL (LCTRIC VHICL ONLY) DRUM, BRAK CLIP, /... QTY AS QTY LC 5 Page 5-3

42 FLOORBOARD RMOVD FOR CLARITY 9 PLACS STOP PLACS 0 4 PLACS PLACS 6 5 RFRNC ASOLIN VHICL FRAM PLACS Page 5-4

43 ITM PART NO. DSCRIPTION 3 4 BRAK PDAL AND CABL ASSMBLY 0004 NUT, HX, 5/ SPACR, QUALIZR KIT, QUALIZR AND PIVOT LIMITR (INCLUDS ITM 4)... 4 N/A PIN, QUALIZR PIVOT NUT, NYLON LOCK, 5/ KIT, BRAK CABL (INCLUDS ITMS 7-9) CLIP, / PIN, COTTR, 3/3 x PIN, CLVIS, 5/ KIT, BRAK PDAL (INCLUDS ITMS - 6, 9 AND 3) SPRIN, BRAK RTURN SCRW, SLOTTD HX WASHR HAD, #0-6 x / PAD, BRAK PDAL ROD, QUALIZR BOLT, HX HAD SHOULDR, 3/8 x NUT, NYLON LOCK, 5/ KIT, PARK BRAK (INCLUDS ITMS 7- AND ITM 4 ON PA 5-7)... 7 N/A ROD AND PAWL PIN, COTTR, 7/64 x / NUT, PUSH, 5/ SLV, PARK BRAK ROD JOINT, BALL, / SPRIN, PARK BRAK TORSION SPACR, PARK BRAK STOP, BRAK NUT, HX, / PACKA, BRAK MOUNTIN BLOCK (CONTAINS UPPR AND LOWR FOR LFT AND RIHT SIDS) WASHR, FLAT, 5/ SCRW, HX HAD CAP, 5/6-8 x / KIT, PARK BRAK PDAL (INCLUDS ITMS 30-33) BUSHIN, NYLON SCRW, SLOTTD HX WASHR HAD, #0-6 x / NUT, PUSH, 3/ PAD, PARK BRAK... QTY AS QTY LC 5 Page 5-5

44 5 4 4 PLACS ASOLIN VHICL FRAM FOR RFRNC ONLY FLOORBOARD RMOVD FOR CLARITY 4 PLACS PLACS 3 4 Page 5-6

45 ITM PART NO. DSCRIPTION 3 4 ACCLRATOR PDAL ASSMBLY SUB-ASSMBLY, ACCLRATOR PDAL (INCLUDS ITM AND 3) PAD, PDAL SCRW, SLOTTD HX WASHR HAD, #0-6 x / SCRW, HX CAP, 3/8-6 x / WASHR, FLAT, 5/ ASSMBLY, ACCLRATOR PIVOT ROD NUT, NYLON LOCK, 5/ WASHR, FLAT, / BARIN, PIVOT SUPPORT NUT, FLAND LOCK, / RTAINR, SPRIN SPRIN, RTURN CUP, SPRIN BUMPR, RTURN SPRIN NUT, NYLON LOCK, / STUD, BALL ASSMBLY, ACCLRATOR ROD (POWRDRIV SYSTM 48 AND V-LID 36 VOLT VHICLS) (INCLUDS ITMS 8 AND 9) ASSMBLY, ACCLRATOR ROD (ASOLIN VHICL ONLY) (INCLUDS ITMS 8 AND 9) NUT, UNF HX JAM, / JOINT, SPRIN-LOADD BALL SPACR SUPPORT, ACCLRATOR PIVOT ROD SCRW, HX CAP, /4-0 x / NUT, NYLON LOCK, 3/ KIT, PARK BRAK (INCLUDS ITM 4 AND ITMS 7- ON PA 5-4)... 4 N/A ASSMBLY, RATCHT WASHR, FLAT, 3/8... QTY AS QTY LC 5 Page 5-7

46 5 Page 5-8

47 STRIN, FRONT AND RAR SUSPNSION 6

48 Page 6-6 ;y ;; ; yy y ; ;; ;; y yy yy PLACS PLACS PLACS 3 PLACS

49 ITM PART NO. DSCRIPTION 3 4 STRIN COLUMN 0386 JOINT, COMPOUND STRIN (INCLUDS ITMS AND 3) SCRW, HX HAD CAP, M8 x.5 x 30MM WASHR, LOCK, 5/ MOUNT, STRIN COLUMN, LFT HAND MOUNT, STRIN COLUMN, RIHT HAND SCRW, HX WASHR HAD THRAD FORMIN, 5/6-8 x WASHR, FLAT, 3/ SCRW, HX HAD CAP, 3/8-6 x NUT, NYLON LOCK, 3/ SCRW, HX WASHR HAD THRAD FORMIN, 5/6-8 x 3/ WASHR, FLAT, 5/ BOOT, STRIN COLUMN ASSMBLY, STRIN COLUMN (INCLUDS ITMS 4-3) RIN, RTAININ WASHR, STL, 5/ SPRIN, COMPRSSION WD ASSMBLY, BARIN SAT, BARIN SHAFT, STRIN COLUMN COLUMN, ALUMINUM STRIN RIN, RTAININ SAL, BARIN COVR, STRIN COLUMN WHL, STRIN NUT, NYLON LOCK, 5/ ASSMBLY, SCORCARD PLAT (INCLUDS ITMS 8-3) SCRW, ROUND HAD, # - 4 x SPRIN, TAPRD COMPRSSION RIP, PNCIL CLIP, SCOR CARD SCRW, PHILLIPS, TYP A, # - x 5/8... QTY AS QTY LC 6 Page 6-3

