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1998 ILLUSTRATED PARTS LIST DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 1019683-01 PRINT CODE 0897B0101A 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 1998 Club Car® DS Tranquility®, 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 titles and numbers, and under them, the individual page titles and numbers to be found in that section. Unless a page title specifies a particular vehicle(s), the page applies to all DS vehicles. Typically, there is a two-page spread for each individual page title in the Table of Contents (however, some titles require several spreads). On the left-hand page is an illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon. The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding to the numbers on the illustration), part descriptions, and quantity of parts used. Some item numbers have more than one part number because several models and/or configurations of a component are represented together on one spread. Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the numbers 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 © 1997, CLUB CAR, INC. All rights reserved. This manual effective August 18, 1997 Manual print code: 0897B0101A 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 6 6-3 6-5 6-7 6-9 6-11 SECTION WIRING - GASOLINE VEHICLE ............................................................................................................................ FORWARD AND 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 SAFETY DECALS - GASOLINE VEHICLE ............................................................................................................ SAFETY DECALS - ELECTRIC VEHICLE ............................................................................................................ 2 2-3 2-5 2-7 2-9 2-11 2-13 SECTION WHEELS AND TIRES ............................................................................................................................................ SAFETY DECALS 1 7 7-3 7-5 7-7 7-9 7-11 7-13 7-15 SECTION FE 290 ENGINE .......................................................................................................................................... 8-3 - 8-13 ENGINE MOUNTING ............................................................................................................................................. 8-15 8 CONTENTS 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 TORQUE CONVERTER ELECTRICAL SYSTEM - ELECTRIC VEHICLE 12 12-3 - 12-7 SECTION ELECTRICAL COMPONENTS, FRONT BODY - ELECTRIC VEHICLE ................................................................ WIRING - V-GLIDE 36 VOLT VEHICLE .................................................................................................................. FORWARD AND 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 AND 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 AND REVERSE SWITCH, TOW SWITCH - POWERDRIVE PLUS VEHICLE .................................... BATTERIES, CHARGER RECEPTACLE - POWERDRIVE PLUS VEHICLE ......................................................... SOLENOIDS, ENERGY DISPLACEMENT MODULE - POWERDRIVE PLUS VEHICLE ...................................... CONTROLLER, ON-BOARD COMPUTER - POWERDRIVE PLUS VEHICLE ...................................................... BATTERY CHARGER 11 11-3 11-5 SECTION UNITIZED TRANSAXLE - GASOLINE VEHICLE ......................................................................................... 10 10-3 SECTION DRIVE CLUTCH ..................................................................................................................................................... DRIVEN CLUTCH .................................................................................................................................................. UNITIZED TRANSAXLE - GASOLINE VEHICLE 9-3 9-5 9-7 9-9 9-11 SECTION EXHAUST SYSTEM ............................................................................................................................................... 9 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 14 ACCU-POWER® CHARGER, DOMESTIC - V-GLIDE 36 VOLT VEHICLE ............................................................ 14-3 ACCU-POWER CHARGER, EXPORT - 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 ELECTRIC MOTOR SECTION MOTOR - V-GLIDE 36 VOLT VEHICLE .................................................................................................................. MOTOR - POWERDRIVE SYSTEM 48 VEHICLE .................................................................................................. MOTOR - POWERDRIVE PLUS VEHICLE ............................................................................................................ 15-3 15-5 15-7 15 CONTENTS TRANSAXLE - ELECTRIC VEHICLE SECTION TRANSAXLE - ELECTRIC VEHICLE ..................................................................................................................... 16-3 16 1 G 1 E 1 Page 1-6 MAINTENANCE AND SERVICE TOOLS 1 G E 1 G 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 24 25 26 MAINTENANCE AND SERVICE TOOLS ITEM PART NO. DESCRIPTION 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1018710-01 1016985 1018132-02 1017295 1018319-01 1014305 1011767 1016417 1016416 1012811 1012812 1018871-01 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 1018084-01 1014510 1014498 1014496 1014497 1014508 1014507 1015524 1018091-01 1018318-01 1016410-02 1011273 1012151 1016627 1016418 CAM INSTALLATION TOOL ....................................................................................... CLUTCH TOOL KIT (INCLUDES ITEMS 14 - 20 ) ..................................................... CLUTCH ALIGNMENT TOOL ................................................................................ DRIVE CLUTCH PULLER ..................................................................................... CLUTCH DRIVE 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 QTY QTY GAS ELEC 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. Page 1-3 1 G E 1 G E 32 31 30 28 33 34 29 35 PULSE ENGINE TACHOMETER PET-1000 Club Car POSTION 36 39 38 37 RESET 41 40 42 43 48 44 47 45 46 - + DM5-XL WAVETEK V OFF 1000 V 500 200 200 200 200 200 200 n 2n 20n 200n 2000k 200k 45° Ω 20k V Ω ! MAX 1000 --750V 49 Page 1-4 50 51 52 53 A 200 2k 45° ! COM FUSED 54 200nA MAINTENANCE AND SERVICE TOOLS ITEM PART NO. DESCRIPTION 1 2 3 QTY QTY GAS ELEC 4 28 29 30 31 32 33 34 35 36 37 38 39 1019331-01 1011478 1013593 1019287-01 1016414 1016415 1012549 1012560 1018231-01 1012809 1016867 1014264 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 ........................................................................................................... STARTER/GENERATOR BELT TENSION TOOL ....................................................... STEERING COLUMN BEARING PRESS TOOL ........................................................ 1 1 1 1 1 1 1 1 1 1 1 1 40 41 42 42 42 42 42 42 43 44 45 46 47 48 49 50 51 52 53 54 55 1014259 1016112 N/A N/A N/A N/A N/A N/A 1014115 1014161 1014162 1016413 1016412-01 1016412-02 1016551 1016552 1016553 1016554 1016411-01 1011480 1016110-02 STEERING COLUMN RETAINING RING TOOL ........................................................ TACHOMETER ........................................................................................................... TOUCH-UP PAINT, LACQUER - BEIGE ..................................................................... TOUCH-UP PAINT, LACQUER - WHITE .................................................................... TOUCH-UP PAINT, LACQUER - GREY ...................................................................... TOUCH-UP PAINT, LACQUER - RED ........................................................................ TOUCH-UP PAINT, LACQUER - DARK BLUE ........................................................... TOUCH-UP PAINT, LACQUER - DARK GREEN ........................................................ TRANSMISSION TOOL KIT ....................................................................................... TRANSAXLE PINION SEAL TOOL ............................................................................ TRANSAXLE AXLE SEAL TOOL ............................................................................... VALVE CLEARANCE ADJUSTER SCREW HOLDER ............................................... VALVE GUIDE REAMER (INCLUDES ITEM 48)........................................................ 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 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. Page 1-5 E 1 G E Page 1-6 BODY AND TRIM 2 G E Front Body Of Car 12 2 Frame Dash G E Center Dash Frame Dash TYPICAL 3 PLACES 2 3 4 9 1 11 8 7 10 TYPICAL 2 PLACES 14 6 15 13 5 TYPICAL 9 PLACES 17 16 25 23 24 23 22 19 20 TYPICAL 2 PLACES 22 21 Page 2-2 TYPICAL 2 PLACES 22 21 18 TYPICAL 2 PLACES BODY TRIM ITEM PART NO. DESCRIPTION 1 2 3 QTY QTY GAS ELEC 4 1 2 3 4 5 6 7 8 9 10 11 12 1013344 1016604-04 1018026-01 1013343 1015032 1014645 N/A N/A N/A N/A 1011017 0007973 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 ........................................................................................ SCREW, FLANGE LOCK ........................................................................................... RIVET, ALUMINUM POP, 3/16 ................................................................................... 1 1 1 1 2 1 1 1 1 2 3 1 1 1 1 1 2 1 1 1 1 2 3 13 14 15 16 17 18 19 20 21 22 23 24 25 1017083-01 0007847 1016952 1017682-02 1010434 1017079 1016379 1016875 0007473 1011697 1016876 1017067-02 1010434 KIT, DRINK HOLDER (INCLUDES ITEMS 14 AND 15) ............................................. BOLT, HEX HEAD, 1/4 - 20 x 3/4 ........................................................................... NUT, “U”, 1/4 - 20 ................................................................................................... KIT, BAGWELL PROTECTOR (INCLUDES ITEM 17) ............................................... FASTENER, PLASTIC BARREL ............................................................................ KIT, REAR BUMPER (INCLUDES ITEMS 19 - 23) .................................................... 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 25) ............................................................. FASTENER, PLASTIC BARREL ............................................................................ 2 2 2 1 9 1 1 1 4 6 4 1 12 2 2 2 1 9 1 1 1 4 6 4 1 12 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 15 FRONT BODY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 7 7 7 7 7 8 8 8 8 8 8 9 10 11 12 13 14 15 16 17 1017080 1016868 0007251 0007473 1016967 1014198 1016925-01 1016925-02 1016925-04 1016925-06 1016925-09 1016925-10 1016939-01 1016939-02 1016939-04 1016939-06 1016939-08 1016939-09 1011014 1010435 0001241 1011017 1011394 1013475-01 1012047 0007251 0007473 2 3 QTY QTY GAS ELEC 4 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 - RED ................................................................................................. BODY, FRONT - DARK BLUE .................................................................................... BODY, FRONT - DARK GREEN ................................................................................. BODY, FRONT WITH HEADLIGHT OPENING - BEIGE ............................................ BODY, FRONT WITH HEADLIGHT OPENING - WHITE ............................................ BODY, FRONT WITH HEADLIGHT OPENING - GRAY .............................................. BODY, FRONT WITH HEADLIGHT OPENING - RED ................................................ BODY, FRONT WITH HEADLIGHT OPENING - DARK BLUE ................................... BODY, FRONT WITH HEADLIGHT OPENING - DARK GREEN ................................ TRIM, FRONT BODY .................................................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1 ................................................................................ WASHER, FLAT, 5/16 ................................................................................................. SCREW, FLANGE LOCK ........................................................................................... NUT, SLAB BASE “T” (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 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 6 1 2 8 2 2 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 6 1 2 8 2 2 Page 2-5 2 G E TYPICAL 2 PLACES 4 2 G E 7 1 FRONT SEAT SUPPORT VERTICAL STRUT 3 1 5 TYPICAL 2 PLACES 6 1 8 9 11 11 TYPICAL 2 PLACES 2 10 12 15 13 17 yyy ;;; ;;; yyy 16 14 22 1 18 23 TYPICAL EACH SIDE OF VEHICLE TYPICAL 2 PLACES 21 TYPICAL EACH SIDE OF VEHICLE 6 6 19 TYPICAL EACH SIDE OF VEHICLE 20 5 TYPICAL 2 PLACES Page 2-6 TYPICAL 2 PLACES REAR BODY AND FENDER - GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 7 8 9 10 11 12 12 12 12 12 12 12 12 12 12 12 12 13 14 15 16 17 18 19 20 21 22 23 0008251 1019041-01 1016952 1012412 0000332 0008233 1015829-02 1015829-01 1015525 N/A N/A N/A 1016926-01 1016926-02 1016926-04 1016926-06 1016926-09 1016926-10 1016962-08 1016962-09 1016962-11 1016962-13 1016962-15 1016962-16 N/A N/A 1017141 1018962-01 1010434 1017748 1012047 0000304 1010434 1017936 1014306 2 3 QTY QTY GAS ELEC 4 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 ..................................................................................... ASSEMBLY, ACCESS DOOR - BLACK ...................................................................... ASSEMBLY, ACCESS DOOR - BEIGE ....................................................................... NUT, BLIND, 1/4 - 20 .................................................................................................. INSULATION, SOUND, FRONT ................................................................................. INSULATION, SOUND, LEFT SIDE BODY ................................................................. INSULATION, SOUND, BODY LEFT / RIGHT FENDER ............................................ BODY - BEIGE ............................................................................................................ BODY - WHITE ........................................................................................................... BODY - GRAY ............................................................................................................. BODY - RED ............................................................................................................... BODY - DARK BLUE .................................................................................................. BODY - DARK GREEN ............................................................................................... BODY WITH TAILLIGHT OPENING - BEIGE ............................................................. BODY WITH TAILLIGHT OPENING - WHITE ............................................................. BODY WITH TAILLIGHT OPENING - GRAY .............................................................. BODY WITH TAILLIGHT OPENING - RED ................................................................. BODY WITH TAILLIGHT OPENING - DARK BLUE .................................................... BODY WITH TAILLIGHT OPENING - DARK GREEN ................................................. INSULATION, SOUND, RIGHT SIDE FENDER - SHORT .......................................... INSULATION, SOUND, LEFT SIDE FENDER - LONG .............................................. SUPPORT, FRONT BODY .......................................................................................... KIT, FORWARD AND REVERSE SWITCH COVER (INCLUDES 2 OF ITEM 17) ..... FASTENER, PLASTIC BARREL ............................................................................ 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 .................................................................................... 10 1 2 2 8 10 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 4 4 2 2 Page 2-7 2 G E 2 16 TYPICAL 2 PLACES 2 G FRONT SEAT SUPPORT VERTICAL STRUT E 5 1 TYPICAL 2 PLACES 4 5 5 17 6 15 3 TYPICAL 2 PLACES 18 19 20 TYPICAL 2 PLACES 5 21 7 6 8 13 9 6 14 TYPICAL EACH SIDE OF VEHICLE 4 10 12 11 TYPICAL EACH SIDE OF VEHICLE Page 2-8 TYPICAL EACH SIDE OF VEHICLE REAR BODY AND FENDER - ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 15 15 15 15 15 15 15 15 15 15 16 16 17 18 19 20 21 1016952 1012412 1019041-01 0000332 0008251 0008233 1017936 1010434 1017814 1012159 0007479 1017815 1017748 1012047 1016933-01 1016933-02 1016933-04 1016933-06 1016933-09 1016933-10 1016962-01 1016962-02 1016962-04 1016962-06 1016962-17 1016962-18 1013032 1013140 1015525 1018962-01 1010434 1017141 1014306 2 3 QTY QTY GAS ELEC 4 NUT, “U”, 1/4 - 20 ........................................................................................................ PLATE, BODY HINGE ................................................................................................ PLATE, BODY KICK .................................................................................................. WASHER, FLAT, 1/4 ................................................................................................... SCREW, PHILLIPS HEAD, 1/4 - 20 x 1 ...................................................................... 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 .............................................................................................................. CLIP, BODY KEEPER ................................................................................................. SCREW, SELF-TAPPING, #8 - 32 .............................................................................. BODY - BEIGE ............................................................................................................ BODY - WHITE ........................................................................................................... BODY - GRAY ............................................................................................................. BODY - RED ............................................................................................................... BODY - DARK BLUE .................................................................................................. BODY - DARK GREEN ............................................................................................... BODY WITH TAILLIGHT OPENING - BEIGE ............................................................. BODY WITH TAILLIGHT OPENING - WHITE ............................................................. BODY WITH TAILLIGHT OPENING - GRAY .............................................................. BODY WITH TAILLIGHT OPENING - RED ................................................................. BODY WITH TAILLIGHT OPENING - DARK BLUE .................................................... BODY WITH TAILLIGHT OPENING - DARK GREEN ................................................. DOOR, ACCESS - BLACK ......................................................................................... DOOR, ACCESS - BEIGE .......................................................................................... NUT, BLIND, 1/4 - 20 .................................................................................................. KIT, FORWARD AND REVERSE SWITCH COVER (INCLUDES 2 OF ITEM 19) .... FASTENER, PLASTIC BARREL ............................................................................ SUPPORT, FRONT BODY .......................................................................................... WASHER, FLAT, TYPE B, 1/4 ..................................................................................... 2 2 1 8 10 10 2 4 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 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 14 2 3 TYPICAL 8 PLACES TYPICAL 4 PLACES 15 5 TYPICAL 8 PLACES 16 TYPICAL 2 PLACES REFERENCE REAR BODY AND FENDER Page 2-10 17 18 TYPICAL 4 PLACES SEAT BOTTOM AND ARMREST ITEM PART NO. DESCRIPTION 1 1 1 1 1 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1015648-04 1015648-05 1015648-07 1015648-08 1015627-01 1015627-02 1015627-04 1015627-10 1010543 1015670 1015625 1019511-01 1018809-01 N/A N/A 1012597 1017384 1012656 1012657 N/A 1018817-01 0000304 1011652 1018809-01 2 3 QTY QTY GAS ELEC 4 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) ............................................................. RIVET, MATING, 3/16 ....................................................................................... ASSEMBLY, ARMREST, LEFT .......................................................................... ASSEMBLY, ARMREST, RIGHT ....................................................................... BUMPER, SEAT ......................................................................................................... SCREW, WASHER HEAD TAP, #12 ........................................................................... GASKET, SEAT, SHORT (GASOLINE VEHICLE ONLY) ............................................ GASKET, SEAT, LONG (GASOLINE VEHICLE ONLY) .............................................. INSULATION, SOUND (GASOLINE VEHICLE ONLY) ............................................... WASHER, FLAT, STAINLESS STEEL, #8 .................................................................. SCREW, HEX HEAD CAP, 1/4 - 20 x 1 ...................................................................... PLATE, SEAT HINGE, STAINLESS STEEL ................................................................ RIVET, POP, STAINLESS STEEL, 3/16 ...................................................................... 1 1 1 1 1 1 1 1 8 1 2 1 8 1 1 1 5 2 1 1 4 8 2 4 1 1 1 1 1 1 1 1 8 1 2 1 8 1 1 1 5 4 8 2 4 Page 2-11 2 G E 2 3 G 7 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 2 5 E 8 9 10 11 1 12 13 4 TYPICAL 2 PLACES TYPICAL 2 PLACES 14 17 18 15 16 19 22 20 TYPICAL 4 PLACES 21 30 28 29 26 27 28 12 TYPICAL 2 PLACES 26 24 TYPICAL 2 PLACES Page 2-12 25 24 23 31 TYPICAL 2 PLACES 24 SEAT BACK AND BAG HOOP ITEM PART NO. DESCRIPTION 1 1 1 1 1 2 3 3 3 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 1015651-02 1015651-05 1015651-06 1015651-07 1013335 1015626-01 1015626-02 1015626-04 1015626-05 1017409 1019462-01 0008248 0008233 0007847 0000332 0008935 1015075 0007473 1013884 1013935 1010434 1010413 1013754 1011708 1011710 1017234 1011706 1017072-06 0008418 1015075 1014482 0008233 0000304 0001241 0007818 1019104-01 1017774 2 3 QTY QTY GAS ELEC 4 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 ...................................................... 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 1/4 .............................................................. 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 ................................................................... FASTENER, PLASTIC BARREL - GRAY ................................................................... 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 ................................................................................. WASHER, FLAT, 5/16 ................................................................................................. BOLT, CARRIAGE, 5/16 - 18 x 1 1/2 .......................................................................... SCREW, SELF-TAPPING, 5/16 - 18 x 1 1/4 ............................................................... SPACER, BODY ......................................................................................................... 2 2 2 2 2 2 2 2 2 2 8 8 6 6 8 2 4 4 2 1 2 1 2 2 2 4 2 1 1 4 1 3 2 2 2 4 4 2 2 2 2 2 2 2 2 2 2 8 8 6 6 8 2 4 4 2 1 2 1 2 2 2 4 2 1 1 4 1 3 2 2 2 4 4 Page 2-13 2 G E 2 G E Page 2-14 WHEELS AND TIRES 3 G E 3 G E 1 2 3 4 5 STANDARD TREAD Page 3-2 PREMIUM TREAD EXTRA TRACTION WHEELS AND TIRES ITEM PART NO. DESCRIPTION 1 1 2 2 2 1010984 1015705-01 1015705-02 N/A 2 2 2 2 1015705-07 1016514-01 1016514-02 N/A 2 3 3 4 4 4 5 1016514-07 1015707 1014771 0007271-02 1015672-02 1017693-02 0007310 2 3 QTY QTY GAS ELEC 4 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 PREMIUM TREAD TIRE, WHITE WALL (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 PREMIUM TREAD TIRE, WHITE WALL (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) ................................ STEM, VALVE ............................................................................................................. 16 4 4 16 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Page 3-3 3 G E 3 G E Page 3-4 SAFETY DECALS 4 G E DRIVER / PASSENGER WARNING DECAL KEY SWITCH 4 OFF G ON 2 E 3 1 OPERATING INSTRUCTIONS DECAL FRAME GROUND AND GOVERNOR WARNING DECAL (ON VEHICLE FRAME NEAR BATTERY) 6 GASOLINE WARNING DECAL (ON VEHICLE FRAME NEAR FUEL TANK) 4 MOVING PARTS AND HOT MANIFOLD DECAL (ON STARTER/GENERATOR AND ENGINE) 5 PERIODIC SERVICE DECAL (ON AIR INTAKE BOX) 7 8 INGERSOLL-RAND DECAL (ON BODY PANEL) Page 4-2 SAFETY DECALS - GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 1019606-01 1018251-01 1016216-01 1015476-01 1019605-01 1019152-01 1019443-01 1019524-01 2 3 QTY QTY GAS ELEC 4 DECAL, DRIVER/PASSENGER WARNING ............................................................... DECAL, KEY SWITCH ............................................................................................... DECAL, OPERATING INSTRUCTIONS ..................................................................... DECAL, GASOLINE DANGER ................................................................................... DECAL, HOT MANIFOLD WARNING ........................................................................ DECAL, NEGATIVE FRAME GROUND WARNING ................................................... DECAL, PERIODIC SERVICE SCHEDULE ............................................................... DECAL, INGERSOLL-RAND ...................................................................................... 1 1 1 1 2 1 1 2 Page 4-3 4 G E DRIVER / PASSENGER WARNING DECAL KEY SWITCH G OFF E ON 3 2 1 OPERATING INSTRUCTIONS DECAL 4 DANGER DECAL (ON BODY UNDER SEAT) MOTOR BRAKING DECAL (POWERDRIVE PLUS VEHICLES ONLY) ! DANGER / POISON NO SHIELD EYES EXPLOSIVE GASES CAN CAUSE • SPARKS • FLAMES • SMOKING SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS BLINDNESS OR INJURY 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. 6 RESISTOR WARNING DECAL 5 (ON FRAME UNDER SEAT ON V-GLIDE 36 VOLT VEHICLE) (ON MOUNTING PLATE UNDER ACCESS PANEL ON POWERDRIVE PLUS VEHICLE) Club Car F N 4 7 9 TOW SWITCH WARNING DECAL (ON TOW SWITCH BRACKET UNDER SEAT) INGERSOLL-RAND DECAL 8 POTENTIOMETER CAUTION DECAL (ON WIPER SWITCH COVER INSIDE BATTERY COMPARTMENT) (POWERDRIVE PLUS VEHICLES ONLY) Page 4-4 SAFETY DECALS - ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 1019606-01 1018251-01 1016216-01 1019599-01 1013496 6 7 8 9 1013677 1019524-01 1016109-01 1019086-01 2 3 QTY QTY GAS ELEC 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/POISON ...................................................................... DECAL, INGERSOLL-RAND ...................................................................................... DECAL, POTENTIOMETER CAUTION ...................................................................... DECAL, TOW SWITCH (POWERDRIVE PLUS VEHICLE) ........................................ 