1
Download USING THE ILLUSTRATED PARTS LIST
Transcript
USING THE ILLUSTRATED PARTS LIST 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 1999 Club Car® DS Tranquility®, DS V-Glide 36-Volt, DS PowerDrive® System 48™ and DS PowerDrive Plus® vehicles. The manual is divided into 16 sections. Sections 1 through 6 pertain to both gasoline and electric vehicles, sections 7 through 12 pertain to gasoline vehicles only, and sections 13 through 16 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 G or E, 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 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. P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 © 1998, CLUB CAR, INC. All rights reserved. This manual effective July 27, 1998 Manual print code: 0898A00000 CONTENTS MAINTENANCE AND SERVICE TOOLS SECTION MAINTENANCE AND SERVICE TOOLS ..................................................................................................... BODY AND TRIM 1- 3 - 1- 5 SECTION BODY TRIM ........................................................................................................................................................... FRONT BODY ....................................................................................................................................................... REAR BODY AND FENDER—GASOLINE VEHICLE ........................................................................................... REAR BODY AND FENDER—ELECTRIC VEHICLE ............................................................................................ SEAT BOTTOM AND ARMREST ......................................................................................................................... SEAT BACK AND BAG HOOP ............................................................................................................................. WHEELS AND TIRES BRAKES, PEDAL, AND CABLE ASSEMBLIES STEERING, FRONT AND REAR SUSPENSION ELECTRICAL SYSTEM— GASOLINE VEHICLE FE 290 ENGINE 1999 DS Golf Car Illustrated Parts List 7 7- 3 7- 5 7- 7 7- 9 7- 11 7- 13 7- 15 SECTION FE 290 ENGINE— SHROUDS AND BRACKETS ................................................................................................ FE 290 ENGINE— IGNITION COMPONENTS AND FLYWHEEL ........................................................................ FE 290 ENGINE— OIL CIRCULATION ................................................................................................................ FE 290 ENGINE— CYLINDER HEAD .................................................................................................................. FE 290 ENGINE— CRANKCASE, CAMSHAFT AND OIL SENSOR .................................................................... 6 6- 3 6- 5 6- 7 6- 9 6- 11 SECTION WIRING—GASOLINE VEHICLE ........................................................................................................................... FORWARD/REVERSE SHIFTER ASSEMBLY— GASOLINE VEHICLE .............................................................. ELECTRICAL COMPONENT BOX— GASOLINE VEHICLE ................................................................................ ELECTRICAL COMPONENTS— GASOLINE VEHICLE ...................................................................................... STARTER/GENERATOR ASSEMBLY ................................................................................................................. STARTER/GENERATOR MOUNTING ................................................................................................................. BATTERY—GASOLINE VEHICLE ........................................................................................................................ 5 5- 3 5- 5 5- 7 SECTION STEERING COLUMN ........................................................................................................................................... STEERING GEAR ASSEMBLY ............................................................................................................................ FRONT SUSPENSION, UPPER .......................................................................................................................... FRONT SUSPENSION, LOWER .......................................................................................................................... REAR SUSPENSION ............................................................................................................................................ 4 4- 3 4- 5 SECTION BRAKE ASSEMBLY .............................................................................................................................................. BRAKE PEDAL AND CABLE ASSEMBLY ............................................................................................................ ACCELERATOR PEDAL ASSEMBLY .................................................................................................................. 3 3- 3 SECTION DECALS—GASOLINE VEHICLE .......................................................................................................................... DECALS—ELECTRIC VEHICLE ........................................................................................................................... 2 2- 3 2- 5 2- 7 2- 9 2- 11 2- 13 SECTION WHEELS AND TIRES ........................................................................................................................................... DECALS 1 8- 3 8- 5 8- 7 8- 9 8- 11 8 CONTENTS FE 290 ENGINE— CRANKCASE AND CRANKSHAFT ....................................................................................... ENGINE MOUNTING ............................................................................................................................................ FUEL, INTAKE, AND GOVERNOR SYSTEMS SECTION FUEL SYSTEM ..................................................................................................................................................... CARBURETOR ASSEMBLY ................................................................................................................................. CARBURETOR INSTALLATION .......................................................................................................................... GOVERNOR AND ACCELERATOR CABLES ..................................................................................................... INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY .......................................................................................... EXHAUST SYSTEM UNITIZED TRANSAXLE— GASOLINE VEHICLE ELECTRICAL SYSTEM— ELECTRIC VEHICLE BATTERY CHARGER 12 12- 3 12- 5 12- 7 SECTION ELECTRICAL COMPONENTS, FRONT BODY— ELECTRIC VEHICLE ............................................................. WIRING—V-GLIDE 36-VOLT VEHICLE ............................................................................................................... FORWARD/REVERSE SWITCH— V-GLIDE 36-VOLT VEHICLE ......................................................................... WIPER SWITCH—V-GLIDE 36-VOLT VEHICLE .................................................................................................. RESISTOR AND BOARD ASSEMBLY— V-GLIDE 36-VOLT VEHICLE ................................................................ BATTERIES, CHARGER RECEPTACLE, SOLENOID— V-GLIDE 36-VOLT VEHICLE ........................................ WIRING—POWERDRIVE SYSTEM 48 VEHICLE ................................................................................................ FORWARD/REVERSE SWITCH— POWERDRIVE SYSTEM 48 VEHICLE ........................................................ BATTERIES, CHARGER RECEPTACLE— POWERDRIVE SYSTEM 48 VEHICLE ........................................... COMPUTER, CONTROLLER, AND SOLENOID— POWERDRIVE SYSTEM 48 VEHICLE ................................ MULTI-STEP POTENTIOMETER— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ............................ WIRING—POWERDRIVE PLUS VEHICLE .......................................................................................................... FORWARD/REVERSE SWITCH, TOW/RUN SWITCH— POWERDRIVE PLUS VEHICLE ................................. BATTERIES, CHARGER RECEPTACLE— POWERDRIVE PLUS VEHICLE ...................................................... SOLENOIDS, ENERGY DISPLACEMENT MODULE— POWERDRIVE PLUS VEHICLE ................................... CONTROLLER, ONBOARD COMPUTER— POWERDRIVE PLUS VEHICLE ..................................................... 11 11- 3 11- 5 SECTION UNITIZED TRANSAXLE, GASOLINE VEHICLE— GEAR CASES AND BRACKETS ........................................... UNITIZED TRANSAXLE, GASOLINE VEHICLE— F&R TRANSMISSION AND GEAR REDUCTION ................. UNITIZED TRANSAXLE, GASOLINE VEHICLE— DIFFERENTIAL AND AXLES ................................................ 10 10- 3 SECTION DRIVE CLUTCH ................................................................................................................................................... DRIVEN CLUTCH ................................................................................................................................................. 9 9- 3 9- 5 9- 7 9- 9 9- 11 SECTION EXHAUST SYSTEM ............................................................................................................................................. TORQUE CONVERTER 8- 13 8- 15 13 13 - 3 13- 5 13- 7 13- 9 13- 11 13- 13 13- 15 13- 17 13- 19 13- 21 13- 23 13- 25 13- 27 13- 29 13- 31 13- 33 SECTION ACCU-POWER CHARGER, DOMESTIC— V-GLIDE 36-VOLT VEHICLE ............................................................ 14- 3 ACCU-POWER CHARGER, EXPORT, 230-VOLT— V-GLIDE 36-VOLT VEHICLE ............................................. 14- 5 ACCU-POWER CHARGER, EXPORT, 100-VOLT— V-GLIDE 36-VOLT VEHICLE ............................................. 14- 7 POWERDRIVE CHARGER, DOMESTIC— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ................ 14- 9 POWERDRIVE CHARGER, EXPORT— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS .................... 14- 11 POWERDRIVE CHARGER, EUROPEAN— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ............... 14- 13 1999 DS Golf Car Illustrated Parts List 14 CONTENTS ELECTRIC MOTOR SECTION MOTOR—V-GLIDE 36-VOLT VEHICLE ................................................................................................................ MOTOR—POWERDRIVE SYSTEM 48 VEHICLE ................................................................................................ MOTOR—POWERDRIVE PLUS VEHICLE ........................................................................................................... TRANSAXLE— ELECTRIC VEHICLE 1999 DS Golf Car Illustrated Parts List 15- 3 15- 5 15- 7 SECTION TRANSAXLE, TYPE G— ELECTRIC VEHICLE ..................................................................................................... TRANSAXLE, TYPE K— ELECTRIC VEHICLE ..................................................................................................... 15 16- 3 16- 5 16 MAINTENANCE AND SERVICE TOOLS 1 G E 1 G 1 AC PE CE DA LE L RA HE TO IG R HT E 1 2 3 5 4 6 7 10 8 9 CALIBRATION & TEST MODULE INSTRUCTIONS SPEED CONTROL SET POWER SWITCH TO "ON". TEST PEDAL CIRCUIT POT CALIBRATION: SET MODE SWITCH TO "POT". CHECK INTERNAL 4.30±.03 VOLT SIGNAL BY PRESSING "TEST" BUTTON. CONNECT TEST SOCKET TO POT PLUG, CONNECT GREEN LEAD TO GREEN/ WHITE POT LIMIT SWITCH LEAD, CONNECT BLUE LEAD TO BATTERY POSITIVE. ILLUMINATION OF THE L.E.D. INDICATES A CLOSED PEDAL LIMIT SWITCH, READ THE POTENTIOMETER SET VOLTAGE FROM THE L.C.D. DISPLAY. SEE SERVICE MANUAL FOR ADJUSTMENT PROCEDURE. SPEED SENSOR TEST: SET MODE SWITCH TO "SSAM", CONNECT TEST SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL. SEE OPERATING INSTRUCTIONS FOR MORE DETAIL POWER ON OFF R Club Car MODE SSAM POT 11 14 13 12 15 WARNIN G COMMUNICATION DISPLAY MODULE DISPLAY FUNCTIONS: PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER. RELEASE BUTTON TO SHOW FUNCTION VALUE. Func1 - Battery voltage. Func2 - Energy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). 16 POWER ON OFF 19 18 R Club Car PART #17075 20 17 21 22 Page 1-2 23 1999 DS Golf Car Illustrated Parts List 24 25 26 MAINTENANCE AND SERVICE TOOLS ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 101871001 101978901 101813202 1017295 101831901 1014305 1011767 1016417 1016416 1012811 1012812 101887101 ACCELERATOR PEDAL ADJUSTMENT TOOL ......................................................... ADHESION PROMOTER—ARMORFLEX® ............................................................... ADHESIVE, GUIDE RING, 3-GRAM TUBE ................................................................ ARMORFLEX REPAIR KIT ......................................................................................... BATTERY DISCHARGE MACHINE, 36/48 VOLT ....................................................... BATTERY TERMINAL PROTECTOR SPRAY ............................................................. BATTERY THERMOMETER ....................................................................................... BEARING AND OIL SEAL REMOVER ASSEMBLY ................................................... BEARING DRIVER SET ............................................................................................. BEARING PULLER .................................................................................................... BEARING PULLER WEDGE ATTACHMENT ............................................................. CALIBRATION TEST MODULE .................................................................................. 13 101808401 1014510 1014498 1014496 1014497 1014508 1014507 1015524 101809101 101831801 101641002 1011273 1012151 1016627 1016418 CAM INSTALLATION TOOL ....................................................................................... CLUTCH TOOL KIT (INCLUDES ITEMS 14 - 20 ) ..................................................... CLUTCH ALIGNMENT TOOL ................................................................................ DRIVE CLUTCH PULLER ..................................................................................... DRIVE CLUTCH HUB PULLER ............................................................................. DRIVEN CLUTCH CAM PULLER .......................................................................... DRIVEN CLUTCH PULLER PLUG ........................................................................ DRIVE CLUTCH HOLDER TOOL ASSEMBLY ...................................................... PRESS WELDMENT ............................................................................................. COMMUNICATION DISPLAY MODULE ..................................................................... COMPRESSION GAUGE AND ADAPTER ................................................................. CONTINUITY TESTER ............................................................................................... DRY MOLY LUBRICANT ............................................................................................ FLY WHEEL PULLER KIT .......................................................................................... GEAR YOKE ............................................................................................................... 14 15 16 17 18 19 20 21 22 23 24 25 26 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PLEASE REFER TO THE MAINTENANCE AND SERVICE MANUAL FOR PROPER TOOL APPLICATION. 1999 DS Golf Car Illustrated Parts List Page 1-3 1 G E 1 G 1 E 27 32 28 34 33 29 30 31 PULSE ENGINE TACHOMETER PET-1000 Club Car POSTION 37 35 38 RESET 39 40 41 36 46 42 45 - + 43 44 WAVETEK V 5XL 1000 OFF V 500 200 200 20 200 2m 2 200 m 20 m 200 m 2000 k 200k 20k Ω 45° 45° V Ω ! 200 ! COM MAX 1000 --750V 47 Page 1-4 48 49 1999 DS Golf Car Illustrated Parts List 50 51 A 2k FUSED 52 200nA MAINTENANCE AND SERVICE TOOLS ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 27 28 29 30 31 32 33 34 35 36 37 38 101933101 1011478 1013593 101928701 1016414 1016415 1012549 1012560 101823101 1012809 1014264 1014259 GOVERNOR SHAFT INSTALLATION TOOL .............................................................. HYDROMETER .......................................................................................................... INTERNAL RETAINING RING PLIERS ...................................................................... LIQUID GASKET (TRANSAXLE CASE) .................................................................... PISTON RING COMPRESSOR KIT ........................................................................... PISTON RING PLIERS ............................................................................................... RETAINING RING PLIERS, 45° EXTERNAL ............................................................. RETAINING RING PLIERS, 90° INTERNAL .............................................................. SAFETY FIRST CARD (50 PER PACK) ..................................................................... SEAL PULLER ........................................................................................................... STEERING COLUMN BEARING PRESS TOOL ........................................................ STEERING COLUMN RETAINING RING TOOL ........................................................ 1 1 1 1 1 1 1 1 1 1 1 1 39 40 40 40 40 40 40 41 42 43 44 45 46 47 48 49 50 51 52 53 1016112 101997201 101997202 101997204 101997209 101997211 101997212 1014115 1014161 1014162 1016413 101641201 101641202 1016551 1016552 1016553 1016554 101641101 1011480 101611002 TACHOMETER ........................................................................................................... PAINT, TOUCH-UP—BEIGE ....................................................................................... PAINT, TOUCH-UP—WHITE ...................................................................................... PAINT, TOUCH-UP—GRAY......................................................................................... PAINT, TOUCH-UP—DARK GREEN .......................................................................... PAINT, TOUCH-UP—CLASSIC BLUE ........................................................................ PAINT, TOUCH-UP—BURGUNDY ............................................................................. TRANSMISSION TOOL KIT ....................................................................................... TRANSAXLE PINION SEAL TOOL ............................................................................ TRANSAXLE AXLE SEAL TOOL ............................................................................... VALVE CLEARANCE ADJUSTER SCREW HOLDER ............................................... VALVE GUIDE REAMER (INCLUDES ITEM 46)........................................................ ARBOR .................................................................................................................. VALVE SEAT CUTTER T-WRENCH ........................................................................... VALVE SEAT CUTTER GUIDE ................................................................................... VALVE SEAT CUTTER, 45° (32MM DIAMETER) ....................................................... VALVE SEAT CUTTER, 32° AND 45° (35MM DIAMETER) ....................................... VALVE SPRING COMPRESSOR ............................................................................... VOLT OHM METER .................................................................................................... TUNE-UP KIT (FE 290) (INCLUDES AIR FILTER, SPARK PLUG, OIL FILTER, FUEL FILTERS) (NOT SHOWN) ................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 G 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PLEASE REFER TO THE MAINTENANCE AND SERVICE MANUAL FOR PROPER TOOL APPLICATION. 1999 DS Golf Car Illustrated Parts List 1 Page 1-5 E BODY AND TRIM 2 G E Front Body Of Car 11 2 Frame Dash G E Center Dash Frame Dash TYPICAL 3 PLACES 2 3 4 9 8 7 10 1 TYPICAL 2 PLACES 13 6 14 12 5 TYPICAL 9 PLACES 16 15 24 22 23 22 21 18 19 TYPICAL 2 PLACES 21 20 Page 2-2 TYPICAL 2 PLACES 21 20 1999 DS Golf Car Illustrated Parts List 17 TYPICAL 2 PLACES BODY TRIM ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1013344 101660404 101802601 1013343 1015032 1014645 N/A N/A N/A N/A 7973 101708301 COMPONENT, LEFT DASH, BLACK ......................................................................... PANEL, CENTER DASH, BLACK ............................................................................... PLUG, HOLE (V-GLIDE 36-VOLT VEHICLE ONLY) ................................................... COMPONENT, RIGHT DASH, BLACK ....................................................................... MAT, FLOOR .............................................................................................................. KIT, SNAP WASHER, BLACK (INCLUDES ITEMS 7 - 10) ......................................... NUT, SPEED .......................................................................................................... WASHER, #10 ....................................................................................................... SCREW, #10 SHEET METAL ................................................................................ COVER, SCREW HEAD ........................................................................................ RIVET, ALUMINUM POP, 3/16 ................................................................................... KIT, DRINK HOLDER (INCLUDES ITEMS 13 AND 14) ............................................. 1 1 2 1 1 1 1 3 2 1 1 1 1 1 2 1 1 1 1 3 2 13 14 15 16 17 18 19 20 21 22 23 24 7847 1016952 101768202 1010434 1017079 1016379 1016875 7473 1011697 1016876 101706702 1010434 BOLT, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................... U-NUT, 1/4 - 20 ...................................................................................................... KIT, BAGWELL PROTECTOR (INCLUDES ITEM 16) ............................................... FASTENER, PLASTIC BARREL ............................................................................ KIT, REAR BUMPER (INCLUDES ITEMS 18 - 22) .................................................... BUMPER, REAR .................................................................................................... PLATE, MOUNTING, LONG .................................................................................. NUT, NYLON LOCK, 5/16 - 18 ............................................................................... WASHER, SPECIAL, 5/16 ..................................................................................... BOLT, PHILLIPS TRUSS HEAD SHOULDER, 3/8 - 18 x 2 .................................... KIT, SCUFF GUARD (INCLUDES ITEM 24) ............................................................. FASTENER, PLASTIC BARREL ............................................................................ 2 2 1 9 1 1 1 4 6 4 1 12 2 2 1 9 1 1 1 4 6 4 1 12 1999 DS Golf Car Illustrated Parts List 1 1 Page 2-3 2 G E 2 G E TYPICAL 2 PLACES 12 10 11 TYPICAL 2 PLACES 13 TYPICAL 6 PLACES 17 16 9 7 8 6 Club Car 2 14 TYPICAL 2 PLACES 1 5 3 TYPICAL 8 PLACES 4 Page 2-4 TYPICAL 2 PLACES 1999 DS Golf Car Illustrated Parts List 15 FRONT BODY ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 7 7 7 7 7 1017080 1016868 7251 7473 1016967 1014198 101692501 101692502 101692504 101692510 101692512 101692513 KIT, FRONT BUMPER (INCLUDES ITEMS 2 - 5) ...................................................... BUMPER, FRONT ................................................................................................. SCREW, PHILLIPS TRUSS HEAD, 5/16 - 18 x 1 ................................................... NUT, NYLON LOCK, 5/16 - 18 ............................................................................... RIVET, PUSH TYPE BLIND ................................................................................... NAMEPLATE—GOLD ................................................................................................ BODY, FRONT—BEIGE ............................................................................................. BODY, FRONT—WHITE ............................................................................................. BODY, FRONT—GRAY .............................................................................................. BODY, FRONT—DARK GREEN ................................................................................. BODY, FRONT—CLASSIC BLUE ............................................................................... BODY, FRONT—BURGUNDY .................................................................................... 1 1 2 2 2 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 8 8 8 8 8 8 9 10 11 12 13 14 15 16 17 101693901 101693902 101693904 101693909 101693911 101693912 1011014 1010435 1241 1011017 1011394 101347501 1012047 7251 7473 BODY, FRONT WITH HEADLIGHT OPENING—BEIGE ............................................ BODY, FRONT WITH HEADLIGHT OPENING—WHITE ........................................... BODY, FRONT WITH HEADLIGHT OPENING—GRAY ............................................. BODY, FRONT WITH HEADLIGHT OPENING—DARK GREEN ............................... BODY, FRONT WITH HEADLIGHT OPENING—CLASSIC BLUE ............................. BODY, FRONT WITH HEADLIGHT OPENING—BURGUNDY ................................... TRIM, FRONT BODY .................................................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1 ................................................................................ WASHER, FLAT, 5/16 ................................................................................................. SCREW, FLANGE LOCK ........................................................................................... T-NUT, SLAB BASE (PACKAGE OF 4) ....................................................................... BUMPER, SIDE GUARD TRIM .................................................................................. SCREW, SELF-TAPPING, #8 - 32 x 3/8 ..................................................................... SCREW, PHILLIPS TRUSS HEAD, 5/16 - 18 x 1 ....................................................... NUT, NYLON LOCK, 5/16 - 18 ................................................................................... 1 1 1 1 1 1 1 2 2 6 1 2 8 2 2 1 1 1 1 1 1 1 2 2 6 1 2 8 2 2 1999 DS Golf Car Illustrated Parts List Page 2-5 2 G E TYPICAL 2 PLACES 4 2 7 1 FRONT SEAT SUPPORT VERTICAL STRUT G E 3 1 5 TYPICAL 2 PLACES 6 1 8 2 TYPICAL 2 PLACES 9 10 15 1 11 16 TYPICAL EACH SIDE OF VEHICLE TYPICAL 2 PLACES 14 TYPICAL EACH SIDE OF VEHICLE 6 6 12 TYPICAL EACH SIDE OF VEHICLE 13 5 TYPICAL 2 PLACES Page 2-6 1999 DS Golf Car Illustrated Parts List TYPICAL 2 PLACES REAR BODY AND FENDER—GASOLINE VEHICLE ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 7 8 9 9 9 8251 101904101 1016952 1012412 332 8233 1013032 1013140 1015525 101692601 101692602 101692604 SCREW, PHILLIPS HEAD, 1/4 - 20 x 1 ...................................................................... PLATE, BODY KICK ................................................................................................... U-NUT, 1/4 - 20 ........................................................................................................... PLATE, BODY HINGE ................................................................................................ WASHER, FLAT, 1/4 ................................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... DOOR, ACCESS—BLACK ......................................................................................... DOOR, ACCESS—BEIGE .......................................................................................... NUT, BLIND, 1/4 - 20 .................................................................................................. BODY—BEIGE ........................................................................................................... BODY—WHITE ........................................................................................................... BODY—GRAY ............................................................................................................ 10 1 2 2 8 10 1 1 2 1 1 1 9 9 9 9 9 9 9 9 9 10 11 12 13 14 15 16 101692610 101692612 101692613 101696208 101696209 101696211 101696216 101696220 101696221 1017141 1017748 1012047 304 1010434 1017936 1014306 BODY—DARK GREEN .............................................................................................. BODY—CLASSIC BLUE ............................................................................................ BODY—BURGUNDY .................................................................................................. BODY WITH TAILLIGHT OPENING—BEIGE ............................................................. BODY WITH TAILLIGHT OPENING—WHITE ............................................................ BODY WITH TAILLIGHT OPENING—GRAY .............................................................. BODY WITH TAILLIGHT OPENING—DARK GREEN ................................................ BODY WITH TAILLIGHT OPENING—CLASSIC BLUE .............................................. BODY WITH TAILLIGHT OPENING—BURGUNDY .................................................... SUPPORT, FRONT BODY .......................................................................................... CLIP, BODY KEEPER ................................................................................................. SCREW, SELF-TAPPING, #8 - 32 x 3/8 ..................................................................... SCREW, HEX HEAD CAP, 1/4 - 20 x 1 ...................................................................... BARREL, PLASTIC .................................................................................................... FENDER, INNER ........................................................................................................ WASHER, FLAT, TYPE B, 1/4 .................................................................................... 