50 PLACS PLACS ;; yy ;; yy Page 6-4

51 ITM PART NO. DSCRIPTION 3 4 STRIN AR ASSMBLY ASSMBLY, STRIN AR BOX (INCLUDS ITMS - ) SAL, DUST, RIHT WRAP, TI ASSMBLY, INNR BALL JOINT WASHR, TAB... 5 N/A BUSHIN, RACK... 6 N/A BOX, STRIN AR... 7 N/A BARIN, LOWR PINION... 8 N/A PINION, STRIN BARIN, UPPR PINION RIN, C-TYP STOP RIN, SNAP SAL, DUST, STRIN PINION UID, STRIN RACK SPRIN, YOK NUT, LOCK, RACK SCRW... 6 N/A SCRW, RACK UID... 7 N/A RACK, STRIN WASHR, STOP RIN, C-TYP STOP SAL, DUST, LFT O-RIN, DUST SAL RTAININ CAP, RACK ND DUST PIN, COTTR, 3/3 x BALL JOINT, LFT HAND THRAD (INCLUDS ITMS 5, 6 AND 7) FITTIN, THRAD FORM RAS, / NUT, HX SLOTTD, 3/ BOOT, DUST NUT, HX, LFT HAND THRAD, / LINK, RACK AND PINION DRA NUT, HX, M x BOLT, HX HAD, 3/8-6 x / WASHR, FLAT, 3/ NUT, DIMPLD LOCK, 3/ QTY AS QTY LC 6 Page 6-5

52 PLACS 8 8 RFRNC STRIN AR 5 4 PLACS PLACS PLACS PLACS 0 3 PLACS Page 6-6

53 ITM PART NO. DSCRIPTION 3 4 FRONT SUSPNSION, UPPR ASSMBLY, DLTA A-PLAT (INCLUDS ITMS, 3 AND 4) BUSHIN, URTHAN SLV, DLTA OUTR SLV, DLTA INNR NUT, NYLON LOCK, 3/ BALL JOINT NUT, HX, / BOLT, HX HAD, 3/8-6 x / NUT, DIMPLD LOCK, 3/ SCRW, HX CAP, 3/8-6 x / ROD, TI NUT, HX, LFT HAND THRAD, / BALL JOINT, LFT HAND THRAD STRAP, A-PLAT SHOCK ABSORBR, FRONT (ASOLIN VHICL ONLY) SHOCK ABSORBR, FRONT (LCTRIC VHICL ONLY) PLAT, SPRIN MOUNTIN BOLT, HX HAD, 3/8-6 x 4 / ASSMBLY, DLTA SHOCK AND AR SUPPORT SAL, DUST NUT, SLOTTD HX, 3/ PIN, COTTR, 3/3 x... QTY AS QTY LC 6 Page 6-7

54 6 RFRNC STRIN AR ASSMBLY PLACS PASSNR'S SID ONLY 5 DRIVR'S SID ONLY 4 PLACS PLACS Page 6-8

55 ITM PART NO. DSCRIPTION 3 4 FRONT SUSPNSION, LOWR ASSMBLY, LFT SPINDL (INCLUDS ITMS 3, 4 AND 5) ASSMBLY, RIHT SPINDL (INCLUDS ITMS 3, 4 AND 5) BUSHIN, BRONZ SPINDL BUSHIN, BRONZ FITTIN, RAS, / SPRIN, TAPRD LAF CCNTRIC NUT, HX, 3/ ASSMBLY, HUB (INCLUDS ITMS 0-3) PACKA, HUB BARIN STUD, LU, / SAL, DOUBL LIP COVR, DUST NUT, NYLON LOCK, 3/ SCRW, HX HAD CAP, 3/8-6 x 3/ CLVIS, UPPR DLTA NUT, NYLON LOCK, / WASHR, FLAT, / BARIN, THRUST WASHR, KINPIN WAV NUT, LU WASHR, FLAT, 3/ NUT, HX SLOTTD, 3/ PIN, COTTR, 5/3 x SCRW, HX HAD CAP, 3/8-6 x 3 3/ KINPIN BUSHIN, URTHAN BUSHIN, STL PLAT, FRONT SPRIN RTAINR SCRW, HX HAD CAP, 3/8-6 x / WASHR, LOCK, 3/ NUT, HX, 3/ QTY AS QTY LC 6 Page 6-9

