ILLUSTRATED PARTS LIST DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER EDITION CODE 0898A00000

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1 999 ILLUSTRATD PARTS LIST DS OLF CARS ASOLIN/LCTRIC MANUAL NUMBR DITION COD 0898A00000

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 999 Club Car DS Tranquility, DS 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 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 July 7, 998 Manual print code: 0898A00000

4 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 DCALS SCTION 4 DCALS ASOLIN VHICL 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/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 SHROUDS AND BRACKTS F 90 NIN INITION COMPONNTS AND FLYWHL F 90 NIN OIL CIRCULATION F 90 NIN CYLINDR HAD F 90 NIN CRANKCAS, CAMSHAFT AND OIL SNSOR DS olf Car Illustrated Parts List

5 CONTNTS F 90 NIN CRANKCAS AND CRANKSHAFT NIN MOUNTIN 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 AR CASS AND BRACKTS UNITIZD TRANSAXL, ASOLIN VHICL F&R TRANSMISSION AND AR RDUCTION UNITIZD TRANSAXL, ASOLIN VHICL DIFFRNTIAL AND AXLS LCTRICAL SYSTM LCTRIC VHICL SCTION 3 LCTRICAL COMPONNTS, FRONT BODY LCTRIC VHICL WIRIN V-LID 36-VOLT VHICL FORWARD/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/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/RVRS SWITCH, TOW/RUN SWITCH POWRDRIV PLUS VHICL BATTRIS, CHARR RCPTACL POWRDRIV PLUS VHICL SOLNOIDS, NRY DISPLACMNT MODUL POWRDRIV PLUS VHICL CONTROLLR, ONBOARD COMPUTR POWRDRIV PLUS VHICL BATTRY CHARR SCTION 4 ACCU-POWR CHARR, DOMSTIC V-LID 36-VOLT VHICL ACCU-POWR CHARR, XPORT, 30-VOLT 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 DS olf Car Illustrated Parts List

6 CONTNTS LCTRIC MOTOR SCTION 5 MOTOR V-LID 36-VOLT VHICL MOTOR POWRDRIV SYSTM 48 VHICL MOTOR POWRDRIV PLUS VHICL TRANSAXL LCTRIC VHICL SCTION 6 TRANSAXL, TYP LCTRIC VHICL TRANSAXL, TYP K LCTRIC VHICL DS olf Car Illustrated Parts List

7 MAINTNANC AND SRVIC TOOLS

8 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 DS olf Car Illustrated Parts List

9 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 DRIV CLUTCH 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. 999 DS olf Car Illustrated Parts List Page -3

10 PULS NIN TACHOMTR PT-000 Club Car POSTION RST WAVTK 5XL V 000 OFF 500 V m 000 k m 0 m 00 m 00k Ω 0k k 00 A V Ω! COM! 00nA MAX V FUSD Page DS olf Car Illustrated Parts List

11 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 STRIN COLUMN BARIN PRSS TOOL STRIN COLUMN RTAININ RIN TOOL TACHOMTR PAINT, TOUCH-UP BI PAINT, TOUCH-UP WHIT PAINT, TOUCH-UP RAY PAINT, TOUCH-UP DARK RN PAINT, TOUCH-UP CLASSIC BLU PAINT, TOUCH-UP BURUNDY TRANSMISSION TOOL KIT TRANSAXL PINION SAL TOOL TRANSAXL AXL SAL TOOL VALV CLARANC ADJUSTR SCRW HOLDR VALV UID RAMR (INCLUDS ITM 46) 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. 999 DS olf Car Illustrated Parts List Page -5

13 BODY AND TRIM

14 Dash Frame Front Body Of Car Frame Dash Center Dash 3 PLACS PLACS PLACS PLACS PLACS PLACS 0 7 Page DS olf Car Illustrated Parts List

