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Download 2007_ds golf cart parts manual
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2007 ILLUSTRATED PARTS LIST Club C ar Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658 USA Web www.clubcar.com Phone 1.706.863.3000 1.800.ClubCar Int’l +1 706.863.3000 Fax 1.706.863.5808 DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 103209002 EDITION CODE 1106B0207A USING THE ILLUSTRATED PARTS LIST ý 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 2007 DS golf cars. The manual is divided into sections. 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 the letter G or E, signifying that the page pertains to the electric or gasoline vehicles only. Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that section. The index can be used to find specific parts and assemblies. There is a two-page spread for each individual page title in the Table of Contents. 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. 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. HOW TO ORDER PARTS Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3281 or 3854. P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 www.clubcar.com NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright © 2006 Club Car, Inc. Club Car and ArmorFlex are registered trademarks of Club Car, Inc. This manual effective July 31, 2006. 2007 DS Golf Cars Illustrated Parts List CONTENTS SECTION 1 – BODY AND TRIM Front Body ........................................................................................................................................ 1-3 Rear Body Trim ................................................................................................................................. 1-5 Dash Components ............................................................................................................................ 1-7 Beverage Holder ............................................................................................................................... 1-9 Front Seat Bottom and Armrests ...................................................................................................... 1-11 Rear Body and Fender – Gasoline Vehicle ...................................................................................... 1-13 Rear Body and Fender – Electric Vehicle ......................................................................................... 1-15 Seat Back and Bag Hoop ................................................................................................................. 1-17 Canopy ............................................................................................................................................. 1-19 SECTION 2 – WHEELS AND TIRES Wheels and Tires .............................................................................................................................. 2-3 SECTION 3 – DECALS Decals – Gasoline Vehicle ................................................................................................................ 3-3 Decals – Electric Vehicle .................................................................................................................. 3-5 SECTION 4 – BRAKES, PEDAL, AND CABLE ASSEMBLIES Brake Assembly, Self-Adjusting ........................................................................................................ 4-3 Brake Pedal Assembly ...................................................................................................................... 4-5 Brake Cable, Equalizer, and Equalizer Rod ..................................................................................... 4-7 Accelerator Pedal Assembly – Gasoline Vehicle .............................................................................. 4-9 Accelerator Pedal Assembly – Electric Vehicles .............................................................................. 4-11 Accelerator Rod ................................................................................................................................ 4-13 SECTION 5 – STEERING, FRONT AND REAR SUSPENSION Steering Column ............................................................................................................................... 5-3 Steering Wheel ................................................................................................................................. 5-5 Steering Gear Assembly ................................................................................................................... 5-7 Front Suspension, Upper .................................................................................................................. 5-9 Front Suspension, Lower .................................................................................................................. 5-11 Front Spindles and Hubs .................................................................................................................. 5-13 Rear Suspension – Gasoline Vehicle ............................................................................................... 5-15 Rear Suspension – Electric Vehicle .................................................................................................. 5-17 2007 DS Golf Cars Illustrated Parts List Page 1 CONTENTS SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLE Wiring ............................................................................................................................................... 6-5 Electrical Component Box – Gasoline Vehicle ................................................................................. 6-7 Electrical Components, Front Body – Gasoline Vehicle ................................................................... 6-9 Starter/Generator Assembly – Gasoline Vehicles ............................................................................ 6-11 FE290 Starter/Generator Mounting – Gasoline Vehicle ................................................................... 6-13 Battery – Gasoline Vehicle ............................................................................................................... 6-15 SECTION 7 – FE290 ENGINE FE290 Engine – Shrouds and Brackets ........................................................................................... 7-3 FE290 Engine – Ignition Components and Flywheel ....................................................................... 7-5 FE290 Engine – Oil Circulation ........................................................................................................ 7-7 FE290 Engine – Cylinder Head ........................................................................................................ 7-9 FE290 Engine – Crankcase, Camshaft, and Oil Sensor .................................................................. 7-11 FE290 Engine – Crankcase and Crankshaft .................................................................................... 7-13 FE290 Engine Mounting ................................................................................................................... 7-15 SECTION 8 – FUEL, INTAKE, AND GOVERNOR SYSTEMS Fuel System ..................................................................................................................................... 8-3 Fuel Tank ......................................................................................................................................... 8-5 Carburetor Assembly – FE290 ......................................................................................................... 8-7 Carburetor Installation – FE290 ....................................................................................................... 8-9 Governor and Accelerator Cables .................................................................................................... 8-11 Air Box and Intake Hose .................................................................................................................. 8-13 Intake System .................................................................................................................................. 8-15 SECTION 9 – EXHAUST SYSTEM Exhaust System – FE290 Engine .................................................................................................... 9-3 SECTION 10 – TORQUE CONVERTER Drive Clutch ...................................................................................................................................... 10-3 Drive Belt – FE290 ........................................................................................................................... 10-5 Driven Clutch .................................................................................................................................... 10-7 SECTION 11 – TRANSAXLE – GASOLINE VEHICLE Transaxle – Gasoline Vehicles, Gear Cases and Brackets ............................................................. 11-3 Transaxle – Gasoline Vehicles, Transmission and Gear Reduction ................................................ 11-5 Page 2 2007 DS Golf Cars Illustrated Parts List CONTENTS Transaxle – Gasoline Vehicles, Differential and Axles ..................................................................... 11-7 Forward/Reverse Shifter Assembly – Gasoline Vehicles ................................................................. 11-9 Forward/Reverse Shifter Cable – Gasoline Vehicles ........................................................................ 11-11 SECTION 12 – ELECTRICAL SYSTEM – ELECTRIC VEHICLE Wiring ................................................................................................................................................ 12-5 Instrument Panel Components ......................................................................................................... 12-7 Motor Controller Output Regulator (MCOR) ..................................................................................... 12-9 Forward/Reverse Switch, Tow/Run Switch ....................................................................................... 12-11 Battery Charger Receptacle ............................................................................................................. 12-13 Batteries, Electric Vehicle ................................................................................................................. 12-15 Computer, Controller, and Solenoid, Electric Vehicle ....................................................................... 12-17 SECTION 13 – ELECTRIC MOTOR Motor (Model 5BC59JBS6365) – Electric Vehicle (Earlier Style) ..................................................... 13-3 Motor (Model 5BC59JBS6365A) – Electric Vehicle (Later Style) ..................................................... 13-5 Motor (Model EJ4-4001) – Electric Vehicle ...................................................................................... 13-7 SECTION 14 – TRANSAXLE – ELECTRIC VEHICLES Transaxle – Electric Vehicles ............................................................................................................ 14-3 SECTION 15 – BATTERY CHARGER PowerDrive 2 Battery Charger (Model 22110), Domestic ................................................................. 15-3 PowerDrive Battery Charger (Model 17930), Domestic .................................................................... 15-5 PowerDrive Battery Charger (Model 18780), Export ........................................................................ 15-7 PowerDrive Battery Charger (Model 20310), European ................................................................... 15-9 SECTION 16 – MAINTENANCE AND SERVICE TOOLS Maintenance and Service Tools ....................................................................................................... 16-3 Maintenance and Service Tools, Continued ..................................................................................... 16-5 Maintenance and Service Tools, Continued ..................................................................................... 16-7 Maintenance and Service Tools, Continued ..................................................................................... 16-9 Maintenance and Service Tools, Continued ..................................................................................... 16-11 SECTION i – INDEX 2007 DS Golf Cars Illustrated Parts List Page 3 BODY AND TRIM 1 G E D 1 G 1 TYPICAL 2 PLACES E 33 D 35 2 TYPICAL 2 PLACES 6 - 27 34 3 5 30 4 TYPICAL 6 PLACES TYPICAL 2 PLACES 29 28 31 TYPICAL 2 PLACES 32 000249-002 Page 1-2 2007 DS Golf Cars Illustrated Parts List FRONT BODY 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 1010435 1011014 1011017 1011394 1015075 101692501 101692502 101692504 101692506 101692509 101692510 101692511 101692512 101692513 101692514 101692515 101693901 101693902 101693904 101693906 101693908 101693909 101693910 101693911 101693912 101693913 101693914 1017080 1016868 1016967 7251 7473 1241 7251 7473 2 3 QTY 4 Bolt, Carriage, 5/16-18 X 1.00 .............................................................................. Trim, Cowl ............................................................................................................. Screw, #8-32 X 0.375 ............................................................................................ T-Nut Package (Set of 4) ...................................................................................... Washer, 5/16 Flat Type A ...................................................................................... Cowl, TPO, Beige ................................................................................................. Cowl, TPO, White ................................................................................................. Cowl, Tpo -gray ..................................................................................................... Cowl, TPO, Red .................................................................................................... Cowl, TPO, Pacific Blue (Royal Blue) ................................................................... Cowl, TPO, Dark Green ........................................................................................ Cowl, TPO, Black .................................................................................................. Cowl, TPO, Classic Blue ....................................................................................... Cowl, TPO, Burgundy ........................................................................................... Cowl, TPO, Dark Gray .......................................................................................... Cowl, TPO, Safety Yellow ..................................................................................... Cowl with Headlight Opening, TPO, Beige ........................................................... Cowl with Headlight Opening, TPO, White ........................................................... Cowl with Headlight Opening, TPO, Gray ............................................................. Cowl with Headlight Opening, TPO, Red .............................................................. Cowl with Headlight Opening, TPO, Pacific Blue (Royal Blue) ............................. Cowl with Headlight Opening, TPO, Dark Green .................................................. Cowl with Headlight Opening, TPO, Black ............................................................ Cowl with Headlight Opening, TPO, Classic Blue ................................................. Cowl with Headlight Opening, TPO, Burgundy ..................................................... Cowl with Headlight Opening, TPO, Dark Gray .................................................... Cowl with Headlight Opening, TPO, Safety Yellow ............................................... Kit, Front Bumper (includes items 29 through 32) ................................................ Front Bumper .................................................................................................... Blind Rivet, Push Type ...................................................................................... Screw, 5/16-18 x 1.0 Truss-Head ...................................................................... Locknut, 5/16-18 Nylon Insert ........................................................................... Washer, 5/16 Type A Flat ...................................................................................... Screw, 5/16-18 x 1.0 Truss-Head .......................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... 2007 DS Golf Cars Illustrated Parts List 2 1 6 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 Page 1-3 1 G E D 1 G E D 3 2 13 11 12 TYPICAL 9 PLACES 1 14 9 9 8 5 6 TYPICAL 2 PLACES TYPICAL 2 PLACES 5 5 10 4 10 000451-001 Page 1-4 2007 DS Golf Cars Illustrated Parts List REAR BODY TRIM ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1013983 101706702 1010434 1017079 1011697 1016379 1016874 1016875 1016876 7473 101768202 1010434 102221201 102310701 2 3 QTY 4 Bumper, Side Trim ................................................................................................ Scuff Guard Kit - Tpo Body (includes item 3) ........................................................ Barrel, Black Plastic .......................................................................................... Kit, Rear Bumper (includes items 5 through 10) ................................................... Washer, 5/16 Flat .............................................................................................. Bumper, Rear .................................................................................................... Plate, Bumper Mounting, Short ......................................................................... Plate, Bumper Mounting, Long ......................................................................... Bolt, 3/8 Shoulder ............................................................................................. Locknut, 5/16-18 Nylon Insert ........................................................................... Bagwell Protector Kit (includes item 12) ............................................................... Barrel, Black Plastic .......................................................................................... Wear Pad .............................................................................................................. Screw, #8-18 x 0.375, Hex-Head Washer ............................................................. 2 1 12 1 6 1 2 1 4 4 1 9 2 8 Note: Item 7 not used in this application. 2007 DS Golf Cars Illustrated Parts List Page 1-5 1 G E D 1 G E D FRONT BODY CENTER DASH FRAME DASH 2 4 9 1 ST OP 5 7 TYPICAL 2 PLACES 6 3 GO 8 10 FRAME DASH BOTTOM TYPICAL: 3 PLACES PASSENGER SIDE DASH 2 PLACES DRIVER SIDE DASH 000252-001 Page 1-6 2007 DS Golf Cars Illustrated Parts List DASH COMPONENTS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 1013343 1013344 1014645 1011019 1011382 1013494 1620 101503202 101660404 7973 2 3 QTY 4 Dash Component, Passenger-Side, Black ............................................................ Dash Component, Driver-Side .............................................................................. Snap Washer Kit, Black (includes items 4 through 7) ........................................... Nut, Speed ........................................................................................................ Washer, #10 Pan-Head Screw .......................................................................... Cover, Screw Head ........................................................................................... Screw, #10-16 X 0.75 Pan-Head Tap ................................................................ Floormat ................................................................................................................ Dash Panel, Black Center ..................................................................................... Rivet, Aluminum Pop ............................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 1 2 1 1 1 1 1 1 5 Page 1-7 1 G E D 1 G E D ST OP GO 4 3 2 5 1 000253-002 Page 1-8 2007 DS Golf Cars Illustrated Parts List BEVERAGE HOLDER ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 101708301 N/A 1016952 N/A 7847 2 3 QTY 4 Drink Holder Kit (includes items 2 through 5) ....................................................... Holder, Dual Cup (includes items 3 and 4) ....................................................... U-Nut, 1/4-20 ................................................................................................ Cup Holder, Dual .......................................................................................... Screw, 1/4-20 X 0.75 Hex-Head Cap ................................................................ 