1 1 1 1 1 1 2 1 1 Page 4-5 4 G E 4 G E Page 4-6 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 BRAKE ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 1 2 2 3 4 5 6 7 8 9 9 10 11 12 13 14 14 15 16 1018233-01 1018233-02 1018240-01 1018240-02 1018165-01 1018165-02 1018239-01 1018238-01 1010850 1018232-01 1011466 1018163-01 1018155-01 1018155-02 1013924 1014153 1010829 0001035 1019008-01 1013207 1017911-01 1011779 2 3 QTY QTY GAS ELEC 4 CLUSTER, RIGHT BRAKE (INCLUDES ITEMS 1 - 9) ............................................... CLUSTER, LEFT BRAKE (INCLUDES ITEMS 1 - 9) ................................................. ASSEMBLY, BACKING PLATE, RIGHT (INCLUDES ITEMS 2, 3 AND 4) ............. ASSEMBLY, BACKING PLATE, LEFT (INCLUDES ITEMS 2, 3 AND 4) ................ MECHANISM, ADJUSTING, RIGHT ................................................................ MECHANISM, ADJUSTING, LEFT ................................................................... WASHER .......................................................................................................... WASHER, PLATE ............................................................................................. COVER, DUST ....................................................................................................... PACKAGE, BRAKE SHOE (FOUR PIECES) ......................................................... KIT, SHOE RETAINER (FOUR PIECES) ............................................................... PACKAGE, BRAKE SPRING (FOUR PIECES) ...................................................... ASSEMBLY, LEVER, RIGHT .................................................................................. ASSEMBLY, LEVER, LEFT .................................................................................... 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) .......................................... DRUM, BRAKE ........................................................................................................... E-CLIP, 1/2 .................................................................................................................. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 2 2 2 2 Page 5-3 5 G E 5 G 14 E 4 3 11 5 1 2 2 9 8 6 FLOORBOARD REMOVED FOR CLARITY TYPICAL 2 PLACES 7 13 10 P O T S 23 18 22 30 19 17 12 TYPICAL 4 PLACES 21 24 20 5 15 16 17 TYPICAL 2 PLACES TYPICAL 2 PLACES 31 25 29 33 Page 5-4 30 32 26 27 TYPICAL 4 PLACES 28 REFERENCE GASOLINE VEHICLE FRAME BRAKE PEDAL AND CABLE 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 27 28 29 30 31 32 33 0001242 1018653-01 1017211 N/A 0007473 1011403 1011779 0001035 1010829 1019540-01 1013531 0007716 1013869 1019531-01 1019530-01 0007473 1011877-02 N/A 1017029 1010877 1010805 1010932 1010933 1010927 1010878 0001028 1011402 0001241 1010921 1011418 0001032 0007716 1013876 1013870 2 3 QTY QTY GAS ELEC 4 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 AND 32) .................................. SPRING, BRAKE RETURN ................................................................................... SCREW, SLOTTED HEX WASHER HEAD, #10 - 16 x 1/2 .................................... PAD, BRAKE PEDAL .............................................................................................. ROD, EQUALIZER ................................................................................................. BOLT, HEX HEAD SHOULDER, 3/8 x 1 ................................................................ NUT, NYLON LOCK, 5/16 - 18 .............................................................................. KIT, PARK BRAKE (INCLUDES ITEMS 17-21 AND ITEM 24 ON PAGE 5-7)............. 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 ............................................................................................. STOP, BRAKE ............................................................................................................ NUT, HEX, 1/4 - 20 ..................................................................................................... PACKAGE, BRAKE MOUNTING BLOCK (CONTAINS UPPER AND LOWER FOR LEFT AND RIGHT 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 2 1 1 1 2 2 2 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 2 2 1 1 4 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 Page 5-5 5 G E TYPICAL 4 PLACES 5 23 2 25 3 G 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 19 13 ACCELERATOR PEDAL ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1017696 1013871 0007716 0001624 0001241 1017325 0007473 0000332 1017424 1019669-01 1018174-01 1017962-01 1017378 1017380 0008233 1018188-01 1018719-01 17 1019124-01 18 19 20 21 22 23 1011084 1011734 1011700 1011694 1018619-01 0008754 1011877-02 N/A 0000334 24 25 2 3 QTY QTY GAS ELEC 4 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 ..................................................................................................... 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 (INCLUDES ITEM 24 AND ITEMS 17-21 ON PAGE 5-4)............. ASSEMBLY, RATCHET ............................................................................................... WASHER, FLAT, 3/8 ................................................................................................... 1 1 4 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 2 2 1 2 4 2 1 1 2 2 2 1 2 4 2 1 1 2 Page 5-7 5 G E 5 G E Page 5-8 STEERING, FRONT AND REAR SUSPENSION 6 G E 6 31 G 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 5 2 TYPICAL 3 PLACES 3 4 1 Page 6-2 16 ;; y ; y yy ;; yy ;; y ;; yy ;; yy 32 18 18 15 TYPICAL 2 PLACES STEERING COLUMN 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 1013861 1017226 0007174 1016185 1016184 1016269 0000334 1016183 0008754 1014288 1011697 1012499 1016181 1012605 1012604 1014217 1014125 1014213 1014126 1015545 1016622 1014214 1014211 1016263 1016156 1017273 1016219 1012565 1012566 1016214 1016154 1016663 2 3 QTY QTY GAS ELEC 4 JOINT, COMPOUND STEERING (INCLUDES ITEMS 2 AND 3) ............................... SCREW, HEX HEAD CAP, M8 x 1.25 x 30MM ...................................................... WASHER, LOCK, 5/16 ........................................................................................... MOUNT, STEERING COLUMN, LEFT HAND ............................................................ MOUNT, STEERING COLUMN, RIGHT HAND ......................................................... 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 ..................................................................................... 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 .............................................................................................. SCREW, PHILLIPS, TYPE A, #12 - 11 x 5/8 .............................................................. 1 3 3 1 1 2 4 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 2 1 3 3 1 1 2 4 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 2 Page 6-3 6 G E 24 25 28 6 29 30 G 1 E 2 27 3 4 23 26 12 11 10 9 5 6 8 7 13 31 14 32 TYPICAL 3 PLACES 33 TYPICAL 3 PLACES 17 18 yy ;; ;; yy ;; yy ;; yy Page 6-4 19 2 20 21 22 15 16 STEERING GEAR 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 27 28 29 30 31 32 33 1018783-02 1013035 0008990 1018802-01 1018803-01 N/A N/A N/A N/A 1018794-01 1018799-01 1013051 1013052 1018797-01 1018798-01 1013044 N/A N/A 1018795-01 1018796-01 1018800-01 1018801-01 1019260-01 0001035 0007540 1015597 0007602 1011930 0007555 1012467 1013042 0001624 0000334 1010138 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, STEERING GEAR BOX (INCLUDES ITEMS 1 - 22) ............................. SEAL, DUST, RIGHT ............................................................................................. WRAP, TIE .............................................................................................................. ASSEMBLY, INNER BALL JOINT .......................................................................... WASHER, TAB ....................................................................................................... BUSHING, RACK ................................................................................................... BOX, STEERING GEAR ........................................................................................ BEARING, LOWER PINION .................................................................................. PINION, STEERING .............................................................................................. BEARING, UPPER PINION ................................................................................... RING, C-TYPE STOP ............................................................................................ RING, SNAP .......................................................................................................... SEAL, DUST, STEERING PINION ......................................................................... GUIDE, STEERING RACK .................................................................................... SPRING, YOKE ...................................................................................................... NUT, LOCK, RACK SCREW .................................................................................. SCREW, RACK GUIDE .......................................................................................... RACK, STEERING ................................................................................................. WASHER, STOP .................................................................................................... RING, C-TYPE STOP ............................................................................................ SEAL, DUST, LEFT ................................................................................................ O-RING, DUST SEAL RETAINING ........................................................................ CAP, RACK END DUST ......................................................................................... PIN, COTTER, 3/32 x 1 .............................................................................................. BALL JOINT, LEFT HAND THREAD (INCLUDES ITEMS 25, 26 AND 27) ................ 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, DIMPLED LOCK, 3/8 - 16 .................................................................................. 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 Page 6-5 6 G E 6 TYPICAL 2 PLACES G 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 FRONT SUSPENSION, UPPER ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 1016353 1016346 1016350 1016349 0008754 0007539 0001308 0001624 1010138 0002402 1010219 0007555 0007540 1017266 1015813 1014235 1010124 1010200 1016385 1011930 0007602 0001035 2 3 QTY QTY GAS ELEC 4 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 ................................................................ 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 .............................................................................................. 2 6 1 2 8 1 1 2 4 4 1 1 1 2 2 1 4 1 3 3 1 2 6 1 2 8 1 1 2 4 4 1 1 1 2 2 1 4 1 3 3 1 Page 6-7 6 G E 6 REFERENCE STEERING GEAR ASSEMBLY G E 15 17 18 14 16 19 3 30 TYPICAL 4 PLACES PASSENGER'S SIDE ONLY 2 1 5 DRIVER'S 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 23 13 6 32 10 24 FRONT SUSPENSION, LOWER 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 1010348 1010347 0008067 0007048 1015597 1012030 0008745 0000706 1011892 1011393 1011304 1013135 1011887 0008754 1016387 1016384 1019031-01 1010028 1010150 1016389 1010984 1010005 0007840 0007910 0008755 1016386 1015583 1012303 1014276 0001624 0000357 0000706 2 3 QTY QTY GAS ELEC 4 ASSEMBLY, LEFT SPINDLE (INCLUDES ITEMS 3, 4 AND 5) .................................. ASSEMBLY, RIGHT SPINDLE (INCLUDES ITEMS 3, 4 AND 5) ............................... BUSHING, BRONZE SPINDLE ............................................................................. BUSHING, BRONZE .............................................................................................. FITTING, GREASE, 1/4 - 28 .................................................................................. SPRING, TAPERED LEAF ......................................................................................... ECCENTRIC ............................................................................................................... NUT, HEX, 3/8 - 16 ..................................................................................................... ASSEMBLY, HUB (INCLUDES ITEMS 10 - 13) .......................................................... PACKAGE, HUB BEARING .................................................................................... STUD, LUG, 1/2 - 20 ............................................................................................... 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 1 1 1 1 1 1 2 2 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 1 1 1 1 1 1 1 1 2 2 4 1 1 4 2 2 2 2 2 2 8 2 2 2 2 2 4 2 1 4 4 4 Page 6-9 6 G E 6 BRAKE CABLE HANGER MOUNTING GASOLINE VEHICLE ONLY G TYPICAL ON EACH SIDE OF VEHICLE E TYPICAL ON EACH SIDE OF VEHICLE 17 17 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 3 8 TYPICAL 2 PLACES 9 Page 6-10 4 4 REAR SUSPENSION ITEM PART NO. DESCRIPTION 1 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 16 17 17 1012304 0007569 0008754 1012303 1015583 1010145 1013164 1014236 1011415 N/A N/A 1012180 1012324 1010974 1014557 1014555 0008755 1012182 1012181 1019008-01 1013207 2 3 QTY QTY GAS ELEC 4 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 ....................................................................................................................... 