15 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 RIVT, ALUMINUM POP, 3/ KIT, DRINK HOLDR (INCLUDS ITMS 3 AND 4) BOLT, HX HAD, /4-0 x 3/ U-NUT, / KIT, BAWLL PROTCTOR (INCLUDS ITM 6) FASTNR, PLASTIC BARRL KIT, RAR BUMPR (INCLUDS ITMS 8 - ) 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 4) FASTNR, PLASTIC BARRL... QTY AS QTY LC 999 DS olf Car Illustrated Parts List Page -3

16 PLACS PLACS PLACS Club Car PLACS PLACS 8 PLACS 5 Page DS olf Car Illustrated Parts List

17 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 DARK RN BODY, FRONT CLASSIC BLU BODY, FRONT BURUNDY BODY, FRONT WITH HADLIHT OPNIN BI BODY, FRONT WITH HADLIHT OPNIN WHIT BODY, FRONT WITH HADLIHT OPNIN RAY BODY, FRONT WITH HADLIHT OPNIN DARK RN BODY, FRONT WITH HADLIHT OPNIN CLASSIC BLU BODY, FRONT WITH HADLIHT OPNIN BURUNDY TRIM, FRONT BODY BOLT, CARRIA, 5/6-8 x... 4 WASHR, FLAT, 5/ SCRW, FLAN LOCK T-NUT, SLAB BAS (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 999 DS olf Car Illustrated Parts List Page -5

18 FRONT SAT SUPPORT VRTICAL STRUT 3 4 PLACS PLACS PLACS ACH SID OF VHICL 4 ACH SID OF VHICL PLACS PLACS ACH SID OF VHICL 3 5 PLACS Page DS olf Car Illustrated Parts List

19 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, / DOOR, ACCSS BLACK DOOR, ACCSS BI NUT, BLIND, / BODY BI BODY WHIT BODY RAY BODY DARK RN BODY CLASSIC BLU BODY BURUNDY BODY WITH TAILLIHT OPNIN BI BODY WITH TAILLIHT OPNIN WHIT BODY WITH TAILLIHT OPNIN RAY BODY WITH TAILLIHT OPNIN DARK RN BODY WITH TAILLIHT OPNIN CLASSIC BLU BODY WITH TAILLIHT OPNIN BURUNDY SUPPORT, FRONT BODY 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 999 DS olf Car Illustrated Parts List Page -7

20 FRONT SAT SUPPORT VRTICAL STRUT 3 PLACS PLACS 5 PLACS 8 PLACS ACH SID OF VHICL 0 5 ACH SID OF VHICL ACH SID OF VHICL Page DS olf Car Illustrated Parts List

21 RAR BODY AND FNDR LCTRIC VHICL ITM PART NO. DSCRIPTION SCRW, PHILLIPS HAD, /4-0 x PLAT, BODY KICK U-NUT, / PLAT, BODY HIN WASHR, FLAT, / 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 DARK RN BODY CLASSIC BLU BODY BURUNDY BODY WITH TAILLIHT OPNIN BI BODY WITH TAILLIHT OPNIN WHIT BODY WITH TAILLIHT OPNIN RAY BODY WITH TAILLIHT OPNIN DARK RN BODY WITH TAILLIHT OPNIN CLASSIC BLU BODY WITH TAILLIHT OPNIN BURUNDY DOOR, ACCSS BLACK DOOR, ACCSS BI NUT, BLIND, / SUPPORT, FRONT BODY WASHR, FLAT, TYP B, /4... QTY AS QTY LC 999 DS olf Car Illustrated Parts List Page -9

22 PLACS 9 8 PLACS PLACS 4 PLACS PLACS PLACS 5 6 RFRNC RAR BODY AND FNDR 7 4 PLACS Page DS olf Car Illustrated Parts List

23 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, DRIVR SID... 9 N/A ASSMBLY, ARMRST, PASSNR SID BUMPR, SAT SCRW, WASHR HAD TAP, # ASKT, SAT, SHORT (ASOLIN VHICL ONLY) ASKT, SAT, LON (ASOLIN VHICL ONLY) WASHR, FLAT, STAINLSS STL, # SCRW, HX HAD CAP, /4-0 x 3/4 (WITH PATCH) PLAT, SAT HIN, STAINLSS STL RIVT, POP, STAINLSS STL, 3/ QTY AS QTY LC 999 DS olf Car Illustrated Parts List Page -