2007 DS Golf Cars Illustrated Parts List 2 1 2 1 2 Page 1-9 1 G E D 1 G 7 E 10 5 11 9 8 D 6 27 TYPICAL 8 PLACES 3 1 TYPICAL 4 PLACES TYPICAL 2 PLACES REFERENCE REAR BODY AND FENDER 2 4 TYPICAL 4 PLACES 000364-003 Page 1-10 2007 DS Golf Cars Illustrated Parts List FRONT SEAT BOTTOM AND ARMRESTS 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 1010543 1011652 1016916 101954301 101985502 101987602 102174201 N/A 101998211 N/A 101998501 102174202 N/A 101998212 N/A 101998501 102174204 N/A 101998214 N/A 101998501 102174205 N/A 101998215 N/A 101998501 332 2 3 QTY 4 Insert, Wood .......................................................................................................... Hinge Plate ........................................................................................................... Screw, 1/4-20 X 1.50 Hex-Head Cap .................................................................... Screw, 1/4-20 X 0.75 Hex-Head Cap .................................................................... Armrest, Passenger (right) .................................................................................... Armrest, Driver (left) .............................................................................................. Seat Bottom Assembly, Buff (includes items 8 through 11) .................................. Plywood Assy .................................................................................................... Vinyl Cover, Seat Bottom, Buff .......................................................................... Foam, Seat ....................................................................................................... Gasket, Seat ..................................................................................................... Seat Bottom Assembly, White (includes items 13 through 16) ............................. Plywood Assy .................................................................................................... Vinyl Cover, Seat Bottom, White ....................................................................... Foam, Seat ....................................................................................................... Gasket, Seat ..................................................................................................... Seat Bottom Assembly, Black (includes items 18 through 21) .............................. Plywood Assy .................................................................................................... Vinyl Cover, Seat Bottom, Black ....................................................................... Foam, Seat ....................................................................................................... Gasket, Seat ..................................................................................................... Seat Bottom Assembly, Gray (includes items 23 through 26) ............................... Plywood Assy .................................................................................................... Vinyl Cover, Seat Bottom, Gray ........................................................................ Foam, Seat ....................................................................................................... Gasket, Seat ..................................................................................................... Washer, 1/4 Type A Narrow Flat ........................................................................... 4 2 8 4 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 8 Note: Sub-components contained in items 12, 17, and 22 are the same as those shown for item 7, except for the vinyl seat covers. 2007 DS Golf Cars Illustrated Parts List Page 1-11 1 G E D 1 G 3 E D 2 FRONT SEAT SUPPORT VERTICAL STRUT TYPICAL 2 PLACES 34 30 TYPICAL 2 PLACES 33 6 34 30 28 32 29 32 TYPICAL 2 PLACES 7-24 25 5 27 TYPICAL 2 PLACES 26 30 34 31 32 TYPICAL 2 PLACES TYPICAL EACH SIDE OF VEHICLE TYPICAL EACH SIDE OF VEHICLE 4 1 32 TYPICAL 2 PLACES 000450-001 Page 1-12 2007 DS Golf Cars Illustrated Parts List REAR BODY AND FENDER – 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 33 34 1012047 1012412 1013032 1014306 1015032 1015525 101692601 101692602 101692604 101692606 101692609 101692610 101692611 101692612 101692613 101696208 101696209 101696211 101696213 101696215 101696216 101696219 101696220 101696221 1017141 1017748 1017936 101904101 102221201 332 7847 8233 8248 8251 2 3 QTY 4 Screw, #8-32 X .375 Self Tap ................................................................................ Body, Hinge Plate .................................................................................................. Molded Access Door Black ................................................................................... Washer, 1/4" Type B Flat ....................................................................................... Floormat, Molded .................................................................................................. Nut, 1/4-20 Blind ................................................................................................... Body, Beige, TPO, Rear ........................................................................................ Body, White, TPO, Rear ........................................................................................ Body, Gray, TPO, Rear ......................................................................................... Body, Red, TPO, Rear .......................................................................................... Body, Pacific Blue (Royal Blue), TPO, Rear ......................................................... Body, Dark Green, TPO, Rear .............................................................................. Body, Black, TPO, Rear ........................................................................................ Body, Classic Blue, TPO, Rear ............................................................................. Body, Burgundy, TPO, Rear .................................................................................. Body, Rear W/tlt -gas Beige .................................................................................. Body, Rear W/tlt -gas White .................................................................................. Body, Rear W/tlt -gas Gray ................................................................................... Body, Rear W/tlt -gas Red ..................................................................................... Body, Rear W/tlt -gas Pacific Blue (Royal Blue) .................................................... Body, Rear W/tlt -gas Dk Green ............................................................................ Body, Rear W/tlt -gas Black .................................................................................. Body, Rear W/tlt -gas Clc Blue .............................................................................. Body, Rear W/tlt -gas Burgundy ............................................................................ Body Support Front ............................................................................................... Body Keeper Clip .................................................................................................. Fender, Inner ......................................................................................................... Body Kick Plate ..................................................................................................... Wear Pad .............................................................................................................. Washer, 1/4 Type A Narrow Flat ........................................................................... Screw, 1/4-20 X 0.75 Hex-Head Cap .................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Screw, 1/4-20 X 0.75 Truss-Head Machine .......................................................... Screw, 1/4-20 X 1.0 Truss-Head Machine ............................................................ 2007 DS Golf Cars Illustrated Parts List 2 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 10 4 12 2 8 Page 1-13 1 G E D 1 G E D TYPICAL 2 PLACES 3 4 37 FRONT SEAT SUPPORT VERTICAL STRUT 37 33 33 32 TYPICAL 2 PLACES 35 36 7 35 31 TYPICAL 2 PLACES 26 8-25 6 TYPICAL 2 PLACES 30 27 28 5 35 1 2 29 33 34 37 TYPICAL EACH SIDE OF VEHICLE 35 TYPICAL EACH SIDE OF VEHICLE 000452-001 Page 1-14 2007 DS Golf Cars Illustrated Parts List 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 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 1012047 1012159 1012412 1013032 1014306 1015032 1015525 101693301 101693302 101693304 101693306 101693309 101693310 101693311 101693312 101693313 101696201 101696202 101696204 101696206 101696217 101696218 101696222 101696223 101696224 1017141 1017748 1017814 1017815 1017936 101904101 102221201 332 7479 8233 8248 8251 2 3 QTY 4 Screw, #8-32 X .375 Self Tap ................................................................................ Bolt, 1/4-20 X 2.75 Hex-Head ............................................................................... Body, Hinge Plate .................................................................................................. Molded Access Door Black ................................................................................... Washer, 1/4" Type B Flat ....................................................................................... Floormat, Molded .................................................................................................. Nut, 1/4-20 Blind ................................................................................................... Body, Beige, TPO, Rear ........................................................................................ Body, White, TPO, Rear ........................................................................................ Body, Gray, TPO, Rear ......................................................................................... Body, Red, TPO, Rear .......................................................................................... Body, Pacific Blue (Royal Blue), TPO, Rear ......................................................... Body, Dark Green, TPO, Rear .............................................................................. Body, Black, TPO, Rear ........................................................................................ Body, Classic Blue, TPO, Rear ............................................................................. Body, Burgundy, TPO, Rear .................................................................................. Body, Rear W/tlt -ele Beige ................................................................................... Body, Rear W/tlt -ele White ................................................................................... Body, Rear W/tlt -ele Gray .................................................................................... Body, Rear W/tlt -ele Red ...................................................................................... Body, Rear W/tlt -ele Pacific Blue (Royal Blue) ..................................................... Body, Rear W/tlt -ele Dk Green ............................................................................. Body, Rear W/tlt -ele Black ................................................................................... Body, Rear W/tlt -ele Clc Blue ............................................................................... Body, Rear W/tlt -ele Burgundy ............................................................................. Body Support Front ............................................................................................... Body Keeper Clip .................................................................................................. Spacer, 1.88-inch .................................................................................................. Spacer, 0.5-inch .................................................................................................... Fender, Inner ......................................................................................................... Body Kick Plate ..................................................................................................... Wear Pad .............................................................................................................. Washer, 1/4 Type A Narrow Flat ........................................................................... Screw, 1/4-20 X 1.25 Hex-Head Cap .................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Screw, 1/4-20 X 0.75 Truss-Head Machine .......................................................... Screw, 1/4-20 X 1.0 Truss-Head Machine ............................................................ 2007 DS Golf Cars Illustrated Parts List 2 2 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 10 2 12 2 8 Page 1-15 1 G E D 1 1 G E 7 D TYPICAL 2 PLACES 28 2 14 17 20 13 23 16 19 22 5 15 11 18 TYPICAL 2 PLACES 4 3 10 21 TYPICAL 4 PLACES 24 12 30 31 7 6 9 7 27 29 28 25 27 TYPICAL 2 PLACES 8 26 TYPICAL 2 PLACES ON EACH SIDE OF VEHICLE 7 TYPICAL 2 PLACES 000453-001 Page 1-16 2007 DS Golf Cars Illustrated Parts List SEAT BACK AND BAG HOOP 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 1010921 1013935 1010413 1010434 1013754 1014482 1015075 1017774 101910401 102076701 102236601 102236703 102238301 102060511 102237001 102238302 102060512 102237001 102238304 102060514 102237001 102238305 102060515 102237001 102242401 1028 1241 7473 7479 7818 8418 2 3 QTY 4 Screw, 5/16-18 X 2.50 Hex Cap ............................................................................ Bag Hoop W/buckle & Strap Asm (includes items 3 through 5) ............................ Bag Strap Assembly .......................................................................................... Barrel, Black Plastic .......................................................................................... Buckle, Bag Strap ............................................................................................. Spacer, Nylon ........................................................................................................ Washer, 5/16 Flat Type A ...................................................................................... Body Spacer .......................................................................................................... Screw, 5/16-18 X 1.25 Thrd Frm ........................................................................... Screw, 1/4-20 X 1.75 Hex Sems ........................................................................... Support Weldment ................................................................................................ Sweater Basket, Black .......................................................................................... Kit-seat Back-comfort-buff (includes items 14 and 15) ......................................... Skin Seat Back-beige Svc ................................................................................. Cap - Seat Back ................................................................................................ Kit-seat Back-comfort-white (includes items 17 and 18) ....................................... Skin Seat Back-wht Svc .................................................................................... Cap - Seat Back ................................................................................................ Kit-seat Back-comfort-black (includes items 20 and 21) ....................................... Skin Seat Back-blk Svc ..................................................................................... Cap - Seat Back ................................................................................................ Kit-seat Back-comfort-grey (includes items 23 and 24) ........................................ Skin Seat Back-gray Svc .................................................................................. Cap - Seat Back ................................................................................................ Nut - Nylon Insert W/cap ....................................................................................... Nut, 1/4-20 Hex ..................................................................................................... Washer, 5/16 Type A Flat ...................................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... Screw, 1/4-20 X 1.25 Hex-Head Cap .................................................................... Bolt, Carriage, 5/16-18 X 1.5 ............................................................................... Screw, 1/4-20 X 1.50 Phillips Truss-Head ............................................................. 2007 DS Golf Cars Illustrated Parts List 2 1 1 2 2 1 8 4 4 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 6 4 2 2 1 Page 1-17 1 G E D 1 G TYPICAL 2 PLACES E 9 TYPICAL 2 PLACES D 6 REF. 1 8 2 REF. 5 9 5 8 6 7 REFERENCE SEAT BACK SUPPORT WELDMENT 3 8 REF. F NT O FRO LE IC VEH 10 11 11 13 12 TYPICAL 4 PLACES 000454 -001 Page 1-18 2007 DS Golf Cars Illustrated Parts List CANOPY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 102061301 102061302 102099101 102155501 101835601 102063901 102064601 102065501 102076701 324 332 8233 102198301 2 3 QTY 4 Canopy-sun-white ................................................................................................. Canopy-sun Beige ................................................................................................ Screw, 5/16-18 X 1.00 Hex Sems ......................................................................... Canopy Kit Struts (includes items 5 through 12) ................................................... Locknut, 1/4-20 Hex Whiz ................................................................................. Weldment - Windshield Frame .......................................................................... Support-rear Canopy -rh ................................................................................... Support Rear Canopy Lh .................................................................................. Screw, 1/4-20 X 1.75 Hex Sems ....................................................................... Screw, 1/4-20 X 2.50 Hx Hd Cap ...................................................................... Washer, 1/4 Type A Narrow Flat ....................................................................... Locknut, 1/4-20 Nylon Insert ............................................................................. Pad-windshield Frame .......................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 2 1 8 1 1 1 8 4 8 4 2 Page 1-19 1 G E D 1 G E D WHEELS AND TIRES 2 G E D 2 G E D Club C ar 1 2 5 6 9 10 13 14 16 18 21 22 25 26 29 30 32 3 7 11 15 19 23 27 31 20 28 33 24 4 12 17 8 STANDARD TREAD Carlisle® PERFORMANCE PREMIUM TREAD EXTRA TRACTION GRADE TREAD Kenda® Duro Duro® Note: The performance grade tire has the wheel and tire matched and balanced at the Duro tire factory. 000457-001 Page 2-2 2007 DS Golf Cars Illustrated Parts List WHEELS AND TIRES 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 1010984 101570501 1015707 727102 7310 101570507 1015707 101769302 7310 101570512 1015707 102569304 7310 101570513 1015707 7310 AM10682 101651401 1014771 727102 7310 101651407 1014771 101769302 7310 101651412 1014771 102569304 7310 101651413 1014771 7310 AM10682 2 3 QTY 4 Nut, 1/2-20 Lug ..................................................................................................... Tire/Wheel Asm, Beige, Standard Tread (includes items 3 through 5) ................. Wheel Rim, Beige ............................................................................................. Tire Unmto Turf Glde 18x8.50-8 ....................................................................... Valve Stem ........................................................................................................ Tire/Wheel Asm, Beige, Xtrac Tread, 6-ply (includes items 7 through 9) .............. Wheel Rim, Beige ............................................................................................. Tire, Unmounted Xtrac 18 x 8.50-8 ................................................................... Valve Stem ........................................................................................................ Tire/Wheel Asm, Beige, Duro Premium Tread (includes items 11 through 13) ..... Wheel Rim, Beige ............................................................................................. Duro 18 X 8.5 X 8, 4-ply .................................................................................... Valve Stem ........................................................................................................ Tire/Wheel Asm, Beige, Kenda Premium Tread (includes items 15 through 17) .. Wheel Rim, Beige ............................................................................................. Valve Stem ........................................................................................................ Unmounted Prem Tire 18.5x8.5x8 .................................................................... Tire/Wheel Asm, White, Standard Tread (includes items 19 through 21) ............. Wheel Rim, White ............................................................................................. Tire Unmto Turf Glde 18x8.50-8 ....................................................................... Valve Stem ........................................................................................................ Tire/Wheel Asm, White, Extra-Traction, 6-Ply (includes items 23 through 25) ..... Wheel Rim, White ............................................................................................. Tire, Unmounted Xtrac 18 x 8.50-8 ................................................................... Valve Stem ........................................................................................................ Tire/Wheel Asm, White, Duro Premium Tread (includes items 27 through 29) ..... Wheel Rim, White ............................................................................................. Duro 18 X 8.5 X 8, 4-ply .................................................................................... Valve Stem ........................................................................................................ Tire/Wheel Asm, White, Kenda Premium Tread (includes items 31 through 33) .. Wheel Rim, White ............................................................................................. Valve Stem ........................................................................................................ Unmounted Prem Tire 18.5x8.5x8 .................................................................... 