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) .................................................... G 4 6 4 12 4 1 2 4 8 8 2 2 4 4 6 1 1 2 6 4 6 4 12 4 1 2 4 8 8 2 2 4 4 6 1 1 2 Page 6-11 E 6 G E Page 6-12 ELECTRICAL SYSTEM GASOLINE VEHICLE 7 G 7 G 14 4 3 13 FORWARD / REVERSE ASSEMBLY CK B LA FRAME GROUND RE D E WHIT E WHIT BL U CK A L B / LIMIT SWITCHES E CK B LA 2 ITE / WH RED YEL KEY SWITCH 1 YE L 2 M- M+ O GE RA N BLA E GRE 3 LOW 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 BL A 6 15 E A NG 7 K LAC E/B WHIT CK 4 E WHIT BLA CK BL U E FRAME GROUND SOLENOID E BL U R ED IRE ND W ROU G IDED RED WHITE / BLACK RE D 16 RED ITE WH RED VOLTAGE REGULATOR BRA NGE O RA UND RO ED G ID BRA WHIT YELLOW BLACK RED E/B 17 8 18 K LAC E STARTER / GENERATOR F2 DF A1 9 E WIR WHIT FUSE BLOCK F1 A2 YELLOW WHITE BLACK BATTERY ENGINE YE L L O W OIL SENDING UNIT / BLACK BLACK YELLO YELLOW W WHITE BLA C K 10 12 N EE GR YELLOW YELLOW RPM LIMITER FRAME GROUND 19 11 Page 7-2 1 N LOW REVERSE BUZZER WHITE BLUE RED ITE / WH WIRING - GASOLINE 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 1018893-02 N/A N/A N/A N/A N/A N/A 1015769 N/A N/A 1014119 N/A 1012382 N/A N/A N/A 1015920 1015737 1015332 1018373-01 2 3 QTY 4 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 ........................................................................................ 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 1 1 1 1 1 1 1 1 1 1 1 1 Page 7-3 7 G 7 22 23 G 2 21 3 24 4 9 1 5 6 25 8 8 2 11 13 10 12 14 20 26 19 7 17 16 15 18 27 19 28 24 29 30 Clu bC Club Car Club Car Page 7-4 ar 20 FORWARD AND REVERSE SHIFTER ASSEMBLY GASOLINE 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 1016947 1012594 0008057 1012431 1014808 1014807 0008058 1013591 1014145 1014727 1016342 1014089 1014065 1013590 1013589 0008717 1013587 1010954 1019515-01 0007893 1012333 1013198 1012987 0008248 0008233 1014065 0008251 1018558-01 0000332 1019226-01 1012285 2 3 QTY 4 ASSEMBLY, FORWARD AND 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 AND REVERSE SHIFTER ................................................................... KIT, NEUTRAL LOCK-OUT CAM (INCLUDES ITEM 12) ................................................... WASHER, FLAT ............................................................................................................. SPRING, FORWARD AND REVERSE CAM ...................................................................... RING, RETAINING .............................................................................................................. NUT, NYLON LOCK, 1/4 - 28 .............................................................................................. WELDMENT, FORWARD AND 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 AND REVERSE SWITCH .................................................................... SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 3/4 ................................................................... NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. WASHER, FLAT, 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 2 4 2 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 4 8 1 4 1 4 1 3 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 9 ELECTRICAL COMPONENT BOX GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1018276-01 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 1018213-01 0008717 0008057 0008058 1014807 1014808 1012431 N/A 1015878 1018561-01 1015777 0007893 0001242 1013609 1012295 1015737 1015741 1015371 1015405 0001241 0007473 2 3 QTY 4 BOX, ELECTRICAL COMPONENT, COMPLETE (INCLUDES ITEMS 1 - 25 AND 1018893-02 - 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 1/2 ........................................................ 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 ................................................................................................ 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'S SIDE OF VEHICLE, BODY REMOVED 8 4 3 2 1 OFF ON 13 14 TYPICAL 3 PLACES Page 7-8 9 11 12 ELECTRICAL COMPONENTS GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1016859 1016849 1016851 N/A 1011229 1015720 1018306-01 1018263-01 1018511-01 1018307-01 1018345-02 1012505 1016630 1019001-01 2 3 QTY 4 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) .............................................................................................................................. LIGHT, OIL WARNING ............................................................................................................. RETAINER, HARNESS ........................................................................................................... 1 2 1 1 1 1 4 1 1 1 1 1 1 3 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 STARTER/GENERATOR 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 27 28 29 30 31 1018337-01 1018752-01 1018751-01 1018750-01 1013001 1013005 1019399-01 1013003 1018765-01 N/A N/A N/A 1018965-01 1018749-01 1018753-01 1018754-01 1018755-01 1018756-01 1018776-01 1018757-01 1018777-01 1013011-02 1018781-01 1018693-02 1018762-02 1018758-02 1018760-01 1018763-01 1017653 1018764-02 1018790-01 1014289 2 3 QTY 4 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 ......................................................... 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 INSULATOR ............................................................................................................ PACKAGE, TERMINAL HARDWARE (F1 AND F2) ............................................................ SET, DF 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) ..................................................................................................... 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1 2 2 1 1 1 4 1 2 1 2 1 1 1 2 1 Page 7-11 7 G 7 17 FRAME CONNECTION G 16 15 14 AS VIEWED FROM THE DRIVER'S 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 THE PASSENGER'S SIDE OF VEHICLE 11 10 Page 7-12 STARTER/GENERATOR MOUNTING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1018337-01 1015240-01 1019167-01 1016883 0008754 1015075 0000705 1019035-01 0007174 1016074 1015932 0001242 1018373-01 1015920 0007473 0001241 0007173 2 3 QTY 4 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 ................................................................................................................ 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 2 1 2 2 3 1 1 1 1 1 1 1 1 Page 7-13 7 G AS SEEN FROM PASSENGER'S SIDE OF VEHICLE 7 1 G 2 3 Club Car ClubC ar 4 5 TO NEGATIVE BATTERY POST TERMINAL 6 7 8 7 8 Page 7-14 AS SEEN FROM DRIVER'S SIDE OF VEHICLE BATTERY - GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 1012328 1014374 1014375 1010934 1018980-01 0007173 0001241 0007473 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 ................................................................................................ 1 2 2 1 1 1 2 2 Page 7-15 7 G 7 G Page 7-16 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 13 FE 290 ENGINE ITEM PART NO. DESCRIPTION 1 1019539-01 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1016507 1016512 1016524 1016456 1016547 1019097-01 1016526 1017221 1019156-01 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 ........................................................................................................................ 8 G 1 1 1 1 15 3 1 1 1 1 1 1 1 1 1 1 1 3 1 Page 8-3 8 G 11 12 13 10 9 8 7 TYPICAL 2 PLACES 1 2 TYPICAL 3 PLACES 3 19 yy ;; ;; yy 18 16 17 15 14 TYPICAL 2 PLACES Page 8-4 24 23 5 22 21 20 4 25 6 FE 290 ENGINE 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 1019157-01 1019158-01 1017448 1016548 1016505 1017455 1016562 1016455 1019092-01 1016578 1016588 1016493 1016111 1016456 1012981 1016579 1016586 1019094-01 1016445 1019095-01 1016497 1016544 1016561 1016587 1019093-01 2 3 QTY 4 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 ..................................................................................................... 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 1 3 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Page 8-5 8 G 8 G 14 13 12 4 11 TYPICAL 2 PLACES 9 10 3 ;yy; 2 8 6 5 1 7 TYPICAL 6 PLACES Page 8-6 FE 290 ENGINE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1016467 1016502 1016457 1016570 1016576 1016432 1017456 1016484 1016435 1016473 1016482-03 1016429 1016537 1016581 2 3 QTY 4 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 ....................................................................................................................... BALL, STEEL, PRESSURE RELIEF .................................................................................. SPRING .............................................................................................................................. 1 1 2 1 1 1 6 1 1 1 1 1 1 1 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 28 FE 290 ENGINE 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 1016442 1016436 1016583 1016569 1016545 1016542 1016451 1016450 1016449 1016523 1016431 1016560 1016519 1016479 1016566 1016448 1016447 1016544 1016474 1016483 1016563 1016489 1016452 1016471 1016549 1016517 1016458 1016430 2 3 QTY 4 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 .................................................................................................................. 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 .................................................................................................................. 1 1 2 2 2 2 2 2 2 2 1 2 2 2 2 1 1 1 1 1 2 2 1 2 1 1 6 1 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 2 PLACES Page 8-10 TYPICAL 6 PLACES FE 290 ENGINE 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 1016535 1016538 1016506 1016544 1016564 1016565 1016567 1016584 1016458 1016520 1016446 1016456 1016510 1016494 1016496 1016454 1016472 1016521 1019154-01 1016453 2 3 QTY 4 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 ...................................................................................... 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 1 1 2 1 1 2 6 1 1 2 1 1 3 2 1 1 1 2 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 21 10 15 19 FE 290 ENGINE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 5 5 6 6 6 7 7 1016568 1019155-01 1016558 1016460 1016459-01 1016459-02 1016459-03 1016461-01 1016461-02 1016461-03 1016475-01 1016475-02 8 9 10 11 12 13 14 15 15 15 15 15 15 15 15 15 16 17 18 19 20 21 1016509 1019223-01 1016533 1016532 1016516 1016580 1016562 1016550-01 1016550-02 1016550-03 1016550-04 1016550-05 1016550-06 1016550-07 1016550-08 1016550-09 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 12) ................................................ GEAR, HELICAL ............................................................................................................ GEAR, SPUR ................................................................................................................. ASSEMBLY, CONNECTING ROD (INCLUDES 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 .......................................................................................... 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 10 6 7 TYPICAL 4 PLACES 6 11 14 8 15 TYPICAL 4 PLACES 16 17 Clu bC ar TYPICAL 2 PLACES 18 9 10 TYPICAL 4 PLACES Page 8-14 REFERENCE UNITIZED TRANSAXLE SECTION 12 ENGINE MOUNTING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 0007473 0001241 1018646-01 1010435 1012164 1013924 1018346-01 1018271-01 1018330-01 1018848-01 1018333-01 1018332-01 1018321-01 1018326-01 1018329-01 1012571 1018559-01 1018327-01 2 3 QTY 4 NUT, NYLON LOCK, 5/16 - 18 ................................................................................................ WASHER, FLAT, 5/16 - 18 ...................................................................................................... RETAINER, SNUBBER ........................................................................................................... BOLT, CARRIAGE, 5/16 - 18 x 1 ............................................................................................. SNUBBER ............................................................................................................................... NUT, HEX LOCK, 5/16 - 24, UNF ........................................................................................... BRACKET, SNUBBER ............................................................................................................. PLATE, MOUNTING ................................................................................................................ NUT, FLANGE, M8 x 1.25 ....................................................................................................... SCREW, HEX WASHER, 5/16 -248 x 7/8 ................................................................................ SCREW, HEX HEAD CAP, M10 x 1.25 x 30MM ...................................................................... STUD, M8 x 1.25 ..................................................................................................................... SPACER .................................................................................................................................. STIFFENER, DRIVE CLUTCH SIDE ....................................................................................... 