24 3 PLACS PLACS PLACS PLACS PLACS PLACS PLACS 6 4 PLACS Page DS olf Car Illustrated Parts List

25 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 SPACR, BODY 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 -/ QTY AS QTY LC 999 DS olf Car Illustrated Parts List Page -3

27 WHLS AND TIRS 3

28 STANDARD TRAD PRMIUM TRAD XTRA TRACTION Page DS olf Car Illustrated Parts List

29 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) 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) 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 DS olf Car Illustrated Parts List Page 3-3

31 DCALS 4

32 4 DRIVR / PASSNR WARNIN DCAL WARNIN! RAD AND FOLLOW THS WARNINS AND TH OPRATIN INSTRUCTIONS BFOR USIN VHICL. FAILUR TO DO SO CAN CAUS SVR INJURY OR DATH. Operation from driver side by authorized persons only and only in designated areas - not on public roads. DO NOT start vehicle until all occupants (two () per seat maximum) are seated. Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times. Drive slowly in turns and straight up and down slopes. Never stand in front of or behind vehicle. DO NOT operate while under the influence of alcohol or drugs. DO NOT leave children unattended on vehicle at any time. CCI KY SWITCH OFF ON 3 OPRATIN INSTRUCTIONS Read Owner's Manual and safety warnings located on dash panel prior Study and understand controls. Make sure wheels are turned in desired direction. Turn key to ON position and be sure nothing is in your path While vehicle is stopped, select direction by placing shift lever or switch in desired position: F Forward N Neutral R Reverse (Buzzer will sound) Vehicle will start moving when accelerator pedal is depresse Slowly depress accelerator pedal to increase speed. Park brake release when accelerator pedal is depressed. To stop, release accelerator pedal and depress brake pedal. After stopping, firmly depress park brake until it locks. Place forward and reverse switch in neutral position. Turn key OFF and remove key when not in use. CCI OPRATIN INSTRUCTIONS DCAL WARNIN WARNIN Negative frame ground. Can cause severe injury. xcessive speed. Do not contact positive (+) battery post or cable to frame. Can cause severe injury or death. Disconnect negative battery lead first. Do not tamper with engine governor adjustmen CCI WARNIN ASOLIN XPLOSION / FIR. CAN CAUS SVR INJURY OR DATH. NO SMOKIN, SPARKS, OR OPN FLAM. STOP NIN, ALLOW TO COOL BFOR RFULIN. TURN FUL VALV ( ) ON DURIN OPRATION. ( ) OFF DURIN STORA OR TRANSPORT. CCI ASOLIN DANR DCAL (ON VHICL FRAM NAR FUL TANK) 4 KP CLAR WARNIN CAN CAUS SVR INJURY Rotating parts HOT manifold & muffler MOVIN PARTS AND HOT MANIFOLD DCAL (ON STARTR/NRATOR AND NIN) 5 CCI FRAM ROUND AND OVRNOR WARNIN DCAL (ON VHICL FRAM NAR BATTRY) 6 7 INRSOLL-RAND DCAL (ON BODY PANL) Page DS olf Car Illustrated Parts List

33 ITM PART NO. DSCRIPTION 3 4 DCALS ASOLIN VHICL DCAL, DRIVR/PASSNR WARNIN DCAL, KY SWITCH DCAL, OPRATIN INSTRUCTIONS DCAL, ASOLIN DANR DCAL, MOVIN PARTS AND HOT MANIFOLD WARNIN DCAL, FRAM ROUND AND OVRNOR WARNIN DCAL, INRSOLL-RAND (OLD)... QTY AS QTY LC DS olf Car Illustrated Parts List Page 4-3