56 6 BRAK CABL HANR MOUNTIN ASOLIN VHICL ONLY 7 ON ACH SID OF VHICL 7 ON ACH SID OF VHICL BRAK CABL HANR MOUNTIN LCTRIC VHICL ONLY PLACS 4 Page 6-0

57 ITM PART NO. DSCRIPTION 3 4 RAR SUSPNSION 0304 SHACKL, RAR SPRIN (ASOLIN VHICL) SHACKL, RAR SPRIN (LCTRIC VHICL) NUT, NYLON LOCK, 3/ BUSHIN, STL BUSHIN, URTHAN NUT, UNF HX, 3/ KIT, SHOCK ABSORBR (INCLUDS ITMS 7, 9 AND 0) SHOCK ABSORBR, RAR KIT, SHOCK ABSORBR CUSHION (INCLUDS ITMS 9 AND 0) N/A RTAINR, SHOCK ABSORBR CUSHION N/A CUSHION, SHOCK ABSORBR U-BOLT SPRIN, RAR LAF (ASOLIN VHICL) SPRIN, RAR LAF (LCTRIC VHICL) WASHR, FLAT, 7/ NUT, NYLON LOCK, 7/ SCRW, HX HAD CAP, 3/8-6 x 3 3/ PAD, SPRIN LFT PAD, SPRIN RIHT HANR, BRAK CABL (ASOLIN VHICL) HANR, BRAK CABL (LCTRIC VHICL)... QTY AS QTY LC 6 Page 6-

58 6 Page 6-

59 LCTRICAL SYSTM ASOLIN VHICL 7

60 WHIT RD / WHIT WHIT / BLACK RD YLLOW YLLOW FRAM ROUND YLLOW 3 WHIT RD / WHIT RD WHIT / BLACK YLLOW OIL LIHT BLACK BLU BLACK RVRS BUZZR RD / WHIT M+ BLACK RN M- KY SWITCH 3 LIMIT SWITCHS 5 ORAN FORWARD / RVRS ASSMBLY RD / WHIT BLACK RN WHIT 6 LIMIT SWITCHS 5 BLU BLACK WHIT/BLACK WHIT WHIT / BLACK 4 BLACK ORAN 7 BLU FRAM ROUND VOLTA RULATOR BLU 0 BLACK RD RD ORAN 8 BLACK YLLOW FUS BLOCK WHIT / BLACK BLACK BLACK 9 YLLOW RD RD 7 8 SOLNOID RPM LIMITR RD WHIT BRAIDD ROUND WIR WHIT BRAIDD ROUND WIR A YLLOW WHIT / BLACK A F YLLOW WHIT NIN DF F RN 6 STARTR / NRATOR YLLOW OIL SNDIN UNIT BATTRY FRAM ROUND 9 Page 7-

61 WIRIN - ASOLIN VHICL ITM PART NO. DSCRIPTION QTY WIR HARNSS (INCLUDS ITMS - )... N/A WIR ASSMBLY, #8 RD/WHIT... N/A WIR ASSMBLY, #8 YLLOW... 3 N/A WIR ASSMBLY, #8 YLLOW AND #6 BLU... 4 N/A WIR ASSMBLY, #8 WHIT/BLACK AND #8 WHIT... 5 N/A WIR ASSMBLY, #8 RN... 6 N/A WIR ASSMBLY, #8 BLACK WIR ASSMBLY, #6 WHIT... 8 N/A WIR ASSMBLY, #6 RD AND #6 ORAN... 9 N/A WIR ASSMBLY, #6 YLLOW WIR ASSMBLY, #6 RD... N/A WIR ASSMBLY, #8 YLLOW WIR ASSMBLY, #6 BLACK... 3 N/A WIR ASSMBLY, #8 BLACK... 4 N/A WIR ASSMBLY, #8 BLACK (PART OF RVRS BUZZR KIT)... 5 N/A WIR ASSMBLY, #6 ORAN (PART OF TH LCTRICAL COMPONNT BOX) WIR ASSMBLY, #6 BRAIDD ROUND WIR ASSMBLY, #0 RD (PART OF TH LCTRICAL COMPONNT BOX) WIR ASSMBLY, #0 BRAIDD ROUND WIR ASSMBLY, #6 RN... 7 Page 7-3