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 2 1 2 1 10 1 1 6 10 4 2 2 1 4 4 4 1 Page 8-15 8 G 8 G Page 8-16 FUEL, INTAKE, AND GOVERNOR SYSTEMS 9 G 9 27 5 G 6 25 4 2 9 24 3 11 10 7 8 26 1 24 ENGINE REMOVED FOR CLARITY 19 27 28 18 28 28 SEE ABOVE GAS TANK FUEL PICKUP TUBE 17 19 12 13 17 21 14 15 19 23 20 16 28 6 20 21 22 21 TO ENGINE CRANKCASE Page 9-2 FUEL SYSTEM 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 1016003 1015188 1014535 1015143 1015139 1015137 1016059 1018244-01 1018969-01 1014928 1019553-01 1014523 1014524 1010433 0000451 0001028 1013134-01 1013684 1012293 1013692 1012649 1014522 1013687 1014116 1013746 1019556-01 1011988 1013134-02 2 3 QTY 4 KIT, FUEL TANK, (INCLUDES ITEMS 2 - 9) ........................................................................... CAP, FUEL TANK, NONVENTED (INCLUDES ITEM 3) .................................................... GASKET, FUEL CAP ..................................................................................................... ASSEMBLY, FUEL TANK VENT .......................................................................................... GROMMET, INSULATION ................................................................................................... LINE, BULK VENT (AVAILABLE BY THE FOOT) ............................................................... CLIP, STUD ......................................................................................................................... BARB, VENT ....................................................................................................................... VALVE, FUEL PICKUP TUBE WITH SHUT-OFF ................................................................ ASSEMBLY, REAR FUEL STRAP ........................................................................................... ASSEMBLY, FRONT FUEL STRAP ......................................................................................... PUMP, FUEL IMPULSE, SQUARE BODY ................................................................................ PUMP, FUEL IMPULSE, SQUARE BODY REBUILD KIT ........................................................ STUD, FLUSH HEAD, 1/4 - 20 x 3/4 ........................................................................................ WASHER, LOCK, 1/4 .............................................................................................................. NUT, HEX, 1/4 - 20 .................................................................................................................. CLAMP, HOSE (BLACK) .......................................................................................................... FILTER , PRIMARY FUEL (WHITE) ......................................................................................... LINE, BULK FUEL (YELLOW) ................................................................................................. LINE, BULK FUEL (BLACK) .................................................................................................... CLAMP, HOSE (RED) .............................................................................................................. FILTER, SECONDARY FUEL (BLUE) ..................................................................................... CLAMP, HOSE, 3/8 .................................................................................................................. NUT, U-TYPE SPEED, 1/4 - 20 ............................................................................................... CLAMP, HOSE ......................................................................................................................... T-FITTING ............................................................................................................................... SCREW, PHILLIPS TRUSS HEAD, 1/4 - 20 x 2 ...................................................................... CLAMP, HOSE (GREEN) ........................................................................................................ 1 1 1 1 1 A/R 1 1 1 1 1 1 1 2 2 2 2 1 A/R A/R 3 1 1 3 1 1 3 4 Page 9-3 9 G 9 G 2 3 1 4 5 8 6 9 7 10 11 Page 9-4 CARBURETOR ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 1019056-01 1016501 N/A 1019731-01 1016486 1019732-01 7 7 7 7 7 8 9 10 11 1016425-82 1016425-80 1016425-78 1016425-75 1016425-72 1016437 1017461 1016499 1016585 2 3 QTY 4 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 .............................................................................. GASKET, FLOAT CHAMBER .............................................................................................. ASSEMBLY, FLOAT CHAMBER (INCLUDES ITEM 10) ..................................................... ASSEMBLY, SCREW ..................................................................................................... ASSEMBLY, BOLT ............................................................................................................... 1 1 1 1 1 1 A/R A/R A/R A/R A/R 1 1 1 1 Page 9-5 9 G 9 9 7 G 8 5 6 yyy ;;; ;;; ;;;yyy yyy ;;; yyy ;;;; yyyy ;;;; yyyy 1 2 3 4 11 12 14 16 yyy ;;; ;;; yyy ;;; yyy 14 19 TYPICAL 2 PLACES Page 9-6 20 10 17 15 18 13 CARBURETOR INSTALLATION 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 1016440 1016481-02 1016439 1016444 1018202-01 1016103 0000332 0000334 1018876-01 1013746 1016441 1016582 1019056-01 1017466 1015137 1016572 1016438 1016480 1016490-02 1016547 2 3 QTY 4 GASKET, INSULATOR ............................................................................................................ INSULATOR, CARBURETOR .................................................................................................. GASKET, CARBURETOR INSULATOR TO THROTTLE BRACKET ....................................... BRACKET, THROTTLE ............................................................................................................ GUARD, GOVERNOR ............................................................................................................. SCREW, PAN/TORX HEAD SELF-TAPPING, #6 - 32 x 1/4 .................................................... WASHER, FLAT, 1/4 ................................................................................................................ WASHER, FLAT, 3/8 ................................................................................................................ NUT, NYLON LOCK, M6 x 1 .................................................................................................... CLAMP, HOSE ......................................................................................................................... GASKET, THROTTLE BRACKET TO CARBURETOR ........................................................... SPRING, THROTTLE RETURN .............................................................................................. ASSEMBLY, CARBURETOR ................................................................................................... CLAMP, HOSE ......................................................................................................................... LINE, BULK VENT ................................................................................................................... TUBE, CRANKCASE VENT ..................................................................................................... GASKET, CARBURETOR TO INTAKE MANIFOLD ................................................................. PIPE, INTAKE .......................................................................................................................... SCREW, 2-ENDED STUD, M6 x 1 x 90MM ............................................................................. NUT, FLANGED, M6 x 1 .......................................................................................................... 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 2 2 Page 9-7 9 G 9 7 G 6 4 5 3 1 2 7 8 9 10 7 8 12 13 14 9 11 Page 9-8 6 GOVERNOR AND ACCELERATOR CABLES ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1018325-01 1018324-01 1013700 1016546 1018323-01 1012285 1016202 1015408 1014413 1018322-01 1015845 1019035-01 0007174 1011697 2 3 QTY 4 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 ....................................................................... WASHER, LOCK, 5/16 ............................................................................................................ WASHER, FLAT, 5/16 .............................................................................................................. 1 1 2 2 1 4 3 2 2 1 1 1 1 1 Page 9-9 9 G 17 9 REFERENCE CARBURETOR 18 5 6 G 1 TYPICAL 2 PLACES 15 7 16 2 3 15 TYPICAL 3 PLACES 8 11 17 4 19 20 9 21 22 12 10 13 ;; yy yy ;; ;; yy ;; yy 14 25 26 27 26 27 23 27 24 TYPICAL 3 PLACES 27 Page 9-10 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 27 1018215-01 1018043-01 1018817-01 1019257-01 1018118-01 1018130-01 1019176-01 1019443-01 N/A N/A N/A 1018123-01 1015426 1018119-01 1019215-01 1019713-01 1018371-01 1018503-01 1019177-01 1018057-01 1018115-01 1018562-01 1018114-01 0000332 1015752 1019581-01 0001606 0000183 1019710-01 2 3 QTY 4 ASSEMBLY, AIR BOX (INCLUDES ITEMS 1 - 14) .................................................................. SCREW, HI-LO HEX HEAD, #8 - 1/2 .................................................................................. WASHER, STAINLESS STEEL, #8 ..................................................................................... LATCH, WIRE ..................................................................................................................... ASSEMBLY, AIR BOX TOP (INCLUDES ITEMS 5 - 11) ..................................................... E-CLIP ........................................................................................................................... LEVER, CHOKE ............................................................................................................ DECAL, SERVICE ......................................................................................................... O-RING, 5/16 (RED) ...................................................................................................... O-RING, 3/8 (GREEN) ................................................................................................... VALVE, CHOKE ............................................................................................................. SPRING, RETURN ........................................................................................................ FILTER, AIR ........................................................................................................................ BOTTOM, AIR BOX ............................................................................................................. SEAL, INTAKE .................................................................................................................... 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 .................................................................................................................... WASHER, FLAT, #10 ............................................................................................................... AIR DUCT REPAIR KIT (NOT SHOWN) .................................................................................. 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 3 3 1 2 4 A/R Page 9-11 9 G 9 G Page 9-12 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 EXHAUST SYSTEM ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1018593-01 1015814 0000332 0000451 0007847 1017689 1019035-01 0007174 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 ................................................................................................................ 1 1 2 2 2 1 1 1 1 2 2 1 Page 10-3 10 G 10 G Page 10-4 TORQUE CONVERTER 11 G 11 G 4 1 3 2 5 10 6 7 14 8 14 9 13 16 12 11 19 18 21 20 Page 11-2 17 15 DRIVE CLUTCH 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 1018339-02 1016801 1019298-01 N/A N/A 1014049 1014050 1014051 1016289 1014057 1014059 1019256-01 1014453 1014058 1014056 1014052 N/A 1014055 1016203 1019167-01 1019165-01 1017328 2 3 QTY 4 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 ...................................................................................................... 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 1 1 3 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Page 11-3 11 G 11 G 8 6 7 5 4 3 2 9 12 11 1 10 Page 11-4 DRIVEN CLUTCH ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1018340-01 1014080 1014078 1017686 1018362-01 1014454 1014072 1014070 1018334-01 1016203 0007173 1017327 2 3 QTY 4 ASSEMBLY, DRIVEN CLUTCH (INCLUDES ITEMS 2 - 8) ..................................................... RING, RETAINING .............................................................................................................. KEY ..................................................................................................................................... CAM .................................................................................................................................... SPRING - GREEN .............................................................................................................. KIT, BUTTON ...................................................................................................................... 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 .......................................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 Page 11-5 11 G 11 G Page 11-6 UNITIZED TRANSAXLE GASOLINE VEHICLE 12 G 3 5 12 7 4 G 11 12 6 13 8 REFERENCE FORWARD AND 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 29 UNITIZED TRANSAXLE - GASOLINE 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 1019226-01 1012285 1013061 0000183 1010954 1016341 1017082 0008717 1017231 1018348-01 1018861-01 0000332 0008233 1018336-01 1018902-01 1019273-01 1018929-01 1019272-01 1018901-01 1012752 1019286-01 1016513 1019271-01 1018938-01 1018913-01 1018906-01 1018905-01 1019269-01 1012896 1013759 1016432 1012711 1019287-01 2 3 QTY 4 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, FLAT ....................................................................................................................... 