34 4 DRIVR / PASSNR WARNIN DCAL WARNIN! RAD AND FOLLOW THS WARNINS AND TH OPRATIN INSTRUCTIONS BFOR USIN VHICL. FAILUR TO DO SO CAN CAUS SVR INJURY OR DATH. Operation from driver side by authorized persons only and only in designated areas - not on public roads. DO NOT start vehicle until all occupants (two () per seat maximum) are seated. Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times. Drive slowly in turns and straight up and down slopes. Never stand in front of or behind vehicle. DO NOT operate while under the influence of alcohol or drugs. DO NOT leave children unattended on vehicle at any time. CCI KY SWITCH OFF ON 3 OPRATIN INSTRUCTIONS Read Owner's Manual and safety warnings located on dash panel prio Study and understand controls. Make sure wheels are turned in desired direction. Turn key to ON position and be sure nothing is in your pat While vehicle is stopped, select direction by placing shift lever or switch in desired position: F Forward N Neutral R Reverse (Buzzer will sound Vehicle will start moving when accelerator pedal is depress Slowly depress accelerator pedal to increase speed. Park brak release when accelerator pedal is depressed. To stop, release accelerator pedal and depress brake pedal. After stopping, firmly depress park brake until it locks. Place forward and reverse switch in neutral position. Turn key OFF and remove key when not in use. CCI OPRATIN INSTRUCTIONS DCAL MOTOR BRAKIN DCAL 4 IMPORTANT NOTIC VHICL QUIPPD TO LIMIT DOWNHILL SPD WARNIN Maximum vehicle speed is limited during downhill operation with accelerator pedal depressed. Vehicle will brake gently when accelerator pedal is released. System is activated only when tow switch is in the "RUN" position. When towing vehicle, tow switch must be in the "TOW" position. CCI 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 BATTRY DANR DCAL (ON BODY UNDR SAT) 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 7 TOW SWITCH WARNIN DCAL (ON TOW SWITCH BRACKT UNDR SAT) 9 INRSOLL-RAND DCAL WARNIN TOW RUN 8 PLAC TOW SWITCH IN "TOW" POSITION BFOR: TOWIN XTNDD STORA SRVICIN DISCONNCTIN BATTRIS FAILUR TO DO SO COULD RSULT IN DAMA TO VHICL OR BATTRY XPLOSION. (POWRDRIV PLUS VHICL ONLY) CCI NOTIC DO NOT OPRAT VHICL WITHOUT COVR IN PLAC. DO NOT DIRCT WATR STRAM AT THIS SWITCH. CCI POTNTIOMTR CAUTION DCAL (ON WIPR SWITCH COVR INSID BATTRY COMPARTMNT) Page DS olf Car Illustrated Parts List

35 ITM PART NO. DSCRIPTION 3 4 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 DCAL, INRSOLL-RAND (OLD) DCAL, POTNTIOMTR CAUTION DCAL, TOW SWITCH (POWRDRIV PLUS VHICL)... QTY AS QTY LC DS olf Car Illustrated Parts List Page 4-5

37 BRAKS, PDAL, AND CABL ASSMBLIS 5

38 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 DS olf Car Illustrated Parts List

39 ITM PART NO. DSCRIPTION 3 4 BRAK ASSMBLY CLUSTR, BRAK, PASSNR SID (INCLUDS ITMS - 9) CLUSTR, BRAK, DRIVR SID (INCLUDS ITMS - 9) ASSMBLY, BACKIN PLAT, PASSNR SID (INCLUDS ITMS - 4) ASSMBLY, BACKIN PLAT, DRIVR SID (INCLUDS ITMS - 4) MCHANISM, ADJUSTIN, PASSNR SID MCHANISM, ADJUSTIN, DRIVR SID WASHR WASHR, PLAT COVR, DUST PACKA, BRAK SHO (FOUR PICS) KIT, SHO RTAINR (FOUR PICS) PACKA, BRAK SPRIN (FOUR PICS) ASSMBLY, LVR, PASSNR SID ASSMBLY, LVR, DRIVR SID 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) CLIP, / DRUM, BRAK... QTY AS QTY LC DS olf Car Illustrated Parts List Page 5-3