62 ClubCar ClubCar ClubCar Page 7-4

63 ITM PART NO. DSCRIPTION FORWARD AND RVRS SHIFTR ASSMBLY ASOLIN VHICL ASSMBLY, FORWARD AND RVRS SHIFTR (INCLUDS ITMS - 7) SCRW, MACHIN, #4-40 x / NUT, HX HAD, # WASHR, FLAT, # SWITCH, LIMIT SWITCH, LIMIT WASHR, LOCK, # PIN, ROLL, / BUSHIN, BRONZ WASHR, NYLON FLAT, # BAS, FORWARD AND RVRS SHIFTR KIT, NUTRAL LOCK-OUT CAM (INCLUDS ITM ) WASHR, FLAT SPRIN, FORWARD AND RVRS CAM RIN, RTAININ NUT, NYLON LOCK, / WLDMNT, FORWARD AND RVRS BLL CRANK STUD, BALL, /4-8 x / CABL, TRANSMISSION (INCLUDS ITMS 9 AND 0) NUT, HX, # JOINT, BALL SCRW, PHILLIPS OVAL COUNTRSUNK MACHIN, #8-3 x 5/ HANDL, FORWARD AND RVRS SWITCH SCRW, PHILLIPS TRUSS HAD, /4-0 x 3/ NUT, NYLON LOCK, / WASHR, FLAT, 3/ SCRW, PHILLIPS HAD, /4-0 x RTAINR, CABL WASHR, FLAT, / BRACKT, TRANSMISSION CABL SUPPORT SCRW, THRAD ROLLIN, /4-0 x 5/ QTY 7 Page 7-5

64 7 PLACS 0 RFRNC ACCLRATOR CABL ORAN WIR ASSMBLY PLACS PLACS 7 6 PLACS 5 PLACS PLACS PLACS RFRNC ACCLRATOR ROD PLACS FRONT OF VHICL Page 7-6

65 ITM PART NO. DSCRIPTION 3 4 LCTRICAL COMPONNT BOX ASOLIN VHICL BOX, LCTRICAL COMPONNT, COMPLT (INCLUDS ITMS - 5 AND S PA 7-3) COVR, LCTRICAL COMPONNT BOX SCRW, HI-LO, # - 6 x 5/ RIN, RTAININ CAM, LCTRICAL BOX BUSHIN, BRONZ WASHR, FLAT STUD, BALL, / ASSMBLY, BLL CRANK SHAFT NUT, NYLON LOCK, / NUT, HX, # WASHR, LOCK, # SWITCH, LIMIT SWITCH, LIMIT WASHR, FLAT, # N/A WIR ASSMBLY, #6 ORAN SCRW, HX HAD MACHIN, #4-40 x 5/ SCRW, HX WASHR HAD HI-LO, /4-5 x / ASSMBLY, VOLTA RULATOR NUT, HX, # NUT, HX, 5/ SOLNOID, VOLT FUS, 0 AMP WIR ASSMBLY, #0 RD BLOCK, FUS BOX, LCTRICAL COMPONNT BOLT, CARRIA, 5/6-8 x WASHR, FLAT, 5/ NUT, NYLON LOCK, 5/ QTY 7 Page 7-7

66 PLACS OFF ON 7 M- 4 PLACS M+ 0 AS SN FROM FRONT DRIVR'S SID OF VHICL, BODY RMOVD OFF ON PLACS Page 7-8

67 ITM PART NO. DSCRIPTION 3 4 LCTRICAL COMPONNTS ASOLIN VHICL KIT, RVRS BUZZR (INCLUDS ITMS, 3 AND 4) SCRW, PAN HAD HI-LO, #4-4 x 5/ BUZZR, RVRS... 4 N/A WIR ASSMBLY, #8 BLACK NUT, K LOCK, # BOLT, HX WASHR HAD, #6-3 x / ASSMBLY, SCRW AND WASHR SWITCH, KY WASHR NUT, KY SWITCH CAP, KY SWITCH (BLACK) KY (PAIR) LIHT, OIL WARNIN RTAINR, HARNSS... 3 QTY 7 Page 7-9

68 7 PLACS 30 3 PLACS 7 9 PLACS PLACS 4 PLACS 4 PLACS PLACS 4 8 PLACS AT F AND F TRMINALS PLACS AT A AND A TRMINALS DF TRMINAL 6 PLACS PLACS Page 7-0

69 STARTR/NRATOR ASSMBLY ITM PART NO. DSCRIPTION QTY STARTR/NRATOR (CLOCKWIS ROTATION) (INCLUDS ITMS - 30) HOUSIN, FILD COIL ASSMBLY, ARMATUR (INCLUDS ITMS 3, 4 AND 5) RTAINR, BARIN BALL BARIN, OUTPUT SHAFT COMMUTATOR, BALL BARIN SPACR, 5/ KY, WOODRUFF KIT, PULLY NUT AND SCRW (INCLUDS ITMS 9 - )... 9 N/A WASHR, LOCK, M N/A NUT, HX, M4 x... N/A SCRW, CROSS - RCSSD, M5 x.8 x 8MM SCRW, CROSS - RCSSD, M5 x.8 x 6MM (WITH LOCK WASHR) ND BLL, OUTPUT SHAFT ST, POL (ST OF 4) SCRW, POL PIC (ST OF 4) ASSMBLY, FILD COIL ST, F INSULATOR PACKA, TRMINAL HARDWAR (F AND F) ST, DF INSULATOR PACKA, TRMINAL HARDWAR (DF) HOLDR, BRUSH (INCLUDS ITMS - 5) SPRIN, BRUSH PACKA, BRUSH (INCLUDS 4 BRUSHS, 4 SCRWS, 4 WASHRS) ASSMBLY, BRUSH CONNCTOR A CONNCTOR (ST OF ) PACKA, TRMINAL HARDWAR (A AND A) COVR, BRUSH INSPCTION PORT (ST OF 4) (INCLUDS ITM 8) COVR, BRUSH INSPCTION PORT, WITH DRAIN ND BLL, COMMUTATOR BOLT, CLAMP, M6 x x 80MM PULLY (SILVR COLOR)... 7 Page 7-