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 3 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 15 2 2 1 1 A/R 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'S SIDE CASE 64 63 62 Clu bC Page 12-4 ar REFERENCE PASSENGER'S SIDE CASE UNITIZED TRANSAXLE - GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 1018920-01 1018900-01 1012748 1012747 1018894-01 0007336 1016338 1018924-01 1018922-01 1018897-01 1019276-01 1019275-01 1012742 1012741 1019280-01 1012740 1019279-01 1019277-01 1018899-01 1018896-01 1016337 1019278-01 1012714 1018926-01 1018932-01 1018925-01 1019281-01 1018895-01 1019282-01 1018939-01 1018923-01 1018916-01 1018919-01 0007335 2 3 QTY 4 ROD, SHIFT ........................................................................................................................ FORK, SHIFT ...................................................................................................................... SPRING .............................................................................................................................. BALL, STEEL ...................................................................................................................... GUIDE ................................................................................................................................. BEARING, BALL ................................................................................................................. WASHER, SPRING ............................................................................................................. GEAR, SPUR ...................................................................................................................... PLATE, THRUST ................................................................................................................. GEAR ASSEMBLY, 28 TOOTH, INPUT (13°) (SEE PARTS BULLETIN 98-21) .................. BEARING, NEEDLE ........................................................................................................... BEARING, NEEDLE ........................................................................................................... RING, SYNCHRONIZER (13°) (SEE PARTS BULLETIN 98-21) ........................................ SPRING, SYNCHRONIZER ................................................................................................ HUB, SYNCHRONIZER CLUTCH ...................................................................................... INSERT, SYNCHRONIZER ................................................................................................. SLEEVE, SYNCHRONIZER ............................................................................................... PIN, DOWEL ....................................................................................................................... SHAFT, INPUT .................................................................................................................... GEAR ASSEMBLY, 25 TOOTH, INPUT (13°) (SEE PARTS BULLETIN 98-21) .................. 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 ................................................................................................................. 1 1 1 1 1 4 2 1 3 1 3 1 2 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Page 12-5 12 G 12 G 75 73 78 71 77 69 REFERENCE PASSENGER'S 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'S SIDE CASE 76 68 71 70 72 73 69 Page 12-6 UNITIZED TRANSAXLE - GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 1018915-01 1018914-01 1013787 1013792 1011291 1014207 1016672 1013794 1018910-01 1018909-01 1013790 1013791 0007330 1019283-01 1018927-01 1014193 1019105-01 1013768 1013774 1013773 1013769 1013772 1013770 1013771 2 3 QTY 4 AXLE ASSEMBLY, LEFT (INCLUDES ITEMS 69 - 73) ....................................................... AXLE ASSEMBLY, RIGHT (INCLUDES ITEMS 69 - 73) ..................................................... STUD, LUG .................................................................................................................... RING, RETAINING ......................................................................................................... BEARING, OUTER AXLE TUBE ................................................................................... COLLAR, 25 MM I. D. ..................................................................................................... RING, RETAINING ......................................................................................................... SEAL, OIL ........................................................................................................................... ASSEMBLY, AXLE TUBE, LEFT SIDE ................................................................................ ASSEMBLY, AXLE TUBE, RIGHT SIDE ............................................................................. BOLT, M10 x 1.5 x 30MM .................................................................................................... WASHER, LOCK, M10 ........................................................................................................ 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 ...................................................................................................... 1 1 4 1 1 1 1 1 1 1 14 14 2 8 1 1 1 1 2 1 1 1 2 2 Page 12-7 12 G 12 G Page 12-8 ELECTRICAL SYSTEM 13 E 13 E TYPICAL 2 PLACES OFF ON 4 8 7 AS SEEN FROM FRONT DRIVER'S SIDE OF VEHICLE, BODY REMOVED 5 3 2 1 OFF ON 10 11 12 TYPICAL 3 PLACES Page 13-2 6 9 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 1018306-01 1018262-01 1018511-01 1018307-01 1018345-02 1012505 1018026-01 1019355-01 1019009-01 2 3 QTY 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) ............................................................................................................. RETAINER, HARNESS ........................................................................................................... 1 2 1 2 1 1 1 1 1 1 1 3 Page 13-3 13 E 13 E 22 UE BL 20 1 D RE 2 16 ITE WH E G AN OR KEY SWITCH BR REVERSE BUZZER 15 N RE 1 UE 2 LE EE LIMIT SWITCH 1 N RP GR FORWARD / REVERSE SWITCH OW PU D BL 24 D RE YE LL WH OW ITE WH ITE 21 10 WH ITE 23 SOLENOID N EE FUSE AND RECEPTACLE GE O E GR GR 13 N RA EN 17 12 25 BL K UE GR RE BL ITE WH EE D RE D N K AC - AC BL K AC BL BULLET CONNECTOR N EE GR 5 + 6 WHITE WHITE SPEED SWITCH 7 18 G RE EN W H E IT + - GR AY + 2 3 4 AC TYPICAL 5 PLACES AY LE A2 RP PU K K BL AC R BL 4 RESISTOR BOARD 26 G 5 + 8 - - - 6 + BATTERY BANK BLUE + WHITE - 1 ORANGE 11 - YELLOW D + GREEN 9 D RE RE 19 BLACK 14 N OW S2 S1 A1 BR MOTOR 3 Page 13-4 WIRING - V-GLIDE 36 VOLT 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 1016070 1016069 1012651 1016068 1014036 1014035 1014034 1014033 1014032 1014828 1014030 1014029 N/A 1013092 N/A N/A N/A 1020180-01 1011010 N/A 1014039 N/A 1011069 N/A N/A 1010958 2 3 QTY 4 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 ................................................................................................. 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 1 1 1 1 1 1 1 1 1 1 1 1 5 Page 13-5 13 E 13 E 3 TYPICAL 2 PLACES 2 9 10 4 5 TYPICAL 2 PLACES 6 TYPICAL 3 PLACES 11 1 8 7 TYPICAL 2 PLACES SEAT SUPPORT FRONT PANEL 12 TYPICAL 3 PLACES Page 13-6 FORWARD AND REVERSE SWITCH V-GLIDE 36 VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1017530-03 1014808 0008057 0008058 1011991 1017799 0000451 0001028 1012987 1013198 1016845 0008233 2 3 QTY 4 13 E ASSEMBLY, FORWARD AND REVERSE SWITCH (INCLUDES ITEMS 2 - 8) ...................... SWITCH, LIMIT ................................................................................................................... NUT, HEX, #4 - 40 ............................................................................................................... WASHER, LOCK, #4 ........................................................................................................... SCREW, SLOTTED ROUND HEAD, #4 - 40 x 1 1/8 ........................................................... BAR, BUS ........................................................................................................................... WASHER, LOCK, 1/4 .......................................................................................................... NUT, HEX, 1/4 - 20 .............................................................................................................. HANDLE, FORWARD AND 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 .................................................................................................. 1 1 2 2 2 1 2 2 1 1 3 3 Page 13-7 13 E 21 25 TYPICAL 8 PLACES 32 26 20 22 16 TYPICAL 2 PLACES 33 1 REFERENCE SEE PAGE 5-6 4 6 19 8 18 17 16 5 15 7 14 13 27 32 12 33 3 2 11 TYPICAL 2 PLACES 3 8 23 28 24 9 10 31 29 Club Car 30 MOUNTING DETAIL Page 13-8 TYPICAL 2 PLACES WIPER SWITCH - V-GLIDE 36 VOLT 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 1016140 1014999 1014414 1014253 0007473 1012353 1014003 0008449 1012903 1014189 1013886 0007893 1014017 1013998 1014000 1014019 0008058 1013887 1013860 0008056 1014807 1014010 0008057 0000451 1014413 N/A N/A 1017692 1014109 1016175 0001017 1019492-01 0001014 0000451 2 3 QTY 4 ASSEMBLY, V-GLIDE WIPER SWITCH (INCLUDES ITEMS 1 - 27) ....................................... 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, HEX, #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 .......................................................................................................... PIN, HAIR SPRING COTTER ............................................................................................. 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, BRASS HEX, 1/4 - 20 ..................................................................................................... WASHER, LOCK, 1/4 .............................................................................................................. 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 2 1 1 2 1 1 1 1 1 2 2 2 1 9 9 Page 13-9 13 E 12 13 E F CAR FRONT O 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 TYPICAL 2 PLACES RESISTOR AND BOARD ASSEMBLY V-GLIDE 36 VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 0001028 0000451 1011931 1014045 1014728 0000332 1014476 1014012 1014013 1014014 1014729 1012285 1013971 2 3 QTY 4 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 ........................................................................... SHIELD, RESISTOR ................................................................................................................ 12 12 6 6 1 6 1 1 1 1 1 4 1 Page 13-11 13 E 13 E VEHICLE BODY 25 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES 25 30 TYPICAL 2 PLACES 26 27 17 15 22 18 16 19 21 TYPICAL 2 PLACES 24 20 TYPICAL 2 PLACES 21 23 28 11 12 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES 1 TYPICAL 6 PLACES 29 14 3 2 TYPICAL 6 PLACES TYPICAL 5 PLACES TYPICAL 12 PLACES 4 31 TYPICAL 6 PLACES 6 13 TYPICAL 2 PLACES 7 10 9 8 5 TYPICAL 6 PLACES Page 13-12 BATTERIES, CHARGER RECEPTACLE, SOLENOID V-GLIDE 36 VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 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 2 3 QTY 4 1015072 1011578 1010908 1013683 1016616-01 1016616-02 1010958 1018314-01 1012022 0001606 N/A 0007174 0001242 1012285 0007893 1013425-01 1014516 N/A N/A N/A 0001016 0008797 0004107 1013092 1013628 0008796 0008795 1013649 0008797 0001016 1013266 1014304 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 ........................................................................................................... CLAMP, CABLE ....................................................................................................................... RIVET, POP, 3/16 .................................................................................................................... SOLENOID, 36 VOLT (FOR REPLACEMENT SOLENOID, SEE BOTTOM OF PAGE) ........... WASHER, LOCK, 5/16 ............................................................................................................ NUT, HEX, 5/16 - 18 ................................................................................................................ SCREW, THREAD ROLLING, 1/4 - 20 x 5/8 ........................................................................... NUT, HEX, #10 - 32 ................................................................................................................. KIT, FUSE AND RECEPTACLE (INCLUDES ITEMS 16 - 30) ................................................. KIT, FUSE (INCLUDES ITEMS 17 - 21) .............................................................................. 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 .......................................... NUT, HEX, STAINLESS STEEL, 5/6 - 18 ................................................................................ 6 6 3 6 6 6 5 6 2 2 1 2 2 2 2 1 1 1 1 1 2 4 1 1 1 6 2 1 2 2 2 12 1019759-01 SOLENOID, 36 VOLT (NOT SHOWN) ...................................................................................... IF ORDERING SOLENOID 1019759-01, THE FOLLOWING ITEMS WILL ALSO BE REQUIRED: 1 1014948 1020472-01 1020483-01 8639 DIODE (NOT SHOWN)............................................................................................................. SNUBBER (NOT SHOWN)....................................................................................................... BASE, MOUNTING (NOT SHOWN) ......................................................................................... TIE, WIRE (NOT SHOWN) ....................................................................................................... 