2007 DS Golf Cars Illustrated Parts List 16 4 1 1 1 2 1 1 1 4 1 1 1 4 1 1 1 4 1 1 1 2 1 1 1 4 1 1 1 4 1 1 1 Page 2-3 2 G E D 2 G E D DECALS 3 G E D 3 WARNING G E D ROLLOVER OR FALLING OFF MAY CAUSE DEATH. OFF ON OPERATING INSTRUCTIONS • Before using vehicle, read operating instructions. • Remain seated and hold on to seat handle while moving. • Do not start vehicle until all occupants are seated. • Two (2) persons per seat maximum. • Operate from driver side only and not on public roads. • Keep entire body inside vehicle while moving. • Drive slowly in turns and straight up and down slopes. • Do not leave children unattended on vehicle. • Never operate under the influence of alcohol or drugs. • Use brakes to reduce speed when coasting downhill. • Never stand in front of or behind vehicle. CCI 1019606-01 4 3 7 • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. • Make sure wheels are turned in desired direction. • Turn key to “ON” position and be sure nothing is in your path. • While vehicle is stopped, select direction by placing shift lever or switch in desired position: F – Forward N – Neutral R – Reverse (Buzzer will sound) • Vehicle will start moving when accelerator pedal is depressed. • Slowly depress accelerator pedal to increase speed. Park brake will release when accelerator pedal is depressed. • To stop, release accelerator pedal and depress brake pedal. • After stopping the vehicle: - Firmly depress park brake until it locks. - Place Forward/Reverse switch in "NEUTRAL" position. - Turn key “OFF” and remove key when not in use. CCI 101621601 WARNING CAN CAUSE SEVERE INJURY Rotating parts HOT manifold & muffler KEEP CLEAR CCI 1019605-01 (ON STARTER/GENERATOR AND ENGINE) 6 (ON VEHICLE FRAME NEAR FUEL TANK) 2 1 Club Car 5 (ON VEHICLE FRAME NEAR BATTERY) 000458-001 Page 3-2 2007 DS Golf Cars Illustrated Parts List DECALS – GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 1014198 101547601 101621601 101825101 101915201 101960501 101960601 2 3 QTY 4 Nameplate Kit (gold) ............................................................................................. Decal, Gasoline Explosion/Fire Warning ............................................................... Decal, Operating Instructions ................................................................................ Decal, Off/On ........................................................................................................ Decal, Frame Ground and Governor Warning ...................................................... Decal, Rotating Parts/Hot Manifold ....................................................................... Decal, Dash Warning ............................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 2 1 Page 3-3 3 G E D 3 E D OFF WARNING ON ROLLOVER OR FALLING OFF MAY CAUSE DEATH. 3 • Before using vehicle, read operating instructions. • Remain seated and hold on to seat handle while moving. • Do not start vehicle until all occupants are seated. • Two (2) persons per seat maximum. • Operate from driver side only and not on public roads. • Keep entire body inside vehicle while moving. • Drive slowly in turns and straight up and down slopes. • Do not leave children unattended on vehicle. • Never operate under the influence of alcohol or drugs. • Use brakes to reduce speed when coasting downhill. • Never stand in front of or behind vehicle. CCI 101960601 OPERATING INSTRUCTIONS 2 7 • Read Owner's Manual and safety warnings located on dash panel prior to driving. • Study and understand controls. • Make sure wheels are turned in desired direction. • Turn key to “ON” position and be sure nothing is in your path. • While vehicle is stopped, select direction by placing shift lever or switch in desired position: F – Forward N – Neutral R – Reverse (Buzzer will sound) • Vehicle will start moving when accelerator pedal is depressed. • Slowly depress accelerator pedal to increase speed. Park brake will release when accelerator pedal is depressed. • To stop, release accelerator pedal and depress brake pedal. • After stopping the vehicle: - Firmly depress park brake until it locks. - Place Forward/Reverse switch in "NEUTRAL" position. - Turn key “OFF” and remove key when not in use. CCI 101621601 6 IMPORTANT NOTICE • Maximum vehicle speed is limited by motor braking during downhill operation with accelerator pedal depressed. • If motor brake enabled, vehicle motor will brake when accelerator pedal is released. • Beeping alarm indicates reduction in motor braking. Apply brakes to reduce speed. • System is activated only when tow switch is in the "RUN" position. 101959902 • When towing vehicle, tow switch must be in the "TOW" position. (ON TOW/RUN SWITCH BRACKET UNDER SEAT) TOW Place Tow/Run switch in TOW position before: • Disconnecting or connecting batteries • Towing • Extended storage • Servicing RUN FAILURE TO HEED THIS WARNING COULD RESULT IN A BATTERY EXPLOSION OR SEVERE PERSONAL CCI 101908601 INJURY. 4 1 Club C ar F N G 5 (ON SPEED CONTROLLER COVER) NOTICE Do not operate vehicle without this cover properly installed. Do not direct water stream in this area; will cause damage to components. CCI 101931501 See vehicle maintenance and service manual before servicing. 000459-001 Page 3-4 2007 DS Golf Cars Illustrated Parts List DECALS – ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 1014198 101621601 101825101 101908601 101931501 101959902 101960601 2 3 QTY 4 Nameplate Kit (gold) ............................................................................................. Decal, Operating Instructions ................................................................................ Decal, Off/On ........................................................................................................ Decal, Tow/Run Switch Warning ........................................................................... Decal, Component Cover ...................................................................................... Decal, IQ System Motor Braking ........................................................................... Decal, Dash Warning ............................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 Page 3-5 3 G E D 3 G E D BRAKES, PEDAL, AND CABLE ASSEMBLIES 4 G E D 4 G 1 11 TYPICAL 4 PLACES TYPICAL 4 PLACES E 2 D 10 12 3 11 14 15 7 8 13 REF. BRAKE CABLE 6 TYPICAL 2 PLACES 9 5 000186-001 Page 4-2 2007 DS Golf Cars Illustrated Parts List BRAKE ASSEMBLY, SELF-ADJUSTING 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 1013924 1014153 101791101 101823301 1010850 1011466 N/A N/A 101815501 101816301 101823201 101824001 101816501 101823801 101823901 101823302 1010850 1011466 N/A N/A 101815502 101816301 101823201 101824002 101816502 101823801 101823901 2 3 QTY 4 Nut, 5/16-24 Hex Head Cone ................................................................................ Bolt, Brake Cluster Mounting ................................................................................ Drum without Center Hole, Brake ......................................................................... Cluster Assembly, Right (Passenger) Brake (includes items 5 through 12) .......... Dust Cover ........................................................................................................ Kit, Shoe Retainer (includes items 7 and 8) ...................................................... Pin ................................................................................................................ Shoe Clamp Spring ...................................................................................... Lever Assembly, Self-Adjusting Brake, Right (Passenger) ............................... Package, Brake Spring, Self-Adjusting ............................................................. Package, Brake Shoe, Self-Adjusting ............................................................... Plate Assembly, Right Brake Backing (includes items 13 through 15) .............. Adj Mechanism, S.A. Brakes, Right (Passenger) ......................................... Plate, Washer, Brake, Self-Adjusting ........................................................... Washer, Brake, Self-Adjusting ...................................................................... Cluster Assembly, Left Brake (includes items 17 through 24) ............................... Dust Cover ........................................................................................................ Kit, Shoe Retainer (includes items 19 and 20) .................................................. Pin ................................................................................................................ Shoe Clamp Spring ...................................................................................... Lever Assembly, Self-Adjusting Brake, Left ...................................................... Package, Brake Spring, Self-Adjusting ............................................................. Package, Brake Shoe, Self-Adjusting ............................................................... Plate Assembly, Left Brake Backing (includes items 25 through 27) ................ Adjusting Mechanism, Self-Adjusting Brake, Left ......................................... Plate, Washer, Brake, Self-Adjusting ........................................................... Washer, Brake, Self-Adjusting ...................................................................... 8 8 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 Note: Driver-side brake cluster not shown. Components have a similar appearance to passenger-side brake cluster components. 2007 DS Golf Cars Illustrated Parts List Page 4-3 4 G E D 4 G E D TYPICAL 2 PLACES 9 11 6 19 REF. 10 7 8 21 22 OP T S TYPICAL 4 PLACES FLOORBOARD REMOVED FOR CLARITY REF. 28 3 4 17 24 14 18 15 10 25 1 13 23 TYPICAL 3 PLACES SERVICE PART BRAKE PEDAL HAS SECOND WELDMENT 16 5 26 TYPICAL 2 PLACES 27 TYPICAL 4 PLACES 2 000187-001 Page 4-4 2007 DS Golf Cars Illustrated Parts List BRAKE PEDAL 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 1010878 1010921 1010927 1010933 1011402 1011418 1013870 1013876 N/A 1032 7716 101187702 1010805 1010877 1010932 N/A 1017029 N/A N/A 101878201 1013869 N/A 7716 102323101 102323201 1028 1241 7473 2 3 QTY 4 Bumper, Rubber .................................................................................................... Screw, 5/16-18 X 2.50 Hex Cap ............................................................................ Hill Brake Spacer ................................................................................................... Spring, Hill Brake Torsion ...................................................................................... Package, Brake Mounting Block ........................................................................... Kit, Hill Brake Pedal (includes items 7 through 11) ............................................... Pad, Hill Brake .................................................................................................. Pushnut, 3/8 ...................................................................................................... Hill Brake Weld Assembly ................................................................................. Bushing, Nylon .................................................................................................. Screw, #10-16 Type AB, Sheet Metal ............................................................... Kit, Hill Brake Latch (includes items 13 through 19) ............................................. Sleeve, Hill Brake Rod ...................................................................................... Pushnut, 3/8 ...................................................................................................... Ball Joint, 1/4-28 ............................................................................................... Rod, Hill Brake .................................................................................................. Pin, Cotter, 7/64 x 1/2 Stainless-Steel ............................................................... Pawl, Hill Brake ................................................................................................. Ratchet Assembly ............................................................................................. Brake Pedal Kit (includes items 21 through 23) .................................................... Pad, Brake Pedal .............................................................................................. Brake Pedal Weld Asm ..................................................................................... Screw, #10-16 Type AB, Sheet Metal ............................................................... Pin, Bow Tie Locking ............................................................................................. Pin, 3/8 X 1-5/16 Clevis ........................................................................................ Nut, 1/4-20 Hex ..................................................................................................... Washer, 5/16 Type A Flat ...................................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... 2007 DS Golf Cars Illustrated Parts List 1 4 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 4 4 Page 4-5 4 G E D 4 G E 3 D 10 11 7 TYPICAL 2 PLACES 12 1 VIEWED FROM UNDERSIDE OF VEHICLE 4 VIEWED FROM TOP OF VEHICLE 2 6 SOME COMPONENTS REMOVED FOR CLARITY 8 5 TYPICAL 2 PLACES 9 7 VIEWED FROM TOP OF VEHICLE 000245-001 Page 4-6 2007 DS Golf Cars Illustrated Parts List BRAKE CABLE, EQUALIZER, AND EQUALIZER ROD ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1013531 101900801 101953101 101990801 102022101 1010829 1011779 N/A 1035 1241 1242 7473 2 3 QTY 4 Spring, Brake Return ............................................................................................. Hanger, Brake Cable ............................................................................................. Rod, Equalizer ...................................................................................................... Equalizer Bracket .................................................................................................. Brake Cable Kit (includes items 6 through 9) ........................................................ Pin, Clevis, 5/16 X 3/4 ....................................................................................... E-Clip, 1/2 ......................................................................................................... Cable, Brake ..................................................................................................... Pin, 3/32 X 1.00 Sq Cut Cotter .......................................................................... Washer, 5/16 Type A Flat ...................................................................................... Nut, 5/16-18 Hex ................................................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... 2007 DS Golf Cars Illustrated Parts List 1 2 1 1 2 1 2 1 1 5 1 5 Page 4-7 4 G E D 4 G 7 6 E 8 9 D GO 21 24 14 11 10 3 TYPICAL 4 PLACES 21 5 20 12 4 19 22 18 15 17 TYPICAL 4 PLACES 16 23 2 1 TYPICAL 4 PLACES 13 24 1 000188-001 Page 4-8 2007 DS Golf Cars Illustrated Parts List ACCELERATOR PEDAL 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 1011694 1014007 1017378 1017380 1017424 1017696 1013871 N/A 7716 101796201 101817401 101818801 101861901 101966901 102026001 1011700 N/A N/A 1241 1624 334 7473 8233 8754 2 3 QTY 4 Accelerator Bracket and Bearing Assembly .......................................................... Washer, 1/4 Flat .................................................................................................... Cup, Spring ........................................................................................................... Bumper, Spring Return .......................................................................................... Bearing, Pivot Support .......................................................................................... Sub Asm, Accelerator Pedal (includes items 7 through 9) .................................... Pad, Accelerator Pedal ..................................................................................... Accelerator Pedal Weldment ............................................................................ Screw, #10-16 Type AB, Sheet Metal ............................................................... Spring, Accelerator Return .................................................................................... Retainer, Spring .................................................................................................... Stud, 1/4-28 X 1.35 Ball ........................................................................................ Screw, 1/4-20 X 1.125 Hex Cap ............................................................................ Locknut, 1/4-28 Hex Flange Nylon ........................................................................ Kit, Accelerator Pivot Rod Assembly (includes items 16 through 18) ................... Spacer Assembly (includes item 17) ................................................................. Spacer, Accelerator ...................................................................................... Pivot Rod Weldment ......................................................................................... Washer, 5/16 Type A Flat ...................................................................................... Screw, 3/8-16 X 1.50 Hex-Head Cap .................................................................... Washer, 3/8 Type A Flat ........................................................................................ Locknut, 5/16-18 Nylon Insert ............................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Locknut, 3/8-16 Hex .............................................................................................. 2007 DS Golf Cars Illustrated Parts List 2 4 1 1 1 1 1 1 4 1 1 1 4 1 1 1 1 1 1 1 2 1 4 2 Page 4-9 4 G E D 4 G 7 6 E 8 9 D GO 21 24 14 11 10 3 TYPICAL 4 PLACES 21 5 20 13 4 19 22 18 15 17 TYPICAL 4 PLACES 16 23 2 1 TYPICAL 4 PLACES 12 24 1 000188-002 Page 4-10 2007 DS Golf Cars Illustrated Parts List ACCELERATOR PEDAL ASSEMBLY – ELECTRIC VEHICLES 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 1011694 1014007 1017378 1017380 1017424 1017696 1013871 N/A 7716 101796201 101817401 101861901 101862001 101966901 102026001 1011700 N/A N/A 1241 1624 334 7473 8233 8754 2 3 QTY 4 Accelerator Bracket and Bearing Assembly .......................................................... Washer, 1/4 Flat .................................................................................................... Cup, Spring ........................................................................................................... Bumper, Spring Return .......................................................................................... Bearing, Pivot Support .......................................................................................... Sub Asm, Accelerator Pedal (includes items 7 through 9) .................................... Pad, Accelerator Pedal ..................................................................................... Accelerator Pedal Weldment ............................................................................ Screw, #10-16 Type AB, Sheet Metal ............................................................... Spring, Accelerator Return .................................................................................... Retainer, Spring .................................................................................................... Screw, 1/4-20 X 1.125 Hex Cap ............................................................................ Screw, 1/4-20 X 1.500 Flange ............................................................................... Locknut, 1/4-28 Hex Flange Nylon ........................................................................ Kit, Accelerator Pivot Rod Assembly (includes items 16 through 18) ................... Spacer Assembly (includes item 17) ................................................................. Spacer, Accelerator ...................................................................................... Pivot Rod Weldment ......................................................................................... Washer, 5/16 Type A Flat ...................................................................................... Screw, 3/8-16 X 1.50 Hex-Head Cap .................................................................... Washer, 3/8 Type A Flat ........................................................................................ Locknut, 5/16-18 Nylon Insert ............................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Locknut, 3/8-16 Hex .............................................................................................. 2007 DS Golf Cars Illustrated Parts List 2 4 1 1 1 1 1 1 4 1 1 4 1 1 1 1 1 1 1 1 2 1 4 2 Page 4-11 4 G E D 4 G E D 3 2 4 1 2 3 REFERENCE 000362-001 Page 4-12 2007 DS Golf Cars Illustrated Parts List ACCELERATOR ROD ITEM PART NO. DESCRIPTION 1 1 2 3 4 101912401 1011084 1011734 N/A 2 3 QTY 4 Rod, Accelerator (includes items 2 through 4) ...................................................... Nut, 1/4-28 Hex Jam ......................................................................................... Joint, Ball .......................................................................................................... Accelerator Rod ................................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 2 2 1 Page 4-13 4 G E D 4 G E D STEERING, FRONT AND REAR SUSPENSION 5 G E D 5 G E 27 D 25 REF. 20 REF. 24 19 21 17 22 16 32 23 21 18 19 20 34 TYPICAL 2 PLACES 33 TYPICAL 2 PLACES 27 33 26 REF. 28 3 TYPICAL 3 PLACES 4 2 30 1 15 TYPICAL 2 PLACES 31 29 000247-002 Page 5-2 2007 DS Golf Cars Illustrated Parts List 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 33 34 1011697 1013861 1017226 7174 1014216 1012466 1012605 1014125 1014126 1014211 1014212 1014213 1014214 1014217 1014288 1016181 1012604 1012605 1014125 1014126 1014213 1014214 1014217 1015545 1016622 1016183 1016263 1016269 101984801 N/A N/A 102278001 334 8754 2 3 QTY 4 Washer, 5/16 Flat .................................................................................................. Intermediate Steering Shaft (includes items 3 and 4) ........................................... Bolt, Hex-Head, 8mm X 1.25 - 30 ..................................................................... Lockwasher, 5/16 Split ...................................................................................... Steering Column Rebuild Kit (includes items 6 through 14) .................................. Dust Cover ........................................................................................................ Ring, 0.579 Internal Retaining .......................................................................... Wedge, Molded ................................................................................................. Seat, Plastic Bearing ......................................................................................... Seal, Bearing .................................................................................................... Spacer, Shaft ..................................................................................................... Bearing, Ball ...................................................................................................... Ring, Retaining ................................................................................................. Spring, Steering Shaft ....................................................................................... Screw, 5/16-18 X 0.75 Thread-Forming ................................................................ Steering Shaft Assembly (includes items 17 through 25) ...................................... Washer, 0.675 ID X 1.19 OD ............................................................................. Ring, 0.579 Internal Retaining .......................................................................... Wedge, Molded ................................................................................................. Seat, Plastic Bearing ......................................................................................... Bearing, Ball ...................................................................................................... Ring, Retaining ................................................................................................. Spring, Steering Shaft ....................................................................................... Shaft, Steering Column ..................................................................................... Column, Aluminum Steering ............................................................................. Screw, 3/8-16 X 7.00 Hex Cap .............................................................................. Cover, Steering Column Tube ............................................................................... Screw, 5/16-18 Thrd Forming ............................................................................... Kit, Steering Column Mounting Bracket (includes items 30 and 31) ..................... Bracket, RH Steering Column Mount ................................................................ Bracket, LH Steering column mount ................................................................. Boot, Steering Column Round .............................................................................. Washer, 3/8 Type A Flat ........................................................................................ Locknut, 3/8-16 Hex .............................................................................................. 1 1 3 3 1 1 1 2 2 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 2 1 2 1 1 1 1 4 2 Note: Item 5 is not illustrated. 2007 DS Golf Cars Illustrated Parts List Page 5-3 5 G E D 5 G E D 5 7 2 6 4 3 9 1 8 REF. STEERING COLUMN 000246-002 Page 5-4 2007 DS Golf Cars Illustrated Parts List STEERING WHEEL ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 1016156 1016219 1012565 1012566 1016154 N/A 1016214 1016663 1017273 2 3 QTY 4 Wheel, Steering ..................................................................................................... Plate, Scorecard (includes items 3 through 7) ...................................................... Screw, #12 Phillips Round Head ....................................................................... Tapered Compression Spring ............................................................................ Clip, Scorecard ................................................................................................. Plate, Score Card .............................................................................................. Pencil Grip ........................................................................................................ Screw, #12-14 X 0.625 .......................................................................................... Nut, 5/8-18 Nylon Insert Jam ................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 1 2 2 1 1 1 2 1 Page 5-5 5 G E D 5 G E D 30 2 28 4 27 23 29 16 17 1 32 31 24 7 6 13 8 18 20 19 11 25 12 5 21 26 TYPICAL 3 PLACES 33 TYPICAL 3 PLACES 14 22 9 15 10 23 000189-001 Page 5-6 2007 DS Golf Cars Illustrated Parts List 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 1012467 1013042 101878302 1013035 1013044 1013051 1013052 101879401 101879501 101879601 101879701 101879801 101879901 101880001 101880101 101880201 101880301 N/A N/A N/A N/A N/A 8990 1035 1624 334 7540 N/A 1011930 1015597 7602 7555 8754 2 3 QTY 4 Link, Rack and Pinion Drag .................................................................................. Nut, 12mm Hex ..................................................................................................... Steering Gear Assembly (without yoke) (includes items 4 through 23) ................ Bellows, Long .................................................................................................... Rack Screw Locknut ......................................................................................... Snap Ring ......................................................................................................... Seal, Steering Pinion Dust ................................................................................ Bearing, Ball ...................................................................................................... Stop Washer ...................................................................................................... Stop Ring, C-Type ............................................................................................. Support Yoke ..................................................................................................... Rack Guide Pressure Spring ............................................................................. Ring, Stop, C-Type ............................................................................................ Bellows, Short ................................................................................................... Dust Seal Retaining Ring .................................................................................. Inner Ball Joint Asm .......................................................................................... Washer, Tab ...................................................................................................... Box, Steering Gear ............................................................................................ Bearing, Lower Pinion ....................................................................................... Pinion, Steering ................................................................................................. Screw, Rack Guide ........................................................................................... Rack, Steering ................................................................................................... Tie Wrap, 8" Nylon ............................................................................................ Pin, 3/32 X 1.00 Sq Cut Cotter .............................................................................. Screw, 3/8-16 X 1.50 Hex-Head Cap .................................................................... Washer, 3/8 Type A Flat ........................................................................................ Ball Joint, Left (includes items 28 through 31) ...................................................... Socket, LH Vertical ............................................................................................ Seal, Vertical Socket Dust ................................................................................. Fitting, 1/4-28 Thread-Forming Grease ............................................................ Nut, 3/8-24 UNF Hex ........................................................................................ Nut, 1/2-20 Hex, Left-Hand Thread ....................................................................... Locknut, 3/8-16 Hex .............................................................................................. 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 3 1 1 1 1 1 1 3 Page 5-7 5 G E D 5 TYPICAL 2 PLACES G 25 E D 26 14 17 15 12 19 9 13 16 22 24 20 3 21 2 1 13 10 25 3 1 25 13 10 25 TYPICAL 2 PLACES 6 TYP. 2 PLACES 5 TYP. 6 PLACES 8 7 4 11 23 INCLUDED WITH ITEM 19. 18 11 INCLUDED WITH ITEM 14. 000312-001 Page 5-8 2007 DS Golf Cars Illustrated Parts List FRONT SUSPENSION, UPPER 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 1010138 1010219 1014235 1016353 1016346 1016349 1016350 N/A 1016385 1017266 1035 1308 2402 7539 N/A 1011930 1015597 7602 7540 N/A 1011930 1015597 7602 7555 8754 8861 2 3 QTY 4 Locknut, 3/8-16 Dimpled ....................................................................................... Tie Rod .................................................................................................................. Shock Absorber .................................................................................................... Sub-Assembly, Delta A-Plate (includes items 5 through 8) ................................... Bushing, Urethane ............................................................................................ Sleeve, Delta Inner ........................................................................................... Sleeve, Delta Outer ........................................................................................... Detla A-Plate ..................................................................................................... Delta Shock and Gear Support Assembly ............................................................. A-Plate Strap ......................................................................................................... Pin, 3/32 X 1.00 Sq Cut Cotter .............................................................................. Nut, 1/2-20 Hex ..................................................................................................... Screw, 3/8-16 X 2.25 Hx Hd Cap .......................................................................... Ball Joint, Right-Hand (includes items 15 through 18) .......................................... Socket, RH Vertical ........................................................................................... Seal, Vertical Socket Dust ................................................................................. Fitting, 1/4-28 Thread-Forming Grease ............................................................ Nut, 3/8-24 UNF Hex ........................................................................................ Ball Joint, Left (includes items 20 through 23) ...................................................... Socket, LH Vertical ............................................................................................ Seal, Vertical Socket Dust ................................................................................. Fitting, 1/4-28 Thread-Forming Grease ............................................................ Nut, 3/8-24 UNF Hex ........................................................................................ Nut, 1/2-20 Hex, Left-Hand Thread ....................................................................... Locknut, 3/8-16 Hex .............................................................................................. Bolt, 3/8-16 X 1.75 Hex ......................................................................................... 2007 DS Golf Cars Illustrated Parts List 2 1 2 2 6 2 1 1 1 2 2 1 4 1 1 1 1 1 1 1 1 1 1 1 6 2 Page 5-9 5 G E D 5 G E D 17 12 TYPICAL 4 PLACES 8 10 17 2 10 12 8 17 2 13 TYPICAL 4 PLACES 1 11 9 18 7 17 3 5 11 9 16 15 18 7 TYPICAL 4 PLACES 4 14 7 6 15 5 17 7 000311-001 Page 5-10 2007 DS Golf Cars Illustrated Parts List 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 1010124 1010150 1010200 1012030 1012303 1014276 1015583 1016384 1016386 1016387 1016389 101903101 1624 357 706 8745 8754 8755 2 3 QTY 4 Plate, Spring Mount ............................................................................................... Bearing, Thrust ..................................................................................................... Bolt, 3/8-16 X 4.25 Hex Head ............................................................................... Spring, Front Leaf ................................................................................................. Bushing, Steel ....................................................................................................... Plate, Front Spring Retainer .................................................................................. Bushing, Urethane ................................................................................................ Clevis, Delta Upper ............................................................................................... King Pin Assembly ................................................................................................ Screw, 3/8-16 X 2.75 Hx Hd Cap .......................................................................... Washer, 1.125 Od Wave ....................................................................................... Locknut, 1/2-20 Nylon Insert ................................................................................. Screw, 3/8-16 X 1.50 Hex-Head Cap .................................................................... Washer, 3/8 Split Lock ........................................................................................... Nut, 3/8-16 Hex ..................................................................................................... Screw, Eccentric Adjustment ................................................................................ Locknut, 3/8-16 Hex .............................................................................................. Screw, 3/8-16 X 3.375 Hex Cap ............................................................................ 2007 DS Golf Cars Illustrated Parts List 1 2 4 1 2 1 4 2 2 2 2 2 4 4 5 1 8 2 Page 5-11 5 G E D 5 PASSENGER SIDE G 28 E 26 D 24 25 27 TYP. 4 PLACES 20 21 19 23 22 18 DRIVER SIDE 17 15 13 14 16 TYP. 4 PLACES REPLACEMENT HUB FOR DRIVER OR PASSENGER SIDE 9 10 8 12 11 TYPICAL 4 PLACES 7 3 4 2 6 5 1 Page 5-12 2007 DS Golf Cars Illustrated Parts List 000301-002 FRONT SPINDLES AND HUBS 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 102357701 N/A 102353401 N/A 102353201 102353301 N/A N/A 102353401 N/A 102353201 102353301 102354203 1015597 N/A 7048 8067 N/A N/A 102353401 N/A 102353201 102353301 102354103 1015597 N/A 7048 8067 2 3 QTY 4 Replacement Kit, Front Hub (includes items 2 through 6) .................................... Front Hub Assembly, Ball Bearing (includes items 3 and 4) ............................. Lug Stud, 1/2-20 UNF, 4037 Stl .................................................................... Hub, Front .................................................................................................... Cap, Front Hub ................................................................................................. Hex Nut, Locking Flange, M14x2 ...................................................................... Asm, Front Hub And Spindle, Lh (includes items 8 through 13) ........................... Front Hub Assembly, Ball Bearing (includes items 9 and 10) ........................... Lug Stud, 1/2-20 UNF, 4037 Stl .................................................................... Hub, Front .................................................................................................... Cap, Front Hub ................................................................................................. Hex Nut, Locking Flange, M14x2 ...................................................................... Assembly, Spindle, Left-Hand (includes items 14 through 17) .......................... Fitting, 1/4-28 Thread-Forming Grease ........................................................ Sub-Assembly, Spindle, Left-Hand ............................................................... Bushing, Flanged Bronze ............................................................................. Bushing, Bronze Spindle .............................................................................. Asm, Front Hub And Spindle, Rh (includes items 19 through 24) ......................... Front Hub Assembly, Ball Bearing (includes items 20 and 21) ......................... Lug Stud, 1/2-20 UNF, 4037 Stl .................................................................... Hub, Front .................................................................................................... Cap, Front Hub ................................................................................................. Hex Nut, Locking Flange, M14x2 ...................................................................... Assembly, Spindle, Right-Hand (includes items 25 through 28) ....................... Fitting, 1/4-28 Thread-Forming Grease ........................................................ Sub-Assembly, Spindle, Right-Hand ............................................................ Bushing, Flanged Bronze ............................................................................. Bushing, Bronze Spindle .............................................................................. 2007 DS Golf Cars Illustrated Parts List 2 1 4 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 Page 5-13 5 G E D 5 G E TYPICAL ON EACH SIDE OF VEHICLE D 17 16 19 8 19 18 5 16 9 8 16 10 18 14 9 19 11 18 4,13 6 7 15 8 3,12 4,13 1 Page 5-14 2007 DS Golf Cars Illustrated Parts List 16 2 TYPICAL 2 PLACES 16 000461-001 REAR SUSPENSION – 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 1010145 1011415 N/A N/A 1012180 1012181 1012182 1012303 1012304 1012324 1013164 N/A N/A 102706401 1014555 1015583 101900801 8754 8755 2 3 QTY 4 Nut, 3/8-24 Hex ..................................................................................................... Kit, Shock Absorber Cushion (includes items 3 and 4) ......................................... Cushion, Shock Absorber ................................................................................. Retainer, Shock Absorber Cushion ................................................................... U-Bolt .................................................................................................................... Bracket, Shock Mounting, Right (Passenger) ....................................................... Bracket, Shock Mounting, Left (Driver) ................................................................. Bushing, Steel ....................................................................................................... Shackle, Rear Spring ............................................................................................ Spring, Rear Leaf (gasoline vehicle) ..................................................................... Shock Absorber Kit (includes items 12 through 14) .............................................. Cushion, Shock Absorber ................................................................................. Retainer, Shock Absorber Cushion ................................................................... Shock Absorber Rear ........................................................................................ Locknut, 7/16-14 Nylon Insert ............................................................................... Bushing, Urethane ................................................................................................ Hanger, Brake Cable ............................................................................................. Locknut, 3/8-16 Hex .............................................................................................. Screw, 3/8-16 X 3.375 Hex Cap ............................................................................ 2007 DS Golf Cars Illustrated Parts List 4 4 2 2 2 1 1 6 4 2 1 8 8 2 4 12 2 6 6 Page 5-15 5 G E D 5 G E D 14 TYPICAL ON EACH SIDE OF VEHICLE 16 19 9 19 18 6 16 17 9 16 2 18 13 17 19 10 18 5,12 16 7 8 15 4,11 5,12 1 Page 5-16 2007 DS Golf Cars Illustrated Parts List 9 3 TYPICAL 2 PLACES 16 000461-002 REAR SUSPENSION – 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 1010145 1010974 1011415 N/A N/A 1012180 1012181 1012182 1012303 1013164 N/A N/A 102706401 1013207 1014555 1015583 7569 8754 8755 2 3 QTY 4 Nut, 3/8-24 Hex ..................................................................................................... Spring, Rear Leaf (electric vehicle) ....................................................................... Kit, Shock Absorber Cushion (includes items 4 and 5) ......................................... Cushion, Shock Absorber ................................................................................. Retainer, Shock Absorber Cushion ................................................................... U-Bolt .................................................................................................................... Bracket, Shock Mounting, Right (Passenger) ....................................................... Bracket, Shock Mounting, Left (Driver) ................................................................. Bushing, Steel ....................................................................................................... Shock Absorber Kit (includes items 11 through 13) .............................................. Cushion, Shock Absorber ................................................................................. Retainer, Shock Absorber Cushion ................................................................... Shock Absorber Rear ........................................................................................ Hanger, Brake Cable ............................................................................................. Locknut, 7/16-14 Nylon Insert ............................................................................... Bushing, Urethane ................................................................................................ Shackle, Rear Spring ............................................................................................ Locknut, 3/8-16 Hex .............................................................................................. Screw, 3/8-16 X 3.375 Hex Cap ............................................................................ 2007 DS Golf Cars Illustrated Parts List 4 2 4 2 2 2 1 1 6 1 8 8 2 2 4 12 4 6 6 Page 5-17 5 G E D 5 G E D ELECTRICAL SYSTEM – GASOLINE VEHICLE 6 G E D 6 G GASOLINE VEHICLE E D CENTER DASH PANEL ASSEMBLY 18_BLK(W10) 18_GRN(W11) 1 OIL SENDING UNIT COM 18_YEL(W14) NO 18_YEL(W08) NC OIL LIGHT 18_WHT(W03) FORWARD/REVERSE LIMIT SWITCHES POS (+) NO NEG (-) 2 COM REVERSE BUZZER 18_RED/WHT(W05) COM NC 1 18_WHT/BLK(W06) M+ 1 18_BLK(W22) COM NO M- 18_WHT/BLK(W04) TO ENGINE KILL HOOK UP 2 2 16_BLK(W19) FUSE BLOCK 10_RED(W23) 18_BLK(W20) KEY SWITCH NO 16_ORG(W24) 18_BLK(W21) 18_YEL(W01) 16_BLU(W09) 16_BLU(W09) 16_ORG(W02) 16_RED(W07) 000468-001 Page 6-2 2007 DS Golf Cars Illustrated Parts List 6 G E D 1 6_BLK(W26) 2 10_NON INSUL(W16) ENGINE BARE BATTERY 6_RED(W25) 16_YEL(W13) 6_WHT(W12) 18_RED(W17) A1 SOLENOID 16_ORG(W24) A2 STARTER GENERATOR F1 6_GRN HIGH TEMP(W27) DF F2 16_BLU(W09) 5 18_YEL(W18) 4 16_BLK(W19) 10_RED(W23) 6_BLK(W15) VOLTAGE REGULATOR 3 ELECTRICAL COMPONENT BOX 000468-001 2007 DS Golf Cars Illustrated Parts List Page 6-3 6 G E D See previous two pages for diagram. Page 6-4 2007 DS Golf Cars Illustrated Parts List WIRING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 1012382 1015332 1015737 1015920 101837301 101889301 2 3 QTY 4 Wire Assy, #6 Black .............................................................................................. Wire Assembly, #10, Uninsulated ......................................................................... Wire Assy, #10 Red ............................................................................................... Ground Wire Assembly ......................................................................................... Wire Assy, #6 Green ............................................................................................. Wire Harness Assy, Ds Gas .................................................................................. 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 Page 6-5 6 G E D 6 28 1 G 15 E 29 TYPICAL 2 PLACES D 13 30 11 6 12 ORANGE WIRE ASSEMBLY 22 27 29 TYPICAL 2 PLACES 5 TYPICAL 2 PLACES 16 9 RED WIRE (TO BATTERY) 10 21 24 26 TYPICAL 2 PLACES 20 35 TYPICAL 2 PLACES 7 10 4 18 20 TYPICAL 2 PLACES 17 TO FRAME GROUND 32 TYPICAL 2 PLACES 10 14 19 8 TYPICAL 2 PLACES FRO NT VEH OF ICLE 3 23 34 33 31 25 WIRE HARNESS (NOT SHOWN) 000464-001 Page 6-6 2007 DS Golf Cars Illustrated Parts List ELECTRICAL COMPONENT BOX – 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 33 34 35 1015752 101827601 1010954 1012295 1012431 1013589 1013609 1014065 1014119 1014145 1014807 1014808 1014948 1015371 1015372 1015373 1015405 1015737 1015741 1015752 1015878 N/A 101821301 101856102 101889301 102711201 1242 7893 8057 8058 8717 8990 1241 7473 7818 2 3 QTY 4 Screw, #12-16 X 0.625 Hi-Lo ................................................................................ Elec Component Box Asm (includes items 3 through 32) ..................................... Stud, 1/4-28 X 0.560 Ball .................................................................................. Fuse, 10-Amp ................................................................................................... Washer, #4 Flat ................................................................................................. Ring, 0.338" Internal Retaining ......................................................................... Solenoid, 12-Volt ............................................................................................... Washer, 0.38" ID Delrin Flat .............................................................................. Wire Assembly #6 Red ..................................................................................... Bushing, Secondary Weight, Split ..................................................................... Switch, Limit ...................................................................................................... Switch, Limit ...................................................................................................... Diode ................................................................................................................. Box, Electrical Component ................................................................................ Cover, Electric Box ............................................................................................ Cam, Electric Box ............................................................................................. Bolt, Carriage, 5/16-18 X 2.0 ............................................................................ Wire Assy, #10 Red .......................................................................................... Fuse Block ........................................................................................................ Screw, #12-16 X 0.625 Hi-Lo ............................................................................ Screw, #4-40 Hex Head Machine ..................................................................... Wire Assy, #16 Orange ..................................................................................... Bell Crank Weld Asm ........................................................................................ Screw, 1/4-15 X 1.50 Hi-lo Hex ......................................................................... Wire Harness Assy, Ds Gas .............................................................................. Voltage Regulator ............................................................................................. Nut, 5/16-18 Hex ............................................................................................... Nut, #10-32 Hex ................................................................................................ Nut, #4-40 Hex Machine ................................................................................... Lockwasher, #4 Helical Split ............................................................................. Locknut, 1/4-28 Nylon Insert ............................................................................. Tie Wrap, 8" Nylon ............................................................................................ Washer, 5/16 Type A Flat ...................................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... Bolt, Carriage, 5/16-18 X 1.5 ............................................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 2 2 4 2 1 2 2 2 1 Page 6-7 6 G E D 6 G AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED 1 E 3 D M- 1 2 M+ 17 ON OFF 11 18 2 10 5 9 15 16 19 TYPICAL 4 PLACES OFF ON 4 20 TYPICAL 3 PLACES 000465-001 Page 6-8 2007 DS Golf Cars Illustrated Parts List ELECTRICAL COMPONENTS, FRONT BODY – 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 1011229 1012505 1015720 1016630 1016859 1011229 1012431 1015720 1016849 1016851 N/A 8056 8057 8058 101826301 101830601 101830701 101834502 101851101 101900901 AM10079 2 3 QTY 4 Locknut, #6-32 Whiz ............................................................................................. Keys (set of 2) ....................................................................................................... Screw, #6-32 X 1/2 Hex Washer-Head ................................................................. Light, Oil ................................................................................................................ Kit, Reverse Buzzer (includes items 6 through 14) ............................................... Locknut, #6-32 Whiz ......................................................................................... Washer, #4 Flat ................................................................................................. Screw, #6-32 X 1/2 Hex Washer-Head ............................................................. Screw, #4-24 X 0.33 Pan-Head Machine .......................................................... Buzzer, Reverse (9-48 VDC) ............................................................................ Wire Assembly Black #18 ................................................................................. Screw, #4-40 X 0.75 Round-Head Machine ...................................................... Nut, #4-40 Hex Machine ................................................................................... Lockwasher, #4 Helical Split ............................................................................. Key Switch, 12-Volt, Off/On ................................................................................... Screw and Washer Assembly ............................................................................... Nut, Key Switch ..................................................................................................... Cap, Black Key Switch .......................................................................................... Washer, Key Switch .............................................................................................. Harness Retainer .................................................................................................. Bulk Std Keys (50) * .............................................................................................. 1 1 1 1 1 1 2 1 2 1 1 2 2 2 1 4 1 1 1 3 1 Note: Some parts in Reverse Buzzer Kit are not used in this application. 2007 DS Golf Cars Illustrated Parts List Page 6-9 6 G E D 6 G TYPICAL 3 PLACES 25 21 23 TYPICAL 2 PLACES 4 E D 15 TYPICAL 4 PLACES 6 TYPICAL 2 PLACES AT F1 AND F2 TERMINALS 34 TYPICAL 2 PLACES TYPICAL 4 PLACES 14 32 33 DF TERMINAL 17 18 TYPICAL 2 PLACES AT A1 AND A2 TERMINALS 16 20 5 19 24 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 27 26 TYPICAL 3 PLACES 31 13 29 3 10 8 30 11 9 12 7 1 000124-001 Page 6-10 2007 DS Golf Cars Illustrated Parts List STARTER/GENERATOR ASSEMBLY – GASOLINE VEHICLES 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 1014289 101833701 1013003 101301102 101878101 101869302 101874901 101875101 1013001 1013005 101875001 101939901 101875201 101875301 101875401 101875501 101875601 101875701 101875802 101876001 101876202 101876301 N/A N/A 101876402 101876501 101896501 N/A N/A N/A N/A 101877601 101877701 101879001 2 3 QTY 4 Pulley, Starter/Generator ....................................................................................... Starter/Generator (cw) (includes items 3 through 34) ........................................... Key, Starter/Generator ...................................................................................... Brush Holder Assembly (cw) (includes item 5) ................................................. Brush Spring Set .......................................................................................... Brush and Screw Set (cw) ................................................................................ Front Bracket .................................................................................................... Armature (includes items 9 through 12) ............................................................ Bearing, Output Shaft Ball ............................................................................ Bearing, Ball ................................................................................................. Retainer ........................................................................................................ Spacer .......................................................................................................... Field Coil Housing ............................................................................................. Pole Set ............................................................................................................ Screw Set .......................................................................................................... Field Stator Coil Assembly ................................................................................ F Insulator Set ................................................................................................... DF Insulator ...................................................................................................... A Connector (cw) .............................................................................................. Screw and Mold Assembly ................................................................................ Brush Connector Assembly (cw) ....................................................................... Cover Set (includes items 23 and 24) ............................................................... Brush Inspection Port Cover ........................................................................ Brush Port Cover w/Drain ............................................................................. Rear Bracket (cw) ............................................................................................. Nut and Screw Set (includes items 27 through 31) ........................................... Brush Holder Asm Screw ............................................................................. Washer, M5 Flat ........................................................................................... Washer, M14 Lock ........................................................................................ Nut, Hex, M14 x 2 ......................................................................................... Screw, M5 x 0.8 x 18mm .............................................................................. Nut and Washer Set .......................................................................................... Nut and Washer Set .......................................................................................... Through Bolt Set ............................................................................................... 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 3 1 1 1 2 1 1 1 3 2 1 2 Note: Item 28 is not used in this application. 2007 DS Golf Cars Illustrated Parts List Page 6-11 6 G E D 6 G 12 E D 9 14 A1 F1 A2 3 REFERENCE STARTER/GENERATOR ASSEMBLY 1 7 TYPICAL 2 PLACES 11 15 13 9 1 13 2 F2 DF 8 6 10 13 AS VIEWED FROM PASSENGER SIDE OF VEHICLE Page 6-12 4 2007 DS Golf Cars Illustrated Parts List 5 000238-003 FE290 STARTER/GENERATOR MOUNTING – GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1012830 101524001 1015920 1015932 1016074 1016883 101837301 101916701 1241 1242 705 7173 7174 7473 8754 2 3 QTY 4 Screw, M8-125 X 22 Hex-Head ............................................................................ Bracket, Starter/Generator Mounting (FE290) ...................................................... Ground Wire Assembly ......................................................................................... Bolt, Carriage, 5/16-18 .......................................................................................... Screw, M8-1.25 X 18mm Torx ............................................................................... Bracket, Starter/Generator Adjustment ................................................................. Wire Assy, #6 Green ............................................................................................. V-Belt .................................................................................................................... Washer, 5/16 Type A Flat ...................................................................................... Nut, 5/16-18 Hex ................................................................................................... Bolt, 3/8-16 X 1.25 Hex Head ............................................................................... Screw, 5/16-18 X 0.75 Hex-Head Cap .................................................................. Lockwasher, 5/16 Split .......................................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... Locknut, 3/8-16 Hex .............................................................................................. 2007 DS Golf Cars Illustrated Parts List 2 1 1 1 1 1 1 1 1 1 2 1 3 1 2 Page 6-13 6 G E D 6 G 6 2 E AS SEEN FROM PASSENGER SIDE OF VEHICLE D 4 5 1 TO NEGATIVE BATTERY POST TERMINAL 8 3 7 9 7 9 AS SEEN FROM DRIVER SIDE OF VEHICLE 000240-001 Page 6-14 2007 DS Golf Cars Illustrated Parts List BATTERY – GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 1010934 1012328 1014288 1014375 101898001 102355301 1241 7173 7473 2 3 QTY 4 Screw, 5/16-18 X 1.00 Hex Cap ............................................................................ Battery, 12-Volt ...................................................................................................... Screw, 5/16-18 X 0.75 Thread-Forming ................................................................ Screw, 3/8-16 X 0.50 Stainless Steel Hex-Head ................................................... Clamp, Battery ...................................................................................................... Lockwasher, 3/8 Stainless Stl ................................................................................ Washer, 5/16 Type A Flat ...................................................................................... Screw, 5/16-18 X 0.75 Hex-Head Cap .................................................................. Locknut, 5/16-18 Nylon Insert ............................................