70 7 7 6 FRAM CONNCTION 5 4 A TRMINAL AS VIWD FROM TH DRIVR'S SID OF VHICL A TRMINAL F TRMINAL PLACS F DF AS VIWD FROM TH PASSNR'S SID OF VHICL 0 Page 7-

71 STARTR/NRATOR MOUNTIN ITM PART NO. DSCRIPTION QTY STARTR/NRATOR BRACKT, MOUNTIN, F BLT BRACKT, ADJUSTIN NUT, NYLON LOCK, 3/ WASHR, FLAT, 5/ BOLT, HX HAD, 3/8-6 x / SCRW, HX HAD CAP, M8 x.5 x 4MM WASHR, LOCK, 5/ SCRW, TORX HAD, M8 x.5 x 8MM BOLT, CARRIA, 5/6-8 x NUT, HX, 5/ WIR ASSMBLY, #6 RN WIR ASSMBLY, #6 BRAIDD ROUND NUT, NYLON LOCK, 5/ WASHR, FLAT, 5/ SCRW, HX HAD CAP, 5/6-8 x 3/ Page 7-3

72 ClubCar ClubCar 7 AS SN FROM PASSNR'S SID OF VHICL TO NATIV BATTRY POST TRMINAL AS SN FROM DRIVR'S SID OF VHICL 8 Page 7-4

73 BATTRY - ASOLIN VHICL ITM PART NO. DSCRIPTION QTY BATTRY, VOLT SPACR, BATTRY TRMINAL BOLT SCRW, HX HAD CAP, STAINLSS STL, 3/8-6 x / BOLT, HX HAD, 5/6-8 x CLAMP, BATTRY SCRW, HX CAP, 5/6-8 x 3/ WASHR, FLAT, 5/ NUT, NYLON LOCK, 5/ Page 7-5

74 7 Page 7-6

75 F 90 NIN 8

76 PLACS PLACS PLACS 4 PLACS 5 6 PLACS 7 CARBURTOR RMOVD FOR CLARITY PLACS Page 8-

77 ITM PART NO. DSCRIPTION 3 4 F 90 NIN F 90 OHV ASOLIN NIN (CLOCKWIS ROTATION) WITH CARBURTOR (DOS NOT INCLUD ITMS 5 THROUH 8) BOLT, -NDD, M6 x x 9MM WASHR, FLAT, 6MM SHROUD, NIN, F BOLT, FLAND, M6 x x MM NUT, M6 x BOLT, -NDD, M6 x x 7MM SHROUD, NIN, F 90 (LOWR) SCRW, -NDD, M6 x x 46MM HOUSIN, FAN SHROUD, NIN, F 90 (UPPR) BRACKT O-RIN TUB, OIL FILLR, F DIPSTICK NUT, M6 x WIR ASSMBLY, #0 BRAIDD ROUND SCRW, PAN HAD, M6 x x 4MM SHROUD, FAN... QTY 8 Page 8-3

78 PLACS 7 3 PLACS ;; yy PLACS Page 8-4

79 F 90 NIN ITM PART NO. DSCRIPTION QTY FLYWHL FAN, FLYWHL, RAY SCRW, FLAND HX HAD, M6 x x 0MM WASHR, FLAT, 6MM NUT, HX, M6 x PLAT, FLYWHL FAN KY BOLT, FLAND, M5 x.8 x 5MM COIL, INITION (WITH INTRNAL INITR) ROMMT TUB, 7MM x 70MM ASSMBLY, PLU CAP SPARK PLU - OHV BOLT, FLAND, M6 x x MM CLAMP MOUNT, RPM LIMITR DAMPR, RPM LIMITR LIMITR, RPM - OHV BRACKT, RPM LIMITR CLAMP SCRW, CROSS PAN HAD, M5 x.8 x 8MM SCRW, CROSS PAN HAD SLF-TAPPIN, M5 x.8 x MM CLAMP CLAMP WIR, LAD... 8 Page 8-5

80 PLACS ;y PLACS Page 8-6

81 F 90 NIN ITM PART NO. DSCRIPTION QTY ASSMBLY, OIL FILTR, OHV BRACKT, OIL FILTR BOLT, FLAND HX HAD, M6 x x 40MM O-RIN, OIL FILTR MOUNT PLU, DRAIN, F ASKT, DRAIN PLU SCRW, FLAND HX HAD, M6 x x MM COVR, PUMP ASKT, OIL PUMP PLAT, OIL PUMP PUMP, OIL, AND ROTOR SAT, VALV BALL, STL, PRSSUR RLIF SPRIN... 8 Page 8-7