1 1 1 1 1 1 1 1 1 1 2 2 4 4 2 2 1999 DS Golf Car Illustrated Parts List Page 2-7 2 G E 2 16 TYPICAL 2 PLACES 4 G FRONT SEAT SUPPORT VERTICAL STRUT E 1 3 TYPICAL 2 PLACES 5 1 1 17 6 15 2 TYPICAL 2 PLACES 18 TYPICAL 2 PLACES 1 19 7 6 8 13 9 6 14 TYPICAL EACH SIDE OF VEHICLE 12 5 10 11 TYPICAL EACH SIDE OF VEHICLE Page 2-8 1999 DS Golf Car Illustrated Parts List TYPICAL EACH SIDE OF VEHICLE REAR BODY AND FENDER—ELECTRIC VEHICLE ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 8251 101904101 1016952 1012412 332 8233 1017936 1010434 1017814 1012159 7479 1017815 SCREW, PHILLIPS HEAD, 1/4 - 20 x 1 ...................................................................... PLATE, BODY KICK .................................................................................................. U-NUT, 1/4 - 20 ........................................................................................................... PLATE, BODY HINGE ................................................................................................ WASHER, FLAT, 1/4 ................................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... FENDER, INNER ........................................................................................................ FASTENER, PLASTIC BARREL ................................................................................ SPACER, 1 7/8 ........................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2-3/4 ............................................................................. BOLT, HEX HEAD, 1/4 - 20 x 1-1/4 ............................................................................. SPACER, 1/2 .............................................................................................................. 10 1 2 2 8 10 2 4 2 2 2 2 13 14 15 15 15 15 15 15 15 15 15 15 15 15 16 16 17 18 19 1017748 1012047 101693301 101693302 101693304 101693310 101693312 101693313 101696201 101696202 101696204 101696218 101696223 101696224 1013032 1013140 1015525 1017141 1014306 CLIP, BODY KEEPER ................................................................................................. SCREW, SELF-TAPPING, #8 - 32 .............................................................................. BODY—BEIGE ........................................................................................................... BODY—WHITE ........................................................................................................... BODY—GRAY ............................................................................................................ BODY—DARK GREEN .............................................................................................. BODY—CLASSIC BLUE ............................................................................................ BODY—BURGUNDY .................................................................................................. BODY WITH TAILLIGHT OPENING—BEIGE ............................................................. BODY WITH TAILLIGHT OPENING—WHITE ............................................................ BODY WITH TAILLIGHT OPENING—GRAY .............................................................. BODY WITH TAILLIGHT OPENING—DARK GREEN ................................................ BODY WITH TAILLIGHT OPENING—CLASSIC BLUE .............................................. BODY WITH TAILLIGHT OPENING—BURGUNDY .................................................... DOOR, ACCESS—BLACK ......................................................................................... DOOR, ACCESS—BEIGE .......................................................................................... NUT, BLIND, 1/4 - 20 .................................................................................................. SUPPORT, FRONT BODY .......................................................................................... WASHER, FLAT, TYPE B, 1/4 ..................................................................................... 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1999 DS Golf Car Illustrated Parts List Page 2-9 2 G E 4 6 2 9 8 7 G 5 E 10 11 TYPICAL 5 PLACES 9 8 TYPICAL 2 PLACES 1 12 13 2 3 TYPICAL 8 PLACES TYPICAL 4 PLACES 14 5 TYPICAL 8 PLACES 15 TYPICAL 2 PLACES REFERENCE REAR BODY AND FENDER Page 2-10 16 17 1999 DS Golf Car Illustrated Parts List TYPICAL 4 PLACES SEAT BOTTOM AND ARMREST ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 1 1 1 2 2 2 2 3 4 5 6 101564804 101564805 101564807 101564808 101562701 101562702 101562704 101562710 1010543 1015670 1015625 101951101 ASSEMBLY, SEAT BOTTOM—BUFF (INCLUDES ITEMS 2 AND 3) ......................... ASSEMBLY, SEAT BOTTOM—WHITE (INCLUDES ITEMS 2 AND 3) ....................... ASSEMBLY, SEAT BOTTOM—GRAY (INCLUDES ITEMS 2 AND 3) ......................... ASSEMBLY, SEAT BOTTOM—BLACK (INCLUDES ITEMS 2 AND 3) ....................... COVER, VINYL SEAT BOTTOM—BUFF ............................................................... COVER, VINYL SEAT BOTTOM—WHITE ............................................................. COVER, VINYL SEAT BOTTOM—BLACK ............................................................. COVER, VINYL SEAT BOTTOM—GRAY ............................................................... INSERT, WOOD ..................................................................................................... ASSEMBLY, SEAT BOTTOM AND ARMREST (INCLUDES ITEMS 5 - 9) ................. BRACKET, SEAT SUPPORT .................................................................................. KIT, ARMREST (INCLUDES ITEMS 7 - 9) ............................................................. 1 1 1 1 1 1 1 1 8 1 2 1 1 1 1 1 1 1 1 1 8 1 2 1 7 8 9 10 11 12 13 14 15 16 17 101880901 N/A N/A 1012597 1017384 1012656 1012657 101881701 101954301 1011652 101880901 RIVET, MATING, 3/16 ....................................................................................... ASSEMBLY, ARMREST, DRIVER SIDE ........................................................... ASSEMBLY, ARMREST, PASSENGER SIDE ................................................... BUMPER, SEAT ......................................................................................................... SCREW, WASHER HEAD TAP, #12 ........................................................................... GASKET, SEAT, SHORT (GASOLINE VEHICLE ONLY) ............................................ GASKET, SEAT, LONG (GASOLINE VEHICLE ONLY) .............................................. WASHER, FLAT, STAINLESS STEEL, #8 .................................................................. SCREW, HEX HEAD CAP, 1/4 - 20 x 3/4 (WITH PATCH) .......................................... PLATE, SEAT HINGE, STAINLESS STEEL ................................................................ RIVET, POP, STAINLESS STEEL, 3/16 ...................................................................... 8 1 1 1 5 2 1 4 8 2 4 8 1 1 1 5 1999 DS Golf Car Illustrated Parts List 4 8 2 4 Page 2-11 2 G E 2 3 G 7 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 2 9 5 E 8 10 11 1 12 13 4 TYPICAL 2 PLACES TYPICAL 2 PLACES 14 17 18 15 16 19 22 TYPICAL 4 PLACES 21 30 28 29 26 27 28 12 TYPICAL 2 PLACES 26 24 TYPICAL 2 PLACES Page 2-12 1999 DS Golf Car Illustrated Parts List 25 24 23 20 TYPICAL 2 PLACES 24 SEAT BACK AND BAG HOOP ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 1 1 1 2 3 3 3 3 4 5 6 101565102 101565105 101565106 101565107 1013335 101562601 101562602 101562604 101562605 1017409 101946201 8248 ASSEMBLY, SEAT BACK—WHITE (INCLUDES ITEMS 2 AND 3) ............................ ASSEMBLY, SEAT BACK—BUFF (INCLUDES ITEMS 2 AND 3) .............................. ASSEMBLY, SEAT BACK—GRAY (INCLUDES ITEMS 2 AND 3) .............................. ASSEMBLY, SEAT BACK—BLACK (INCLUDES ITEMS 2 AND 3) ............................ CAP, SEAT BACK—BLACK ................................................................................... COVER, VINYL, SEAT BACK—BUFF .................................................................... COVER, VINYL, SEAT BACK—WHITE ................................................................. COVER, VINYL, SEAT BACK—BLACK ................................................................. COVER, VINYL, SEAT BACK—GRAY ................................................................... MOUNT, SEAT BACK ................................................................................................. WASHER, EXTERNAL TOOTH LOCK, 1/4 ................................................................ SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 3/4 ...................................................... 2 2 2 2 2 2 2 2 2 2 8 8 2 2 2 2 2 2 2 2 2 2 8 8 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 8233 7847 332 1010921 1015075 7473 1013884 1013935 1010434 1010413 1013754 1011708 1011710 1017774 1011706 101707206 8418 1015075 1014482 8233 7974 1241 7818 101910401 NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... SCREW, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................... WASHER, FLAT, 1/4 ................................................................................................... SCREW, CAP HEX HEAD, 5/16 - 18 x 2-1/2 .............................................................. WASHER, FLAT, 5/16 ................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................... SPACER, BAG HOOP ................................................................................................ ASSEMBLY, BAG HOOP (INCLUDES ITEMS 15 - 17) .............................................. FASTENER, PLASTIC BARREL ............................................................................ STRAP, BAG .......................................................................................................... BUCKLE, BAG STRAP .......................................................................................... SUPPORT, SEAT BACK, MAIN .................................................................................. ASSEMBLY, KNEE BRACE WELDMENT ................................................................... SPACER, BODY ......................................................................................................... PAD, MOUNTING, SEAT BACK SUPPORT ............................................................... KIT, SWEATER BASKET (INCLUDES ITEMS 23 - 27) .............................................. SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 1-1/2 .............................................. WASHER, FLAT, 5/16 ............................................................................................. SPACER, NYLON .................................................................................................. NUT, NYLON LOCK, 1/4 - 20 ................................................................................. BOLT, HEX HEAD, 1/4-20 x 1-1/4 ........................................................................... WASHER, FLAT, 5/16 ................................................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1-1/2 .......................................................................... SCREW, SELF-TAPPING, 5/16 - 18 x 1-1/4 ............................................................... 6 6 8 2 4 4 2 1 2 1 2 2 2 4 2 1 1 4 1 3 2 2 2 4 6 6 8 2 4 4 2 1 2 1 2 2 2 4 2 1 1 4 1 3 2 2 2 4 1999 DS Golf Car Illustrated Parts List Page 2-13 2 G E WHEELS AND TIRES 3 G E 3 G E 1 2 3 4 5 STANDARD TREAD Page 3-2 1999 DS Golf Car Illustrated Parts List PREMIUM TREAD EXTRA TRACTION WHEELS AND TIRES ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 2 2 2 2 2 3 3 4 4 4 1010984 101570501 101570502 101570507 101651401 101651402 101651407 1015707 1014771 727102 101567202 101769302 NUT, LUG ................................................................................................................... ASSEMBLY, BEIGE WHEEL AND STANDARD TREAD TIRE (18 x 8.5 - 8) .............. ASSEMBLY, BEIGE WHEEL AND PREMIUM TREAD TIRE (18 x 8.5 - 8) ................. ASSEMBLY, BEIGE WHEEL AND EXTRA TRACTION TIRE, 6-PLY (18 x 8.5 - 8) .... ASSEMBLY, WHITE WHEEL AND STANDARD TREAD TIRE (18 x 8.5 - 8) .............. ASSEMBLY, WHITE WHEEL AND PREMIUM TREAD TIRE (18 x 8.5 - 8) ................ ASSEMBLY, WHITE WHEEL AND EXTRA TRACTION TIRE, 6-PLY (18 x 8.5 - 8) .... WHEEL RIM, BEIGE .................................................................................................. WHEEL RIM, WHITE .................................................................................................. TIRE, UNMOUNTED, STANDARD TREAD (18 x 8.5 - 8) ........................................... TIRE, UNMOUNTED, PREMIUM TREAD (18 x 8.5 - 8) ............................................. TIRE, UNMOUNTED, EXTRA TRACTION, 6-PLY (18 x 8.5 - 8) ................................ 16 4 4 4 4 4 4 4 4 4 4 4 16 4 4 4 4 4 4 4 4 4 4 4 5 7310 STEM, VALVE ............................................................................................................. 4 4 1999 DS Golf Car Illustrated Parts List Page 3-3 3 G E DECALS 4 G E DRIVER / PASSENGER WARNING DECAL 4 G ! • • • E KEY SWITCH WARNING READ AND FOLLOW THESE WARNINGS AND THE OPERATING INSTRUCTIONS BEFORE USING VEHICLE. FAILURE TO DO SO CAN CAUSE SEVERE INJURY OR DEATH. • • • • OPERATING INSTRUCTIONS OFF 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 (2) 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. ON • 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. 2 3 CCI 1019606-01 1 CCI 1016216-01 OPERATING INSTRUCTIONS DECAL WARNING WARNING Negative frame ground. Can cause severe injury. Excessive 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 1019152-01 FRAME GROUND AND GOVERNOR WARNING DECAL WARNING (ON VEHICLE FRAME NEAR BATTERY) CAN CAUSE SEVERE INJURY WARNING • • • • • GASOLINE EXPLOSION / FIRE. CAN CAUSE SEVERE INJURY OR DEATH. NO SMOKING, SPARKS, OR OPEN FLAME. STOP ENGINE, ALLOW TO COOL BEFORE REFUELING. TURN FUEL VALVE ( ) ON DURING OPERATION. ( ) OFF DURING STORAGE OR TRANSPORT. CCI 1015476-01 GASOLINE DANGER DECAL (ON VEHICLE FRAME NEAR FUEL TANK) 4 6 Rotating parts HOT manifold & muffler KEEP CLEAR CCI 1019605-01 MOVING PARTS AND HOT MANIFOLD DECAL (ON STARTER/GENERATOR AND ENGINE) 5 7 INGERSOLL-RAND DECAL (ON BODY PANEL) Page 4-2 1999 DS Golf Car Illustrated Parts List DECALS—GASOLINE VEHICLE ITEM PART NO. 1 1 2 3 4 5 6 7 101960601 101825101 101621601 101547601 101960501 101915201 101952401 QTY QTY GAS ELEC DESCRIPTION 2 3 4 DECAL, DRIVER/PASSENGER WARNING ............................................................... DECAL, KEY SWITCH ............................................................................................... DECAL, OPERATING INSTRUCTIONS ..................................................................... DECAL, GASOLINE DANGER ................................................................................... DECAL, MOVING PARTS AND HOT MANIFOLD WARNING .................................... DECAL, FRAME GROUND AND GOVERNOR WARNING ........................................ DECAL, INGERSOLL-RAND (GOLD) ........................................................................ 1999 DS Golf Car Illustrated Parts List 1 1 1 1 2 1 2 Page 4-3 4 G E DRIVER / PASSENGER WARNING DECAL 4 G ! OPERATING INSTRUCTIONS OFF WARNING READ AND FOLLOW THESE WARNINGS AND THE OPERATING INSTRUCTIONS BEFORE USING VEHICLE. FAILURE TO DO SO CAN CAUSE SEVERE INJURY OR DEATH. • • • • • • • 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 (2) 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. ON • 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. 2 3 1 CCI 1019606-01 CCI 1016216-01 OPERATING INSTRUCTIONS DECAL MOTOR BRAKING DECAL • IMPORTANT NOTICE • • VEHICLE EQUIPPED TO LIMIT DOWNHILL SPEED • 4 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. BATTERY DANGER DECAL (ON BODY UNDER SEAT) ! CCI 1019599-01 DANGER / POISON NO EXPLOSIVE SHIELD EYES • SPARKS • FLAMES • SMOKING GASES CAN CAUSE BLINDNESS OR INJURY SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS FLUSH EYES IMMEDIATELY WITH WATER GET MEDICAL HELP FAST KEEP OUT OF THE REACH OF CHILDREN – DO NOT TIP – KEEP VENT CAPS TIGHT AND LEVEL WARNING HOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS. RESISTOR WARNING DECAL (ON FRAME UNDER SEAT ON V-GLIDE 36 VOLT VEHICLE) 6 5 (ON MOUNTING PLATE UNDER ACCESS PANEL ON POWERDRIVE PLUS VEHICLE) Club Car F N E KEY SWITCH 7 INGERSOLL-RAND DECAL 9 TOW SWITCH WARNING DECAL (ON TOW SWITCH BRACKET UNDER SEAT) WARNING 8 TOW PLACE TOW SWITCH IN "TOW" POSITION BEFORE: •TOWING •EXTENDED STORAGE •SERVICING •DISCONNECTING BATTERIES RUN FAILURE TO DO SO COULD RESULT IN DAMAGE TO VEHICLE OR BATTERY EXPLOSION. CCI 1019086-01 (POWERDRIVE PLUS VEHICLE ONLY) Page 4-4 1999 DS Golf Car Illustrated Parts List • DO NOT OPERATE VEHICLE WITHOUT COVER IN PLACE. DO NOT DIRECT WATER NOTICE• STREAM AT THIS SWITCH. CCI 1016109-01 POTENTIOMETER CAUTION DECAL (ON WIPER SWITCH COVER INSIDE BATTERY COMPARTMENT) DECALS—ELECTRIC VEHICLE ITEM PART NO. 1 1 2 3 4 5 101960601 101825101 101621601 101959901 1013496 6 7 8 9 1013677 101952401 101610901 101908601 QTY QTY GAS ELEC DESCRIPTION 2 3 4 DECAL, DRIVER/PASSENGER WARNING ............................................................... DECAL, KEY SWITCH ............................................................................................... DECAL, OPERATING INSTRUCTIONS ..................................................................... DECAL, MOTOR BRAKING (POWERDRIVE PLUS VEHICLE) ................................. DECAL, RESISTOR WARNING (V-GLIDE 36-VOLT AND POWERDRIVE PLUS VEHICLES) ............................................................................. DECAL, BATTERY DANGER ..................................................................................... DECAL, INGERSOLL-RAND (GOLD) ........................................................................ DECAL, POTENTIOMETER CAUTION ...................................................................... DECAL, TOW SWITCH (POWERDRIVE PLUS VEHICLE) ........................................ 1999 DS Golf Car Illustrated Parts List 1 1 1 1 1 1 2 1 1 Page 4-5 4 G E BRAKES, PEDAL, AND CABLE ASSEMBLIES 5 G E 5 G 11 TYPICAL 4 PLACES 10 E TYPICAL 4 PLACES 8 6 1 8 15 yy ,, ,, yy ,, yy ,,yy yy ,, 7 TYPICAL 2 PLACES 7 TYPICAL 2 PLACES 6 12 9 13 16 4 5 3 2 14 ELECTRIC VEHICLE ONLY 14 GASOLINE VEHICLE ONLY SEE REAR SUSPENSION— SECTION 6 FOR MOUNTING Page 5-2 1999 DS Golf Car Illustrated Parts List BRAKE ASSEMBLY ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 1 2 2 3 4 5 6 7 8 101823301 101823302 101824001 101824002 101816501 101816502 101823901 101823801 1010850 101823201 1011466 101816301 CLUSTER, BRAKE, PASSENGER SIDE (INCLUDES ITEMS 1 - 9) ......................... CLUSTER, BRAKE, DRIVER SIDE (INCLUDES ITEMS 1 - 9) .................................. ASSEMBLY, BACKING PLATE, PASSENGER SIDE (INCLUDES ITEMS 2 - 4) ... ASSEMBLY, BACKING PLATE, DRIVER SIDE (INCLUDES ITEMS 2 - 4) ............ MECHANISM, ADJUSTING, PASSENGER SIDE ............................................ MECHANISM, ADJUSTING, DRIVER SIDE ..................................................... WASHER .......................................................................................................... WASHER, PLATE ............................................................................................. COVER, DUST ....................................................................................................... PACKAGE, BRAKE SHOE (FOUR PIECES) ......................................................... KIT, SHOE RETAINER (FOUR PIECES) ............................................................... PACKAGE, BRAKE SPRING (FOUR PIECES) ...................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9 9 10 11 12 13 14 15 16 17 101815501 101815502 1013924 1014153 1010829 1035 101900801 1013207 1011779 101791101 ASSEMBLY, LEVER, PASSENGER SIDE .............................................................. ASSEMBLY, LEVER, DRIVER SIDE ....................................................................... NUT, HEX HEAD LOCK, GRADE 8, 5/16 - 24 ........................................................... BOLT, BRAKE CLUSTER MOUNTING ...................................................................... PIN, CLEVIS, 5/16 ...................................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. HANGER, BRAKE CABLE (GASOLINE VEHICLE ONLY) ......................................... HANGER, BRAKE CABLE (ELECTRIC VEHICLE ONLY) .......................................... E-CLIP, 1/2 .................................................................................................................. DRUM, BRAKE ........................................................................................................... 1 1 8 8 2 2 2 1 1 8 8 2 2 1999 DS Golf Car Illustrated Parts List 2 2 2 2 2 Page 5-3 5 G E 5 G OFF ON E 13 10 P O T S FLOORBOARD REMOVED FOR CLARITY TYPICAL 4 PLACES 14 5 23 18 22 30 19 17 12 16 21 TYPICAL 4 PLACES 24 20 15 SERVICE PART BRAKE PEDAL HAS SECOND WELDMENT 17 TYPICAL 2 PLACES 31 26 25 TYPICAL 2 PLACES 27 TYPICAL 4 PLACES 29 33 TYPICAL 2 PLACES 28 7 30 32 4 5 1 11 2 3 2 9 8 6 TYPICAL 2 PLACES Page 5-4 1999 DS Golf Car Illustrated Parts List BRAKE PEDAL AND CABLE ASSEMBLY ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1242 101865301 1017211 N/A 7473 1011403 1011779 1035 1010829 101954001 1013531 7716 NUT, HEX, 5/16 - 18 ................................................................................................... SPACER, EQUALIZER ............................................................................................... KIT, EQUALIZER AND PIVOT LIMITER (INCLUDES ITEM 4) ................................... PIN, EQUALIZER PIVOT ....................................................................................... NUT, NYLON LOCK, 5/16 - 18 ................................................................................... KIT, BRAKE CABLE (INCLUDES ITEMS 7 - 9) .......................................................... E-CLIP, 1/2 ............................................................................................................. PIN, COTTER, 3/32 x 1 .......................................................................................... PIN, CLEVIS, 5/16 ................................................................................................. KIT, BRAKE PEDAL (INCLUDES ITEMS 11 - 16, 19, 24 AND 32) ............................ SPRING, BRAKE RETURN ................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... 1 2 1 1 5 2 2 2 2 1 1 4 1 2 1 1 5 2 2 2 2 1 1 4 13 14 15 16 1013869 101953101 101953001 7473 101187702 N/A 1017029 1010877 1010805 1010932 1010933 1010927 1010878 1028 1011402 PAD, BRAKE PEDAL .............................................................................................. ROD, EQUALIZER ................................................................................................. BOLT, HEX HEAD SHOULDER, 3/8 x 1 ................................................................ NUT, NYLON LOCK, 5/16 - 18 .............................................................................. KIT, PARK BRAKE LATCH (INCLUDES ITEMS 17 - 21 AND 24 ON PAGE 5-6) ....... ROD AND PAWL ................................................................................................... PIN, COTTER, 7/64 x 1/2 ....................................................................................... NUT, PUSH, 5/16 ................................................................................................... SLEEVE, PARK BRAKE ROD ................................................................................ JOINT, BALL, 1/4 - 28 ............................................................................................ SPRING, PARK BRAKE TORSION ............................................................................ SPACER, PARK BRAKE ............................................................................................. BUMPER, RUBBER ................................................................................................... NUT, HEX, 1/4 - 20 ..................................................................................................... PACKAGE, BRAKE MOUNTING BLOCK (CONTAINS UPPER AND LOWER FOR DRIVER AND PASSENGER SIDES).................................................................. WASHER, FLAT, 5/16 ................................................................................................. SCREW, HEX HEAD CAP, 5/16 - 18 x 2-1/2 .............................................................. KIT, PARK BRAKE PEDAL (INCLUDES ITEMS 30 - 33) ........................................... BUSHING, NYLON ................................................................................................ SCREW, SLOTTED HEX WASHER HEAD, #10 -16 x 1/2 ..................................... NUT, PUSH, 3/8 ..................................................................................................... PAD, PARK BRAKE ................................................................................................ 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 2 2 1 1 1 4 4 1 2 2 1 1 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 1241 1010921 1011418 1032 7716 1013876 1013870 1999 DS Golf Car Illustrated Parts List Page 5-5 5 G E TYPICAL 4 PLACES 5 G 23 2 25 3 10 11 6 12 1 E 25 9 4 16 19 18 17 14 5 7 GASOLINE VEHICLE FRAME FOR REFERENCE ONLY 17 18 FLOORBOARD REMOVED FOR CLARITY TYPICAL 4 PLACES 15 8 21 20 TYPICAL 4 PLACES 22 23 21 24 Page 5-6 1999 DS Golf Car Illustrated Parts List 19 13 ACCELERATOR PEDAL ASSEMBLY ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1017696 1013871 7716 1624 1241 1017325 7473 332 1017424 101966901 101817401 101796201 SUB-ASSEMBLY, ACCELERATOR PEDAL (INCLUDES ITEM 2 AND 3) .................. PAD, PEDAL ........................................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... SCREW, HEX CAP, 3/8 - 16 x 1-1/2 ........................................................................... WASHER, FLAT, 5/16 ................................................................................................. ASSEMBLY, ACCELERATOR PIVOT ROD ................................................................ NUT, NYLON LOCK, 5/16 - 18 ................................................................................... WASHER, FLAT, 1/4 ................................................................................................... BEARING, PIVOT SUPPORT ..................................................................................... NUT, FLANGED LOCK, 1/4 - 28 ................................................................................. RETAINER, SPRING .................................................................................................. SPRING, RETURN ..................................................................................................... 1 1 4 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 1 13 14 15 16 17 1017378 1017380 8233 101818801 101871901 1 1 4 1 1 1 4 1 17 101912401 18 19 20 21 22 23 1011084 1011734 1011700 1011694 101861901 8754 101187702 24 25 N/A 334 CUP, SPRING ............................................................................................................. BUMPER, RETURN SPRING .................................................................................... NUT, NYLON LOCK, 1/4 - 20 ..................................................................................... STUD, BALL ............................................................................................................... ASSEMBLY, ACCELERATOR ROD (POWERDRIVE SYSTEM 48 AND V-GLIDE 36-VOLT VEHICLES) (INCLUDES ITEMS 18 AND 19).............................................. ASSEMBLY, ACCELERATOR ROD (GASOLINE VEHICLE ONLY) (INCLUDES ITEMS 18 AND 19) ................................................................................. NUT, UNF HEX JAM, 1/4 - 28 ............................................................................... JOINT, SPRING-LOADED BALL ........................................................................... SPACER .................................................................................................................... SUPPORT, ACCELERATOR PIVOT ROD .................................................................. SCREW, HEX CAP, 1/4 - 20 x 1-1/8 ........................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... KIT, PARK BRAKE LATCH (INCLUDES ITEM 24 AND ITEMS 17 - 21 ON PAGE 5-4) .................................................................................... RACHET, PARK BRAKE ........................................................................................ WASHER, FLAT, 3/8 ................................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 2 2 1 2 4 2 2 2 1 2 4 2 1 1 2 1 1 2 Page 5-7 5 G E STEERING, FRONT AND REAR SUSPENSION 6 G E 6 G 31 E 27 29 28 30 21 24 26 19 20 25 17 13 yy ,, ,, yy ,, yy 12 22 23 17 21 19 9 14 7 7 TYPICAL 2 PLACES 11 8 10 TYPICAL 2 PLACES 20 6 24 2 TYPICAL 3 PLACES 3 4 1 Page 6-2 16 yy ,y, yy, ,, yy ,, yy ,, yy ,, 5 18 18 15 1999 DS Golf Car Illustrated Parts List TYPICAL 2 PLACES STEERING COLUMN ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1013861 1017226 7174 101984801 1016663 1016269 334 1016183 8754 1014288 1011697 1012499 JOINT, COMPOUND STEERING (INCLUDES ITEMS 2 AND 3) ............................... SCREW, HEX HEAD CAP, M8 x 1.25 x 30MM ...................................................... WASHER, LOCK, 5/16 ........................................................................................... KIT, STEERING COLUMN MOUNTING BRACKET .................................................... SCREW, PHILLIPS, TYPE A, #12 - 11 x 5/8 .............................................................. SCREW, HEX WASHER HEAD THREAD FORMING, 5/16 - 18 x 2 .......................... WASHER, FLAT, 3/8 ................................