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 2 1 2 2 1 2 Page 6-15 6 G E D 6 G E D FE290 ENGINE 7 G E D 7 G FE290 ENGINE REF. E 8 16 9 REF. TYPICAL 6 PLACES 19 7 18 D TYPICAL 4 PLACES 3 7 TYPICAL 4 PLACES 11 17 TYPICAL 2 PLACES CARBURETOR REMOVED FOR CLARITY 2 19 15 TYPICAL 2 PLACES 8 4 15 10 TYPICAL 3 PLACES 7 1 12 14 13 6 7 TYPICAL 2 PLACES 000194-001 Page 7-2 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE – SHROUDS AND BRACKETS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1015332 1015649 1015969 101887601 101953901 1016443 1016456 1016507 1016524 1016525 1016526 1016531 1016536 1016539 1016547 1017221 101909701 101915601 N/A 2 3 QTY 4 Wire Assembly, #10, Uninsulated ......................................................................... Shroud, Fan .......................................................................................................... Screw, M6-1.00 X 10mm Pan Hd .......................................................................... Locknut, M6-1.00 Nylon Insert .............................................................................. Engine, FE290 (cw) * (includes items 6 through 19) ............................................. Bracket .............................................................................................................. Bolt, Flange Head, M6 x 1 x 12 mm .................................................................. Bolt, Two-Ended ................................................................................................ Shroud, Engine, FE290D .................................................................................. Shroud, Engine, FE290D .................................................................................. Shroud, Engine, FE290D .................................................................................. Dipstick ............................................................................................................. Tube, Oil Filler, FE290D .................................................................................... O-Ring ............................................................................................................... Nut .................................................................................................................... Screw, M6-1.00 Stud ......................................................................................... Stud, M6-1.00, Two-Ended ............................................................................... Housing, FE290 Fan ......................................................................................... Washer, 6 mm Flat ............................................................................................ 1 1 4 1 1 1 15 1 1 1 1 1 1 1 3 1 2 1 1 * Note: FE290 engine component listings span several pages. 2007 DS Golf Cars Illustrated Parts List Page 7-3 7 G E D 7 G FE290 ENGINE E D 16 5 19 26 12 20 3 TYPICAL 2 PLACES 11 2 22 13 15 10 24 25 8 6 14 21 TYPICAL 3 PLACES 23 17 1 4 TYPICAL 2 PLACES 7 9 18 000195-001 Page 7-4 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE – IGNITION COMPONENTS AND FLYWHEEL 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 1012981 1016445 1016455 1016456 1016493 1016497 1016505 1016544 1016548 1016561 1016562 1016578 1016579 1016586 1016587 1016588 1017448 1017455 101881101 101909201 101909301 101909401 101909501 101915701 101915801 AM10724 2 3 QTY 4 Clamp .................................................................................................................... Bracket, RPM Limiter ............................................................................................ Bolt, Flange Head ................................................................................................. Bolt, Flange Head, M6 x 1 x 12 mm ...................................................................... Cap, Spark Plug .................................................................................................... Screw, Pan WP Cross ........................................................................................... Nut, Hex, Fine ....................................................................................................... Screw .................................................................................................................... Washer, M16 Flat .................................................................................................. Clamp .................................................................................................................... Key ........................................................................................................................ Grommet ............................................................................................................... Band, RPM Limiter Mount ..................................................................................... Damper, RPM Limiter ............................................................................................ Clamp .................................................................................................................... Tube, 7mm X 10mm X 70mm ............................................................................... Bolt, Flanged ......................................................................................................... Plate, Flywheel Fan .............................................................................................. Spark Plug, OHV (Autolite) .................................................................................... Coil, Ignition .......................................................................................................... Lead Wire Assy ..................................................................................................... Limiter, RPM ......................................................................................................... Clamp, Steel .......................................................................................................... Flywheel Complete, FE290 ................................................................................... Fan, FE290 (cw) ................................................................................................... Spark Plug, OHV (NGK) ........................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 Page 7-5 7 G E D 7 G FE290 ENGINE E D 11 13 10 TYPICAL 2 PLACES 1 15 7 6 3 8 4 TYPICAL 2 PLACES 2 9 12 5 14 TYPICAL 6 PLACES 000196-001 Page 7-6 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE – OIL CIRCULATION ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1016429 1016432 1016435 1016457 1016467 1016473 101648203 1016484 1016502 1016537 1016570 1016576 1016581 1017456 1017507 2 3 QTY 4 Seat, Value Oil Press Relief .................................................................................. Gasket, Drain Plug ................................................................................................ Gasket, Oil Pump .................................................................................................. Bolt, Flange Head ................................................................................................. Filter, Oil ................................................................................................................ Plate, Oil Pump ..................................................................................................... Oil Pump And Rotor .............................................................................................. Cover, Pump ......................................................................................................... Bracket, Oil Filter Mount ....................................................................................... Ball, Steel, Press, Relief ........................................................................................ O-Ring ................................................................................................................... Plug, Drain ............................................................................................................ Spring .................................................................................................................... Bolt, Flanged ......................................................................................................... Plug ....................................................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 2 1 1 1 1 1 1 1 1 1 6 2 Page 7-7 7 G E D 7 G FE290 ENGINE E D 23 21 11 TYPICAL 2 PLACES 10 9 20 16 6 26 5 4 3 EXHAUST 8 22 INTAKE 15 7 17 18 2 TYPICAL 2 PLACES AT EXHAUST CONNECTION TYPICAL 2 PLACES 25 28 27 TYPICAL 2 PLACES 12 24 19 14 TYPICAL 2 PLACES 13 TYPICAL 6 PLACES 1 31 000197-001 Page 7-8 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE – CYLINDER HEAD 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 1016430 1016431 1016519 1016560 1016436 1016442 1016447 1016448 1016449 1016450 1016451 1016452 1016458 1016471 1016474 1016479 1016483 1016489 1016517 1016523 1016542 1016544 1016545 1016549 1016563 1016566 1016569 1016583 102304701 1015330 1016430 1016440 1016446 2 3 QTY 4 Gasket, Head, FE290 ........................................................................................... Head Assembly, FE290 Cylinder (includes items 3 and 4) ................................... Guide, Valve, Intake .......................................................................................... Snap Ring ......................................................................................................... Gasket, Rocker Case ............................................................................................ Case, Rocker ........................................................................................................ Valve, Intake .......................................................................................................... Valve, Exhaust ...................................................................................................... Retainer, Valve Spring ........................................................................................... Collet ..................................................................................................................... Arm, Rocker .......................................................................................................... Shaft, Rocker ........................................................................................................ Bolt, Flange Head, M8 x 1.25 x 45 mm ................................................................. Rod, Push ............................................................................................................. Plate ...................................................................................................................... Seat, Spring .......................................................................................................... Valve ..................................................................................................................... Stud, Two-Ended, M8-1.25 ................................................................................... Circlip, Type-E ....................................................................................................... Spring, Engine Valve ............................................................................................. Screw .................................................................................................................... Screw .................................................................................................................... Nut ........................................................................................................................ Washer, 12.1x19x1.8 ............................................................................................ Pin ......................................................................................................................... Seal, Oil ................................................................................................................ O-Ring ................................................................................................................... Bolt, 6x35 .............................................................................................................. Kit, Gasket, FE290 (includes items 30 through 33) .............................................. Gasket, Exhaust ................................................................................................ Gasket, Head, FE290 ....................................................................................... Gasket, Engine to Insulator ............................................................................... Gasket, Crankcase Cover ................................................................................. 2007 DS Golf Cars Illustrated Parts List 1 1 2 2 1 1 1 1 2 4 2 1 6 2 1 2 1 2 1 2 2 1 2 1 2 2 2 2 1 1 1 1 1 Page 7-9 7 G E D 7 G FE290 ENGINE E D TYPICAL 2 PLACES 16 13 CLAMP ONLY 14 15 9 17 12 6 3 TYPICAL 2 PLACES 8 7 18 10 TYPICAL 3 PLACES 4 1 TYPICAL 2 PLACES 11 2 5 TYPICAL 6 PLACES 19 20 TYPICAL 2 PLACES 000198-001 Page 7-10 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE – CRANKCASE, CAMSHAFT, AND OIL SENSOR 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 1016446 1016453 1016454 1016456 1016458 1016472 1016494 1016496 1016506 1016510 1016520 1016521 1016535 1016538 1016544 1016564 1016565 1016567 1016584 101915401 2 3 QTY 4 Gasket, Crankcase Cover ..................................................................................... Tappet ................................................................................................................... Bolt, Flange Head, M5 x 0.8 x 8 mm ..................................................................... Bolt, Flange Head, M6 x 1 x 12 mm ...................................................................... Bolt, Flange Head, M8 x 1.25 x 45 mm ................................................................. Plate, Oil Filter Screen .......................................................................................... Sensor, Oil Level ................................................................................................... Screw, Cross Pan-Head, M4 x 0.7 x 8 mm ........................................................... Clamp .................................................................................................................... Bracket, Switch, Oil Level ..................................................................................... Cover, Crankcase ................................................................................................. Screen, Oil Filter ................................................................................................... Connector, Cord .................................................................................................... O-Ring ................................................................................................................... Screw .................................................................................................................... Pin ......................................................................................................................... Bearing, Ball .......................................................................................................... Seal, Crankshaft .................................................................................................... Bolt, Two-Ended, M8 x 1.25 x 69 mm ................................................................... Camshaft Complete, FE290 .................................................................................. 2007 DS Golf Cars Illustrated Parts List 1 2 2 2 6 1 1 3 1 1 1 1 1 1 1 2 1 1 2 1 Page 7-11 7 G E D 7 G FE290 ENGINE E D 5 6 7 25 4 28 30 13 11 TYPICAL 2 PLACES 25 1 10 12 2 3 10 12 31 27 26 32 33 32 14 33 TYPICAL 4 PLACES 34 29 TYPICAL 4 PLACES 8 35 16 - 24 9 15 000199-001 Page 7-12 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE – CRANKCASE AND CRANKSHAFT 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 101645901 101645902 101645903 1016460 101646101 101646102 101646103 1016469 1016470 101647501 1016509 101647502 1016509 1016541 1016547 101655001 101655002 101655003 101655004 101655005 101655006 101655007 101655008 101655009 1016558 1016559 1016562 1016568 1016571 101915501 101922301 1016516 1016580 1016532 1016533 2 3 QTY 4 Piston .................................................................................................................... Piston, Engine 0.25 mm Over ............................................................................... Piston, Engine 0.50 mm Over ............................................................................... Pin, Piston ............................................................................................................. Ring Set, Piston .................................................................................................... Ring Set, Piston 0.25 mm Over ............................................................................ Ring Set, Piston 0.50 mm Over ............................................................................ Weight, Counterbalance ........................................................................................ Shaft, Guide, Counterbalance ............................................................................... Rod Assembly (includes item 11) .......................................................................... Bolt .................................................................................................................... Rod Assembly, Connecting 0.50 mm Under (includes item 13) ............................ Bolt .................................................................................................................... Stud, 6x14 ............................................................................................................. Nut ........................................................................................................................ Shim, Crankshaft T=1.13 ...................................................................................... Shim, Crankshaft T=1.18 ...................................................................................... Shim, Crankshaft T=1.23 ...................................................................................... Shim, Crankshaft T=1.28 ...................................................................................... Shim, Crankshaft T=1.33 ...................................................................................... Shim, Crankshaft T=1.38 ...................................................................................... Shim, Crankshaft T=1.43 ...................................................................................... Shim, Crankshaft T=1.48 ...................................................................................... Shim, Crankshaft T=1.53 ...................................................................................... Ring, Snap ............................................................................................................ Spacer ................................................................................................................... Key ........................................................................................................................ Seal, Oil ................................................................................................................ O-Ring ................................................................................................................... Crankcase Complete, FE290 (cw) ........................................................................ Crankshaft, FE290 Left-Hand Thread (includes items 32 through 35) .................. Rod (includes item 33) ...................................................................................... Bearing, Plane .............................................................................................. Gear, Spur ......................................................................................................... Gear, Helical ..................................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 2 1 2 4 4 A/R A/R A/R A/R A/R A/R A/R A/R A/R 2 1 1 1 1 1 1 2 1 1 1 Page 7-13 7 G E D 7 G E D FR O VE NT O HIC F LE REFERENCE ENGINE TYPICAL 2 PLACES TYPICAL 4 PLACES 7 5 10 12 TYPICAL 2 PLACES 9 3 TYPICAL 2 PLACES 3 TYPICAL 4 PLACES 8 14 TYPICAL 4 PLACES 13 4 11 TYPICAL 4 PLACES 2 TYPICAL 4 PLACES 1 TYPICAL 2 PLACES 6 15 9 TYPICAL 4 PLACES 000200-001 Page 7-14 2007 DS Golf Cars Illustrated Parts List FE290 ENGINE MOUNTING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1010577 1012571 1013924 101827101 101832101 101832701 101833201 101834601 101884801 101963401 102065901 102540301 334 705 N/A 2 3 QTY 4 Bolt, Hex-Head, 5/16-18 X 1.50 ............................................................................ Washer, 5/16 Extra Thick Flat ............................................................................... Nut, 5/16-24 Hex Head Cone ................................................................................ Plate, Engine Mounting ......................................................................................... Spacer, Powdered Metal ....................................................................................... Stiffener (Flywheel Side) ....................................................................................... Stud, M8-1.25 X 60mm Two-Ended ...................................................................... Snubber Bracket ................................................................................................... Screw, 5/16-24 X 0.875 Grade-8 .......................................................................... Locknut, 5/16-18 Hex Flange ................................................................................ Locknut, 3/8-16 Flanged Dimple ........................................................................... Inner Frame Snubber ............................................................................................ Washer, 3/8 Type A Flat ........................................................................................ Bolt, 3/8-16 X 1.25 Hex Head ............................................................................... Nut Flg, M8 X 1.25 Serrated ................................................................................. 2007 DS Golf Cars Illustrated Parts List 4 4 6 1 2 1 2 1 6 4 4 1 4 4 2 Page 7-15 7 G E D 7 G E D FUEL, INTAKE, AND GOVERNOR SYSTEMS 8 G E D 8 G 16 11 13 12 11 14 E 15 17 9 D 12 5 19 12 10 6 ENGINE REMOVED FOR CLARITY 4 1 23 21 2 SEE ITEM SIX ABOVE 2 4 7 8 2 2 4 3 22 18 20 4 12 2 21 4 Page 8-2 2 TO ENGINE CRANKCASE 2007 DS Golf Cars Illustrated Parts List 000496-001 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 1011988 1012649 1013687 1013692 1013746 1014116 1014523 1014524 1014928 1016003 1013746 1015137 1015139 1015143 1015188 101824401 101896901 1017203 101824401 101987701 102003201 8233 8248 2 3 QTY 4 Screw, 1/4-20 X 2.00 Phillips Truss-Head ............................................................. Clamp, 0.460 Red Hose ........................................................................................ Clamp, 3/8" Hose (screw type) ............................................................................. Fuel Line * ............................................................................................................. Clamp, 0.301 ID Hose ........................................................................................... Nut, 1/4-20 Speed ................................................................................................. Pump, Impulse Fuel .............................................................................................. Kit, Impulse Pump Rebuild .................................................................................... Fuel Strap Assembly Rear .................................................................................... Kit, Fuel Tank - Vented (includes items 11 through 17) ........................................ Clamp, 0.301 ID Hose ....................................................................................... Fuel Line (available by the foot) ........................................................................ Insulation Grommet ........................................................................................... Vent, Fuel Tank ................................................................................................. Cap, Non-Vented Fuel Tank .............................................................................. Vent Barb .......................................................................................................... Fuel Pickup w/Shut-Off Valve ............................................................................ Carriage Bolt ......................................................................................................... Vent Barb .............................................................................................................. Clamp, Plastic Tie ................................................................................................. Filter, Fuel, 30 Micron ........................................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Screw, 1/4-20 X 0.75 Truss-Head Machine .......................................................... 1 9 1 A/R 2 2 1 1 1 1 2 A/R 1 1 1 1 1 2 1 1 2 2 1 Note: Total fuel line length: 47 inches (119.4 cm) 2007 DS Golf Cars Illustrated Parts List Page 8-3 8 G E D 8 G E D 3 2 5 4 6 8 1 7 000466-001 Page 8-4 2007 DS Golf Cars Illustrated Parts List FUEL TANK ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 1016003 1013746 1015137 1015139 1015143 1015188 101824401 101896901 2 3 QTY 4 Kit, Fuel Tank - Vented (includes items 2 through 8) ........................................... Clamp, 0.301 ID Hose ....................................................................................... Fuel Line (available by the foot) ........................................................................ Insulation Grommet ........................................................................................... Vent, Fuel Tank ................................................................................................. Cap, Non-Vented Fuel Tank .............................................................................. Vent Barb .......................................................................................................... Fuel Pickup w/Shut-Off Valve ............................................................................ 2007 DS Golf Cars Illustrated Parts List 1 2 A/R 1 1 1 1 1 Page 8-5 8 G E D 8 G E D 9 15 5 13 8 7 14 11 1-4 6 12 10 000211-001 Page 8-6 2007 DS Golf Cars Illustrated Parts List CARBURETOR ASSEMBLY – FE290 ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 101642572 101642575 101642578 101642580 101905601 101642582 1016437 1016486 1016501 1016585 1017461 1016499 101973101 101973201 N/A 2 3 QTY 4 Jet, Altitude, # 72 .................................................................................................. Jet, Altitude, # 75 .................................................................................................. Jet, Altitude, # 78 .................................................................................................. Jet, Altitude, # 80 .................................................................................................. Carburetor Assembly, FE290D (includes items 6 through 15) .............................. Jet, Altitude, # 82 .............................................................................................. Gasket, Carburetor Bowl OHV .......................................................................... Float Assembly ................................................................................................. Screw Assembly ............................................................................................... Bolt .................................................................................................................... Chamber Assembly, Float (includes item 12) ................................................... Screw Assembly ........................................................................................... Jet, #40 Pilot ..................................................................................................... Nozzle, Main ..................................................................................................... Assembly, Pilot Air Screw ................................................................................. A/R A/R A/R A/R 1 1 1 1 1 1 1 1 1 1 1 Note: 101642582 for 0 - 3,000 feet; 101642580 for 3,000 - 5,000 feet; 101642578 for 5,000 - 8,000 feet; 101642575 for 8,000 - 10,000 feet; 101642572 for 10,000 feet and higher. 2007 DS Golf Cars Illustrated Parts List Page 8-7 8 G E D 8 4 G 18 E 1 17 D 7 11 6 9 8 15 16 14 16 2 5 3 10 12 TYPICAL 2 PLACES 13 000213-001 Page 8-8 2007 DS Golf Cars Illustrated Parts List CARBURETOR INSTALLATION – FE290 ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1011697 1013746 1015137 1016103 1016438 1016439 1016440 1016441 1016444 1016480 101648102 101649002 1016547 1016572 1016582 1017466 101820201 101887601 2 3 QTY 4 Washer, 5/16 Flat .................................................................................................. Clamp, 0.301 ID Hose ........................................................................................... Fuel Line (available by the foot) ............................................................................ Screw, Pan Hd Tx, Taptite 6-32 ............................................................................ Gasket, Carb To Intake Manifold ........................................................................... Gasket, Insulator ................................................................................................... Gasket, Engine to Insulator ................................................................................... Gasket, Sprg Brkt To Carb OHV ........................................................................... Bracket, Throttle Spring Return ............................................................................. Pipe, Intake Manifold ............................................................................................. Insulator, Carburetor ............................................................................................. Stud, M6-1.00 Two-Ended .................................................................................... Nut ........................................................................................................................ Tube, Crankcase Vent ........................................................................................... Spring, Throttle Return .......................................................................................... Clamp .................................................................................................................... Shield, Governor ................................................................................................... Locknut, M6-1.00 Nylon Insert .............................................................................. 2007 DS Golf Cars Illustrated Parts List 1 1 A/R 2 1 1 1 1 1 1 1 2 2 1 1 2 1 1 Page 8-9 8 G E D 8 G E D 2 8 4 6 TYPICAL 2 PLACES 9 TYPICAL 2 PLACES 10 7 3 11 TYPICAL 2 PLACES 2 1 5 000215-001 Page 8-10 2007 DS Golf Cars Illustrated Parts List GOVERNOR AND ACCELERATOR CABLES ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 1011697 1012285 1012830 1013700 101584502 1016546 101832202 101832302 102336001 102336101 7174 2 3 QTY 4 Washer, 5/16 Flat .................................................................................................. Screw, 1/4 X 0.625 Hex-Head ............................................................................... Screw, M8-125 X 22 Hex-Head ............................................................................ Clamp .................................................................................................................... Bracket, Governor Cable Snap-In ......................................................................... Nut ........................................................................................................................ Bracket, Rear Governor Cable Snap-In ................................................................ Bracket, Rear Accelerator Cable Snap-In ............................................................. Cable, Governor, Snap-In ..................................................................................... Cable, Accelerator, Snap-In .................................................................................. Lockwasher, 5/16 Split .......................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 4 1 2 1 2 1 1 1 1 1 Page 8-11 8 G E D 8 G 17 E 15 D 16 18 11 14 9 12 13 10 TYPICAL 2 PLACES 4 6 8 2 3 5 7 REFERENCE INTAKE DUCT 19 1 TYPICAL 3 PLACES 000332-001 Page 8-12 2007 DS Golf Cars Illustrated Parts List AIR BOX AND INTAKE HOSE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1015752 101821501 1015426 101804301 101811901 101881701 101921501 101925701 101972801 N/A N/A N/A N/A 101812301 101813001 101917601 101837101 101971301 332 2 3 QTY 4 Screw, #12-16 X 0.625 Hi-Lo ................................................................................ Assembly, Air Box (includes items 3 through 9) .................................................... Filter, Air ............................................................................................................ Screw, #8 X 0.500, Hex-Head Hi-Lo ................................................................. Bottom, Air Box ................................................................................................. Washer, #8 Stainless-Steel Flat ........................................................................ Seal, Intake ....................................................................................................... Latch, Wireform ................................................................................................. Top Assy, Air Box (includes items 10 through 16) ............................................. Valve, Choke ................................................................................................ Top, Air Box .................................................................................................. O-Ring, 5/16 ................................................................................................. O-Ring, 3/8 ................................................................................................... Spring, Extension Return .............................................................................. Retaining Ring 0.25, Shaft ........................................................................... Lever, Choke ................................................................................................ Hose, Air Intake ..................................................................................................... Clamp, 1.58" ID Hose ........................................................................................... Washer, 1/4 Type A Narrow Flat ........................................................................... 2007 DS Golf Cars Illustrated Parts List 3 1 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 2 3 Page 8-13 8 G E D 8 G TYPICAL 3 PLACES E 5 6 5 1 D 3 4 2 7 8 9 TYPICAL 2 PLACES 000338-004 Page 8-14 2007 DS Golf Cars Illustrated Parts List INTAKE SYSTEM ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 101805701 101811401 101811501 101856201 101850301 101917701 101958101 1606 183 2 3 QTY 4 Button Assembly, Choke (includes items 2 through 4) .......................................... Lever, Choke (Button) ....................................................................................... Guide, Choke Lever .......................................................................................... Compression Spring .......................................................................................... Screw, #12-16 X 0.50 Washer-Head Hi-Lo ........................................................... Choke Positioner ................................................................................................... Duct Assembly ...................................................................................................... Rivet, 3/16 X .500 Alum Pop ................................................................................. Washer, #10 Type A Flat ....................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 4 1 1 2 4 Page 8-15 8 G E D 8 G E D EXHAUST SYSTEM 9 G E D 9 G TYPICAL 2 PLACES 1 E 3 D 2 11 6 8 4 12 10 9 TYPICAL 2 PLACES 7 5 000208-001 Page 9-2 2007 DS Golf Cars Illustrated Parts List EXHAUST SYSTEM – FE290 ENGINE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 1012528 1012830 1013734 1015330 1015814 1017689 101859301 1241 332 451 7174 7847 2 3 QTY 4 Nut, M8-1.25 Hex .................................................................................................. Screw, M8-125 X 22 Hex-Head ............................................................................ Lockwasher, 8mm Split ......................................................................................... Gasket, Exhaust .................................................................................................... Bracket, Muffler Mounting ..................................................................................... Clamp, 5" Muffler Hose ......................................................................................... Exhaust System, FE290 ....................................................................................... Washer, 5/16 Type A Flat ...................................................................................... Washer, 1/4 Type A Narrow Flat ........................................................................... Lockwasher, 1/4 Helical Split ................................................................................ Lockwasher, 5/16 Split .......................................................................................... Screw, 1/4-20 X 0.75 Hex-Head Cap .................................................................... 2007 DS Golf Cars Illustrated Parts List 2 1 2 1 1 1 1 1 2 2 1 2 Page 9-3 9 G E D 9 G E D TORQUE CONVERTER 10 G E D 10 24 G TYPICAL 2 PLACES 20 22 TYPICAL 3 PLACES 19 23 25 26 E 21 D TYPICAL 3 PLACES 13 17 2 16 30 14 15 31 28 29 3 4 18 9 10 11 6 12 27 8 5 7 1 33 35 32 34 000217-001 Page 10-2 2007 DS Golf Cars Illustrated Parts List 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 22 23 24 25 26 27 28 29 30 31 32 33 34 35 101833902 1014049 1014050 1014051 1014052 N/A 1014055 N/A 1014056 1014057 1014058 1014059 1014453 1014062 1014287 183 8450 1016289 1016801 1014063 N/A 1014065 N/A N/A 1016201 N/A N/A 101929801 N/A 1014288 N/A 101916501 101916701 357 808 2 3 QTY 4 Clutch, Drive (includes items 2 through 28) .......................................................... Bearing, Idler ..................................................................................................... Retainer, Spring ................................................................................................ Spring, Drive Clutch .......................................................................................... Movable-Face Assembly (includes items 6 through 8) ..................................... Drive Clutch Movable Face .......................................................................... Retainer ........................................................................................................ Bushing, Split, Drive Clutch .......................................................................... Ring, Spiral Backup ........................................................................................... Ring, 0.810" Internal Retaining ......................................................................... Washer, Thrust .................................................................................................. Drive Hub Assy, Drive Clutch ............................................................................ Kit, Drive Clutch Button (includes items 14 through 17) ................................... Driver, Drive Clutch ...................................................................................... Spring, Drive Button ..................................................................................... Washer, #10 Type A Flat .............................................................................. Screw, #10-24 X 0.50 Hex-Head .................................................................. Spacer, Fixed Face Shaft .................................................................................. Kit, Drive Clutch Weight (includes items 20 through 26) ................................... Screw, 1/4-20 X 1.00 Hex Head ................................................................... Pin, 0.3752 X 1.50 Dowel ............................................................................. Washer, 0.38" ID Delrin Flat ......................................................................... Clutch Weight, Secondary ............................................................................ Washer ......................................................................................................... Washer, Wave .............................................................................................. Weight, Primary ............................................................................................ Plug, Drive Clutch ............................................................................................. Assembly, Fixed-Face Drive (includes items 29 through 31) ............................ Fixed Face Assembly, Drive Clutch .............................................................. Screw, 5/16-18 X 0.75 Thread-Forming ....................................................... Pulley, Clutch ................................................................................................ Screw, 3/8-24 X 5.50 Hex-Head ........................................................................... V-Belt .................................................................................................................... Washer, 3/8 Split Lock ........................................................................................... Washer, 3/8 Type B Flat ........................................................................................ 