82 PLACS XHAUST INTAK 7 PLACS AT XHAUST CONNCTION PLACS 3 4 PLACS PLACS 6 PLACS 8 Page 8-8

83 F 90 NIN ITM PART NO. DSCRIPTION QTY CAS, ROCKR ASKT, ROCKR CAS BOLT, FLAND, M6 x x 35MM O-RIN NUT, HX, M5 x SCRW, STUD, M5 x ARM, ROCKR COLLT RTAINR, VALV SPRIN SPRIN, NIN VALV ASSMBLY, CYLINDR HAD, OHV (INCLUDS ITMS AND 3) RIN, SNAP UID, VALV SAT, SPRIN SAL, VALV VALV, XHAUST VALV, INTAK SCRW, CROSS PAN HAD SLF-TAPPIN, M5 x.8 x MM PLAT VALV PIN BOLT, STUD, M8 x.5 x 9MM SHAFT, ROCKR ROD, PUSH WASHR, FLAT, M CIRCLIP, TYP BOLT, FLAND, M8 x.5 x 45MM ASKT, HAD... 8 Page 8-9

84 8 PLACS 5 7 CLAMP ONLY ;;; yyy ; y ; y ;; yy ; y ; y ; y PLACS 6 7 PLACS 8 0 PLACS PLACS 6 PLACS Page 8-0

85 F 90 NIN ITM PART NO. DSCRIPTION QTY CONNCTOR, CORD O-RIN CLAMP SCRW, CROSS PAN HAD SLF-TAPPIN, M5 x.8 x MM PIN BARIN, BALL SAL, CRANKSHAFT BOLT, -NDD, M8 x.5 x 69MM BOLT, FLAND, M8 x.5 x 45MM COVR, CRANKCAS ASKT, CRANKCAS COVR BOLT, FLAND, M6 x x MM BRACKT, OIL LVL SWITCH SNSOR, OIL LVL SCRW, CROSS PAN HAD, M4 x.7 x 8MM BOLT, FLAND, M5 x.8 x 8MM PLAT, OIL FILTR SCRN SCRN, OIL FILTR CAMSHAFT, COMPLT TAPPT... 8 Page 8-

86 PLACS PLACS 4 PLACS Page 8-

87 ITM PART NO. DSCRIPTION 3 4 F 90 NIN SAL, OIL CRANKCAS, COMPLT, OHV RIN, SNAP PIN, PISTON PISTON, STANDARD PISTON,.5MM OVRSIZD PISTON,.50MM OVRSIZD RIN ST, PISTON, STANDARD RIN ST, PISTON,.5MM OVRSIZD RIN ST, PISTON,.50MM OVRSIZD ASSMBLY, CONNCTIN ROD, STANDARD (INCLUDS ACH OF ITM 8) ASSMBLY, CONNCTIN ROD,.50MM UNDRSIZD (INCLUDS ACH OF ITM 8) BOLT, HX HAD, M7 x x 36MM CRANKSHAFT, OHV (INCLUDS ITMS 0, AND ) AR, HLICAL AR, SPUR ASSMBLY, CONNCTIN ROD (INCLUDS ITM 3) BARIN, PLAIN KY SHIM, CRANKSHAFT,.3MM THICK... A/R SHIM, CRANKSHAFT,.8MM THICK... A/R SHIM, CRANKSHAFT,.3MM THICK... A/R SHIM, CRANKSHAFT,.8MM THICK... A/R SHIM, CRANKSHAFT,.33MM THICK... A/R SHIM, CRANKSHAFT,.38MM THICK... A/R SHIM, CRANKSHAFT,.43MM THICK... A/R SHIM, CRANKSHAFT,.48MM THICK... A/R SHIM, CRANKSHAFT,.53MM THICK... A/R SPACR BOLT, STUD, M6 x x MM NUT, FLAND, M6 x SHAFT, UID COUNTRBALANC O-RIN WIHT, COUNTRBALANC... QTY 8 Page 8-3

88 ClubCar 8 PLACS 3 4 PLACS FRONT OF VHICL RFRNC NIN SCTION PLACS 9 0 ClubCar PLACS 3 6 PLACS PLACS PLACS 6 7 PLACS PLACS RFRNC UNITIZD TRANSAXL SCTION Page 8-4

89 NIN MOUNTIN ITM PART NO. DSCRIPTION QTY NUT, NYLON LOCK, 5/ WASHR, FLAT, 5/ RTAINR, SNUBBR BOLT, CARRIA, 5/6-8 x SNUBBR NUT, HX LOCK, 5/6-4, UNF BRACKT, SNUBBR PLAT, MOUNTIN NUT, FLAN, M8 x SCRW, HX WASHR, 5/6-48 x 7/ SCRW, HX HAD CAP, M0 x.5 x 30MM STUD, M8 x SPACR STIFFNR, DRIV CLUTCH SID NUT, FLAN, M0 x WASHR, HAVY FLAT, 5/ SCRW, HX HAD CAP, M8 x.5 x 43MM STIFFNR, FLYWHL SID... 8 Page 8-5