40 5 OFF ON 3 0 STOP 4 PLACS 5 4 FLOORBOARD RMOVD FOR CLARITY PLACS PLACS PLACS SRVIC PART BRAK PDAL HAS SCOND WLDMNT PLACS PLACS PLACS 8 6 Page DS olf Car Illustrated Parts List

41 ITM PART NO. DSCRIPTION 3 4 BRAK PDAL AND CABL ASSMBLY 4 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, 4 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 LATCH (INCLUDS ITMS 7 - AND 4 ON PA 5-6)... 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 BUMPR, RUBBR NUT, HX, / PACKA, BRAK MOUNTIN BLOCK (CONTAINS UPPR AND LOWR FOR DRIVR AND PASSNR 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 DS olf Car Illustrated Parts List Page 5-5

42 5 4 4 PLACS ASOLIN VHICL FRAM FOR RFRNC ONLY FLOORBOARD RMOVD FOR CLARITY 4 PLACS PLACS 3 4 Page DS olf Car Illustrated Parts List

43 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 LATCH (INCLUDS ITM 4 AND ITMS 7 - ON PA 5-4)... 4 N/A RACHT, PARK BRAK WASHR, FLAT, 3/8... QTY AS QTY LC DS olf Car Illustrated Parts List Page 5-7

45 STRIN, FRONT AND RAR SUSPNSION 6

46 , y,, yy yy, y,y PLACS PLACS 4 6 PLACS 3 PLACS 3 4 Page DS olf Car Illustrated Parts List

47 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/ KIT, STRIN COLUMN MOUNTIN BRACKT SCRW, PHILLIPS, TYP A, # - x 5/ 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... QTY AS QTY LC DS olf Car Illustrated Parts List Page 6-3

48 PLACS 3 3 PLACS ,, yy,, yy Page DS olf Car Illustrated Parts List

49 ITM PART NO. DSCRIPTION 3 4 STRIN AR ASSMBLY ASSMBLY, STRIN AR BOX (INCLUDS ITMS - 0) SAL, DUST, PASSNR SID WRAP, TI ASSMBLY, INNR BALL JOINT WASHR, TAB... 5 N/A BOX, STRIN AR... 6 N/A BARIN, LOWR PINION... 7 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... 5 N/A SCRW, RACK UID... 6 N/A RACK, STRIN WASHR, STOP RIN, C-TYP STOP SAL, DUST, DRIVR SID RIN, RTAININ PIN, COTTR, 3/3 x BALL JOINT, LFT-HAND THRAD (INCLUDS ITMS 3, 4 AND 5) 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, NYLON LOCK, 3/ QTY AS QTY LC DS olf Car Illustrated Parts List Page 6-5

50 6 PLACS RFRNC STRIN AR 5 4 PLACS PLACS PLACS PLACS 0 3 PLACS Page DS olf Car Illustrated Parts List

51 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 DS olf Car Illustrated Parts List Page 6-7

52 6 RFRNC STRIN AR ASSMBLY PLACS PASSNR SID ONLY 5 DRIVR SID ONLY 4 PLACS PLACS Page DS olf Car Illustrated Parts List

53 ITM PART NO. DSCRIPTION 3 4 FRONT SUSPNSION, LOWR ASSMBLY, SPINDL, DRIVR SID (INCLUDS ITMS 3, 4 AND 5) ASSMBLY, SPINDL, PASSNR SID (INCLUDS ITMS 3, 4 AND 5) BUSHIN, BRONZ SPINDL BUSHIN, BRONZ FITTIN, RAS, / SPRIN, TAPRD LAF (ASOLIN VHICL ONLY) SPRIN, TAPRD LAF (LCTRIC VHICL ONLY) 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 DS olf Car Illustrated Parts List Page 6-9

54 6 BRAK CABL HANR MOUNTIN ASOLIN VHICL ONLY 7 ON ACH SID OF VHICL 8 ON ACH SID OF VHICL BRAK CABL HANR MOUNTIN LCTRIC VHICL ONLY PLACS 4 Page DS olf Car Illustrated Parts List