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 7 ...................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SCREW, HEX WASHER HEAD THREAD FORMING, 5/16 - 18 x 3/4 ....................... WASHER, FLAT, 5/16 ................................................................................................. BOOT, STEERING COLUMN ..................................................................................... 1 3 3 1 2 2 4 2 2 1 1 1 1 3 3 1 2 2 4 2 2 1 1 1 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1016181 1012605 1012604 1014217 1014125 1014213 1014126 1015545 1016622 1014214 1014211 1016263 1016156 1017273 1016219 1012565 1012566 1016214 1016154 ASSEMBLY, STEERING COLUMN (INCLUDES ITEMS 14 - 23) .............................. RING, RETAINING ................................................................................................. WASHER, STEEL, 5/8 ........................................................................................... SPRING, COMPRESSION .................................................................................... WEDGE ................................................................................................................. ASSEMBLY, BEARING .......................................................................................... SEAT, BEARING .................................................................................................... SHAFT, STEERING COLUMN ............................................................................... COLUMN, ALUMINUM STEERING ....................................................................... RING, RETAINING ................................................................................................. SEAL, BEARING .................................................................................................... COVER, STEERING COLUMN .................................................................................. WHEEL, STEERING .................................................................................................. NUT, NYLON LOCK, 5/8 - 18 ..................................................................................... ASSEMBLY, SCORECARD PLATE (INCLUDES ITEMS 28 - 31) .............................. SCREW, ROUND HEAD, #12 - 14 x 1 ................................................................... SPRING, TAPERED COMPRESSION ................................................................... GRIP, PENCIL ........................................................................................................ CLIP, SCORE CARD .............................................................................................. 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 1999 DS Golf Car Illustrated Parts List Page 6-3 6 G E 22 23 26 6 G 27 28 1 E 2 25 3 4 21 24 11 10 9 8 5 7 6 12 29 13 30 TYPICAL 3 PLACES 31 TYPICAL 3 PLACES 19 16 17 yy ,, ,, yy ,, yy ,, yy Page 6-4 1999 DS Golf Car Illustrated Parts List 18 2 20 14 15 STEERING GEAR ASSEMBLY ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 101878302 1013035 8990 101880201 101880301 N/A N/A N/A 101879401 101879901 1013051 1013052 ASSEMBLY, STEERING GEAR BOX (INCLUDES ITEMS 1 - 20) ............................. SEAL, DUST, PASSENGER SIDE ......................................................................... WRAP, TIE .............................................................................................................. ASSEMBLY, INNER BALL JOINT .......................................................................... WASHER, TAB ....................................................................................................... BOX, STEERING GEAR ........................................................................................ BEARING, LOWER PINION .................................................................................. PINION, STEERING .............................................................................................. BEARING, UPPER PINION ................................................................................... RING, C-TYPE STOP ............................................................................................ RING, SNAP .......................................................................................................... SEAL, DUST, STEERING PINION ......................................................................... 1 1 2 1 2 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 101879701 101879801 1013044 N/A N/A 101879501 101879601 101880001 101880101 1035 7540 1015597 7602 1011930 7555 1012467 1013042 1624 334 8754 GUIDE, STEERING RACK .................................................................................... SPRING, YOKE ...................................................................................................... NUT, LOCK, RACK SCREW .................................................................................. SCREW, RACK GUIDE .......................................................................................... RACK, STEERING ................................................................................................. WASHER, STOP .................................................................................................... RING, C-TYPE STOP ............................................................................................ SEAL, DUST, DRIVER SIDE .................................................................................. RING, RETAINING ................................................................................................ PIN, COTTER, 3/32 x 1 .............................................................................................. BALL JOINT, LEFT-HAND THREAD (INCLUDES ITEMS 23, 24 AND 25) ................ FITTING, THREAD FORM GREASE, 1/4 - 28 ....................................................... NUT, HEX SLOTTED, 3/8 - 24 ............................................................................... BOOT, DUST........................................................................................................... NUT, HEX, LEFT-HAND THREAD, 1/2 - 20 ................................................................ LINK, RACK AND PINION DRAG .............................................................................. NUT, HEX, M12 x 1.75 ............................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 1- 1/2 ............................................................................ WASHER, FLAT, 3/8 ................................................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1999 DS Golf Car Illustrated Parts List Page 6-5 6 G E 6 G TYPICAL 2 PLACES 9 8 E REFERENCE STEERING GEAR 6 7 18 5 11 TYPICAL 4 PLACES 10 9 12 13 2 19 14 15 TYPICAL 3 PLACES 5 10 4 2 3 2 14 5 TYPICAL 2 PLACES 2 4 1 2 16 17 TYPICAL 4 PLACES 20 TYPICAL 3 PLACES 21 Page 6-6 1999 DS Golf Car Illustrated Parts List FRONT SUSPENSION, UPPER ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1016353 1016346 1016350 1016349 8754 7539 1308 1624 1010138 2402 1010219 7555 ASSEMBLY, DELTA A-PLATE (INCLUDES ITEMS 2, 3 AND 4) ................................. BUSHING, URETHANE ......................................................................................... SLEEVE, DELTA OUTER ....................................................................................... SLEEVE, DELTA INNER ........................................................................................ NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... BALL JOINT ............................................................................................................... NUT, HEX, 1/2 - 20 ..................................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 1-1/2 ............................................................................. NUT, DIMPLED LOCK, 3/8 - 16 .................................................................................. SCREW, HEX CAP, 3/8 - 16 x 2-1/4 ........................................................................... ROD, TIE ..................................................................................................................... NUT, HEX, LEFT-HAND THREAD, 1/2 - 20 ................................................................ 2 6 1 2 8 1 1 2 4 4 1 1 2 6 1 2 8 1 1 2 4 4 1 1 13 14 15 15 16 17 18 19 20 21 7540 1017266 1015813 1014235 1010124 1010200 1016385 1011930 7602 1035 BALL JOINT, LEFT-HAND THREAD ........................................................................... STRAP, A-PLATE ........................................................................................................ SHOCK ABSORBER, FRONT (GASOLINE VEHICLE ONLY) .................................... SHOCK ABSORBER, FRONT (ELECTRIC VEHICLE ONLY) .................................... PLATE, SPRING MOUNTING .................................................................................... BOLT, HEX HEAD, 3/8 - 16 x 4-1/4 ............................................................................. ASSEMBLY, DELTA SHOCK AND GEAR SUPPORT ................................................. SEAL, DUST ............................................................................................................... NUT, SLOTTED HEX, 3/8 - 24 .................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. 1 2 2 1 2 1999 DS Golf Car Illustrated Parts List 1 4 1 3 3 1 2 1 4 1 3 3 1 Page 6-7 6 G E 6 G REFERENCE STEERING GEAR ASSEMBLY E 15 17 18 14 16 19 3 30 TYPICAL 4 PLACES PASSENGER SIDE ONLY 2 1 5 DRIVER SIDE ONLY TYPICAL 4 PLACES 11 21 4 7 22 20 12 8 10 27 TYPICAL 4 PLACES 31 9 29 28 25 27 26 14 Page 6-8 1999 DS Golf Car Illustrated Parts List 23 13 6 32 10 24 FRONT SUSPENSION, LOWER ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 2 3 4 5 6 6 7 8 9 10 11 1010348 1010347 8067 7048 1015597 1015108 1012030 8745 706 1011892 1011393 1011304 ASSEMBLY, SPINDLE, DRIVER SIDE (INCLUDES ITEMS 3, 4 AND 5) ................... ASSEMBLY, SPINDLE, PASSENGER SIDE (INCLUDES ITEMS 3, 4 AND 5) .......... BUSHING, BRONZE SPINDLE ............................................................................. BUSHING, BRONZE .............................................................................................. FITTING, GREASE, 1/4 - 28 .................................................................................. SPRING, TAPERED LEAF (GASOLINE VEHICLE ONLY) ......................................... SPRING, TAPERED LEAF (ELECTRIC VEHICLE ONLY) .......................................... ECCENTRIC ............................................................................................................... NUT, HEX, 3/8 - 16 ..................................................................................................... ASSEMBLY, HUB (INCLUDES ITEMS 10 - 13) .......................................................... PACKAGE, HUB BEARING .................................................................................... STUD, LUG, 1/2 - 20 ............................................................................................... 1 1 1 1 1 1 1 1 2 2 4 1 1 1 2 2 4 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1013135 1011887 8754 1016387 1016384 101903101 1010028 1010150 1016389 1010984 1010005 7840 7910 8755 1016386 1015583 1012303 1014276 1624 357 706 SEAL, DOUBLE LIP ............................................................................................... COVER, DUST ....................................................................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 2-3/4 ................................................................ CLEVIS, UPPER DELTA ............................................................................................. NUT, NYLON LOCK, 1/2 - 20 ..................................................................................... WASHER, FLAT, 1/2 ................................................................................................... BEARING, THRUST ................................................................................................... WASHER, KINGPIN WAVE ........................................................................................ NUT, LUG ................................................................................................................... WASHER, FLAT, 3/4 ................................................................................................... NUT, HEX SLOTTED, 3/4 - 16 .................................................................................... PIN, COTTER, 5/32 x 1 .............................................................................................. SCREW, HEX HEAD CAP, 3/8 - 16 x 3-3/8 ................................................................ KINGPIN ..................................................................................................................... BUSHING, URETHANE ............................................................................................. BUSHING, STEEL ...................................................................................................... PLATE, FRONT SPRING RETAINER ......................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 1-1/2 ................................................................ WASHER, LOCK, 3/8 ................................................................................................. NUT, HEX, 3/8 - 16 ..................................................................................................... 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 1999 DS Golf Car Illustrated Parts List 1 1 1 1 1 Page 6-9 6 G E 6 G BRAKE CABLE HANGER MOUNTING— GASOLINE VEHICLE ONLY TYPICAL ON EACH SIDE OF VEHICLE E TYPICAL ON EACH SIDE OF VEHICLE 17 18 BRAKE CABLE HANGER MOUNTING— ELECTRIC VEHICLE ONLY 15 2 11 4 3 15 4 3 4 1 7 12 6 2 15 1 2 16 9 13 14 10 10 5 1999 DS Golf Car Illustrated Parts List 3 8 TYPICAL 2 PLACES 9 Page 6-10 4 4 REAR SUSPENSION ITEM PART NO. QTY QTY GAS ELEC DESCRIPTION 1 2 3 4 1 1 2 3 4 5 6 7 8 9 10 11 1012304 7569 8754 1012303 1015583 1010145 1013164 1014236 1011415 N/A N/A 1012180 SHACKLE, REAR SPRING (GASOLINE VEHICLE) .................................................. SHACKLE, REAR SPRING (ELECTRIC VEHICLE) ................................................... NUT, NYLON LOCK, 3/8 - 16 ..................................................................................... BUSHING, STEEL ...................................................................................................... BUSHING, URETHANE ............................................................................................. NUT, UNF HEX, 3/8 - 24 ............................................................................................. KIT, SHOCK ABSORBER (INCLUDES ITEMS 7, 9 AND 10) .................................... SHOCK ABSORBER, REAR ................................................................................. KIT, SHOCK ABSORBER CUSHION (INCLUDES ITEMS 9 AND 10) ....................... RETAINER, SHOCK ABSORBER CUSHION ........................................................ CUSHION, SHOCK ABSORBER ........................................................................... U-BOLT ....................................................................................................................... 12 12 13 14 15 16 16 17 18 1012324 1010974 1014557 1014555 8755 1012182 1012181 101900801 1013207 SPRING, REAR LEAF (GASOLINE VEHICLE) .......................................................... SPRING, REAR LEAF (ELECTRIC VEHICLE) .......................................................... WASHER, FLAT, 7/16 ................................................................................................. NUT, NYLON LOCK, 7/16 - 24 ................................................................................... SCREW, HEX HEAD CAP, 3/8 - 16 x 3-3/8 ................................................................ PAD, SPRING LEFT ................................................................................................... PAD, SPRING RIGHT ................................................................................................. HANGER, BRAKE CABLE (GASOLINE VEHICLE) ................................................... HANGER, BRAKE CABLE (ELECTRIC VEHICLE) .................................................... 1999 DS Golf Car Illustrated Parts List G 4 6 4 12 4 1 2 4 8 8 2 4 6 4 12 4 1 2 4 8 8 2 2 4 4 6 1 1 2 6 2 4 4 6 1 1 2 Page 6-11 E ELECTRICAL SYSTEM— GASOLINE VEHICLE 7 G 7 G 14 4 3 13 FORWARD / REVERSE ASSEMBLY CK B LA FRAME GROUND RED E WHIT E WHIT BLU CK A L B / LIMIT SWITCHES E CK B LA 2 ITE / WH RED YEL O 3 LOW RED E GRE ITE / WH CK 5 OIL LIGHT 2 E WHIT RED / E WHIT RED / WHITE 1 LIMIT SWITCHES CK BLA EEN GR OR K LAC TE/B WHI BLA 6 15 E A NG 7 K LAC E/B WHIT CK 4 E WHIT CK BLA BL U E FRAME GROUND SOLENOID E BLU R ED IRE ND W ROU G IDED RED WHITE / BLACK RED 16 RED ITE WH RED VOLTAGE REGULATOR BRA NGE O RA UND RO ED G ID BRA WHIT YELLOW BLACK RED 17 8 18 E WIR K LAC E/B WHIT FUSE BLOCK E STARTER / GENERATOR F2 DF A1 9 F1 A2 YELLOW WHITE BLACK BATTERY N OIL SENDING UNIT / BLACK YELLO YELLOW W WHITE BLACK 12 EE ENGINE YELLOW BLACK 10 GR YELLOW YELLOW RPM LIMITER FRAME GROUND 19 11 Page 7-2 1 N LOW REVERSE BUZZER WHITE BLUE BLA GE RAN KEY SWITCH 1 YEL 2 M- M+ 1999 DS Golf Car Illustrated Parts List WIRING—GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 101889302 N/A N/A N/A N/A N/A N/A 1015769 N/A N/A 1014119 N/A WIRE HARNESS (INCLUDES ITEMS 1 - 11) ......................................................................... WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 YELLOW AND #16 BLUE .............................................................. WIRE ASSEMBLY, #18 WHITE/BLACK AND #18 WHITE .................................................. WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 BLACK ........................................................................................... WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #16 RED AND #16 ORANGE ............................................................... WIRE ASSEMBLY, #16 YELLOW ........................................................................................ WIRE ASSEMBLY, #6 RED ................................................................................................. WIRE ASSEMBLY, #18 YELLOW ........................................................................................ 1 1 1 1 1 1 1 1 1 1 1 1 12 13 14 15 16 17 18 19 1012382 N/A N/A N/A 1015920 1015737 1015332 101837301 WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #18 BLACK (PART OF REVERSE BUZZER KIT) ..................................... WIRE ASSEMBLY, #16 ORANGE (PART OF THE ELECTRICAL COMPONENT BOX) ......... WIRE ASSEMBLY, #6 BRAIDED GROUND ............................................................................ WIRE ASSEMBLY, #10 RED (PART OF THE ELECTRICAL COMPONENT BOX) ................. WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ 1 1 1 1 1 1 1 1 1999 DS Golf Car Illustrated Parts List Page 7-3 7 G 7 22 23 G 2 21 3 24 4 9 1 5 6 NC NO M CO 25 8 8 2 11 13 10 12 14 20 26 19 7 18 16 17 15 27 19 28 24 29 30 Clu bC Club Car Club Car Page 7-4 1999 DS Golf Car Illustrated Parts List ar 20 FORWARD/REVERSE SHIFTER ASSEMBLY— GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 1016947 1012594 8057 1012431 101979101 1014807 8058 1013591 1014145 1014727 1016342 1014089 ASSEMBLY, FORWARD/REVERSE SHIFTER (INCLUDES ITEMS 1 - 17) ............................ SCREW, MACHINE, #4 - 40 x 1 1/2 ................................................................................... NUT, HEX HEAD, #4 - 40 .................................................................................................... WASHER, FLAT, #4 ............................................................................................................. SWITCH, LIMIT ................................................................................................................... SWITCH, LIMIT ................................................................................................................... WASHER, LOCK, #4 ........................................................................................................... PIN, ROLL, 1/8 .................................................................................................................... BUSHING, BRONZE ........................................................................................................... WASHER, NYLON FLAT, #4 ............................................................................................... BASE, FORWARD/REVERSE SHIFTER ............................................................................ KIT, NEUTRAL LOCK-OUT CAM (INCLUDES ITEM 12) ................................................... 1 2 4 4 1 1 2 1 2 2 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1014065 1013590 1013589 8717 1013587 1010954 101951501 7893 1012333 1013198 1012987 8248 8233 1016201 8251 101855801 332 101922601 1012285 WASHER, FLAT ............................................................................................................. SPRING, FORWARD/REVERSE CAM ............................................................................... RING, RETAINING .............................................................................................................. NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. WELDMENT, FORWARD/REVERSE BELL CRANK .......................................................... STUD, BALL, 1/4 - 28 x 1/4 ................................................................................................. CABLE, TRANSMISSION (INCLUDES ITEMS 19 AND 20) ................................................... NUT, HEX, #10 - 32 ............................................................................................................. JOINT, BALL ....................................................................................................................... SCREW, PHILLIPS OVAL COUNTERSUNK MACHINE, #8 - 32 x 5/8 ................................... HANDLE, FORWARD/REVERSE SWITCH ............................................................................ SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 3/4 ................................................................... NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. WASHER, WAVE, 3/8 .............................................................................................................. SCREW, PHILLIPS HEAD, 1/4 - 20 x 1 .................................................................................... RETAINER, CABLE ................................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................ BRACKET, TRANSMISSION CABLE SUPPORT .................................................................... SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... 1 1 1 1 1 1 1 2 2 1 1 4 8 1 4 1 4 1 3 1999 DS Golf Car Illustrated Parts List Page 7-5 7 G 7 2 G 1 10 TYPICAL 2 PLACES 11 REFERENCE ACCELERATOR CABLE 12 3 13 ORANGE WIRE ASSEMBLY 15 10 19 TYPICAL 2 PLACES 14 4 2 16 17 TYPICAL 2 PLACES 20 5 TYPICAL 2 PLACES TYPICAL 2 PLACES 18 10 21 22 23 2 TYPICAL 2 PLACES 26 TYPICAL 2 PLACES 24 5 25 6 REFERENCE ACCELERATOR ROD TYPICAL 2 PLACES FRO NT VEH OF ICLE 7 8 28 Page 7-6 27 1999 DS Golf Car Illustrated Parts List 9 ELECTRICAL COMPONENT BOX— GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 101827601 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1015372 1015752 1013589 1015373 1014145 1014065 1010954 101821301 8717 8057 8058 1014807 1014808 1012431 N/A 1015878 101856102 1015777 7893 1242 1013609 1012295 1015737 1015741 1015371 1015405 1241 7473 2 3 QTY 4 BOX, ELECTRICAL COMPONENT, COMPLETE (INCLUDES ITEMS 1 - 25 AND 101889302—SEE PAGE 7-3)................................................ COVER, ELECTRICAL COMPONENT BOX ...................................................................... SCREW, HI-LO, #12 - 16 x 5/8 ............................................................................................ RING, RETAINING .............................................................................................................. CAM, ELECTRICAL BOX .................................................................................................... BUSHING, BRONZE ........................................................................................................... WASHER, FLAT .................................................................................................................. STUD, BALL, 1/4 - 28 .......................................................................................................... ASSEMBLY, BELL CRANK SHAFT ..................................................................................... NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. NUT, HEX, #4 - 40 ............................................................................................................... WASHER, LOCK, #4 ........................................................................................................... SWITCH, LIMIT ................................................................................................................... SWITCH, LIMIT ................................................................................................................... WASHER, FLAT, #4 ............................................................................................................. WIRE ASSEMBLY, #16 ORANGE ....................................................................................... SCREW, HEX HEAD MACHINE, #4 - 40 x 1-5/8 ................................................................ SCREW, HEX WASHER HEAD HI-LO, 1/4 - 15 x 1-1/2 .................................................... ASSEMBLY, VOLTAGE REGULATOR ................................................................................. NUT, HEX, #10 - 32 ............................................................................................................. NUT, HEX, 5/16 - 18 ............................................................................................................ SOLENOID, 12-VOLT .......................................................................................................... FUSE, 10-AMP ................................................................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... BLOCK, FUSE .................................................................................................................... BOX, ELECTRICAL COMPONENT .................................................................................... BOLT, CARRIAGE, 5/16 - 18 x 2 ............................................................................................. WASHER, FLAT, 5/16 .............................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ 1999 DS Golf Car Illustrated Parts List 7 G 1 1 5 1 1 2 1 1 1 1 4 2 1 1 2 1 2 1 1 2 2 1 1 1 1 1 2 2 2 Page 7-7 7 G 5 6 TYPICAL 4 PLACES OFF ON 7 M- 1 2 TYPICAL 4 PLACES M+ 10 AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED 8 4 3 2 1 OFF ON 13 14 TYPICAL 3 PLACES Page 7-8 1999 DS Golf Car Illustrated Parts List 9 11 12 ELECTRICAL COMPONENTS— GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 1016859 1016849 1016851 N/A 1011229 1015720 101830601 101826301 101851101 101830701 101834502 1012505 KIT, REVERSE BUZZER (INCLUDES ITEMS 2, 3 AND 4) ..................................................... SCREW, PAN HEAD HI-LO, #4 - 24 x 5/16 ......................................................................... BUZZER, REVERSE ........................................................................................................... WIRE ASSEMBLY, #18 BLACK ........................................................................................... NUT, K LOCK, #6 - 32 ............................................................................................................. BOLT, HEX WASHER HEAD, #6 - 32 x 1/2 ............................................................................. ASSEMBLY, SCREW AND WASHER ...................................................................................... SWITCH, KEY ......................................................................................................................... WASHER ................................................................................................................................. NUT, KEY SWITCH ................................................................................................................. CAP, KEY SWITCH (BLACK) .................................................................................................. KEY (PAIR) .............................................................................................................................. 1 2 1 1 1 1 4 1 1 1 1 1 13 14 1016630 101900101 LIGHT, OIL WARNING ............................................................................................................. RETAINER, HARNESS ........................................................................................................... 1 3 1999 DS Golf Car Illustrated Parts List Page 7-9 7 G 7 G TYPICAL 2 PLACES TYPICAL 3 PLACES 30 TYPICAL 4 PLACES 15 27 29 21 TYPICAL 2 PLACES TYPICAL 25 2 PLACES 24 23 14 TYPICAL 4 PLACES TYPICAL 4 PLACES 22 18 TYPICAL 2 PLACES AT F1 AND F2 TERMINALS 20 TYPICAL 2 PLACES AT A1 AND A2 TERMINALS 17 19 26 DF TERMINAL 16 28 TYPICAL 2 PLACES 12 1 TYPICAL 3 PLACES 7 11 5 8 9 2 3 10 4 6 13 31 Page 7-10 1999 DS Golf Car Illustrated Parts List STARTER/GENERATOR ASSEMBLY ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 101833701 101875201 101875101 101875001 1013001 1013005 101939901 1013003 101876501 N/A N/A N/A STARTER/GENERATOR (CLOCKWISE ROTATION) (INCLUDES ITEMS 1 - 30) .................. HOUSING, FIELD COIL ...................................................................................................... ASSEMBLY, ARMATURE (INCLUDES ITEMS 3, 4 AND 5) ................................................ RETAINER, BEARING ................................................................................................... BALL BEARING, OUTPUT SHAFT ............................................................................... COMMUTATOR, BALL BEARING .................................................................................. SPACER, 5/16 .................................................................................................................... KEY, WOODRUFF ............................................................................................................... KIT, PULLEY NUT AND SCREW (INCLUDES ITEMS 9 - 12) ............................................ WASHER, LOCK, M14 .................................................................................................. NUT, HEX, M14 x 2 ........................................................................................................ SCREW, CROSS - RECESSED, M5 x .8 x 18MM ......................................................... 1 1 1 1 1 1 1 1 1 1 1 3 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 101896501 101874901 101875301 101875401 101875501 101875601 101877601 101875701 101877701 101301102 101878101 101869302 101876202 101875802 101876001 101876301 1017653 101876402 101879001 1014289 SCREW, CROSS - RECESSED, M5 x .8 x 16MM (WITH LOCK WASHER) ...................... END BELL, OUTPUT SHAFT ............................................................................................. SET, POLE (SET OF 4) ....................................................................................................... SCREW, POLE PIECE (SET OF 4) .................................................................................... ASSEMBLY, FIELD COIL .................................................................................................... SET, F TERMINAL INSULATOR ......................................................................................... PACKAGE, TERMINAL HARDWARE (F1 AND F2) ............................................................ SET, DF TERMINAL INSULATOR ....................................................................................... PACKAGE, TERMINAL HARDWARE (DF) ......................................................................... HOLDER, BRUSH (INCLUDES ITEMS 22 - 25) ................................................................. SPRING, BRUSH ........................................................................................................... PACKAGE, BRUSH (INCLUDES 4 BRUSHES, 4 SCREWS, 4 WASHERS) ................. ASSEMBLY, BRUSH CONNECTOR .............................................................................. A CONNECTOR (SET OF 2) ......................................................................................... PACKAGE, TERMINAL HARDWARE (A1 AND A2) ............................................................ COVER, BRUSH INSPECTION PORT (SET OF 4) (INCLUDES ITEM 28) ........................ COVER, BRUSH INSPECTION PORT, WITH DRAIN ................................................... END BELL, COMMUTATOR ................................................................................................ BOLT, CLAMP, M6 x 1 x 180MM ......................................................................................... PULLEY (SILVER COLOR) ..................................................................................................... 2 1 1 1 1 2 2 1 1 1 4 1 2 1 2 1 1 1 2 1 1999 DS Golf Car Illustrated Parts List Page 7-11 7 G 7 17 FRAME CONNECTION G 16 15 14 AS VIEWED FROM DRIVER SIDE OF VEHICLE A1 TERMINAL F1 TERMINAL A2 TERMINAL TYPICAL 2 PLACES 7 5 13 8 9 6 8 9 1 2 F2 DF 3 4 12 9 AS VIEWED FROM PASSENGER SIDE OF VEHICLE 11 10 Page 7-12 1999 DS Golf Car Illustrated Parts List STARTER/GENERATOR MOUNTING ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 101833701 101524001 101916701 1016883 8754 1015075 705 101903501 7174 1016074 1015932 1242 STARTER/GENERATOR ......................................................................................................... BRACKET, MOUNTING, FE 290 ............................................................................................. BELT ........................................................................................................................................ BRACKET, ADJUSTING .......................................................................................................... NUT, NYLON LOCK, 3/8 - 16 .................................................................................................. WASHER, FLAT, 5/16 .............................................................................................................. BOLT, HEX HEAD, 3/8 - 16 x 1 1/4 .......................................................................................... SCREW, HEX HEAD CAP, M8 x 1.25 x 24MM ........................................................................ WASHER, LOCK, 5/16 ............................................................................................................ SCREW, TORX HEAD, M8 x 1.25 x 18MM ............................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................................. NUT, HEX, 5/16 - 18 ................................................................................................................ 1 1 1 1 2 1 2 2 3 1 1 1 13 14 15 16 17 101837301 1015920 7473 1241 7173 WIRE ASSEMBLY, #6 GREEN ............................................................................................... WIRE ASSEMBLY, #6 BRAIDED GROUND ............................................................................ NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. SCREW, HEX HEAD CAP, 5/16 - 18 x 3/4 .............................................................................. 1 1 1 1 1 1999 DS Golf Car Illustrated Parts List Page 7-13 7 G AS SEEN FROM PASSENGER SIDE OF VEHICLE 7 1 G 2 3 4 Club Car ClubC ar 5 TO NEGATIVE BATTERY POST TERMINAL 9 7 8 7 8 Page 7-14 1999 DS Golf Car Illustrated Parts List AS SEEN FROM DRIVER SIDE OF VEHICLE 6 BATTERY—GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 1012328 1014374 1014375 1010934 101898001 7173 1241 7473 1014288 2 3 QTY 4 BATTERY, 12-VOLT ................................................................................................................. SPACER, BATTERY TERMINAL BOLT ................................................................................... SCREW, HEX HEAD CAP, STAINLESS STEEL, 3/8 - 16 x 1/2 ............................................... BOLT, HEX HEAD, 5/16 - 18 x 1 ............................................................................................. CLAMP, BATTERY ................................................................................................................... SCREW, HEX CAP, 5/16 - 18 x 3/4 ......................................................................................... WASHER, FLAT, 5/16 .............................................................................................................. NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ SCREW, THREAD-FORMING, 5/16 - 18 x 3/4 ....................................................................... 1999 DS Golf Car Illustrated Parts List 1 2 2 1 1 1 2 2 1 Page 7-15 7 G FE 290 ENGINE 8 G 8 G 1 TYPICAL 6 PLACES 8 3 4 2 9 TYPICAL 3 PLACES 17 18 TYPICAL 4 PLACES 4 TYPICAL 2 PLACES 5 7 6 TYPICAL 2 PLACES CARBURETOR REMOVED FOR CLARITY 16 15 5 10 TYPICAL 3 PLACES 4 14 12 11 Page 8-2 1999 DS Golf Car Illustrated Parts List 13 FE 290 ENGINE— SHROUDS AND BRACKETS ITEM PART NO. DESCRIPTION 1 101953901 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1016507 1016512 1016524 1016456 1016547 101909701 1016526 1017221 101915601 1016525 1016443 1016539 1016536 1016531 1011114 1015332 1015969 1015649 2 3 QTY 4 FE 290 OHV GASOLINE ENGINE (CLOCKWISE ROTATION) WITH CARBURETOR (DOES NOT INCLUDE ITEMS 15 THROUGH 18) .................................................................. BOLT, 2-ENDED, M6 x 1 x 29MM ....................................................................................... WASHER, FLAT, 6MM ......................................................................................................... SHROUD, ENGINE, FE 290 ............................................................................................... BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... NUT, M6 x 1 ........................................................................................................................ BOLT, 2-ENDED, M6 x 1 x 27MM ....................................................................................... SHROUD, ENGINE, FE 290 (LOWER) ............................................................................... SCREW, 2-ENDED, M6 x 1 x 46MM ................................................................................... HOUSING, FAN .................................................................................................................. SHROUD, ENGINE, FE 290 (UPPER) ................................................................................ BRACKET ............................................................................................................................ O-RING ............................................................................................................................... TUBE, OIL FILLER, FE 290 ................................................................................................ DIPSTICK ........................................................................................................................... NUT, M6 x1 .............................................................................................................................. WIRE ASSEMBLY, #10 BRAIDED GROUND .......................................................................... SCREW, PAN HEAD, M6 x 1 x 14MM ..................................................................................... SHROUD, FAN ........................................................................................................................ 1999 DS Golf Car Illustrated Parts List 1 1 1 1 15 3 1 1 1 1 1 1 1 1 1 1 1 3 1 Page 8-3 8 G 8 G 11 12 13 10 9 8 7 TYPICAL 2 PLACES 1 2 TYPICAL 3 PLACES 3 19 yy ,, ,, yy 18 16 24 23 21 20 17 15 14 TYPICAL 2 PLACES Page 8-4 5 22 1999 DS Golf Car Illustrated Parts List 4 25 6 FE 290 ENGINE— IGNITION COMPONENTS AND FLYWHEEL ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 101915701 101915801 1017448 1016548 1016505 1017455 1016562 1016455 101909201 1016578 1016588 1016493 FLYWHEEL ......................................................................................................................... FAN, FLYWHEEL, GRAY .................................................................................................... SCREW, FLANGED HEX HEAD, M6 x 1 x 10MM .............................................................. WASHER, FLAT, 16MM ....................................................................................................... NUT, HEX, M16 x 2 ............................................................................................................. PLATE, FLYWHEEL FAN .................................................................................................... KEY ..................................................................................................................................... BOLT, FLANGED, M5 x .8 x 25MM ..................................................................................... COIL, IGNITION (WITH INTERNAL IGNITER) ................................................................... GROMMET ......................................................................................................................... TUBE, 7MM x 70MM ........................................................................................................... ASSEMBLY, PLUG CAP ..................................................................................................... 1 1 3 1 1 1 1 2 1 1 1 1 13 14 15 16 17 18 19 20 21 22 23 24 25 1016111 1016456 1012981 1016579 1016586 101909401 1016445 101909501 1016497 1016544 1016561 1016587 101909301 SPARK PLUG—OHV .......................................................................................................... BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... CLAMP ................................................................................................................................ MOUNT, RPM LIMITER ...................................................................................................... DAMPER, RPM LIMITER .................................................................................................... LIMITER, RPM—OHV ......................................................................................................... BRACKET, RPM LIMITER .................................................................................................. CLAMP ................................................................................................................................ SCREW, CROSS PAN HEAD, M5 x .8 x 8MM .................................................................... SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... CLAMP ................................................................................................................................ CLAMP ................................................................................................................................ WIRE, LEAD ....................................................................................................................... 1 2 1 1 1 1 1 1 1 1 1 1 1 1999 DS Golf Car Illustrated Parts List Page 8-5 8 G 8 G 14 13 12 4 11 TYPICAL 2 PLACES 9 10 3 y , , y 2 8 6 5 1 7 TYPICAL 6 PLACES Page 8-6 1999 DS Golf Car Illustrated Parts List FE 290 ENGINE— OIL CIRCULATION ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 1016467 1016502 1016457 1016570 1016576 1016432 1017456 1016484 1016435 1016473 101648203 1016429 ASSEMBLY, OIL FILTER, OHV ........................................................................................... BRACKET, OIL FILTER ....................................................................................................... BOLT, FLANGED HEX HEAD, M6 x 1 x 40MM ................................................................... O-RING, OIL FILTER MOUNT ............................................................................................ PLUG, DRAIN, FE 290 ....................................................................................................... GASKET, DRAIN PLUG ...................................................................................................... SCREW, FLANGED HEX HEAD, M6 x 1 x 12MM .............................................................. COVER, PUMP ................................................................................................................... GASKET, OIL PUMP ........................................................................................................... PLATE, OIL PUMP .............................................................................................................. PUMP, OIL, AND ROTOR ................................................................................................... SEAT, VALVE ....................................................................................................................... 1 1 2 1 1 1 6 1 1 1 1 1 13 14 1016537 1016581 BALL, STEEL, PRESSURE RELIEF .................................................................................. SPRING .............................................................................................................................. 1 1 1999 DS Golf Car Illustrated Parts List Page 8-7 8 G 8 G 5 6 7 TYPICAL 2 PLACES 8 9 10 14 1 15 2 12 13 EXHAUST 16 18 INTAKE 19 17 20 22 11 TYPICAL 2 PLACES AT EXHAUST CONNECTION TYPICAL 2 PLACES 21 3 4 TYPICAL 2 PLACES 23 25 26 24 TYPICAL 2 PLACES Page 8-8 27 TYPICAL 6 PLACES 1999 DS Golf Car Illustrated Parts List 28 FE 290 ENGINE— CYLINDER HEAD ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 1016442 1016436 1016583 1016569 1016545 1016542 1016451 1016450 1016449 1016523 1016431 1016560 CASE, ROCKER ................................................................................................................. GASKET, ROCKER CASE .................................................................................................. BOLT, FLANGED, M6 x 1 x 35MM ...................................................................................... O-RING ............................................................................................................................... NUT, HEX, M5 x .8 .............................................................................................................. SCREW, STUD, M5 x .8 ...................................................................................................... ARM, ROCKER ................................................................................................................... COLLET ............................................................................................................................... RETAINER, VALVE SPRING ............................................................................................... SPRING, ENGINE VALVE ................................................................................................... ASSEMBLY, CYLINDER HEAD, OHV (INCLUDES ITEMS 12 AND 13) ............................. RING, SNAP .................................................................................................................. 1 1 2 2 2 2 2 2 2 2 1 2 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1016519 1016479 1016566 1016448 1016447 1016544 1016474 1016483 1016563 1016489 1016452 1016471 1016549 1016517 1016458 1016430 GUIDE, VALVE ............................................................................................................... SEAT, SPRING .................................................................................................................... SEAL, VALVE ...................................................................................................................... VALVE, EXHAUST .............................................................................................................. VALVE, INTAKE ................................................................................................................... SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... PLATE ................................................................................................................................. VALVE ................................................................................................................................. PIN ...................................................................................................................................... BOLT, STUD, M8 x 1.25 x 29MM ........................................................................................ SHAFT, ROCKER ............................................................................................................... ROD, PUSH ........................................................................................................................ WASHER, FLAT, M12 .......................................................................................................... CIRCLIP, TYPE E ................................................................................................................ BOLT, FLANGED, M8 x 1.25 x 45MM ................................................................................. GASKET, HEAD .................................................................................................................. 2 2 2 1 1 1 1 1 2 2 1 2 1 1 6 1 1999 DS Golf Car Illustrated Parts List Page 8-9 8 G 8 G TYPICAL 2 PLACES 5 1 CLAMP ONLY 2 yyyyy ,,,,, ,,,,, yyyyy ,,,,, yyyyy ,,,,, yyyyy ,,,,, yyyyy ,,,,, yyyyy ,,,,, yyyyy ,,,,, yyyyy 4 3 7 6 18 17 16 15 14 13 TYPICAL 2 PLACES TYPICAL 3 PLACES 12 11 TYPICAL 2 PLACES 10 20 20 19 9 8 TYPICAL 6 PLACES TYPICAL 2 PLACES Page 8-10 1999 DS Golf Car Illustrated Parts List FE 290 ENGINE— CRANKCASE, CAMSHAFT AND OIL SENSOR ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 1016535 1016538 1016506 1016544 1016564 1016565 1016567 1016584 1016458 1016520 1016446 1016456 CONNECTOR, CORD ........................................................................................................ O-RING ............................................................................................................................... CLAMP ................................................................................................................................ SCREW, CROSS PAN HEAD SELF-TAPPING, M5 x .8 x 12MM ....................................... PIN ...................................................................................................................................... BEARING, BALL ................................................................................................................. SEAL, CRANKSHAFT ........................................................................................................ BOLT, 2-ENDED, M8 x 1.25 x 69MM .................................................................................. BOLT, FLANGED, M8 x 1.25 x 45MM ................................................................................. COVER, CRANKCASE ....................................................................................................... GASKET, CRANKCASE COVER ........................................................................................ BOLT, FLANGED, M6 x 1 x 12MM ...................................................................................... 1 1 1 1 2 1 1 2 6 1 1 2 13 14 15 16 17 18 19 20 1016510 1016494 1016496 1016454 1016472 1016521 101915401 1016453 BRACKET, OIL LEVEL SWITCH ........................................................................................ SENSOR, OIL LEVEL ......................................................................................................... SCREW, CROSS PAN HEAD, M4 x .7 x 8MM .................................................................... BOLT, FLANGED, M5 x .8 x 8MM ....................................................................................... PLATE, OIL FILTER SCREEN ............................................................................................ SCREEN, OIL FILTER ........................................................................................................ CAMSHAFT, COMPLETE ................................................................................................... TAPPET ............................................................................................................................... 1 1 3 2 1 1 1 2 1999 DS Golf Car Illustrated Parts List Page 8-11 8 G 8 G 6 3 4 1 2 8 TYPICAL 2 PLACES 3 5 7 7 9 14 16 12 13 12 17 13 TYPICAL 4 PLACES 11 20 TYPICAL 4 PLACES 18 Page 8-12 1999 DS Golf Car Illustrated Parts List 21 10 15 19 FE 290 ENGINE— CRANKCASE AND CRANKSHAFT ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 5 5 6 6 6 7 7 1016568 101915501 1016558 1016460 101645901 101645902 101645903 101646101 101646102 101646103 101647501 101647502 8 9 10 11 12 13 14 15 15 15 15 15 15 15 15 15 16 17 18 19 20 21 1016509 101922301 1016533 1016532 1016516 1016580 1016562 101655001 101655002 101655003 101655004 101655005 101655006 101655007 101655008 101655009 1016559 1016541 1016547 1016470 1016571 1016469 2 3 QTY 4 SEAL, OIL ........................................................................................................................... CRANKCASE, COMPLETE, OHV ...................................................................................... RING, SNAP ....................................................................................................................... PIN, PISTON ....................................................................................................................... PISTON, STANDARD .......................................................................................................... PISTON, .25MM OVERSIZED ............................................................................................ PISTON, .50MM OVERSIZED ............................................................................................ RING SET, PISTON, STANDARD ....................................................................................... RING SET, PISTON, .25MM OVERSIZED .......................................................................... RING SET, PISTON, .50MM OVERSIZED .......................................................................... ASSEMBLY, CONNECTING ROD, STANDARD (INCLUDES 2 EACH OF ITEM 8) ............ ASSEMBLY, CONNECTING ROD, .50MM UNDERSIZED (INCLUDES 2 EACH OF ITEM 8) ....................................................................................... BOLT, HEX HEAD, M7 x 1 x 36MM ................................................................................ CRANKSHAFT, OHV (INCLUDES ITEMS 10, 11 AND ONE EACH OF ITEM 12) ............. GEAR, HELICAL ............................................................................................................ GEAR, SPUR ................................................................................................................. ASSEMBLY, CONNECTING ROD (INCLUDES ONE EACH OF ITEM 13) .................... BEARING, PLAIN ..................................................................................................... KEY ..................................................................................................................................... SHIM, CRANKSHAFT, 1.13MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.18MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.23MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.28MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.33MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.38MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.43MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.48MM THICK ............................................................................... SHIM, CRANKSHAFT, 1.53MM THICK ............................................................................... SPACER .............................................................................................................................. BOLT, STUD, M6 x 1 x 22MM ............................................................................................. NUT, FLANGED, M6 x 1 ...................................................................................................... SHAFT, GUIDE COUNTERBALANCE ................................................................................ O-RING ............................................................................................................................... WEIGHT, COUNTERBALANCE .......................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 A/R A/R A/R A/R A/R A/R A/R A/R A/R 1 4 4 1 1 1 Page 8-13 8 G 3 8 G 1 2 TYPICAL 2 PLACES 4 TYPICAL 2 PLACES FR O VE NT O HIC F LE REFERENCE ENGINE SECTION 8 TYPICAL 4 PLACES 5 Clu 9 TYPICAL 2 PLACES bC ar 12 13 10 6 TYPICAL 2 PLACES 6 7 11 8 14 TYPICAL 4 PLACES 15 16 Clu bC ar TYPICAL 2 PLACES 17 9 10 TYPICAL 4 PLACES Page 8-14 1999 DS Golf Car Illustrated Parts List REFERENCE UNITIZED TRANSAXLE— SECTION 12 ENGINE MOUNTING ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 7473 1241 101864601 7818 1012164 1013924 101834601 101827101 101833001 101884801 101833301 101833201 NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ WASHER, FLAT, 5/16 - 18 ...................................................................................................... RETAINER, SNUBBER ........................................................................................................... BOLT, CARRIAGE, 5/16 - 18 x 1-1/2 ....................................................................................... SNUBBER ............................................................................................................................... NUT, HEX LOCK, 5/16 - 24, UNF ........................................................................................... BRACKET, SNUBBER ............................................................................................................. PLATE, MOUNTING ................................................................................................................ NUT, FLANGE, M8 x 1.25 ....................................................................................................... SCREW, HEX WASHER, 5/16 -24 x 7/8 .................................................................................. SCREW, HEX HEAD CAP, M10 x 1.25 x 30MM ...................................................................... STUD, M8 x 1.25 x 60MM ........................................................................................................ 2 2 1 2 1 6 1 1 6 6 4 2 13 14 15 16 17 101832101 101832901 1012571 101855901 101832701 SPACER .................................................................................................................................. NUT, FLANGE, M10 x 1.25 ..................................................................................................... WASHER, HEAVY FLAT, 5/16 ................................................