90 8 Page 8-6

91 FUL, INTAK, AND OVRNOR SYSTMS 9

92 NIN RMOVD FOR CLARITY S ABOV AS TANK FUL PICKUP TUB TO NIN CRANKCAS Page 9-

93 FUL SYSTM ITM PART NO. DSCRIPTION QTY KIT, FUL TANK, (INCLUDS ITMS - 9) CAP, FUL TANK, NONVNTD (INCLUDS ITM 3) ASKT, FUL CAP ASSMBLY, FUL TANK VNT ROMMT, INSULATION LIN, BULK VNT (AVAILABL BY TH FOOT)... A/R CLIP, STUD BARB, VNT VALV, FUL PICKUP TUB WITH SHUT-OFF ASSMBLY, RAR FUL STRAP ASSMBLY, FRONT FUL STRAP PUMP, FUL IMPULS, SQUAR BODY PUMP, FUL IMPULS, SQUAR BODY RBUILD KIT STUD, FLUSH HAD, /4-0 x 3/ WASHR, LOCK, / NUT, HX, / CLAMP, HOS (BLACK) FILTR, PRIMARY FUL (WHIT) LIN, BULK FUL (YLLOW)... A/R LIN, BULK FUL (BLACK)... A/R 0649 CLAMP, HOS (RD) FILTR, SCONDARY FUL (BLU) CLAMP, HOS, 3/ NUT, U-TYP SPD, / CLAMP, HOS T-FITTIN SCRW, PHILLIPS TRUSS HAD, /4-0 x CLAMP, HOS (RN) Page 9-3

94 Page 9-4

95 CARBURTOR ASSMBLY ITM PART NO. DSCRIPTION QTY ASSMBLY, CARBURTOR (INCLUDS ITMS - ) ASSMBLY, IDL SCRW... 3 N/A ASSMBLY, PILOT AIR SCRW JT, PILOT, # ASSMBLY, FLOAT NOZZL, MAIN... STANDARD JTTIN: JT, MAIN, 0-3,000 FT... A/R JT, MAIN, 3,000-5,000 FT... A/R JT, MAIN, 5,000-8,000 FT... A/R JT, MAIN, 8,000-0,000 FT... A/R JT, MAIN, 0,000 FT AND ABOV... A/R ASKT, FLOAT CHAMBR ASSMBLY, FLOAT CHAMBR (INCLUDS ITM 0) ASSMBLY, SCRW ASSMBLY, BOLT... 9 Page 9-5

96 ;; yy 4 ;; yy ;; yy ;; yy ;; yy PLACS 0 Page 9-6

97 CARBURTOR INSTALLATION ITM PART NO. DSCRIPTION QTY ASKT, INSULATOR INSULATOR, CARBURTOR ASKT, CARBURTOR INSULATOR TO THROTTL BRACKT BRACKT, THROTTL UARD, OVRNOR SCRW, PAN/TORX HAD SLF-TAPPIN, #6-3 x / WASHR, FLAT, / WASHR, FLAT, 3/ NUT, NYLON LOCK, M6 x CLAMP, HOS ASKT, THROTTL BRACKT TO CARBURTOR SPRIN, THROTTL RTURN ASSMBLY, CARBURTOR CLAMP, HOS LIN, BULK VNT TUB, CRANKCAS VNT ASKT, CARBURTOR TO INTAK MANIFOLD PIP, INTAK SCRW, -NDD STUD, M6 x x 90MM NUT, FLAND, M6 x... 9 Page 9-7

98 Page 9-8

99 OVRNOR AND ACCLRATOR CABLS ITM PART NO. DSCRIPTION QTY CABL, ACCLRATOR CABL, OVRNOR CLAMP, CABL RTAININ NUT, FLAND HX, M8 x BRACKT, ACCLRATOR SUPPORT SCRW, THRAD ROLLIN, /4-0 x 5/ RIN PIN, OVRNOR CABL CLVIS PIN, HAIR SPRIN COTTR, /8 I.D. x 5/ BRACKT, SUPPORT BRACKT, OVRNOR CABL NIN SCRW, HX HAD CAP, M8 x.5 x 4 MM WASHR, LOCK, 5/ WASHR, FLAT, 5/ Page 9-9