55 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 DS olf Car Illustrated Parts List Page 6-

57 LCTRICAL SYSTM ASOLIN VHICL 7

58 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 WHIT 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 7 RD SOLNOID 8 RPM LIMITR RD WHIT BRAIDD ROUND WIR WHIT BRAIDD ROUND WIR A YLLOW WHIT / BLACK A F YLLOW WHIT DF F RN NIN 6 STARTR / NRATOR YLLOW OIL SNDIN UNIT BATTRY FRAM ROUND 9 Page DS olf Car Illustrated Parts List

59 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 DS olf Car Illustrated Parts List Page 7-3

60 ClubCar ClubCar NC NO COM ClubCar Page DS olf Car Illustrated Parts List

61 ITM PART NO. DSCRIPTION FORWARD/RVRS SHIFTR ASSMBLY ASOLIN VHICL ASSMBLY, FORWARD/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/RVRS SHIFTR KIT, NUTRAL LOCK-OUT CAM (INCLUDS ITM ) WASHR, FLAT SPRIN, FORWARD/RVRS CAM RIN, RTAININ NUT, NYLON LOCK, / WLDMNT, FORWARD/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/RVRS SWITCH SCRW, PHILLIPS TRUSS HAD, /4-0 x 3/ NUT, NYLON LOCK, / WASHR, WAV, 3/ SCRW, PHILLIPS HAD, /4-0 x RTAINR, CABL WASHR, FLAT, / BRACKT, TRANSMISSION CABL SUPPORT SCRW, THRAD ROLLIN, /4-0 x 5/ QTY DS olf Car Illustrated Parts List Page 7-5

62 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 DS olf Car Illustrated Parts List

63 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 DS olf Car Illustrated Parts List Page 7-7

64 PLACS OFF ON 7 M- 4 PLACS M+ 0 AS SN FROM FRONT DRIVR SID OF VHICL, BODY RMOVD OFF ON PLACS Page DS olf Car Illustrated Parts List

65 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 DS olf Car Illustrated Parts List Page 7-9

66 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 DS olf Car Illustrated Parts List

67 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 TRMINAL INSULATOR PACKA, TRMINAL HARDWAR (F AND F) ST, DF TRMINAL 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) DS olf Car Illustrated Parts List Page 7-

68 7 7 6 FRAM CONNCTION 5 4 A TRMINAL AS VIWD FROM DRIVR SID OF VHICL A TRMINAL F TRMINAL PLACS F DF AS VIWD FROM PASSNR SID OF VHICL 0 Page DS olf Car Illustrated Parts List

69 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... 4 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/ DS olf Car Illustrated Parts List Page 7-3

70 ClubCar 7 AS SN FROM PASSNR SID OF VHICL 3 4 ClubCar 5 TO NATIV BATTRY POST TRMINAL AS SN FROM DRIVR SID OF VHICL Page DS olf Car Illustrated Parts List

71 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/ SCRW, THRAD-FORMIN, 5/6-8 x 3/ DS olf Car Illustrated Parts List Page 7-5

73 F 90 NIN 8

74 PLACS PLACS PLACS 4 PLACS 5 6 PLACS 7 CARBURTOR RMOVD FOR CLARITY PLACS Page DS olf Car Illustrated Parts List

75 ITM PART NO. DSCRIPTION 3 4 F 90 NIN SHROUDS AND BRACKTS 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 DS olf Car Illustrated Parts List Page 8-3

76 PLACS 7 3 PLACS ,, yy PLACS Page DS olf Car Illustrated Parts List

77 ITM PART NO. DSCRIPTION 3 4 F 90 NIN INITION COMPONNTS AND FLYWHL 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... QTY DS olf Car Illustrated Parts List Page 8-5

78 PLACS ,y PLACS Page DS olf Car Illustrated Parts List

79 ITM PART NO. DSCRIPTION 3 4 F 90 NIN OIL CIRCULATION 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... QTY DS olf Car Illustrated Parts List Page 8-7