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 43MM ........................................................................ STIFFENER, FLYWHEEL SIDE .............................................................................................. 2 4 4 4 1 1999 DS Golf Car Illustrated Parts List Page 8-15 8 G FUEL, INTAKE, AND GOVERNOR SYSTEMS 9 G 9 G 4 5 11 3 2 6 10 7 8 9 1 17 ENGINE REMOVED FOR CLARITY 19 18 21 20 21 21 SEE ITEM SIX ABOVE 21 19 12 13 21 21 14 16 23 19 15 19 21 19 5 21 22 21 TO ENGINE CRANKCASE Page 9-2 1999 DS Golf Car Illustrated Parts List FUEL SYSTEM ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 1016003 1015188 1015143 1015139 1015137 101896901 1016059 101824401 101955601 1014928 1013746 1014523 KIT, FUEL TANK, (INCLUDES ITEMS 2 - 8) ........................................................................... CAP, FUEL TANK, NONVENTED ........................................................................................ ASSEMBLY, FUEL TANK VENT .......................................................................................... GROMMET, INSULATION ................................................................................................... LINE, BULK VENT (AVAILABLE BY THE FOOT) ............................................................... VALVE, FUEL PICKUP TUBE WITH SHUT-OFF ................................................................ CLIP, STUD ......................................................................................................................... BARB, VENT ....................................................................................................................... T-FITTING ............................................................................................................................... ASSEMBLY, REAR FUEL STRAP ........................................................................................... CLAMP, HOSE ........................................................................................................................ PUMP, FUEL IMPULSE ............................................................................................................ 1 1 1 1 A/R 1 1 1 1 1 1 1 13 14 15 16 17 18 19 20 21 22 23 1014524 1017203 101987701 8233 1014116 1011988 1013692 1013684 1012649 1014522 1013687 REBUILD KIT, FUEL IMPULSE PUMP ................................................................................... 1 BOLT, CARRIAGE, 1/4 - 20 x 1 ............................................................................................... 2 CLAMP, HOSE ......................................................................................................................... 1 NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. 2 NUT, U-TYPE SPEED, 1/4 - 20 ............................................................................................... 2 SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 2 ...................................................................... 2 LINE, BULK FUEL (GRAY) ...................................................................................................... A/R* FILTER , PRIMARY FUEL (WHITE) ......................................................................................... 1 CLAMP, HOSE (RED) .............................................................................................................. 9 FILTER, SECONDARY FUEL (BLUE) ..................................................................................... 1 CLAMP, HOSE, 3/8 .................................................................................................................. 1 * THE TOTAL FUEL LINE LENGTH FOR THE DS GOLF CAR IS 47 INCHES. 1999 DS Golf Car Illustrated Parts List Page 9-3 9 G 9 G 2 3 1 4 5 8 6 9 7 10 11 Page 9-4 1999 DS Golf Car Illustrated Parts List CARBURETOR ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 101905601 1016501 N/A 101973101 1016486 101973201 7 7 7 7 7 8 9 10 11 2 3 QTY 4 101642582 101642580 101642578 101642575 101642572 ASSEMBLY, CARBURETOR (INCLUDES ITEMS 2 - 11) ....................................................... ASSEMBLY, IDLE SCREW ................................................................................................. ASSEMBLY, PILOT AIR SCREW ........................................................................................ JET, PILOT, #40 .................................................................................................................. ASSEMBLY, FLOAT ............................................................................................................. NOZZLE, MAIN ................................................................................................................... STANDARD JETTING: JET, MAIN, 0 - 3,000 FEET ................................................................................................. JET, MAIN, 3,000 - 5,000 FEET .......................................................................................... JET, MAIN, 5,000 - 8,000 FEET .......................................................................................... JET, MAIN, 8,000 - 10,000 FEET ........................................................................................ JET, MAIN, 10,000 FEET AND ABOVE .............................................................................. A/R A/R A/R A/R A/R 1016437 1017461 1016499 1016585 GASKET, FLOAT CHAMBER .............................................................................................. ASSEMBLY, FLOAT CHAMBER (INCLUDES ITEM 10) ..................................................... ASSEMBLY, SCREW ..................................................................................................... ASSEMBLY, BOLT ............................................................................................................... 1 1 1 1 1999 DS Golf Car Illustrated Parts List 1 1 1 1 1 1 Page 9-5 9 G 9 G 1 2 3 19 yyy ,,, ,,, yyy ,,, yyy ,,, yyy ,,,, yyyy ,,,, yyyy 4 5 6 7 8 9 13 14 yyy ,,, ,,, yyy ,,, yyy 13 11 15 17 TYPICAL 2 PLACES Page 9-6 18 1999 DS Golf Car Illustrated Parts List 12 16 10 CARBURETOR INSTALLATION ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 101887601 1011697 101820201 1016440 101648102 1016439 1016444 1016441 1016582 101905601 1013746 1015137 NUT, NYLON LOCK, M6 x 1 .................................................................................................... WASHER, SPECIAL, 5/16 ....................................................................................................... GUARD, GOVERNOR ............................................................................................................. GASKET, INSULATOR ............................................................................................................ INSULATOR, CARBURETOR .................................................................................................. GASKET, CARBURETOR INSULATOR TO THROTTLE BRACKET ....................................... BRACKET, THROTTLE ............................................................................................................ GASKET, THROTTLE BRACKET TO CARBURETOR ............................................................ SPRING, THROTTLE RETURN .............................................................................................. ASSEMBLY, CARBURETOR ................................................................................................... CLAMP, HOSE ......................................................................................................................... LINE, BULK VENT ................................................................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 13 14 15 16 17 18 19 1017466 1016572 1016438 1016480 101649002 1016547 1016103 CLAMP, HOSE ......................................................................................................................... TUBE, CRANKCASE VENT ..................................................................................................... GASKET, CARBURETOR TO INTAKE MANIFOLD ................................................................. PIPE, INTAKE .......................................................................................................................... SCREW, 2-ENDED STUD, M6 x 1 x 90MM ............................................................................. NUT, FLANGED, M6 x 1 .......................................................................................................... SCREW, PAN/TORX HEAD SELF-TAPPING, #6 - 32 x 1/4 .................................................... 2 1 1 1 2 2 2 1999 DS Golf Car Illustrated Parts List Page 9-7 9 G 9 G 7 6 4 5 3 1 2 7 8 9 10 7 8 12 13 14 9 11 Page 9-8 1999 DS Golf Car Illustrated Parts List 6 GOVERNOR AND ACCELERATOR CABLES ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 101832501 101832401 1013700 1016546 101832301 1012285 1016202 1015408 1014413 101832201 1015845 101903501 CABLE, ACCELERATOR ........................................................................................................ CABLE, GOVERNOR .............................................................................................................. CLAMP, CABLE RETAINING ................................................................................................... NUT, FLANGED HEX, M8 x 1.25 ............................................................................................ BRACKET, ACCELERATOR SUPPORT .................................................................................. SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... E-RING ..................................................................................................................................... PIN, GOVERNOR CABLE CLEVIS ......................................................................................... PIN, HAIR SPRING COTTER, 1/8 I.D. x 5/8 ............................................................................ BRACKET, SUPPORT .............................................................................................................. BRACKET, GOVERNOR CABLE ENGINE .............................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 24 MM ....................................................................... 1 1 2 2 1 4 3 2 2 1 1 1 13 14 7174 1011697 WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. 1 1 1999 DS Golf Car Illustrated Parts List Page 9-9 9 G 17 9 G REFERENCE CARBURETOR 18 5 6 1 TYPICAL 2 PLACES 15 16 2 3 15 TYPICAL 3 PLACES 7 10 17 4 19 20 8 21 11 22 9 12 ,, yy yy ,, ,, yy ,, yy 13 25 26 14 26 14 23 14 24 TYPICAL 3 PLACES 14 Page 9-10 1999 DS Golf Car Illustrated Parts List INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2 3 QTY 4 101821501 101804301 101881701 101925701 101972801 101813001 101917601 N/A N/A N/A 101812301 1015426 ASSEMBLY, AIR BOX (INCLUDES ITEMS 1 - 13) .................................................................. SCREW, HI-LO HEX HEAD, #8 - 1/2 .................................................................................. WASHER, STAINLESS STEEL, #8 ..................................................................................... LATCH, WIRE ..................................................................................................................... ASSEMBLY, AIR BOX TOP (INCLUDES ITEMS 5 - 10) ..................................................... E-CLIP ........................................................................................................................... LEVER, CHOKE ............................................................................................................ O-RING, 5/16 (RED) ...................................................................................................... O-RING, 3/8 (GREEN) ................................................................................................... VALVE, CHOKE ............................................................................................................. SPRING, RETURN ........................................................................................................ FILTER, AIR ........................................................................................................................ 1 2 2 2 1 1 1 1 1 1 1 1 101811901 101921501 183 101971301 101837101 101850301 101917701 101805701 101811501 101856201 101811401 332 1015752 101958101 1606 101971001 BOTTOM, AIR BOX ............................................................................................................. SEAL, INTAKE .................................................................................................................... WASHER, FLAT, #10 ............................................................................................................... CLAMP, HOSE (AIR INTAKE) .................................................................................................. HOSE, INTAKE ........................................................................................................................ SCREW, HI-LO, #12 x 1/2 ....................................................................................................... POSITIONER, CHOKE ............................................................................................................ ASSEMBLY, CHOKE BUTTON (INCLUDES ITEMS 20, 21 AND 22) ...................................... GUIDE, CHOKE LEVER ..................................................................................................... SPRING, COMPRESSION ................................................................................................. LEVER, CHOKE ................................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................. SCREW, HI-LO, #12 - 16 x 5/8 ................................................................................................ ASSEMBLY, AIR DUCT ........................................................................................................... RIVET, POP, 3/16 .................................................................................................................... AIR DUCT REPAIR KIT (NOT SHOWN) .................................................................................. 1 1 4 2 1 4 1 1 1 1 1 3 3 1 2 A/R 1999 DS Golf Car Illustrated Parts List Page 9-11 9 G EXHAUST SYSTEM 10 G 10 G 7 8 y , , y ,y y , 6 9 12 10 11 TYPICAL 2 PLACES 5 1 4 3 2 TYPICAL 2 PLACES REFERENCE ENGINE MOUNTING— SECTION 8 Page 10-2 1999 DS Golf Car Illustrated Parts List EXHAUST SYSTEM ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 101859301 1015814 332 451 7847 1017689 101903501 7174 1015075 1012528 1013734 1015330 2 3 QTY 4 SYSTEM, EXHAUST ............................................................................................................... BRACKET, MUFFLER MOUNTING ......................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. SCREW, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................................ CLAMP, MUFFLER .................................................................................................................. SCREW, HEX HEAD CAP, M8 x 1.25 x 24MM ........................................................................ WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. NUT, HEX, M8 x 1.25 .............................................................................................................. WASHER, LOCK, 8MM ........................................................................................................... GASKET, EXHAUST ................................................................................................................ 1999 DS Golf Car Illustrated Parts List 1 1 2 2 2 1 1 1 1 2 2 1 Page 10-3 10 G TORQUE CONVERTER 11 G 11 G 4 1 3 2 5 10 6 7 14 8 14 9 13 16 TYPICAL 3 PLACES (ONE SPRING PER CLUTCH) 11 12 19 18 21 20 Page 11-2 1999 DS Golf Car Illustrated Parts List 17 15 DRIVE CLUTCH ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 101833902 1016801 101929801 N/A N/A 1014049 1014050 1014051 1016289 1014057 1014059 101925601 ASSEMBLY, DRIVE CLUTCH (INCLUDES ITEMS 1 - 17) ...................................................... KIT, DRIVE CLUTCH WEIGHT ........................................................................................... ASSEMBLY, FIXED FACE (INCLUDES ITEMS 3 AND 4) ................................................... PULLEY .......................................................................................................................... SCREW, WASHER HEAD HEX MACHINE .................................................................... BEARING, IDLER ................................................................................................................ RETAINER, SPRING............................................................................................................ SPRING, DRIVE CLUTCH - BLACK ................................................................................... SPACER, FIXED FACE SHAFT ........................................................................................... RING, RETAINING ............................................................................................................... ASSEMBLY, DRIVE HUB .................................................................................................... PLUG, DRIVE CLUTCH ...................................................................................................... 1 1 1 1 3 1 1 1 1 1 1 1 12 13 14 15 16 17 18 19 20 21 1014453 1014058 1014056 1014052 N/A 1014055 1016203 101916701 101916501 1017328 KIT, DRIVE CLUTCH BUTTON ........................................................................................................................ WASHER, THRUST ............................................................................................................ RING, SPIRAL BACK-UP ................................................................................................... ASSEMBLY, MOVEABLE FACE (INCLUDES ITEMS 16 AND 17)....................................... BUSHING ....................................................................................................................... RETAINER ..................................................................................................................... BELT, DRIVE ........................................................................................................................... BELT, STARTER/GENERATOR ............................................................................................... SCREW, HEX HEAD CAP, 3/8 - 24 x 5 1/2 (LEFT-HAND THREADS) .................................... WASHER, MOUNTING—GREEN ............................................................................................ 1 1 2 1 1 1 1 1 1 1 1999 DS Golf Car Illustrated Parts List Page 11-3 11 G 11 G 8 TYPICAL 3 PLACES 6 7 5 4 3 2 9 12 11 1 10 Page 11-4 1999 DS Golf Car Illustrated Parts List DRIVEN CLUTCH ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 101834001 1014080 1014078 1017686 101836201 1014454 1014072 1014070 101833401 1016203 7173 1017327 2 3 QTY 4 ASSEMBLY, DRIVEN CLUTCH (INCLUDES ITEMS 2 - 8) ..................................................... RING, RETAINING .............................................................................................................. KEY ..................................................................................................................................... CAM .................................................................................................................................... SPRING—GREEN .............................................................................................................. KIT, BUTTON (INCLUDES 3 SCREWS AND 3 BUTTONS) ................................................ ASSEMBLY, MOVEABLE FACE, WITH BUSHING ............................................................. ASSEMBLY, FIXED FACE ................................................................................................... KEY, SQUARE TRANSMISSION ............................................................................................. BELT, DRIVE ........................................................................................................................... SCREW, HEX HEAD CAP, 5/16 - 18 x 3/4 .............................................................................. WASHER, MOUNTING—YELLOW ......................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 1 1 Page 11-5 11 G UNITIZED TRANSAXLE— GASOLINE VEHICLE 12 G 3 5 12 7 4 G 11 12 6 13 8 REFERENCE FORWARD/ REVERSE SHIFTER— GASOLINE SECTION 9 14 15 10 27 16 17 21 19 20 31 1 22 2 28 18 23 24 30 Clu bCa 32 r 25 REFERENCE AXLE TUBES ON PAGE 12-6 26 ClubC ar Club Car Page 12-2 1999 DS Golf Car Illustrated Parts List 29 UNITIZED TRANSAXLE, GASOLINE VEHICLE— GEAR CASES AND BRACKETS ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 12 101922601 1012285 1013061 183 1010954 1016341 1017082 8717 1017231 101834801 101886101 1014007 BRACKET, TRANSMISSION CABLE SUPPORT .................................................................... SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... NUT, NYLON LOCK, #10 - 32 ................................................................................................. WASHER, FLAT, #10 ............................................................................................................... STUD, BALL, 1/4 - 28 x 9/16 ................................................................................................... LEVER, TRANSMISSION SHIFTER ....................................................................................... SCREW, HEX WASHER HEAD, #10 - 32 x 3/4 ....................................................................... NUT, NYLON LOCK, 1/4 - 28 .................................................................................................. KEY, WOODRUFF ................................................................................................................... ARM, GOVERNOR LEVER ..................................................................................................... SCREW, SQUARE HEAD, 1/4 - 20 x 1 .................................................................................... WASHER, TYPE B, 1/4 ........................................................................................................... 1 3 1 1 1 1 1 1 1 1 1 1 13 8233 101833601 101890201 101927301 101892901 101927201 101890101 1012752 101928601 1016513 101927101 101893801 101891301 101890601 101890501 101926901 1012896 1013759 1016432 1012711 101928701 NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. UNITIZED TRANSAXLE (INCLUDES ITEMS 14 - 90) ............................................................ SHAFT, SHIFTER ............................................................................................................... RING, SNAP ....................................................................................................................... WASHER, FLAT .................................................................................................................. SEAL, OIL ........................................................................................................................... LEVER, SHIFTER ............................................................................................................... PIN, ROLL ........................................................................................................................... PIN, COTTER ..................................................................................................................... WASHER, FLAT .................................................................................................................. SEAL, OIL ........................................................................................................................... WASHER ............................................................................................................................ ARM, PIVOT ........................................................................................................................ GEAR CASE (RIGHT) ......................................................................................................... GEAR CASE (LEFT) ........................................................................................................... BOLT, FLANGED, M8 x 1.25 x 40MM ................................................................................. PIN, DOWEL ....................................................................................................................... PLUG, DRAIN (INCLUDES ITEM 30) ................................................................................. GASKET ......................................................................................................................... BREATHER ......................................................................................................................... GASKET, LIQUID, 8.8 OZ. (250 GRAMS) ........................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 2 2 1 1 A/R 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1999 DS Golf Car Illustrated Parts List Page 12-3 12 G 36 12 35 34 G 33 47 48 49 46 41 45 43 42 46 44 55 54 48 39 41 40 53 39 52 38 37 43 41 45 51 50 59 58 57 56 38 61 60 66 65 66 REFERENCE DRIVER SIDE CASE 64 63 62 Clu bC Page 12-4 ar 1999 DS Golf Car Illustrated Parts List REFERENCE PASSENGER SIDE CASE UNITIZED TRANSAXLE, GASOLINE VEHICLE— F&R TRANSMISSION AND GEAR REDUCTION ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 33 34 35 36 37 38 39 40 41 42 43 44 101892001 101890001 1012748 1012747 101889401 7336 1016338 101892401 101892201 101980901 101927601 101927501 ROD, SHIFT ........................................................................................................................ FORK, SHIFT ...................................................................................................................... SPRING .............................................................................................................................. BALL, STEEL ...................................................................................................................... GUIDE ................................................................................................................................. BEARING, BALL ................................................................................................................. WASHER, SPRING ............................................................................................................. GEAR, SPUR ...................................................................................................................... PLATE, THRUST ................................................................................................................. GEAR ASSEMBLY, 28 TOOTH, INPUT ............................................................................... BEARING, NEEDLE ........................................................................................................... BEARING, NEEDLE ........................................................................................................... 1 1 1 1 1 2 2 1 3 1 3 1 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 101981001 1012741 101928001 1012740 101927901 101927701 101889901 101980801 1016337 101927801 1012714 101892601 101893201 101892501 101928101 101889501 101928201 101893901 101892301 101891601 101891901 7335 RING, SYNCHRONIZER .................................................................................................... SPRING, SYNCHRONIZER ................................................................................................ HUB, SYNCHRONIZER CLUTCH ...................................................................................... INSERT, SYNCHRONIZER ................................................................................................. SLEEVE, SYNCHRONIZER ............................................................................................... PIN, DOWEL ....................................................................................................................... SHAFT, INPUT .................................................................................................................... GEAR ASSEMBLY, 25 TOOTH, INPUT ............................................................................... WASHER, THRUST ............................................................................................................ BEARING, BALL ................................................................................................................. SEAL, OIL, INPUT SHAFT ................................................................................................. GEAR, 17 TOOTH ............................................................................................................... KEY ..................................................................................................................................... GEAR, 61 TOOTH ............................................................................................................... BEARING, BALL ................................................................................................................. GUIDE, OIL ......................................................................................................................... SCREW, M8 x 1.25 x 10 MM .............................................................................................. WASHER ............................................................................................................................. GOVERNOR ASSEMBLY ................................................................................................... SLEEVE .............................................................................................................................. GEAR, CLUSTER IDLER ................................................................................................... BEARING, BALL ................................................................................................................. 