100 9 PLACS RFRNC CARBURTOR PLACS ;y ;y PLACS Page 9-0

101 INTAK DUCT, CHOK, AND AIR BOX ASSMBLY ITM PART NO. DSCRIPTION QTY ASSMBLY, AIR BOX (INCLUDS ITMS - 4) SCRW, HI-LO HX HAD, #8 - / WASHR, STAINLSS STL, # LATCH, WIR ASSMBLY, AIR BOX TOP (INCLUDS ITMS 5 - ) CLIP LVR, CHOK DCAL, SRVIC... 8 N/A O-RIN, 5/6 (RD)... 9 N/A O-RIN, 3/8 (RN)... 0 N/A VALV, CHOK SPRIN, RTURN FILTR, AIR BOTTOM, AIR BOX SAL, INTAK CLAMP, HOS (AIR INTAK) HOS, INTAK SCRW, HI-LO, # x / POSITIONR, CHOK ASSMBLY, CHOK BUTTON (INCLUDS ITMS 0, AND ) UID, CHOK LVR SPRIN, COMPRSSION LVR, CHOK WASHR, FLAT, / SCRW, HI-LO, # - 6 x 5/ ASSMBLY, AIR DUCT RIVT, POP, 3/ WASHR, FLAT, # AIR DUCT RPAIR KIT (NOT SHOWN)... A/R 9 Page 9-

102 9 Page 9-

103 XHAUST SYSTM 0

104 ;; yy PLACS PLACS RFRNC NIN MOUNTIN SCTION 8 Page 0-

105 XHAUST SYSTM ITM PART NO. DSCRIPTION QTY SYSTM, XHAUST BRACKT, MUFFLR MOUNTIN WASHR, FLAT, / WASHR, LOCK, / SCRW, HX HAD, /4-0 x 3/ CLAMP, MUFFLR SCRW, HX HAD CAP, M8 x.5 x 4MM WASHR, LOCK, 5/ WASHR, FLAT, 5/ NUT, HX, M8 x WASHR, LOCK, 8MM ASKT, XHAUST... 0 Page 0-3

106 0 Page 0-4

107 TORQU CONVRTR

108 Page -

109 DRIV CLUTCH ITM PART NO. DSCRIPTION QTY ASSMBLY, DRIV CLUTCH (INCLUDS ITMS - 7) KIT, DRIV CLUTCH WIHT ASSMBLY, FIXD FAC (INCLUDS ITMS 3 AND 4)... 3 N/A PULLY... 4 N/A SCRW, WASHR HAD HX MACHIN BARIN, IDLR RTAINR, SPRIN SPRIN, DRIV CLUTCH - BLACK SPACR, FIXD FAC SHAFT RIN, RTAININ ASSMBLY, DRIV HUB PLU, DRIV CLUTCH KIT, DRIV CLUTCH BUTTON WASHR, THRUST RIN, SPIRAL BACK-UP ASSMBLY, MOVABL FAC (INCLUDS ITMS 6 AND 7)... 6 N/A BUSHIN RTAINR BLT, DRIV BLT, STARTR/NRATOR SCRW, HX HAD CAP, 3/8-4 x 5 / (LFT HAND THRADS) WASHR, MOUNTIN - RN... Page -3

110 Page -4

111 DRIVN CLUTCH ITM PART NO. DSCRIPTION QTY ASSMBLY, DRIVN CLUTCH (INCLUDS ITMS - 8) RIN, RTAININ KY CAM SPRIN - RN KIT, BUTTON ASSMBLY, MOVABL FAC, WITH BUSHIN ASSMBLY, FIXD FAC KY, SQUAR TRANSMISSION BLT, DRIV SCRW, HX HAD CAP, 5/6-8 x 3/ WASHR, MOUNTIN - YLLOW... Page -5

112 Page -6

113 UNITIZD TRANSAXL ASOLIN VHICL

114 ClubCar ClubCar RFRNC FORWARD AND RVRS SHIFTR ASOLIN SCTION ClubCar 3 5 RFRNC AXL TUBS ON PA -6 6 Page -

115 UNITIZD TRANSAXL - ASOLIN VHICL ITM PART NO. DSCRIPTION QTY BRACKT, TRANSMISSION CABL SUPPORT SCRW, THRAD ROLLIN, /4-0 x 5/ NUT, NYLON LOCK, # WASHR, FLAT, # STUD, BALL, /4-8 x 9/ LVR, TRANSMISSION SHIFTR SCRW, HX WASHR HAD, #0-3 x 3/ NUT, NYLON LOCK, / KY, WOODRUFF ARM, OVRNOR LVR SCRW, SQUAR HAD, /4-0 x WASHR, FLAT NUT, NYLON LOCK, / UNITIZD TRANSAXL (INCLUDS ITMS 4-90) SHAFT, SHIFTR RIN, SNAP WASHR, FLAT SAL, OIL LVR, SHIFTR PIN, ROLL PIN, COTTR WASHR, FLAT SAL, OIL WASHR ARM, PIVOT AR CAS (RIHT) AR CAS (LFT) BOLT, FLAND, M8 x.5 x 40MM PIN, DOWL PLU, DRAIN (INCLUDS ITM 30) ASKT BRATHR ASKT, LIQUID, 8.8 OZ. (50 RAMS)... A/R Page -3