1 1 1 1 Page 13-13 13 E 13 E N EE GR 2 1 D RE E NG RA KEY SWITCH TE O I WH / GE AN N OR W RO B FRONT REVERSE BUZZER WARNING LIGHT 10 33 FORWARD / REVERSE SWITCH 3 1 UE BLUE OR AN W H YE T/B L L N LO K /W W H T E PL R UE WH ITE LIMIT SWITCHES 8 PU R G W 7 13 N/ W N YE 24 WHITE 23 LE RP PU D BLK - 1 + + GREY 3 6 1 B- CONTROLLER LE E RP HIT PU D/W RE LOW ITE L WH YE GE AN OR B+ BLACK 4 2 M- YELLOW RED BROWN BLACK - D RE 3 BLACK + 27 YELLOW 2 BLUE YELLOW 21 - GREEN + - TYPICAL 5 PLACES SOLENOID 26 D RE RED + RED/WHITE PURPLE 25 RE 20 5 EN EY GR FUSE D + RED K AC BL BATTERY BANK OW LL YE RE - FUSE 18 + RED D RE 22 19 GRE 17 WHITE/ BLACK 16 FUSE AND RECEPTACLE BLUE LL O BL W RP AC LE K N BL A BL TE PU EE UE CK HI ORANGE GE D GR 15 12 6 EE OW AN 3 ITE GR BR RE 2 WH 5 OR 1 CK LA E E HIT HIT W / W N D/ E EE RE ANG R N G EE OR GR /B E HIT SIX PIN CONNECTOR 4 GE BL 9 2 11 BL MULTI-STEP POTENTIOMETER GREEN UE BL 28 BL 29 AC K ON-BOARD COMPUTER 32 - Page 13-14 30 THREE PIN CONNECTOR 14 A2 S1 S2 A1 31 MOTOR WIRING - POWERDRIVE SYSTEM 48 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 1019110-01 N/A 1019327-01 N/A N/A N/A N/A N/A N/A N/A 1019014-01 1019012-01 1019015-01 N/A 1019013-01 N/A N/A N/A N/A N/A N/A 1017957-01 N/A 1014947 1019028-01 1014948 1019030-01 N/A N/A N/A 1019201-01 1019029-01 1018278-01 N/A 2 3 QTY 4 WIRE HARNESS (INCLUDES ITEMS 1 - 17) ......................................................................... 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 ......................................................................................... 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, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #18 GREY (PART OF ON-BOARD COMPUTER ASSEMBLY) ................ WIRE ASSEMBLY, #10 RED (PART OF FUSE AND RECEPTACLE ASSEMBLY) ................. WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #18 RED ................................................................................................... ASSEMBLY, RESISTOR .......................................................................................................... WIRE ASSEMBLY, #6 RED .................................................................................................... ASSEMBLY, DIODE ................................................................................................................. WIRE ASSEMBLY, #6 YELLOW .............................................................................................. WIRE ASSEMBLY, #18 RED ................................................................................................... WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #18 YELLOW ............................................................................................ HOUSING, MALE, 3-WIRE ..................................................................................................... WIRE ASSEMBLY, #6 GREEN ................................................................................................ KIT, WIRE AND TERMINAL, #6 BLACK .................................................................................. WIRE ASSEMBLY, #18 ORANGE/WHITE ............................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 Page 13-15 13 E 13 E 4 TYPICAL 2 PLACES 3 10 2 SEAT SUPPORT FRONT PANEL 11 5 6 TYPICAL 3 PLACES 12 TYPICAL 2 PLACES 1 9 8 TYPICAL 4 PLACES 7 TYPICAL 2 PLACES Page 13-16 13 TYPICAL 3 PLACES FORWARD AND REVERSE SWITCH POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1017530-05 1014807 1014808 0008057 0008058 1014871 1017799 0000451 0001028 1012987 1013198 1016845 0008233 2 3 QTY 4 ASSEMBLY, FORWARD AND REVERSE SWITCH (INCLUDES ITEMS 2 - 9) ...................... SWITCH, LIMIT ................................................................................................................... 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 AND 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 .................................................................................................. 1 1 2 2 2 2 2 4 4 1 1 3 3 Page 13-17 13 E 11 13 E TYPICAL 4 PLACES 10 TYPICAL 2 PLACES 6 5 7 8 2 TYPICAL 3 PLACES 17 TYPICAL 6 PLACES 9 15 18 TYPICAL 12 PLACES 1 14 19 TYPICAL 6 PLACES 13 12 Page 13-18 3 16 TYPICAL 6 PLACES TYPICAL 5 PLACES 4 TYPICAL 3 PLACES BATTERIES, CHARGER RECEPTACLE POWERDRIVE SYSTEM 48 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 1018021-01 1017965-01 N/A N/A N/A 1017968-01 1013061 1017705 1018949-01 1018010-01 1018320-01 1017977-01 1017977-02 1017978-01 1017957-01 1014304 1018030-01 1015072 1011578 1013683 2 3 QTY 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 ..................................................................................................................................... 1 1 1 1 1 1 2 3 1 1 4 6 6 6 5 12 3 6 6 6 Page 13-19 13 E 13 E TYPICAL 2 PLACES TYPICAL 2 PLACES 1 2 TYPICAL 2 PLACES 5 6 3 7 4 8 9 10 TYPICAL 4 PLACES 10 11 TYPICAL 2 PLACES TYPICAL 2 PLACES SOLENOID 2 12 ON-BOARD 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 COMPUTER, CONTROLLER, AND SOLENOID POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1019652-01 1014288 0007893 1014948 0001242 0007174 1019026-01 1014947 1019087-01 1012285 1018402-01 0001241 0007173 0001218 1019099-01 1018949-01 1018278-01 1019423-01 2 3 QTY 4 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 .............................................................................................................. BOLT, HEX HEAD, 5/16 - 18 x 3/4 ........................................................................................... BOLT, HEX HEAD, 5/16 - 18 x 1 1/4 ........................................................................................ COMPUTER, ON-BOARD (INCLUDES ITEMS 16, 17 AND 18) ............................................. FUSE ASSEMBLY, 3/8 AMP ............................................................................................... KIT, WIRE AND TERMINAL, #6 BLACK ............................................................................. RECEPTACLE, 3-PIN ......................................................................................................... 1 4 2 1 5 5 1 1 1 8 1 6 2 1 1 2 1 1 Page 13-21 13 E 2 11 3 31 NO TI TYPICAL 7 PLACES 36 10 9 4 C E 13 E 6 5 15 12 14 1 13 16 27 17 24 26 14 38 25 7 23 21 9 22 32 20 30 8 19 REFERENCE ACCELERATOR ROD 30 28 9 33 22 18 35 29 39 Club Car 40 41 37 Page 13-22 34 MULTI-STEP POTENTIOMETER POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS 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 1019320-03 1014999 1019580-02 1019326-01 N/A N/A N/A N/A N/A 0000451 0001014 1019469-01 1019711-01 0008056 0008058 1014807 0008057 1014414 1014413 0007893 1014017 1013998 1012903 1014000 1014010 1014019 1013887 1013860 1013461 1014189 1014253 0008990 0007473 1012353 1014003 0008449 1016109-01 1013886 1014109 1019492-01 1016175 0001017 2 3 QTY 4 ASSEMBLY, WIPER SWITCH (INCLUDES ITEMS 1 - 37) ...................................................... 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, BRASS HEX, 1/4 - 20 ................................................................................................ PROTECTOR, WIPER SWITCH RESISTOR ...................................................................... KIT, RESISTOR ASSEMBLY ............................................................................................... SCREW, ROUND HEAD MACHINE, #4 - 40 x 3/4 ........................................................... WASHER, LOCK, #4 .......................................................................................................... SWITCH, LIMIT.................................................................................................................... NUT, HEX, #4 - 40 ............................................................................................................... BUMPER, WIPER SWITCH ................................................................................................ PIN, HAIR SPRING COTTER ............................................................................................. NUT, HEX, #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 ................................................................................. COVER, WIPER SWITCH ................................................................................................... BOLT, CARRIAGE, #10 - 24 x 1 ............................................................................................... SHIM, WIPER SWITCH ........................................................................................................... WASHER, LOCK, #10 ............................................................................................................. NUT, HEX, #10 - 24 ................................................................................................................. 1 1 1 1 1 1 1 1 1 17 15 1 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 1 2 1 2 2 Page 13-23 13 E N EE GR 2 D RE E NG RA TE 1 HI O TOW SWITCH KEY SWITCH /W N O WARNING LIGHT R 2 K FRONT REVERSE BUZZER TWO PIN CONNECTOR K OW BR AC BL GE N RA AC BL 13 E RE D/ W BL HI F K BL UE / ED FORWARD / REVERSE SWITCH BLUE ITE WH ITE /WH RED E BLU MULTI-STEP POTENTIOMETER E IT WH R 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 WHITE B- EY BLUE A1 GREEN 5 OW LL YE N ON-BOARD COMPUTER 6 BLU/WHT GR 7 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 WHITE - BLUE BLUE + ORANGE/WHITE D GR WHITE RE OR HI TE N SOLENOID B+ 4 1 11 OW E LL YE WHIT E/ EEN N U BL /GR REE D G RE HT CK LIG BLA BR OW N 14 ITE WH 13 TE TE THREE PIN CONNECTOR HI HI /W W GE N RA O 1 2 9 3 10 4 11 5 12 6 13 7 14 W SOLENOID HI TE RESISTOR 8 15 RE G R G D EE BL RE N AC EN K BLUE 12 (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 A2 F2 12 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 WIRING - POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1019648-01 N/A N/A 1018278-01 N/A N/A N/A 1017957-01 1018535-02 1019028-01 1018536-02 1019687-01 1019029-01 1019200-01 2 3 QTY 4 WIRE HARNESS .................................................................................................................... WIRE ASSEMBLY, #18 ORANGE/WHITE ............................................................................... WIRE ASSEMBLY, #10 RED (PART OF FUSE AND RECEPTACLE ASSEMBLY) ................. KIT, WIRE AND TERMINAL, #6 BLACK .................................................................................. WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #18 GRAY (PART OF ON-BOARD COMPUTER ASSEMBLY) ................. WIRE ASSEMBLY, #10 BLACK (PART OF ON-BOARD COMPUTER ASSEMBLY) ............... WIRE ASSEMBLY, #6 BLACK ................................................................................................. WIRE ASSEMBLY, #10 ORANGE ........................................................................................... WIRE ASSEMBLY, #6 RED ..................................................................................................... WIRE ASSEMBLY, #10 BLUE ................................................................................................. WIRE ASSEMBLY, #6 WHITE ................................................................................................. WIRE ASSEMBLY, #6 GREEN (SEE SERVICE BULLETIN 00-09) ......................................... WIRE ASSEMBLY, #6 YELLOW .............................................................................................. 1 1 1 1 1 1 1 5 1 1 1 2 1 1 Page 13-25 13 E 13 E 1 6 2 5 F 4 ING 3 TOW RUN WARN TYPICAL 3 PLACES REFERENCE DECALS— SECTION 3 7 8 9 F 10 10 Page 13-26 FORWARD AND REVERSE SWITCH, TOW SWITCH POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 1018560-01 1018550-01 1018561-01 0008248 1019225-01 1019084-01 0000332 0008233 1019081-01 0008990 2 3 QTY 4 SWITCH, FORWARD AND REVERSE .................................................................................. CASE, FORWARD AND 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 .............................................................................................................. WASHER, FLAT, 1/4 ................................................................................................................ NUT, NYLON LOCK, 1/4 - 20 .................................................................................................. SWITCH, TOW ........................................................................................................................ TIE, WIRE ................................................................................................................................ 1 1 3 2 1 1 2 2 1 A/R Page 13-27 13 E 11 13 E TYPICAL 4 PLACES 10 6 5 7 TYPICAL 2 PLACES 8 2 TYPICAL 3 PLACES 17 YPICAL LACES 3 16 15 18 4 TYPICAL 12 PLACES 1 14 19 TYPICAL 6 PLACES 13 12 TYPICAL 6 PLACES F Page 13-28 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 1018021-01 1017965-01 N/A N/A N/A 1017968-01 1013061 1017705 1018949-01 1018010-01 1018320-01 1017977-01 1017977-02 1017978-01 1017957-01 1014304 1018030-01 1015072 1011578 1013683 2 3 QTY 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 ..................................................................................................................................... 