80 PLACS XHAUST INTAK 7 PLACS AT XHAUST CONNCTION PLACS 3 4 PLACS PLACS 6 PLACS 8 Page DS olf Car Illustrated Parts List

81 ITM PART NO. DSCRIPTION 3 4 F 90 NIN CYLINDR HAD 0644 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... QTY DS olf Car Illustrated Parts List Page 8-9

82 8 PLACS 5 7,,, yyy, y, y, y CLAMP ONLY 3 4, y, y, y PLACS 6 7 PLACS 8 0 PLACS PLACS 6 PLACS Page DS olf Car Illustrated Parts List

83 ITM PART NO. DSCRIPTION F 90 NIN CRANKCAS, CAMSHAFT AND OIL SNSOR 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... QTY DS olf Car Illustrated Parts List Page 8-

84 PLACS PLACS 4 PLACS Page DS olf Car Illustrated Parts List

85 ITM PART NO. DSCRIPTION 3 4 F 90 NIN CRANKCAS AND CRANKSHAFT 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 ON ACH OF ITM ) AR, HLICAL AR, SPUR ASSMBLY, CONNCTIN ROD (INCLUDS ON ACH OF 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 DS olf Car Illustrated Parts List Page 8-3

86 ClubCar 8 PLACS 3 4 PLACS FRONT OF VHICL RFRNC NIN SCTION PLACS 9 0 ClubCar PLACS 3 6 PLACS PLACS 5 6 PLACS PLACS RFRNC UNITIZD TRANSAXL SCTION Page DS olf Car Illustrated Parts List

87 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, 5/6-4 x 7/ SCRW, HX HAD CAP, M0 x.5 x 30MM STUD, M8 x.5 x 60MM SPACR NUT, FLAN, M0 x WASHR, HAVY FLAT, 5/ SCRW, HX HAD CAP, M8 x.5 x 43MM STIFFNR, FLYWHL SID DS olf Car Illustrated Parts List Page 8-5

89 FUL, INTAK, AND OVRNOR SYSTMS 9

90 NIN RMOVD FOR CLARITY S ITM SIX ABOV TO NIN CRANKCAS Page DS olf Car Illustrated Parts List

91 FUL SYSTM ITM PART NO. DSCRIPTION QTY KIT, FUL TANK, (INCLUDS ITMS - 8) CAP, FUL TANK, NONVNTD ASSMBLY, FUL TANK VNT ROMMT, INSULATION LIN, BULK VNT (AVAILABL BY TH FOOT)... A/R VALV, FUL PICKUP TUB WITH SHUT-OFF CLIP, STUD BARB, VNT T-FITTIN ASSMBLY, RAR FUL STRAP CLAMP, HOS PUMP, FUL IMPULS RBUILD KIT, FUL IMPULS PUMP BOLT, CARRIA, /4-0 x CLAMP, HOS NUT, NYLON LOCK, / NUT, U-TYP SPD, / SCRW, PHILLIPS TRUSS HAD, /4-0 x LIN, BULK FUL (RAY)... A/R* FILTR, PRIMARY FUL (WHIT) CLAMP, HOS (RD) FILTR, SCONDARY FUL (BLU) CLAMP, HOS, 3/ * TH TOTAL FUL LIN LNTH FOR TH DS OLF CAR IS 47 INCHS. 999 DS olf Car Illustrated Parts List Page 9-3

92 Page DS olf Car Illustrated Parts List

93 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 DS olf Car Illustrated Parts List Page 9-5

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

ILLUSTRATED PARTS LIST DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER PRINT CODE 0897B0101A 998 ILLUSTRATD PARTS LIST DS OLF CARS ASOLIN/LCTRIC MANUAL NUMBR 09683-0 PRINT COD 0897B00A USIN TH ILLUSTRATD PARTS LIST WARNIN THIS MANUAL IS TO B USD ONLY FOR IDNTIFICATION AND ORDRIN OF SRVIC PARTS.