2 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1999 DS Golf Car Illustrated Parts List Page 12-5 12 G 12 G 75 73 78 71 77 69 REFERENCE PASSENGER SIDE CASE 74 80 72 70 88 67 85 90 89 90 81 79 82 89 84 Clu 85 bC ar 86 87 74 77 83 79 78 REFERENCE DRIVER SIDE CASE 76 68 71 70 72 73 69 Page 12-6 1999 DS Golf Car Illustrated Parts List UNITIZED TRANSAXLE, GASOLINE VEHICLE— DIFFERENTIAL AND AXLES ITEM PART NO. DESCRIPTION 1 2 3 QTY 4 67 68 69 70 71 72 73 74 75 76 77 78 101891401 101891501 1013787 1013792 1011291 1014207 1016672 1013794 101891001 101890901 1013790 1013791 AXLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 69 - 73) ......................................... AXLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 69 - 73) ................................ STUD, LUG .................................................................................................................... RING, RETAINING ......................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... COLLAR, 25 MM I. D. ..................................................................................................... RING, RETAINING ......................................................................................................... SEAL, OIL ........................................................................................................................... ASSEMBLY, AXLE TUBE, DRIVER SIDE ........................................................................... ASSEMBLY, AXLE TUBE, PASSENGER SIDE ................................................................... BOLT, M10 x 1.5 x 30MM .................................................................................................... WASHER, LOCK, M10 ........................................................................................................ 1 1 4 1 1 1 1 1 1 1 14 14 79 80 81 82 83 84 85 86 87 88 89 90 7330 101928301 101892701 1014193 101910501 1013768 1013774 1013773 1013769 1013772 1013770 1013771 BEARING, INNER AXLE TUBE .......................................................................................... BOLT, M8 x 1.25 x 37MM .................................................................................................... GEAR, OUTPUT ................................................................................................................. PIN, DOWEL ....................................................................................................................... KIT, DIFFERENTIAL GEAR CASE (INCLUDES ITEMS 84 - 87) ........................................ CASE, GEAR CARRIER ................................................................................................ PLATE, THRUST (IDLER GEAR) .................................................................................. PLATE, THRUST (DIFFERENTIAL GEAR) ................................................................... COVER, GEAR CASE ................................................................................................... PIN, DIFFERENTIAL .......................................................................................................... GEAR, DIFFERENTIAL IDLER ........................................................................................... GEAR, DIFFERENTIAL ...................................................................................................... 2 8 1 1 1 1 2 1 1 1 2 2 1999 DS Golf Car Illustrated Parts List Page 12-7 12 G ELECTRICAL SYSTEM— ELECTRIC VEHICLE 13 E 13 E TYPICAL 2 PLACES OFF ON 4 9 8 7 AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED 5 6 3 2 1 OFF ON 11 12 10 POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES V-GLIDE 36-VOLT VEHICLE Page 13-2 1999 DS Golf Car Illustrated Parts List ELECTRICAL COMPONENTS, FRONT BODY— ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1016859 1016849 1016851 101830601 101826201 101851101 101830701 101834502 1012505 101802601 101935501 8990 2 3 QTY 13 4 KIT, REVERSE BUZZER (INCLUDES ITEMS 2 AND 3) ......................................................... SCREW, PAN HEAD HI-LO, #4 - 24 x 5/16 ......................................................................... BUZZER, REVERSE ........................................................................................................... ASSEMBLY, SCREW AND WASHER ...................................................................................... SWITCH, KEY ......................................................................................................................... WASHER ................................................................................................................................. NUT, KEY SWITCH ................................................................................................................. CAP, KEY SWITCH ................................................................................................................. KEY (PAIR) .............................................................................................................................. PLUG, HOLE (V-GLIDE 36-VOLT VEHICLE ONLY) ................................................................ LIGHT, BATTERY WARNING (AMBER) (POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS) ............................................................................................................. TIE, WIRE ................................................................................................................................ 1999 DS Golf Car Illustrated Parts List 1 2 1 2 1 1 1 1 1 1 1 2 Page 13-3 E 13 22 E UE BL 20 1 D RE 2 16 ITE WH E G AN OR KEY SWITCH BR REVERSE BUZZER 15 EE 1 UE BL YE LL WH OW ITE D D 24 D RE RE 2 LE N RE LIMIT SWITCH 1 N RP GR FORWARD / REVERSE SWITCH OW PU WH 21 ITE E IT WH 18 10 EN E GR 23 SOLENOID N EE FUSE AND RECEPTACLE GR GE N RA O BL BULLET CONNECTOR - 12 17 D RE BL 25 6 WHITE EN H W + BLUE RE E IT BATTERY BANK BLACK G YELLOW + WHITE - 1 ORANGE 11 - GREEN 9 D + 8 GR AY 2 - + - 3 4 K AC K TYPICAL 5 PLACES AY AC BL BL 4 RESISTOR BOARD 26 R G 5 5 7 RE + N EE WHITE SPEED SWITCH 19 - D RE N 14 6 ITE WH EE 13 + - K UE GR GR CK A BL + AC BL K AC LE A2 RP PU N OW S2 S1 A1 BR MOTOR 3 Page 13-4 1999 DS Golf Car Illustrated Parts List WIRING—V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 12 1016070 1016069 1012651 1016068 1014036 1014035 1014034 1014033 1014032 1014828 1014030 1014029 WIRE ASSEMBLY, #6 BROWN ............................................................................................... WIRE ASSEMBLY, #6 PURPLE .............................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #6 GRAY ................................................................................................... WIRE ASSEMBLY, #6 BLACK, 6TH SPEED ............................................................................ WIRE ASSEMBLY, #6 BLUE, 5TH SPEED ............................................................................. WIRE ASSEMBLY, #6 GREEN, 4TH SPEED .......................................................................... WIRE ASSEMBLY, #6 YELLOW, 3RD SPEED ........................................................................ WIRE ASSEMBLY, #6 ORANGE, 2ND SPEED ....................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ WIRE ASSEMBLY, #6 WHITE ................................................................................................ WIRE ASSEMBLY, #6 WHITE ................................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 13 14 15 16 17 18 19 20 21 22 23 24 25 26 N/A 1013092 N/A N/A N/A 1012237 1011010 N/A 1014039 N/A 1011069 N/A N/A 1010958 WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #10 RED ................................................................................................... WIRE ASSEMBLY, #18 ORANGE ........................................................................................... WIRE ASSEMBLY, #18 WHITE ............................................................................................... WIRE ASSEMBLY, #18 GREEN .............................................................................................. WIRE ASSEMBLY, #10 RED ................................................................................................... WIRE ASSEMBLY, #10 WHITE ............................................................................................... WIRE ASSEMBLY, #18 RED ................................................................................................... WIRE ASSEMBLY, #6 WHITE ................................................................................................. WIRE ASSEMBLY, #18 BLUE ................................................................................................. WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #18 YELLOW ............................................................................................ WIRE ASSEMBLY, #18 BLACK ............................................................................................... WIRE ASSEMBLY, #6 BLACK ................................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1999 DS Golf Car Illustrated Parts List Page 13-5 E 13 3 TYPICAL 2 PLACES 2 E 9 10 4 5 TYPICAL 2 PLACES 6 11 TYPICAL 3 PLACES 1 8 7 TYPICAL 2 PLACES SEAT SUPPORT FRONT PANEL 12 Page 13-6 1999 DS Golf Car Illustrated Parts List TYPICAL 3 PLACES FORWARD/REVERSE SWITCH— V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 101753003 1014808 8057 8058 1016896 1017799 451 1028 1012987 1013198 1016845 8233 2 3 QTY 13 4 ASSEMBLY, FORWARD/REVERSE SWITCH (INCLUDES ITEMS 2 - 8) ............................... SWITCH, LIMIT ................................................................................................................... NUT, HEX, #4 - 40 ............................................................................................................... WASHER, LOCK, #4 ........................................................................................................... SCREW, HEX HEAD, #4 - 40 x 1-1/8 .................................................................................. BAR, BUS ........................................................................................................................... WASHER, LOCK, 1/4 .......................................................................................................... NUT, HEX, 1/4 - 20 .............................................................................................................. HANDLE, FORWARD/REVERSE SWITCH ............................................................................ SCREW, PHILLIPS HEAD MACHINE, #8 - 32 x 5/8 ............................................................... SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 2-1/8 ................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. 1999 DS Golf Car Illustrated Parts List 1 1 2 2 2 1 2 2 1 1 3 3 Page 13-7 E 13 21 24 TYPICAL 8 PLACES TYPICAL 5 PLACES 25 20 22 16 TYPICAL 2 PLACES 32 31 1 E 31 REF. SEE PAGE 5-6 4 6 19 8 18 17 5 16 15 7 14 13 26 3 12 32 3 2 11 TYPICAL 2 PLACES 3 8 23 27 9 10 30 28 Club Car 29 MOUNTING DETAIL Page 13-8 1999 DS Golf Car Illustrated Parts List TYPICAL 2 PLACES WIPER SWITCH—V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1014735 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1016140 1014999 1014414 1014253 7473 1012353 1014003 8449 1012903 1014189 1013886 1013061 1014017 1013998 1014 1014019 8058 1013887 1013860 8056 1014807 1014010 8057 451 N/A N/A 1017692 1014109 1016175 1017 101949201 1028 451 2 3 QTY 13 4 ASSEMBLY, V-GLIDE WIPER SWITCH AND RESISTOR GROUP (INCLUDES WIPER SWITCH ASSEMBLY LISTED BELOW, RESISTOR AND BOARD ASSEMBLY —ITEMS 1 - 11 ON PAGE 13-11 AND CONNECTING WIRES—ITEMS 5 - 11 ON PAGE 13-5).......................................................... ASSEMBLY, V-GLIDE WIPER SWITCH (INCLUDES ITEMS 1 - 26) .................................. ASSEMBLY, WIPER SWITCH CASE, 6-SPEED (INCLUDES ITEM 2) ......................... BUMPER, WIPER SWITCH ...................................................................................... NUT, BRASS HEX JAM, 1/4 - 20 ................................................................................... NUT, NYLON LOCK, 5/16 - 18 ....................................................................................... STUD, SHORT BALL, 1/4 - 28 ....................................................................................... CRANK, BELL ............................................................................................................... NUT, DIMPLED LOCK, 1/4 - 28 ..................................................................................... BEARING, BRONZE, 3/8 x 1/2 ...................................................................................... SCREW, BRONZE HEX HEAD CAP, 1/4 - 20 x 2 .......................................................... COVER, WIPER SWITCH CASE ................................................................................... NUT, NYLON LOCK, #10 - 32 ........................................................................................ CARRIER, WIPER SWITCH ARM ................................................................................. SPRING, WIPER SWITCH BRUSH ............................................................................... STUD, WIPER SWITCH ADJUSTING ........................................................................... SCREW, SELF-TAPPING, #4 - 40 x 3/8 ........................................................................ WASHER, LOCK, #4 ..................................................................................................... ARM, SPEED SWITCH ................................................................................................. ASSEMBLY, SWITCH BRUSH ....................................................................................... SCREW, ROUND HEAD MACHINE, #4 - 40 x 3/4 ........................................................ SWITCH, LIMIT ............................................................................................................. GROMMET, SPLIT ......................................................................................................... NUT, HEX, #4 - 40 ......................................................................................................... WASHER, LOCK, 1/4 .................................................................................................... WIRE ASSEMBLY, #18 BLACK ..................................................................................... WIRE ASSEMBLY, #18 GREEN .................................................................................... CAP, PROTECTOR ........................................................................................................ BOLT, CARRIAGE, #10 - 24 x 1 .............................................................................................. WASHER, LOCK, #10 ............................................................................................................. NUT, HEX, #10 - 24 ................................................................................................................. SHIM, WIPER SWITCH ........................................................................................................... NUT, HEX, STEEL, 1/4 - 20 ..................................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. 1999 DS Golf Car Illustrated Parts List E 1 1 1 1 3 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 2 1 1 2 1 1 1 1 2 2 2 1 13 9 Page 13-9 12 13 F CAR FRONT O E 13 7 8 9 10 11 1 2 TYPICAL 6 PLACES 3 TYPICAL 6 PLACES 4 5 6 2 TYPICAL 6 PLACES 1 12 TYPICAL 2 PLACES ,, yy yy ,, ,, yy ,, yy Page 13-10 1999 DS Golf Car Illustrated Parts List TYPICAL 2 PLACES RESISTOR AND BOARD ASSEMBLY— V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 12 1028 451 1011931 1014045 1014728 332 1014476 1014012 1014013 1014014 1014729 1012285 NUT, HEX, 1/4 - 20 .................................................................................................................. WASHER, LOCK, 1/4 .............................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................ STAND-OFF, RESISTOR COIL ............................................................................................... BOARD, RESISTOR MOUNTING ........................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ COIL, RESISTOR, 5TH SPEED, .182" WIRE DIAMETER, 3-COIL ........................................ COIL, RESISTOR, 4TH SPEED, .162" WIRE DIAMETER, 3-COIL ........................................ COIL, RESISTOR, 3RD SPEED, .144" WIRE DIAMETER, 3-COIL ........................................ COIL, RESISTOR, 2ND SPEED, .128" WIRE DIAMETER, 4-COIL ........................................ COIL, RESISTOR, 1ST SPEED, .128" WIRE DIAMETER, 6-COIL ......................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... 12 12 6 6 1 6 1 1 1 1 1 4 13 1013971 SHIELD, RESISTOR ................................................................................................................ 1 1999 DS Golf Car Illustrated Parts List Page 13-11 E 13 VEHICLE BODY 26 TYPICAL 2 PLACES TYPICAL 4 PLACES E TYPICAL 2 PLACES 26 31 TYPICAL 2 PLACES 27 28 18 16 23 19 17 20 22 TYPICAL 2 PLACES 14 22 24 29 30 15 TYPICAL 2 PLACES TYPICAL 3 PLACES 1 TYPICAL 6 PLACES TYPICAL 2 PLACES 25 21 3 2 TYPICAL 6 PLACES TYPICAL 5 PLACES TYPICAL 12 PLACES 4 TYPICAL 2 PLACES 13 6 8 TYPICAL 6 PLACES 12 TYPICAL 2 PLACES 7 11 10 9 5 TYPICAL 6 PLACES Page 13-12 1999 DS Golf Car Illustrated Parts List BATTERIES, CHARGER RECEPTACLE, SOLENOID— V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 5 6 7 8 9 10 11 1015072 1011578 1010908 1013683 101661601 101661602 1010958 101831401 1014304 1012022 1606 101975901 NUT, NYLON LOCK, STAINLESS STEEL, 5/6 - 18 ................................................................ WASHER, FLAT, TYPE B WIDE, 5/16 ..................................................................................... HOLD-DOWN, BATTERY ........................................................................................................ J-BOLT ..................................................................................................................................... BATTERY, 6-VOLT ................................................................................................................... BATTERY, 6-VOLT, DRY .......................................................................................................... WIRE ASSEMBLY, #6 BLACK ................................................................................................. CAP, 6-VOLT BATTERY ........................................................................................................... NUT, HEX, STAINLESS STEEL, 5/6 - 18 ................................................................................ CLAMP, CABLE ....................................................................................................................... RIVET, POP, 3/16 .................................................................................................................... SOLENOID, 36-VOLT .............................................................................................................. 6 6 3 6 6 6 5 6 12 2 2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1012285 7893 1010521 7174 101342501 1014516 N/A N/A N/A 1016 8797 4107 1013092 1013628 8796 8795 1013649 8797 1016 1013266 SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... NUT, HEX, #10 - 32 ................................................................................................................. NUT, HEX, 5/16 - 24 ................................................................................................................ WASHER, LOCK, 5/16 ............................................................................................................ KIT, FUSE AND RECEPTACLE (INCLUDES ITEMS 17 - 31) ................................................. KIT, FUSE (INCLUDES ITEMS 18 - 22) .............................................................................. LENS, FUSE .................................................................................................................. FUSE, 80-AMP .............................................................................................................. HOLDER, FUSE ............................................................................................................ WASHER, LOCK, #10 ................................................................................................... NUT, BRASS, #10 - 32 ................................................................................................... RECEPTACLE, CHARGER, 2-PRONG .............................................................................. WIRE ASSEMBLY, #10 RED ............................................................................................... BRACKET, FUSE AND RECEPTACLE MOUNTING .......................................................... SCREW, PHILLIPS PAN HEAD SELF-TAPPING, #7 -19 x 3/4 ........................................... SCREW, PHILLIPS PAN HEAD SELF-TAPPING, #7 -19 x 1-3/4 ....................................... BEZEL, CHARGER RECEPTACLE .................................................................................... NUT, BRASS, #10 - 32 ........................................................................................................ WASHER, LOCK, #10 ......................................................................................................... SCREW, PHILLIPS PAN HEAD SELF-TAPPING, #8 - 18 x 1/2 .......................................... 2 2 2 2 1 1 1 1 1 2 4 1 1 1 6 2 1 2 2 2 1999 DS Golf Car Illustrated Parts List Page 13-13 E 13 N EE GR 2 1 D RE E NG RA O E KEY SWITCH TE HI /W GE AN N OW OR BR REVERSE BUZZER 33 WARNING LIGHT 3 U E 1 10 FORWARD / REVERSE SWITCH BL UE BL MULTI-STEP POTENTIOMETER OR 11 AN GE BL UE SIX PIN CONNECTOR WH BL U W E H YE T/B G L L K R N LOW /W H T ITE E 9 PL R LIMIT SWITCHES 1 K C LA E 2 /B E HIT ITE HIT /W WH N/W RED NGE E E N A GR EE OR GR ITE WH PU 2 8 5 7 4 3 12 6 OR EE N EE N 16 BLK BL + EY GR D D R 1 + RE 3 2 1 - + - 3 + 4 M- B- 30 + - D YELLOW TYPICAL 5 PLACES BLUE 2 20 GREEN - 21 19 YELLOW YELLOW RED BROWN BLACK + GREY - SOLENOID 26 ED RED + 29 5 25 RE FUSE RE - BLACK BLACK FUSE CONTROLLER LE E RP HIT PU D/W E W R O LL YE B+ THREE PIN CONNECTOR 6 ITE E U BL WH GREEN GE AN OR A2 28 14 S2 BL AC K A1 ONBOARD COMPUTER 32 - Page 13-14 RED/WHITE PURPLE LL YE K AC - BATTERY BANK OW WHITE/ BLACK 22 EN 18 RED 27 RED D RE 17 23 LE RP PU GRE FUSE AND RECEPTACLE 24 WHITE D BL ORANGE GE RE GR 13 UE K AC BL BLUE N/ W HI YE TE LL O PU BL W RP AC LE K OW AN 15 GR BR 1999 DS Golf Car Illustrated Parts List 31 S1 MOTOR WIRING—POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 101911001 N/A 101932701 N/A N/A N/A N/A 101883002 N/A N/A 101901401 101901201 WIRE HARNESS (INCLUDES ITEMS 1 - 20) ......................................................................... WIRE ASSEMBLY, #18 BROWN ......................................................................................... KIT, 6-PIN PLUG ASSEMBLY ............................................................................................. WIRE ASSEMBLY, #18 BLUE ............................................................................................. WIRE ASSEMBLY, #18 PURPLE ........................................................................................ WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #18 GREEN/WHITE ............................................................................. WIRE ASSEMBLY, #18 BLACK (INCLUDES RESISTOR AND #18 WHITE WIRE) ........... WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 WHITE/BLACK .............................................................................. WIRE ASSEMBLY, #6 BLUE ............................................................................................... WIRE ASSEMBLY, #6 ORANGE ......................................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 101901501 N/A 101901301 N/A N/A N/A N/A N/A N/A 101795701 N/A 1014947 101902801 1014948 101903001 N/A N/A N/A 101920101 101902901 101827801 N/A WIRE ASSEMBLY, #6 WHITE ............................................................................................. WIRE ASSEMBLY, #18 RED/WHITE .................................................................................. WIRE ASSEMBLY, #6 BLUE ............................................................................................... WIRE ASSEMBLY, #18 GREEN .......................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 ORANGE ....................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 RED ............................................................................................... WIRE ASSEMBLY, #18 YELLOW ........................................................................................ WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ONBOARD COMPUTER ASSEMBLY) ................ ASSEMBLY, RESISTOR .......................................................................................................... WIRE ASSEMBLY, #6 RED .................................................................................................... ASSEMBLY, DIODE ................................................................................................................. WIRE ASSEMBLY, #6 YELLOW .............................................................................................. WIRE ASSEMBLY, #18 GREY (PART OF ONBOARD COMPUTER ASSEMBLY) .................. WIRE ASSEMBLY, #10 BLACK (PART OF ONBOARD COMPUTER ASSEMBLY) ................ WIRE ASSEMBLY, #10 RED (PART OF FUSE AND RECEPTACLE ASSEMBLY) ................. KIT, 3-PIN PLUG ASSEMBLY .................................................................................................. WIRE ASSEMBLY, #6 GREEN ................................................................................................ KIT, WIRE AND TERMINAL, #6 BLACK .................................................................................. WIRE ASSEMBLY, #18 ORANGE/WHITE (PART OF BATTERY WARNING LIGHT) .............. 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1999 DS Golf Car Illustrated Parts List Page 13-15 E 13 TYPICAL 2 PLACES 5 ANTI-ARCING LIMIT SWITCH E REVERSE BUZZER LIMIT SWITCH 11 2 SEAT SUPPORT FRONT PANEL NC NO M CO NC NO M CO 12 HALF-SPEED LIMIT SWITCH 4 3 6 7 TYPICAL 3 PLACES TYPICAL 2 PLACES 13 1 10 9 TYPICAL 4 PLACES 8 Page 13-16 TYPICAL 2 PLACES 1999 DS Golf Car Illustrated Parts List TYPICAL 3 PLACES 14 FORWARD/REVERSE SWITCH— POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 12 101753005 101977101 101979101 1014808 8057 8058 1014871 1017799 451 1028 1012987 1013198 ASSEMBLY, FORWARD/REVERSE SWITCH (INCLUDES ITEMS 2 - 10) ............................. SWITCH, LIMIT, SEALED ................................................................................................... SWITCH, LIMIT, SEALED ................................................................................................... SWITCH, LIMIT ................................................................................................................... NUT, HEX, #4 - 40 ............................................................................................................... WASHER, LOCK, #4 ........................................................................................................... SCREW, HEX WASHER HEAD, #4 - 40 x 2 ....................................................................... BAR, BUS ............................................................................................................................ WASHER, LOCK, 1/4 .......................................................................................................... NUT, HEX, 1/4 - 20 .............................................................................................................. HANDLE, FORWARD/REVERSE SWITCH ............................................................................ SCREW, PHILLIPS HEAD MACHINE, #8 - 32 x 5/8 .............................................................. 1 1 1 2 2 2 2 2 4 4 1 1 13 14 1016845 8233 SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 2-1/8 ................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. 3 3 1999 DS Golf Car Illustrated Parts List Page 13-17 E 11 2 13 11 TYPICAL 4 PLACES 3 31 E 36 6 10 5 15 TYPICAL 7 PLACES 13 TYPICAL 2 PLACES 6 12 14 C 10 9 4 E NO TI TYPICAL 7 PLACES 5 10 7 8 16 27 17 24 26 14 37 25 17 TYPICAL 6 PLACES 2 TYPICAL 3 PLACES 3 16 23 TYPICAL 12 PLACES 1 14 22 20 19 7 9 15 18 21 TYPICAL 5 PLACES 4 9 32 30 TYPICAL 6 PLACES 19 1 13 8 REFERENCE ACCELERATOR ROD 30 28 9 33 22 38 12 Club Car 34 35 29 TYPICAL 6 PLACES 39 40 18 Page 13-18 TYPICAL 3 PLACES 1999 DS Golf Car Illustrated Parts List BATTERIES, CHARGER RECEPTACLE— POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 12 101802101 101796501 N/A N/A N/A 101796801 1013061 1017705 101894901 101801001 101832001 101797701 KIT, FUSE AND RECEPTACLE (INCLUDES ITEMS 2 - 9) ..................................................... BEZEL, RECEPTACLE ....................................................................................................... WIRE ASSEMBLY, SENSE LEAD, GRAY ........................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... WIRE ASSEMBLY, #10 BLACK ........................................................................................... ASSEMBLY, FUSE, 48-VOLT (INCLUDES ITEM 7) ............................................................ NUT, NYLON LOCK, #10 ............................................................................................... SCREW, PHILLIPS PAN HEAD, #8 TYPE AB .................................................................... ASSEMBLY, FUSE, 3/8-AMP .............................................................................................. PLATE, RECEPTACLE BACKING ........................................................................................... SCREW, PHILLIPS PAN HEAD, #7 - 18 x 3/4 ......................................................................... BATTERY, 8-VOLT POWERDRIVE .......................................................................................... 1 1 1 1 1 1 2 3 1 1 4 6 12 13 14 15 16 17 18 19 101797702 101797801 101795701 1014304 101803001 1015072 1011578 1013683 BATTERY, 8-VOLT POWERDRIVE, DRY ................................................................................ CAP, BATTERY, 4-PORT GANG .............................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. NUT, HEX, STAINLESS STEEL, 5/16 - 18 .............................................................................. HOLD-DOWN, BATTERY ........................................................................................................ NUT, NYLON LOCK, STAINLESS STEEL, 5/16 - 18 .............................................................. WASHER, FLAT, TYPE B WIDE, 5/16 ..................................................................................... J-BOLT ..................................................................................................................................... 6 6 5 12 3 6 6 6 1999 DS Golf Car Illustrated Parts List Page 13-19 E 13 TYPICAL 2 PLACES TYPICAL 2 PLACES 1 2 TYPICAL 2 PLACES 5 6 3 7 4 E 8 9 10 TYPICAL 4 PLACES 10 11 TYPICAL 2 PLACES TYPICAL 2 PLACES SOLENOID 19 12 ONBOARD COMPUTER 14 12 17 CONTROLLER 5 6 13 16 15 12 12 10 5 12 6 TYPICAL 2 PLACES 18 12 13 Page 13-20 6 1999 DS Golf Car Illustrated Parts List COMPUTER, CONTROLLER, AND SOLENOID— POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 12 101965201 1014288 7893 1014948 1242 7174 101902601 1014947 101908701 1012285 101840201 1241 PLATE, COMPONENT MOUNTING ........................................................................................ SCREW, THREAD-FORMING, 5/16 - 18 x 3/4 ........................................................................ NUT, HEX, #10 - 32 ................................................................................................................. ASSEMBLY, DIODE ................................................................................................................. NUT, HEX, 5/16 - 18 ................................................................................................................ WASHER, LOCK, 5/16 ............................................................................................................ BOOT, WIRE ............................................................................................................................ ASSEMBLY, RESISTOR .......................................................................................................... SOLENOID, 48-VOLT .............................................................................................................. SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... CONTROLLER, 48-VOLT (225-AMP) ...................................................................................... WASHER, FLAT, 5/16 .............................................................................................................. 1 2 2 1 5 5 1 1 1 8 1 6 13 14 15 16 17 18 19 7173 1218 101909901 101894901 101827801 101942301 101910401 BOLT, HEX HEAD, 5/16 - 18 x 3/4 ........................................................................................... BOLT, HEX HEAD, 5/16 - 18 x 1-1/4 ........................................................................................ COMPUTER, ONBOARD (INCLUDES ITEMS 16, 17 AND 18) .............................................. FUSE ASSEMBLY, 3/8-AMP ............................................................................................... KIT, WIRE AND TERMINAL, #6 BLACK ............................................................................. KIT, 3-PIN RECEPTACLE ................................................................................................... SCREW, THREAD-FORMING, 5/16 - 18 x 1-1/4 .................................................................... 2 1 1 2 1 1 2 1999 DS Golf Car Illustrated Parts List Page 13-21 E 2 13 11 3 31 C E 36 10 9 4 E NO TI TYPICAL 7 PLACES 6 5 15 12 14 TYPICAL 7 PLACES 13 10 16 27 17 24 26 14 37 25 7 23 21 9 22 32 20 30 19 1 8 REFERENCE ACCELERATOR ROD 30 28 9 33 22 35 29 38 Club Car 39 40 18 Page 13-22 34 1999 DS Golf Car Illustrated Parts List MULTI-STEP POTENTIOMETER— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 101932003 1014999 101958002 101932601 N/A N/A N/A N/A N/A 451 1028 101946901 ASSEMBLY, WIPER SWITCH (INCLUDES ITEMS 1 - 36) ...................................................... ASSEMBLY, WIPER SWITCH CASE, 6-SPEED ................................................................. ASSEMBLY, 5-WIRE AND RECEPTACLE (INCLUDES ITEMS 3 - 8) ................................ KIT, 6-PIN RECEPTACLE .............................................................................................. WIRE ASSEMBLY, #18 GREEN/WHITE ........................................................................ WIRE ASSEMBLY, #18 BLUE ........................................................................................ WIRE ASSEMBLY, #18 BLACK/WHITE ......................................................................... WIRE ASSEMBLY, #18 PURPLE.................................................................................... WIRE ASSEMBLY, #18 YELLOW.................................................................................... WASHER, LOCK, 1/4 .......................................................................................................... NUT, HEX, STEEL, 1/4 - 20 ................................................................................................ PROTECTOR, WIPER SWITCH RESISTOR ...................................................................... 1 1 1 1 1 1 1 1 1 17 15 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 101971101 8056 8058 1014807 8057 1014414 1013886 1013061 1014017 1013998 1012903 1014 1014010 1014019 1013887 1013860 1013461 1014189 1014253 8990 7473 1012353 1014003 8449 101610901 1014109 101949201 1016175 1017 KIT, RESISTOR ASSEMBLY ............................................................................................... SCREW, ROUND HEAD MACHINE, #4 - 40 x 3/4 ........................................................... WASHER, LOCK, #4 .......................................................................................................... SWITCH, LIMIT.................................................................................................................... NUT, HEX, #4 - 40 ............................................................................................................... BUMPER, WIPER SWITCH ................................................................................................ COVER, WIPER SWITCH ................................................................................................... NUT, NYLON LOCK, #10 - 32 ............................................................................................. CARRIER, WIPER SWITCH ARM ...................................................................................... SPRING, WIPER SWITCH BRUSH .................................................................................... BEARING, BRONZE ........................................................................................................... STUD, WIPER SWITCH ADJUSTING ................................................................................ GROMMET, SPLIT .............................................................................................................. SCREW, SELF-TAPPING, #4 - 40 x 3/8 ............................................................................. ARM, SPEED SWITCH ....................................................................................................... ASSEMBLY, SWITCH BRUSH ............................................................................................ SCREW, HEX HEAD HI-LO, #10 - 16 x 1/2 ........................................................................ SCREW, HEX HEAD CAP, 1/4 - 20 x 2 ............................................................................... NUT, BRASS HEX JAM, 1/4 - 20 ........................................................................................ WRAP, TIE ........................................................................................................................... NUT, NYLON LOCK, 5/16 - 18 ............................................................................................ STUD, SHORT BALL, 1/4 - 28 ............................................................................................ CRANK, BELL ..................................................................................................................... NUT, DIMPLED LOCK, 1/4 - 28 .......................................................................................... DECAL, WIPER SWITCH WARNING ................................................................................. BOLT, CARRIAGE, #10 - 24 x 1 ............................................................................................... SHIM, WIPER SWITCH ........................................................................................................... WASHER, LOCK, #10 ............................................................................................................. NUT, HEX, #10 - 24 ................................................................................................................. 1 2 3 1 2 1 1 1 1 1 2 1 1 1 1 1 2 1 3 1 1 1 1 1 1 2 1 2 2 1999 DS Golf Car Illustrated Parts List Page 13-23 E N EE GR 2 13 D RE E NG RA TE 1 HI O /W BL GE N FRONT REVERSE BUZZER K AC BL O R 2 TWO PIN CONNECTOR K OW AC N RA BR E TOW/RUN SWITCH KEY SWITCH RE D/ WARNING LIGHT W BL F HI K / ED FORWARD / REVERSE SWITCH BLUE ITE WH ITE /WH E BLU RED MULTI-STEP POTENTIOMETER E IT WH R BL UE AN BL GE UE /W HI TE RED 1 3 2 OR TE AC BL RE AC GR D/ K EE W HT GRN/W LOW YEL LK T/B WH PLE R PU BR OW N AN GE D + D RE SIX PIN CONNECTOR E LU + B E ITE HIT WH E/W G N A D OR RE D RE EN E GR RE EE N - 2 BATTERY BANK D RE 1 - 3 3 + 4 CK A BL GR AC RE EY K D FUSE /W D RE 6 8 BR OW N SIX PIN CONNECTOR TYPICAL 5 PLACES 10 9 ITE WH UE HITE BL D/W RE GE AN OR F1 FUSE A2 - K BL AC BL YEL AC K GR EY ONBOARD COMPUTER SOLENOID B+ 1 BR 14 OW N 9 3 10 4 11 5 12 6 13 7 14 OW E LL YE WHIT E/ EEN N U BL /GR REE D G RE HT CK LIG BLA TE HI E/W ITE G H W AN OR ITE WH 13 11 THREE PIN CONNECTOR RE G R G D EE BL RE N AC EN K W SOLENOID HI TE RESISTOR 8 15 12 BLUE (PIN 5) BLUE WIRE (PIN 6) YELLOW WIRE (PIN 7) YELLOW/BLACK WIRE (PIN 8) WHITE/BLACK WIRE (PIN 4) WHITE WIRE (PIN 3) GREEN/WHITE WIRE (PIN 2) ORANGE/WHITE WIRE (PIN 1) RED WIRE BLU/WHT GR 7 4 2 OW LL YE N 6 1 WHITE B- BLUE A1 GREEN 5 RED UE BL F2 RED/WHITE WHITE BLUE GREEN/WHITE YELLOW/BLACK WHITE/BLACK PURPLE ORANGE - E HIT RED ORANGE/WHITE BLK BL RED/WHITE + 5 FUSE AND RECEPTACLE + + RED - BLUE BLUE WHITE + A2 F2 15 GE A1 RAN O F1 16 (PIN 16) BLACK WIRE (PIN 9) PURPLE WIRE (PIN 10) ORANGE WIRE (PIN 11) BLUE/WHITE WIRE (PIN 15) RED/GREEN WIRE (PIN 14) LIGHT GREEN WIRE (PIN 13) GREEN WIRE (PIN 12) BROWN WIRE MOTOR Page 13-24 ORANGE/WHITE D GR WHITE RE OR HI TE N 1999 DS Golf Car Illustrated Parts List WIRING—POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 13 4 1 2 3 4 5 6 7 8 9 10 11 12 101964801 N/A N/A 101827801 N/A N/A N/A 101795701 101853502 101902801 101853602 101968701 WIRE HARNESS .................................................................................................................... WIRE ASSEMBLY, #18 ORANGE/WHITE (PART OF BATTERY LIGHT) ................................ WIRE ASSEMBLY, #10 RED (PART OF FUSE AND RECEPTACLE ASSEMBLY) ................. KIT, WIRE AND TERMINAL, #6 BLACK .................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ONBOARD COMPUTER ASSEMBLY) ................ WIRE ASSEMBLY, #18 GRAY (PART OF ONBOARD COMPUTER ASSEMBLY) .................. WIRE ASSEMBLY, #10 BLACK (PART OF ONBOARD COMPUTER ASSEMBLY) ................ WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #10 ORANGE ........................................................................................... WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #10 BLUE ................................................................................................. WIRE ASSEMBLY, #6 WHITE ................................................................................................. 1 1 1 1 1 1 1 5 1 1 1 1 13 14 15 101902901 101920001 1014856 WIRE ASSEMBLY, #6 GREEN ................................................................................................ WIRE ASSEMBLY, #6 YELLOW .............................................................................................. WIRE ASSEMBLY, #6 WHITE ................................................................................................. 1 1 1 1999 DS Golf Car Illustrated Parts List Page 13-25 E 13 1 E 6 2 5 F 4 ING 3 TOW RUN WARN TYPICAL 3 PLACES REFERENCE DECALS— SECTION 4 7 8 9 F 10 10 Page 13-26 1999 DS Golf Car Illustrated Parts List FORWARD/REVERSE SWITCH, TOW/RUN SWITCH— POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 101856001 101855001 101856101 8248 101922501 101908401 332 8233 101908101 8990 2 3 QTY 13 4 SWITCH, FORWARD/REVERSE ........................................................................................... CASE, FORWARD/REVERSE SWITCH ................................................................................. SCREW, HI-LO HEX HEAD, 1/4 - 15 x 1/2 .............................................................................. SCREW, TRUSS PHILLIPS MACHINE, 1/4 - 20 x 3/4 ........................................................... BRACKET, TOW SWITCH ....................................................................................................... BOOT, TOW SWITCH (WITH NUT).......................................................................................... WASHER, FLAT, 1/4 ................................................................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. SWITCH, TOW ........................................................................................................................ TIE, WIRE ................................................................................................................................ 1999 DS Golf Car Illustrated Parts List 1 1 3 2 1 1 2 2 1 A/R Page 13-27 E 11 13 TYPICAL 4 PLACES E 10 6 5 7 TYPICAL 2 PLACES 8 2 TYPICAL 3 PLACES 17 TYPICAL 6 PLACES 3 16 15 18 4 TYPICAL 12 PLACES 1 14 19 TYPICAL 6 PLACES 13 12 TYPICAL 6 PLACES F Page 13-28 1999 DS Golf Car Illustrated Parts List TYPICAL 5 PLACES 9 TYPICAL 3 PLACES BATTERIES, CHARGER RECEPTACLE— POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 101802101 101796501 N/A N/A N/A 101796801 1013061 1017705 101894901 101801001 101832001 101797701 101797702 101797801 101795701 1014304 101803001 1015072 1011578 1013683 2 3 QTY 13 4 KIT, FUSE AND RECEPTACLE (INCLUDES ITEMS 2 - 9) ..................................................... BEZEL, RECEPTACLE ....................................................................................................... WIRE ASSEMBLY, SENSE LEAD, GRAY ........................................................................... WIRE ASSEMBLY, #10 RED ............................................................................................... WIRE ASSEMBLY, #10 BLACK ........................................................................................... ASSEMBLY, FUSE, 48-VOLT (INCLUDES ITEM 7) ............................................................ NUT, NYLON LOCK, #10 ............................................................................................... SCREW, PHILLIPS PAN HEAD, #8 TYPE AB .................................................................... ASSEMBLY, FUSE, 3/8-AMP .............................................................................................. PLATE, RECEPTACLE BACKING ........................................................................................... SCREW, PHILLIPS PAN HEAD, #7 - 18 x 3/4 ......................................................................... BATTERY, 8-VOLT POWERDRIVE .......................................................................................... BATTERY, 8-VOLT POWERDRIVE, DRY ................................................................................ CAP, BATTERY, 4-PORT GANG .............................................................................................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. NUT, HEX, STAINLESS STEEL, 5/16 - 18 .............................................................................. HOLD-DOWN, BATTERY ........................................................................................................ NUT, NYLON LOCK, STAINLESS STEEL, 5/16 - 18 .............................................................. WASHER, FLAT, TYPE B WIDE, 5/16 ..................................................................................... J-BOLT ..................................................................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 1 1 1 1 2 3 1 1 4 6 6 6 5 12 3 6 6 6 Page 13-29 E 13 1 E 3 2 3 8 4 5 6 7 TYPICAL 2 PLACES 4 5 11 6 10 9 TYPICAL 2 PLACES TYPICAL 4 PLACES 12 1 7 TYPICAL 2 PLACES 11 Page 13-30 1999 DS Golf Car Illustrated Parts List SOLENOIDS, ENERGY DISPLACEMENT MODULE— POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1017237 101888201 1015069 1011931 451 1028 1018028 101964401 101957901 1012285 101883601 101902601 2 3 QTY 13 4 NUT, HEX FLANGED LOCK, 5/16 - 24 .................................................................................... TAB, MOUNTING ..................................................................................................................... SCREW, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................................ WASHER, FLAT, 1/4 ................................................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. NUT, HEX, 1/4 - 20 .................................................................................................................. NUT, SERRATED, #10 - 32 ...................................................................................................... MODULE, ENERGY DISPLACEMENT .................................................................................. BRACKET, MOUNTING ........................................................................................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... SOLENOID, 48-VOLT .............................................................................................................. BOOT, WIRE ............................................................................................................................ 1999 DS Golf Car Illustrated Parts List 4 2 2 2 2 2 4 1 2 4 2 1 Page 13-31 E 1 13 TYPICAL 2 PLACES 7 2 8 8 3 9 10 3 E 4 TYPICAL 3 PLACES 6 17 1 1 2 2 3 3 3 5 3 5 11 18 5 3 TYPICAL 2 PLACES 3 2 1 TYPICAL 2 PLACES 19 12 13 14 15 TYPICAL 2 PLACES Page 13-32 17 1999 DS Golf Car Illustrated Parts List 16 CONTROLLER, ONBOARD COMPUTER— POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1242 7174 1241 1218 7173 101887901 8450 1018038 1016175 1017 101965201 8990 101909902 101827801 101894901 101932601 1012285 1014288 101910401 2 3 QTY 13 4 NUT, HEX, 5/16 - 18 ................................................................................................................ WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 1-1/4 ........................................................................................ BOLT, HEX HEAD, 5/16 - 18 x 3/4 ........................................................................................... CONTROLLER, 48-VOLT (225-AMP) ...................................................................................... SCREW, HEX HEAD, #10 - 24 x 1/2 ...................................................................................... WASHER, #10 ......................................................................................................................... WASHER, LOCK, #10 ............................................................................................................. NUT, HEX HEAD, #10 - 24 ...................................................................................................... PLATE, COMPONENT MOUNTING ........................................................................................ TIE, WIRE ................................................................................................................................ COMPUTER, ONBOARD (INCLUDES ITEMS 14, 15 AND 16) .............................................. KIT, WIRE AND TERMINAL, #6 BLACK ............................................................................. FUSE ASSEMBLY, 3/8-AMP ............................................................................................... KIT, 6-PIN RECEPTACLE ................................................................................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... SCREW, THREAD-FORMING, 5/16 - 18 x 3/4 ........................................................................ SCREW, THREAD-FORMING, 5/16 - 18 x 1-1/4 .................................................................... 1999 DS Golf Car Illustrated Parts List 4 4 8 1 3 1 2 4 2 2 1 A/R 1 1 1 1 5 2 2 Page 13-33 E BATTERY CHARGER 14 E 14 1 E 2 4 3 5 6 7 8 9 1 10 11 14 12 Page 14-2 1999 DS Golf Car Illustrated Parts List 13 ACCU-POWER CHARGER, DOMESTIC— V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 101646401 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 12 13 14 1015907 7577 1015912 1015914 1015905 1015911 1015910 101643301 101643302 101643303 1012101 1012098 1012042 1015917 101591601 101591602 1015906 1015913 2 3 QTY 14 4 CHARGER, ACCU-POWER, DOMESTIC, 120-VAC, 36-VDC, 60-HZ (MODEL NUMBER 13800-11) (INCLUDES ITEMS 1 - 14) 108 IN. DC CORD, 72 IN. AC CORD ...................................................................................... ASSEMBLY, CASE (INCLUDES FASTENERS) .................................................................. SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ........................................................ ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ AMMETER (INCLUDES MOUNTING HARDWARE) .......................................................... RELAY, 36-VDC ................................................................................................................. CAPACITOR ........................................................................................................................ CORDSET, DC, 108 INCHES LONG (STANDARD) 12-AWG ............................................. CORDSET, DC, 146 INCHES LONG, 10-AWG .................................................................. CORDSET, DC, 242 INCHES LONG, 10-AWG .................................................................. ASSEMBLY, FUSE (INCLUDES HARDWARE) ................................................................... BUSHING, STRAIN RELIEF, 12-AWG DC CORD .............................................................. BUSHING, STRAIN RELIEF, 10-AWG DC CORD .............................................................. BUSHING, STRAIN RELIEF, AC CORD ............................................................................. CORDSET, AC, 72 INCHES LONG (STANDARD) .............................................................. CORDSET, AC, 108 INCHES LONG .................................................................................. ASSEMBLY, TIMER KIT (INCLUDES MOUNTING HARDWARE) ...................................... ASSEMBLY, CONTROL CABLE ......................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 14-3 E 14 1 E 2 4 3 5 6 7 8 9 1 10 11 14 12 Page 14-4 1999 DS Golf Car Illustrated Parts List 13 ACCU-POWER CHARGER, EXPORT, 230-VOLT— V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 101643401 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 13 14 1015940 7577 1015936 1015914 1015905 1015911 1015910 101643301 101643302 101643303 1012101 1012098 1012042 1015917 1014696 1015906 1015913 2 3 QTY 14 4 CHARGER, ACCU-POWER, EXPORT, 230-VAC, 36-VDC, 50-HZ (MODEL NUMBER 14410-11) (INCLUDES ITEMS 1 - 14) 108 IN. DC CORD, 108 IN. AC CORD ..................................................................................... ASSEMBLY, CASE (INCLUDES FASTENERS) .................................................................. SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ........................................................ ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ AMMETER (INCLUDES MOUNTING HARDWARE) .......................................................... RELAY, 36-VDC ................................................................................................................. CAPACITOR ........................................................................................................................ CORDSET, DC, 108 INCHES LONG, 12-AWG (STANDARD) ............................................ CORDSET, DC, 146 INCHES LONG, 10-AWG .................................................................. CORDSET, DC, 242 INCHES LONG, 10-AWG .................................................................. ASSEMBLY, FUSE (INCLUDES MOUNTING HARDWARE) .............................................. BUSHING, STRAIN RELIEF, 12-AWG DC CORD .............................................................. BUSHING, STRAIN RELIEF, 10-AWG DC CORD .............................................................. BUSHING, STRAIN RELIEF, AC CORD ............................................................................. CORDSET, AC, 108 INCHES LONG (STANDARD) ............................................................ ASSEMBLY, TIMER KIT (INCLUDES MOUNTING HARDWARE) ...................................... ASSEMBLY, CONTROL CABLE ......................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 14-5 E 14 1 E 2 4 3 5 6 7 8 9 1 10 11 14 12 Page 14-6 1999 DS Golf Car Illustrated Parts List 13 ACCU-POWER CHARGER, EXPORT, 100-VOLT— V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 101646201 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 13 14 101590703 7577 1016336 1015914 1015905 1015911 1015939 101643301 101643302 101643303 1012101 1012098 1012042 1015917 1016282 1015906 1015913 2 3 QTY 14 4 CHARGER, ACCU-POWER, EXPORT, 100-VAC, 36-VDC, 50-HZ (MODEL NUMBER 14900) (INCLUDES ITEMS 1 - 14) 108 IN. DC CORD, 108 IN. AC CORD .................................................................................... ASSEMBLY, CASE (INCLUDES FASTENERS) .................................................................. SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ........................................................ ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ AMMETER (INCLUDES MOUNTING HARDWARE) .......................................................... RELAY, 36-VDC ................................................................................................................. CAPACITOR ........................................................................................................................ CORDSET, DC, 108 INCHES LONG, 12-AWG (STANDARD) ............................................ CORDSET, DC, 146 INCHES LONG, 10-AWG .................................................................. CORDSET, DC, 242 INCHES LONG, 10-AWG .................................................................. ASSEMBLY, FUSE (INCLUDES MOUNTING HARDWARE) .............................................. BUSHING, STRAIN RELIEF, 12-AWG DC CORD .............................................................. BUSHING, STRAIN RELIEF, 10-AWG DC CORD .............................................................. BUSHING, STRAIN RELIEF, AC CORD ............................................................................. CORDSET, AC, 108 INCHES LONG .................................................................................. ASSEMBLY, TIMER KIT (INCLUDES MOUNTING HARDWARE) ...................................... ASSEMBLY, CONTROL CABLE ......................................................................................... 1999 DS Golf Car Illustrated Parts List 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 14-7 E 14 1 E 2 4 3 5 6 1 7 8 9 10 C lu b C ar R 11 13 Page 14-8 1999 DS Golf Car Illustrated Parts List 14 12 POWERDRIVE CHARGER, DOMESTIC— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 101802201 101802202 101802203 1 2 3 4 5 6 7 7 7 8 9 10 11 12 13 13 14 101828301 7577 101819701 1015914 101828501 101831101 101828901 101828902 101828903 1012101 1012098 101914401 101828701 101828601 101828801 101828802 1015917 2 3 QTY 14 4 CHARGER, BATTERY, POWERDRIVE, DOMESTIC 120-VAC 48-VDC 60-HZ (MODEL NUMBER 17930-11) (INCLUDES ITEMS 1 - 14) 103 IN. DC CORD WITH MALE 3-PIN PLUG, 12-AWG 74 IN. AC CORD WITH MALE GROUNDED PLUG ................................................................ CHARGER, BATTERY, POWERDRIVE 120-VAC 48-VDC 60-HZ (MODEL NUMBER 17930-18) (INCLUDES ITEMS 1 - 14) 144 IN. DC CORD WITH MALE 3-PIN PLUG, 12-AWG 108 IN. AC CORD WITH MALE GROUNDED PLUG .............................................................. CHARGER, BATTERY, POWERDRIVE 120-VAC 48-VDC 60-HZ (MODEL NUMBER 17930-19) (INCLUDES ITEMS 1 - 14) 240 IN. DC CORD WITH MALE 3-PIN PLUG, 12-AWG 108 IN. AC CORD WITH MALE GROUNDED PLUG ............................................................... ASSEMBLY, CASE (INCLUDES FASTENERS) .................................................................. SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ........................................................ ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ AMMETER (INCLUDES MOUNTING HARDWARE) .......................................................... KIT, WIRE ASSEMBLY ........................................................................................................ CORDSET, DC, 113 INCHES LONG WITH MALE 3-PIN PLUG, 12-AWG ......................... CORDSET, DC, 154 INCHES LONG WITH MALE 3-PIN PLUG, 12-AWG ......................... CORDSET, DC, 250 INCHES LONG WITH MALE 3-PIN PLUG, 12-AWG ......................... ASSEMBLY, FUSE (INCLUDES MOUNTING HARDWARE) .............................................. BUSHING, STRAIN RELIEF, DC CORD, 12-AWG ............................................................. ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. BREAKER, CIRCUIT, 15-AMP ............................................................................................ RELAY, POWER, 48-VDC ................................................................................................... CORDSET, AC, 80 INCHES LONG .................................................................................... CORDSET, AC, 116 INCHES LONG .................................................................................. BUSHING, STRAIN RELIEF, AC CORD ............................................................................. 1999 DS Golf Car Illustrated Parts List E 1 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 14-9 14 1 E 2 4 3 7 6 5 8 9 11 1 12 13 C lu b C ar R 14 15 Page 14-10 10 1999 DS Golf Car Illustrated Parts List 16 POWERDRIVE CHARGER, EXPORT— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 101831503 101831504 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 15 16 101838101 7577 101838201 1015914 101914401 101838501 101828501 101838301 101838701 101838601 101828901 101828902 101828903 1012101 1012098 101838401 101831701 101831702 1015917 2 3 QTY 14 4 CHARGER, BATTERY, POWERDRIVE, EXPORT WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48-VDC 50/60-HZ (MODEL NUMBER 18780-11) (INCLUDES ITEMS 1 - 16) 103 IN. DC CORD WITH MALE 3-PIN PLUG, 12-AWG 74 IN. AC CORD WITH NO PLUG ........................................................................................... CHARGER, BATTERY, POWERDRIVE EXPORT WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48-VDC 50/60-HZ (MODEL NUMBER 18780-18) (INCLUDES ITEMS 1 - 16) 144 IN. DC CORD WITH MALE 3-PIN PLUG, 12-AWG 108 IN. AC CORD WITH NO PLUG ........................................................................................ ASSEMBLY, CASE (INCLUDES FASTENERS) .................................................................. SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ........................................................ ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. KIT, WIRE ASSEMBLY ........................................................................................................ AMMETER (INCLUDES HARDWARE) ............................................................................... RELAY, POWER, 48-VDC (INCLUDES MOUNTING HARDWARE) ................................... BRACKET, POWER RELAY MOUNTING ........................................................................... SWITCH, 4-POSITION, SLIDE ........................................................................................... CORDSET, DC, 113 INCHES LONG WITH MALE 3-PIN PLUG, 12-AWG ......................... CORDSET, DC, 154 INCHES LONG WITH MALE 3-PIN PLUG, 12-AWG ......................... CORDSET, DC, 250 INCHES LONG WITH MALE 3-PIN PLUG, 12-AWG ......................... ASSEMBLY, FUSE (INCLUDES HARDWARE) ................................................................... BUSHING, STRAIN RELIEF, DC CORD, 12-AWG ............................................................. BREAKER, CIRCUIT, 15-AMP ............................................................................................ CORDSET, AC, 80 INCHES LONG, WITH LEADS (NO PLUG) ......................................... CORDSET, AC, 116 INCHES LONG, WITH LEADS (NO PLUG) ....................................... BUSHING, STRAIN RELIEF, AC CORD ............................................................................. 1999 DS Golf Car Illustrated Parts List E 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Page 14-11 14 1 2 E 4 3 7 6 5 8 9 11 1 12 13 C lu b C ar R 14 15 16 17 Page 14-12 10 1999 DS Golf Car Illustrated Parts List POWERDRIVE CHARGER, EUROPEAN— POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 101956201 101956202 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 16 17 101838102 7577 101838201 1015914 101914401 101838501 101976601 101987501 101838701 101838601 101828901 101828902 101828903 1012101 1012098 101838401 101973501 101958301 101958201 2 3 QTY 14 4 CHARGER, BATTERY, POWERDRIVE, EUROPEAN WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48-VDC 50/60-HZ (MODEL NUMBER 20300) (INCLUDES ITEMS 1 - 15) 103" DC CORD WITH MALE 3-PIN PLUG, 12-AWG ............................................................... CHARGER, BATTERY, POWERDRIVE EUROPEAN WITH 4-POSITION SWITCH 100 - 200 - 220 - 240 VAC, 48-VDC 50/60-HZ (MODEL NUMBER 20310) (INCLUDES ITEMS 1 - 15) 144" DC CORD WITH MALE 3-PIN PLUG, 12-AWG .............................................................. ASSEMBLY, CASE (INCLUDES FASTENERS) .................................................................. SCREW, PAN HEAD, SELF-TAPPING, #10 - 16 x 1/2 ........................................................ ASSEMBLY, TRANSFORMER ............................................................................................ ASSEMBLY, HEATSINK, WITH DIODES (INCLUDES MOUNTING HARDWARE) ............ ASSEMBLY, VOLTAGE SUPPRESSOR .............................................................................. KIT, WIRE ASSEMBLY ........................................................................................................ AMMETER (INCLUDES HARDWARE) ............................................................................... RELAY, POWER, 48-VDC (INCLUDES MOUNTING HARDWARE) ................................... BRACKET, POWER RELAY MOUNTING ........................................................................... SWITCH, 4-POSITION, SLIDE ........................................................................................... CORDSET, DC, 103" LONG WITH MALE 3-PIN PLUG, 12-AWG ...................................... CORDSET, DC, 144" LONG WITH MALE 3-PIN PLUG, 12-AWG ...................................... CORDSET, DC, 250" LONG WITH MALE 3-PIN PLUG, 12-AWG ...................................... ASSEMBLY, FUSE (INCLUDES HARDWARE) ................................................................... BUSHING, STRAIN RELIEF, DC CORD, 12-AWG ............................................................. BREAKER, CIRCUIT, 15-AMP ............................................................................................ RECEPTACLE, AC CORD .................................................................................................. CORDSET, AC, CONTINENTAL EUROPE, 96" LONG, WITH MALE 2-PIN PLUG) ............... CORDSET, AC, U.K., 96" LONG, WITH MALE 3-PIN PLUG) ................................................. 1999 DS Golf Car Illustrated Parts List E 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Page 14-13 ELECTRIC MOTOR 15 E TYPICAL 2 PLACES TYPICAL 2 PLACES 9 10 11 15 12 13 E 14 7 19 17 8 TYPICAL 4 PLACES 15 16 2 24 23 18 20 1 6 5 4 22 21 3 TYPICAL 3 PLACES REFERENCE TRANSAXLE— SECTION 16 Page 15-2 1999 DS Golf Car Illustrated Parts List MOTOR—V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 15 4 1 2 3 4 5 6 7 8 9 10 11 101813401 1017944 1017945 1017947 N/A N/A N/A N/A 1017952 1017953 1017951 1017949 ASSEMBLY, 36-VOLT MOTOR, 2.97-HP (INCLUDES ITEMS 1 - 20) ..................................... SHIELD, END ...................................................................................................................... ASSEMBLY, STATOR SHELL AND WINDING .................................................................... PACKAGE, HARDWARE (INCLUDES ITEMS 4 - 7) ........................................................... BUSHING, INSULATOR ................................................................................................. WASHER, FLAT, 5/16 .................................................................................................... NUT, HEX, 5/16 - 18 ...................................................................................................... BUSHING, INSULATOR ................................................................................................. SCREW, CLAMP ................................................................................................................. SCREW, BEARING RETAINER .......................................................................................... SHIELD, END ...................................................................................................................... SCREW, BRUSH HOLDER ................................................................................................. 1 1 1 1 2 4 4 2 4 2 1 2 12 13 14 15 16 17 18 19 20 21 22 23 24 1017948 1017946 1011411 1011290 1017950 N/A 101789101 101813202 101822801 1014201 451 1010934 7174 RIGGING, BRUSH .............................................................................................................. PACKAGE, BRUSH (2 PIECES) ......................................................................................... PACKAGE, BRUSH SPRING (4 PIECES) .......................................................................... BEARING, BALL ................................................................................................................. RETAINER, BEARING ........................................................................................................ ARMATURE ........................................................................................................................ RING, GUIDE ...................................................................................................................... ADHESIVE, GUIDE RING, 3-GRAM TUBE ........................................................................ RING, INTERNAL RETAINING ........................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2 1/4 .......................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 1 .............................................................................................. WASHER, LOCK, 5/16 ............................................................................................................ 1 1 1 1 1 1 1 A/R 1 3 3 1 1 1999 DS Golf Car Illustrated Parts List Page 15-3 E TYPICAL 2 PLACES TYPICAL 2 PLACES 15 12 9 10 11 13 E 14 7 19 17 8 TYPICAL 4 PLACES 15 16 2 24 23 18 20 1 6 5 4 22 21 3 TYPICAL 3 PLACES REFERENCE TRANSAXLE— SECTION 16 Page 15-4 1999 DS Golf Car Illustrated Parts List MOTOR—POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 15 4 1 2 3 4 5 6 7 8 9 10 11 101813301 1017944 1017958 1017947 N/A N/A N/A N/A 1017961 1017953 1017951 1017949 ASSEMBLY, 48-VOLT MOTOR, 3.10-HP (INCLUDES ITEMS 1 - 20) ..................................... SHIELD, END ...................................................................................................................... ASSEMBLY, STATOR SHELL AND WINDING .................................................................... PACKAGE, HARDWARE (INCLUDES ITEMS 4 - 7) ........................................................... BUSHING, INSULATOR ................................................................................................. WASHER, FLAT, 5/16 .................................................................................................... NUT, HEX, 5/16 - 18 ...................................................................................................... BUSHING, INSULATOR ................................................................................................. SCREW, CLAMP ................................................................................................................. SCREW, BEARING RETAINER .......................................................................................... SHIELD, END ...................................................................................................................... SCREW, BRUSH HOLDER ................................................................................................. 1 1 1 1 2 4 4 2 4 2 1 2 12 13 14 15 16 17 18 19 20 21 22 23 24 1017948 1017946 1011411 1011290 1017950 N/A 101789101 101813202 101822801 1014201 451 1010934 7174 RIGGING, BRUSH .............................................................................................................. PACKAGE, BRUSH (2 PIECES) ......................................................................................... PACKAGE, BRUSH SPRING (4 PIECES) .......................................................................... BEARING, BALL ................................................................................................................. RETAINER, BEARING ........................................................................................................ ARMATURE ........................................................................................................................ RING, GUIDE ...................................................................................................................... ADHESIVE, GUIDE RING, 3-GRAM TUBE ........................................................................ RING, INTERNAL RETAINING ........................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2 1/4 .......................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 1 .............................................................................................. WASHER, LOCK, 5/16 ............................................................................................................ 1 1 1 1 1 1 1 A/R 1 3 3 1 1 1999 DS Golf Car Illustrated Parts List Page 15-5 E TYPICAL 2 PLACES TYPICAL 2 PLACES 15 23 9 10 24 12 11 22 E 29 13 21 19 7 17 8 TYPICAL 4 PLACES 15 16 2 28 20 27 18 1 6 5 4 25 26 3 TYPICAL 3 PLACES REFERENCE TRANSAXLE— SECTION 16 Page 15-6 1999 DS Golf Car Illustrated Parts List 14 TYPICAL 3 PLACES MOTOR—POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 15 4 1 2 3 4 5 6 7 8 9 10 11 101854601 1017944 101879201 1017947 N/A N/A N/A N/A 1017961 1017953 101879301 101925801 ASSEMBLY, 48-VOLT MOTOR, 3.10-HP (INCLUDES ITEMS 1 - 24) ..................................... SHIELD, END ...................................................................................................................... ASSEMBLY, STATOR SHELL AND WINDING .................................................................... PACKAGE, HARDWARE (INCLUDES ITEMS 4 - 7) ........................................................... BUSHING, INSULATOR ................................................................................................. WASHER, FLAT, 5/16 .................................................................................................... NUT, HEX, 5/16 - 18 ...................................................................................................... BUSHING, INSULATOR ................................................................................................. SCREW, CLAMP ................................................................................................................. SCREW, BEARING RETAINER .......................................................................................... SHIELD, END (INCLUDES ITEMS 11 - 14) ........................................................................ SENSOR, HALL EFFECT (INCLUDES ITEM 12) .......................................................... 1 1 1 1 2 4 4 2 4 2 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 101895101 N/A N/A 1011290 1017950 N/A 101789101 101813202 101822801 1011411 1017946 1017948 1017949 1014201 451 1010934 7174 101920101 HOUSING, FEMALE 3-WIRE, GREY ....................................................................... PLATE, RETAINING........................................................................................................ SCREW, RETAINING...................................................................................................... BEARING, BALL ................................................................................................................. RETAINER, BEARING ........................................................................................................ ARMATURE ........................................................................................................................ RING, GUIDE ...................................................................................................................... ADHESIVE, GUIDE RING, 3-GRAM TUBE ........................................................................ RING, INTERNAL RETAINING ........................................................................................... PACKAGE, BRUSH SPRING (4 PIECES) .......................................................................... PACKAGE, BRUSH (2 PIECES) ......................................................................................... RIGGING, BRUSH .............................................................................................................. SCREW, BRUSH HOLDER ................................................................................................. BOLT, HEX HEAD, 1/4 - 20 x 2 1/4 .......................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 1 .............................................................................................. WASHER, LOCK, 5/16 ............................................................................................................ KIT, 3-PIN PLUG ASSEMBLY, GRAY ...................................................................................... 1 1 3 1 1 1 1 A/R 1 1 1 1 2 3 3 1 1 1 1999 DS Golf Car Illustrated Parts List Page 15-7 E TRANSAXLE— ELECTRIC VEHICLE 16 E 16 yy,y, ,yy,, E REFERENCE MOTOR— SECTION 15 38 37 12 11 10 9 8 3 1 20 16 17 24 7 36 15 16 16 19 14 4 18 21 23 5 6 22 25 6 32 5 34 36 26 33 4 13 15 13 35 7 30 31 30 28 29 27 Page 16-2 2 8 27 1999 DS Golf Car Illustrated Parts List 9 36 3 TRANSAXLE, TYPE G— ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 2 3 QTY 16 4 1 2 3 4 5 6 7 8 9 10 11 101896001 101895801 101895901 101922201 101972301 1011291 101897101 101975401 101976001 101897901 101923501 101895501 TRANSAXLE, TYPE G (INCLUDES ITEMS 1 - 36) ................................................................ AXLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 3 - 7) .................................... AXLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 3 - 7) ............................................. STUD, LUG .................................................................................................................... SLEEVE ......................................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... RING, RETAINING ......................................................................................................... RING, RETAINING ......................................................................................................... BOLT, M10 x 1.5 x 35MM .................................................................................................... WASHER, LOCK, 20MM ..................................................................................................... SEAL, OIL, INPUT SHAFT ................................................................................................. GEAR CASE, PASSENGER SIDE ...................................................................................... 1 1 1 8 1 2 2 2 10 10 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 101897201 7330 101895601 1013794 7335 101923701 7336 101906901 101895401 101972201 101972101 101923201 101897001 101897601 101923601 101923901 101903601 101923001 101903701 101922101 101906201 101897401 101972401 101895701 101928701 451 1014201 BREATHER ......................................................................................................................... BEARING, DIFFERENTIAL ................................................................................................ ASSEMBLY, AXLE TUBE, PASSENGER SIDE ................................................................... SEAL, OIL, AXLE SHAFT ................................................................................................... BEARING, INPUT GEAR ..................................................................................................... SHAFT, INPUT .................................................................................................................... BEARING, INTERMEDIATE GEAR .................................................................................... ASSEMBLY, INTERMEDIATE GEAR .................................................................................. GEAR CASE, DRIVER SIDE .............................................................................................. PLUG, FILL ......................................................................................................................... PLUG, MAGNETIC ............................................................................................................. GASKET, PLUG .................................................................................................................. BOLT, M8 x 1.25 x 60MM .................................................................................................... PIN, DOWEL ....................................................................................................................... HOUSING, DIFFERENTIAL ................................................................................................ GEAR, DIFFERENTIAL ...................................................................................................... PLATE, THRUST (IDLER GEAR) ........................................................................................ GEAR, DIFFERENTIAL IDLER ........................................................................................... PLATE, THRUST ................................................................................................................. PIN, DIFFERENTIAL .......................................................................................................... GEAR, OUTPUT ................................................................................................................. BOLT, M10 x 1.5 x 25MM .................................................................................................... PIN, DOWEL ....................................................................................................................... ASSEMBLY, AXLE TUBE, DRIVER SIDE ........................................................................... GASKET, LIQUID, 8.8 OZ. (250 GRAM) ............................................................................. WASHER, LOCK, 1/4 ............................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2-1/4 .......................................................................................... 1 2 1 2 3 1 1 1 1 1 1 2 11 2 1 2 2 2 2 1 1 4 1 1 A/R 3 3 NOTE: TRANSAXLE TYPE IS IDENTIFIED BY ORIENTATION OF GEAR CASE BOLTS. THE TYPE G TRANSAXLE HAS GEAR CASE BOLT HEADS FACING TOWARD THE PASSENGER SIDE OF THE VEHICLE. 1999 DS Golf Car Illustrated Parts List Page 16-3 E 16 y,y, ,yy,y,y,y,y, E REFERENCE MOTOR— SECTION 15 43 42 12 11 13 10 9 8 3 1 24 18 15 26 19 7 18 17 16 4 25 18 5 TYPICAL 2 PLACES 23 6 22 30 21 28 27 29 20 6 14 5 41 31 4 37 17 40 38 7 37 33 34 14 34 9 32 36 Page 16-4 2 8 35 1999 DS Golf Car Illustrated Parts List 39 15 3 TRANSAXLE, TYPE K— ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 N/A 1013785 1013786 1013787 1014207 1011291 1013792 1016672 1013790 1013791 1013775 1013756 1012711 1013758 7330 1013789 1017704 1013794 7335 1013764 7336 1013766 1013780 1013765 1013757 1013759 1013763 1012710 1013779 1013782 1013767 1013772 101910501 1013768 1013773 1013774 1013769 1013771 1013770 1013781 1017703 1014193 1014201 451 2 3 QTY 16 4 TRANSAXLE, TYPE K (INCLUDES ITEMS 1 - 41) ................................................................. AXLE ASSEMBLY, PASSENGER SIDE (INCLUDES ITEMS 3 - 7) .................................... AXLE ASSEMBLY, DRIVER SIDE (INCLUDES ITEMS 3 - 7) ............................................. STUD, LUG .................................................................................................................... BUSHING, 25 MM I. D. ................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... CIRCLIP, TYPE C ........................................................................................................... RING, RETAINING ......................................................................................................... BOLT, M10 x 1.5 x 30MM .................................................................................................... WASHER, LOCK, 13/32 ...................................................................................................... SEAL, INPUT SHAFT OIL .................................................................................................. GEAR CASE, PASSENGER SIDE ...................................................................................... BREATHER ......................................................................................................................... GASKET, CASE .................................................................................................................. BEARING, INNER AXLE TUBE .......................................................................................... GASKET, AXLE TUBE ........................................................................................................ ASSEMBLY, AXLE TUBE, PASSENGER SIDE ................................................................... SEAL, AXLE SHAFT OIL .................................................................................................... BEARING, INPUT GEAR .................................................................................................... SHAFT, INPUT .................................................................................................................... BEARING, INTERMEDIATE GEAR .................................................................................... GEAR, INTERMEDIATE, SMALL ........................................................................................ KEY, SUNK ......................................................................................................................... GEAR, INTERMEDIATE, LARGE ....................................................................................... GEAR CASE, DRIVER SIDE .............................................................................................. PLUG, FILL, WITH GASKET .............................................................................................. BOLT, M6 x 1 x 50MM ......................................................................................................... PIN, DOWEL ....................................................................................................................... BOLT, M8 x 1.25 x 37MM .................................................................................................... PLATE, LOCK ..................................................................................................................... GEAR, OUTPUT ................................................................................................................. PIN, DIFFERENTIAL .......................................................................................................... KIT, DIFFERENTIAL GEAR CASE (INCLUDES ITEMS 33 - 36) ........................................ GEAR CASE, DIFFERENTIAL (DRIVER SIDE) ............................................................. PLATE, THRUST (DIFFERENTIAL GEAR) .................................................................... PLATE, THRUST (IDLER GEAR) ................................................................................... GEAR CASE, DIFFERENTIAL (PASSENGER SIDE)..................................................... GEAR, DIFFERENTIAL ...................................................................................................... GEAR, DIFFERENTIAL IDLER ........................................................................................... SHIM ................................................................................................................................... ASSEMBLY, AXLE TUBE, DRIVER SIDE ........................................................................... PIN, DOWEL ....................................................................................................................... BOLT, HEX HEAD, 1/4 - 20 x 2-1/4 .......................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. 1 1 1 8 1 2 2 2 10 10 1 1 1 1 2 2 1 2 3 1 1 1 1 1 1 2 10 2 8 4 1 1 1 1 2 2 1 2 2 1 1 1 3 3 NOTE: TRANSAXLE TYPE IS IDENTIFIED BY ORIENTATION OF GEAR CASE BOLTS. THE TYPE K TRANSAXLE HAS GEAR CASE BOLT HEADS FACING TOWARD THE DRIVER SIDE OF THE VEHICLE. 1999 DS Golf Car Illustrated Parts List Page 16-5 E NOTES NOTES NOTES