1 1 1 1 1 1 2 3 1 1 4 6 6 6 5 12 3 6 6 6 Page 13-29 13 E 13 E 1 3 2 3 8 9 4 8 5 6 7 TYPICAL 2 PLACES 4 5 12 6 11 10 TYPICAL 2 PLACES TYPICAL 4 PLACES 13 1 8 7 TYPICAL 2 PLACES 8 12 Page 13-30 SOLENOIDS, ENERGY DISPLACEMENT MODULE POWERDRIVE PLUS VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1017237 1018882-01 1015069 1011931 0000451 0001028 1018028 1019344-01 1019644-01 1019579-01 1012285 1018836-01 1019026-01 2 3 QTY 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 ...................................................................................................... WASHER, FLAT, BRASS, 5/16 ................................................................................................ MODULE, ENERGY DISPLACEMENT .................................................................................. BRACKET, MOUNTING ........................................................................................................... SCREW, THREAD-ROLLING, 1/4 - 20 x 5/8 ........................................................................... SOLENOID, 48 VOLT ............................................................................................................... BOOT, WIRE ............................................................................................................................ 4 2 2 2 2 2 4 4 1 2 4 2 1 Page 13-31 13 E 1 13 E TYPICAL 2 PLACES 7 2 8 8 3 9 10 3 5 TYPICAL 3 PLACES 6 17 1 1 2 2 3 3 3 4 3 5 11 18 5 3 TYPICAL 2 PLACES 3 2 1 TYPICAL 2 PLACES 18 12 13 14 15 TYPICAL 2 PLACES Page 13-32 17 16 CONTROLLER, ON-BOARD 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 0001242 0007174 0001241 0001218 0007173 1018879-01 0008450 1018038 1016175 0001017 1019652-01 0008990 1019099-02 1018278-01 1018949-01 1019326-01 1012285 1014288 2 3 QTY 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, ON-BOARD (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 ........................................................................ 4 4 8 1 3 1 2 4 2 2 1 A/R 1 1 1 1 5 4 Page 13-33 13 E 13 E Page 13-34 BATTERY CHARGER 14 E 14 1 E 2 4 3 5 6 7 8 9 1 10 11 14 12 Page 14-2 13 ACCU-POWER CHARGER, DOMESTIC V-GLIDE 36 VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1016464-01 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 12 1015907 0007577 1015912 1015914 1015905 1015911 1015910 1016433-01 1016433-02 1016433-03 1012101 1012098 1012042 1015917 1015916-01 1015916-02 13 14 1015906 1015913 2 3 QTY 4 14 E 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) .......................................................... 36 VDC RELAY ................................................................................................................... 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 .................................................................................. 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ASSEMBLY, TIMER KIT (INCLUDES MOUNTING HARDWARE) ...................................... ASSEMBLY, CONTROL CABLE ......................................................................................... 1 1 Page 14-3 14 1 E 2 4 3 5 6 7 8 9 1 10 11 14 12 Page 14-4 13 ACCU-POWER CHARGER, EXPORT, 230 VOLT V-GLIDE 36 VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1016434-01 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 13 N/A 0007577 1015936 1015914 1015905 1015911 1015910 1016433-01 1016433-02 1016433-03 1012101 1012098 1012042 1015917 1014696 1015906 14 1015913 2 3 QTY 4 14 E 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) .......................................................... 36 VDC RELAY ................................................................................................................... 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) ...................................... 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ASSEMBLY, CONTROL CABLE ......................................................................................... 1 Page 14-5 14 1 E 2 4 3 5 6 7 8 9 1 10 11 14 12 Page 14-6 13 ACCU-POWER CHARGER, EXPORT, 100 VOLT V-GLIDE 36 VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1016462-01 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 13 N/A 0007577 1016336 1015914 1015905 1015911 1015939 1016433-01 1016433-02 1016433-03 1012101 1012098 1012042 1015917 1016282 1015906 14 1015913 2 3 QTY 4 14 E 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) .......................................................... 36 VDC RELAY ................................................................................................................... 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) ...................................... 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ASSEMBLY, CONTROL CABLE ......................................................................................... 1 Page 14-7 14 E 1 2 4 3 5 6 1 7 8 9 10 C lu b C ar R 11 13 Page 14-8 14 12 POWERDRIVE CHARGER, DOMESTIC POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 1018022-01 2 3 QTY 4 E 1 2 1018283-01 0007577 CHARGER, BATTERY, POWERDRIVE, DOMESTIC 120VAC 48VDC 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 120VAC 48VDC 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 120VAC 48VDC 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 ........................................................ 3 4 5 6 7 7 7 1018197-01 1015914 1018285-01 1018311-01 1018289-01 1018289-02 1018289-03 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 ......................... 1 1 1 1 1 1 1 8 9 10 11 12 13 13 14 1012101 1012098 1019144-01 1018287-01 1018286-01 1018288-01 1018288-02 1015917 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 ............................................................................. 1 1 1 1 1 1 1 1 1018022-02 1018022-03 14 1 1 1 1 10 Page 14-9 14 E 1 2 4 3 7 6 5 8 9 11 1 12 13 C lu b C ar R 14 15 Page 14-10 10 16 POWERDRIVE CHARGER, EXPORT POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 1018315-03 1018315-04 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 15 16 1018381-01 0007577 1018382-01 1015914 1019144-01 1018385-01 1018285-01 1018383-01 1018387-01 1018386-01 1018289-01 1018289-02 1018289-03 1012101 1012098 1018384-01 1018317-01 1018317-02 1015917 2 3 QTY 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 ............................................................................. 14 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 E 1 2 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 POWERDRIVE CHARGER, EUROPEAN POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ITEM PART NO. DESCRIPTION 1 1019562-01 2 3 QTY 4 1 2 3 4 5 6 7 8 9 10 11 11 1018381-02 0007577 1018382-01 1015914 1019144-01 1018385-01 1019766-01 1019875-01 1018387-01 1018386-01 1018289-01 1018289-02 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 ...................................... 11 12 13 14 15 16 17 1018289-03 1012101 1012098 1018384-01 1019735-01 1019583-01 1019582-01 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) ................................................. 1019562-02 14 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 14 E Page 14-14 ELECTRIC MOTOR 15 E TYPICAL 2 PLACES TYPICAL 2 PLACES 15 12 E 9 10 11 13 14 7 19 17 8 TYPICAL 4 PLACES 15 16 2 24 23 18 20 1 6 5 21 4 22 3 TYPICAL 3 PLACES REFERENCE TRANSAXLE SECTION 16 Page 15-2 MOTOR - V-GLIDE 36 VOLT 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 1018134-01 1017944 1017954 1017947 N/A N/A N/A N/A 1017952 1017953 1017951 1017949 1017948 1017946 1011411 1011290 1017950 N/A 1017891-01 1018132-02 1018228-01 1014201 0000451 1010934 0007174 2 3 QTY 4 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 ................................................................................................. 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 2 4 4 2 4 2 1 2 1 1 1 1 1 1 1 A/R 1 3 3 1 1 Page 15-3 15 E TYPICAL 2 PLACES TYPICAL 2 PLACES 15 12 E 9 10 11 13 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 MOTOR - POWERDRIVE SYSTEM 48 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 1018133-01 1017944 1017958 1017947 N/A N/A N/A N/A 1017961 1017953 1017951 1017949 1017948 1017946 1011411 1011290 1017950 N/A 1017891-01 1018132-02 1018228-01 1014201 0000451 1010934 0007174 2 3 QTY 4 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 ................................................................................................. 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 2 4 4 2 4 2 1 2 1 1 1 1 1 1 1 A/R 1 3 3 1 1 Page 15-5 15 E TYPICAL 2 PLACES TYPICAL 2 PLACES 15 12 9 10 11 29 22 E 21 13 23 14 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 24 MOTOR - 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 20 21 22 23 24 25 26 27 28 29 1018546-01 1017944 1018792-01 1017947 N/A N/A N/A N/A 1017961 1017953 1018793-01 1017949 1017948 1017946 1011411 1011290 1017950 N/A 1017891-01 1018132-02 1018228-01 1019258-01 1018951-01 1019303-01 1019304-01 1014201 0000451 1010934 0007174 1019201-01 2 3 QTY 4 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 (WITH SPEED SENSOR) ............................................................................ SCREW, BRUSH HOLDER ................................................................................................. 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 ........................................................................................... SENSOR, HALL EFFECT (INCLUDES ITEM 22) ............................................................... HOUSING, FEMALE 3-WIRE, GREY ............................................................................ PLATE, RETAINING ............................................................................................................. SCREW, 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 ............................................................................................................ HOUSING, MALE 3-WIRE, GREY .......................................................................................... 1 1 1 1 2 4 4 2 4 2 1 2 1 1 1 1 1 1 1 A/R 1 1 1 1 3 3 3 1 1 1 Page 15-7 15 E 15 E Page 15-8 TRANSAXLE ELECTRIC VEHICLE 16 E 16 E REFERENCE MOTOR SECTION 15 12 11 10 9 14 8 13 3 1 24 15 18 19 7 17 18 16 25 4 TYPICAL 2 PLACES 18 5 23 6 22 30 21 26 28 20 29 31 27 14 6 5 36 4 37 17 41 40 36 7 38 33 34 35 34 32 39 Page 16-2 2 8 9 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 N/A 1013785 1013786 1013787 1014207 1011291 1013792 1016672 1013790 1013791 1013775 1013756 1012711 1013758 0007330 1013789 1017704 1013794 0007335 1013764 0007336 1013766 1013780 1013765 1013757 1013759 1013763 1012710 1013779 1013782 1013767 1013772 1019105-01 1013768 1013773 1013774 1013771 1013770 1013769 1013781 1017703 1014193 2 3 QTY 4 16 E TRANSAXLE (INCLUDES ITEMS 1 - 41) ............................................................................... AXLE ASSEMBLY, RIGHT (INCLUDES ITEMS 3 - 7) ......................................................... AXLE ASSEMBLY, LEFT (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, RIGHT .......................................................................................................... BREATHER ......................................................................................................................... GASKET, CASE .................................................................................................................. BEARING, INNER AXLE TUBE .......................................................................................... GASKET, AXLE TUBE ........................................................................................................ ASSEMBLY, AXLE TUBE, RIGHT SIDE ............................................................................. SEAL, AXLE SHAFT OIL .................................................................................................... BEARING, INPUT GEAR .................................................................................................... SHAFT, INPUT .................................................................................................................... BEARING, INTERMEDIATE GEAR .................................................................................... GEAR, INTERMEDIATE, SMALL ........................................................................................ KEY, SUNK ......................................................................................................................... GEAR, INTERMEDIATE, LARGE ....................................................................................... GEAR CASE, LEFT ............................................................................................................ 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 - 35) ........................................ GEAR CASE, DIFFERENTIAL (LEFT) ........................................................................... PLATE, THRUST (DIFFERENTIAL GEAR) .................................................................... PLATE, THRUST (IDLER GEAR) ................................................................................... GEAR, DIFFERENTIAL ...................................................................................................... GEAR, DIFFERENTIAL IDLER ........................................................................................... GEAR CASE, DIFFERENTIAL (RIGHT) .............................................................................. SHIM ................................................................................................................................... ASSEMBLY, AXLE TUBE, LEFT SIDE ................................................................................ PIN, DOWEL ....................................................................................................................... 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 2 2 1 1 1 1 Page 16-3 NOTES NOTES 16 E Page 16-6 Golf Cars Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658