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 2 1 1 1 1 3 3 3 3 1 1 6 3 6 3 6 3 3 3 1 1 3 1 1 1 1 1 Page 10-3 10 G E D 10 G E D 1 000218-001 Page 10-4 2007 DS Golf Cars Illustrated Parts List DRIVE BELT – FE290 ITEM PART NO. DESCRIPTION 1 1 1016203 2 3 QTY 4 Belt, Drive ............................................................................................................. 1 10 G E D 2007 DS Golf Cars Illustrated Parts List Page 10-5 10 G 2 E 3 D 10 9 4 8 7 6 TYPICAL 3 PLACES 5 13 1 12 14 000219-001 Page 10-6 2007 DS Golf Cars Illustrated Parts List DRIVEN CLUTCH ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 101834001 1014070 1014072 1014078 1014080 1014454 1012836 N/A 1017686 101836201 AM10419 1017327 101833401 102242101 2 3 QTY 4 Assembly, Driven Clutch (includes items 2 through 10) ........................................ Fixed Face Assy, Driven Clutch ........................................................................ Movable-Face Assembly with Bushing ............................................................. Key, Driven Clutch ............................................................................................ Ring, Retaining ................................................................................................. Kit, Driven Clutch Button (includes items 7 and 8) ............................................ Screw, #8-32 X 3/4 Socket-Head Cap .......................................................... Button, Drive ................................................................................................. Cam, Driven Clutch ........................................................................................... Spring, Driven Clutch, Reversed ....................................................................... Kit, Clutch Repair (includes items 12 through 14) ................................................. Washer, Driven Clutch, Belleville ...................................................................... Key, 3/16 Sq X 1.50" ......................................................................................... Screw, 5/16-18 X 3/4 Hex-Head with Patch ...................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 3 3 1 1 1 1 1 1 Page 10-7 10 G E D 10 G E D TRANSAXLE – GASOLINE VEHICLE 11 G E D 11 G E D 1 3 6 31 29 33 5 REFERENCE FORWARD/REVERSE SHIFTER 4 32 7 16 28 22 25 20 24 10 14 26 9 30 2 13 12 23 11 15 21 19 27 18 REFERENCE AXLE TUBE 17 000220-001 Page 11-2 2007 DS Golf Cars Illustrated Parts List TRANSAXLE – GASOLINE VEHICLES, GEAR CASES AND BRACKETS 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 1010954 1012285 1013061 1014007 1016341 1017082 1017231 101833601 1012711 1012752 1012896 1013759 1016432 1016513 101890101 101890201 101890501 101890601 101891301 101892901 101893801 101926901 101927101 101927201 101927301 101928601 101928701 101834801 101886101 102045901 183 8233 8717 2 3 QTY 4 Stud, 1/4-28 X 0.560 Ball ...................................................................................... Screw, 1/4 X 0.625 Hex-Head ............................................................................... Locknut, #10-32 Nylon Insert ................................................................................ Washer, 1/4 Flat .................................................................................................... Lever, Transmission Shift ...................................................................................... Screw, #10-32 X 0.75, Hex-Head Machine ........................................................... Key, Woodruff ........................................................................................................ Transaxle, 11.77 Ratio (includes items 9 through 27) ........................................... Breather ............................................................................................................ Roll Pin .............................................................................................................. Pin, Dowel ......................................................................................................... Fill Plug with Gasket (includes item 13) ............................................................ Gasket, Drain Plug ....................................................................................... Washer, M6 Flat ................................................................................................ Lever, Change ................................................................................................... Shaft - Change .................................................................................................. Gear Case (driver side) ..................................................................................... Gear Case (passenger side) ............................................................................. Arm Pivot .......................................................................................................... Washer .............................................................................................................. Washer .............................................................................................................. Screw, M8-1.25 X 40mm Hex-Head ................................................................. Seal, Oil ............................................................................................................ Seal, Oil ............................................................................................................ Ring, Internal Retaining .................................................................................... Pin, Cotter ......................................................................................................... Sealant .............................................................................................................. Arm, Governor ...................................................................................................... Screw, 1/4-20 X 1.00 Square-Head ...................................................................... Bracket, Shifter ...................................................................................................... Washer, #10 Type A Flat ....................................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Locknut, 1/4-28 Nylon Insert ................................................................................. 2007 DS Golf Cars Illustrated Parts List 1 3 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 15 1 1 1 1 A/R 1 1 1 1 1 1 Page 11-3 11 G E D 11 G 4 5 E 9 12 D 2 24 23 3 28 27 21 13 3 20 1 30 33 2 7 13 15 6 7 26 32 8 21 SEALED C3 BEARING 13 28 29 22 SEALED BEARING 25 16 18 17 32 31 11 31 REFERENCE DRIVER SIDE CASE 10 14 19 REFERENCE PASSENGER SIDE CASE Clu bC ar 000221-001 Page 11-4 2007 DS Golf Cars Illustrated Parts List TRANSAXLE – GASOLINE VEHICLES, TRANSMISSION AND GEAR REDUCTION 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 1012714 1012740 1012741 1012747 1012748 1016337 1016338 101889401 101890001 101891601 101891901 101892001 101892201 101892301 101892401 101892501 101892601 101893201 101893901 101927501 101927601 101927701 101927901 101928001 101928101 101980801 101980901 101981001 102453001 102453101 7335 AM10080 AM10081 2 3 QTY 4 Oil Seal ................................................................................................................. Synchro Insert ....................................................................................................... Synchro Spring ...................................................................................................... Shifter Ball ............................................................................................................. Shifter Spring ........................................................................................................ Washer, Thrust ...................................................................................................... Washer, Spring ...................................................................................................... Guide .................................................................................................................... Fork - Shift ............................................................................................................. Sleeve, Governor .................................................................................................. Gear, Cluster ......................................................................................................... Rod, Shift .............................................................................................................. Plate, Thrust .......................................................................................................... Governor Assembly .............................................................................................. Gear, Spur ............................................................................................................. Gear, Helical (61 Tooth) ........................................................................................ Gear, Helical (17 Tooth) ........................................................................................ Key Sunk ............................................................................................................... Washer .................................................................................................................. Bearing, Needle .................................................................................................... Needle Bearing ..................................................................................................... Pin, .116" Dia X 0.264 Dowel ................................................................................ Sleeve, Synchro .................................................................................................... Hub, Synchro Clutch ............................................................................................. Bearing, Ball .......................................................................................................... Gear Assembly, 16-Degree Synchro (25 Tooth) ................................................... Gear Assembly, 16-Degree Rear Synchro (28 Tooth) ........................................... Ring, 16-Degree Synchronizer .............................................................................. Shaft, Trans, with Circlip ....................................................................................... Circlip .................................................................................................................... Bearing .................................................................................................................. Bearing, Ball, Sealed ............................................................................................ Bearing, Ball, Sealed ............................................................................................ 1 3 2 1 1 1 2 1 1 1 1 1 3 1 1 1 1 1 1 1 3 1 1 1 1 1 1 2 1 1 2 2 1 Note: Items listed on this page are components of the unitized transaxle. 2007 DS Golf Cars Illustrated Parts List Page 11-5 11 G E D 11 G 7 E D 19 15 27 16 4 18 26 17 14 3 25 2 1 2 28 20 5 1 22 Clu bC ar 25 24 4 23 27 21 28 6 8 11 12 10 9 13 Page 11-6 2007 DS Golf Cars Illustrated Parts List 000222-001 TRANSAXLE – GASOLINE VEHICLES, DIFFERENTIAL AND AXLES 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 1013770 1013771 1013772 1013794 1014193 101890901 101891001 101891401 1011291 1013787 1013792 1014207 1016672 101891501 1011291 1013787 1013792 1014207 1016672 101892701 101910501 1013768 1013769 1013773 1013774 101928301 102031901 7330 2 3 QTY 4 Differential Idler Gear ............................................................................................ Gear, Differential ................................................................................................... Pin, Differential ...................................................................................................... Axle Shaft Oil Seal ................................................................................................ Dowel Pin .............................................................................................................. Pipe ....................................................................................................................... Pipe ....................................................................................................................... Axle Assembly, Passenger Side (includes items 9 through 13) ............................ Outer Axle, Tube Bearing .................................................................................. Lug Stud ............................................................................................................ Circlip Type C .................................................................................................... Bushing ............................................................................................................. Retaining Ring .................................................................................................. Axle Assembly, Driver-Side (includes items 15 through 19) ................................. Outer Axle, Tube Bearing .................................................................................. Lug Stud ............................................................................................................ Circlip Type C .................................................................................................... Bushing ............................................................................................................. Retaining Ring .................................................................................................. Gear, Helical ......................................................................................................... Kit, Differential Gear Case (includes items 22 through 25) ................................... Differential Gear Case, Left-Hand ..................................................................... Differential Gear Case, Right-Hand .................................................................. Plate, Thrust (Differential Gear) ........................................................................ Plate, Thrust (Idler Gear) .................................................................................. Screw, M8-1.25 X 35mm Hex Head ...................................................................... Bolt, M10 X 1.5 X 30mm ....................................................................................... Inner Axle, Tube Bearing ...................................................................................... 2 2 1 2 1 1 1 1 1 4 1 1 1 1 1 4 1 1 1 1 1 1 1 1 2 8 14 2 Note: Items listed on this page are components of the unitized transaxle. 2007 DS Golf Cars Illustrated Parts List Page 11-7 11 G E D 11 G E D 1 23 TYPICAL 4 PLACES 2 19 6 22 18 7 15 16 20 NC NO M CO 3 14 14 19 12 10 17 13 9 11 REF. 5 8 21 000236-001 Page 11-8 2007 DS Golf Cars Illustrated Parts List FORWARD/REVERSE SHIFTER ASSEMBLY – GASOLINE VEHICLES 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 1012987 1015064 1016201 1016947 1010954 1012431 1012594 1013587 1013589 1013590 1013591 1014089 1014065 1014145 1014727 1014807 1016342 101979101 8057 8058 8717 8233 8248 2 3 QTY 4 Handle, FNR ......................................................................................................... Screw, #8-32 X 0.63 Machine ............................................................................... Washer, Wave ....................................................................................................... Assembly, FNR Shifter (includes items 5 through 21) ........................................... Stud, 1/4-28 X 0.560 Ball .................................................................................. Washer, #4 Flat ................................................................................................. Screw, #4-40 Machine ...................................................................................... FNR Bell Crank Weldment ................................................................................ Ring, 0.338" Internal Retaining ......................................................................... Spring, FNR Cam .............................................................................................. Pin, 1/8 X 1/2 Roll ............................................................................................. Neutral Lockout Cam Kit (includes item 13) ...................................................... Washer, 0.38" ID Delrin Flat ......................................................................... Bushing, Secondary Weight, Split ..................................................................... Washer, #4 Nylon Flat ....................................................................................... Switch, Limit ...................................................................................................... FNR Shifter Base .............................................................................................. Assembly, Switch, Limit .................................................................................... Nut, #4-40 Hex Machine ................................................................................... Lockwasher, #4 Helical Split ............................................................................. Locknut, 1/4-28 Nylon Insert ............................................................................. Locknut, 1/4-20 Nylon Insert ................................................................................. Screw, 1/4-20 X 0.75 Truss-Head Machine .......................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 4 2 1 1 1 1 1 1 2 2 1 1 1 4 2 1 4 4 Page 11-9 11 G E D 11 G 4 6 E D 10 3 4 6 5 2 8 9 UNDER DRIVER SIDE SEAT BOTTOM 7 TYPICAL 3 PLACES 1 000248-001 Page 11-10 2007 DS Golf Cars Illustrated Parts List FORWARD/REVERSE SHIFTER CABLE – GASOLINE VEHICLES ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 1012285 101855801 101951501 1012333 N/A 7893 102045901 332 8233 8251 2 3 QTY 4 Screw, 1/4 X 0.625 Hex-Head ............................................................................... Cable Retainer ...................................................................................................... FNR Shifter Cable (includes items 4 through 6) .................................................... Joint, #10-32 Ball .............................................................................................. Cable, Forward/Reverse Shifter ........................................................................ Nut, #10-32 Hex ................................................................................................ Bracket, Shifter ...................................................................................................... Washer, 1/4 Type A Narrow Flat ........................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Screw, 1/4-20 X 1.0 Truss-Head Machine ............................................................ 2007 DS Golf Cars Illustrated Parts List 3 1 1 2 1 2 1 4 4 4 Page 11-11 11 G E D 11 G E D ELECTRICAL SYSTEM – ELECTRIC VEHICLE 12 G E D 12 G DS IQ SYSTEM WITH FOUR 12-VOLT BATTERIES E D SONIC WELD 18_LT_GREEN(W23) 18_RED(W06) 18_ORG(W24) 10_BLK(W58) SOLENOID WARNING LIGHT 10_BLK(W60) 18_WHT(W22) 18_BRN_WHT(W08) RESISTOR POS (+) NEG (-) REVERSE BUZZER FRONT 18_GRAY(W31) 18_LT_BLU(W11) 18_GRN(W25) 6_RED(W57) 18_PINK(W21) 16_BLK_WHT(W42) 18_GRAY(W01) SONIC WELD 6_WHT(W62) 6_YEL(W59) 6_GRN(W64) PROGRAMMER PLUG 3 PIN CONNECTOR 18_BRN(W16) 18_BLU(W17) #18 BLK/YEL 18_BLU(W03) FORWARD 10_ORG(W61) 10_BLU(W63) 18_BLU_WHT_STP(W20) 18_RED_YEL(W29) 18_BLU_YEL(W33) 18_GRN_YEL(W15) #18 BLU/YEL 1 #18 RED/YEL KEY SWITCH 6_BLK(W55) 10_BLK(W49) #18 GRN/YEL 2 6_YEL(W59) REVERSE 4 PIN CONNECTOR 10_ORG(W61) 18_YEL(W13) 18_BLK_YEL(W14) 18_BLU(W07) 18_TAN(W12) CONTROLLER 18_LHT_BLU(W10) 10_BLU(W63) 6_GRN(W64) 18_WHT(W04) 18_YEL(W18) 18_GRN(W28) 18_PUR_WHT(W34) 2 PIN CONNECTOR SONIC WELD 18_GRN(W32) MCOR SPEED SWITCH ASM (THROTTLE DEVICE) DETAIL B (CONTROLLER) 18_ORG_WHT(W05) 6_WHT(W62) 18_BLK_WHT(W09) 18_LT_GREEN(W02) 18_RED(W19) 18_GRN_WHT(W30) 10_BLK(W49) 3 PIN CONNECTOR 6_BLK(W55) (PIN 13) BLK/WHT : TO LOW SIDE OF MOTOR SPEED SENSOR (PIN 14) LT GREEN: TO MOTOR SPEED SENSOR OUTPUT (PIN 15) RED : TO HIGH SPEED OF MOTOR SPEED SENSOR (PIN 12) BLU/WHT : TO LOW SIDE OF SOLENOID COIL (PIN 11) : OPEN (PIN 10) TAN : TO KEY SWITCH SONIC WELD (PIN 9) GRAY : AUX (PIN 16) BLUE : TO FNR SWITCH "REV" 16 9 8 1 (PIN 8) BROWN : TO FNR SWITCH "FOR" (PIN 1) WHITE (PIN 7) ORG/WHT : TO LOW SIDE OF REVERSE BUZZER (PIN 6) GREEN : TO ACCELERATOR LIMIT SWITCH (PIN 2) YELLOW (PIN 3) PUR/WHT (PIN 4) GRN/WHT (PIN 5) LT BLUE : TO HIGH SIDE OF POTENTIOMETER : TO SLIDER OF POTENTIOMETER : TO LOW SIDE OF POTENTIOMETER : TO S. O. C : TO OBC "CONTROLLER LOCKOUT" 000412-002 Page 12-2 2007 DS Golf Cars Illustrated Parts List 12 G E D 18_LT_GREEN(W23) 6_RED(W57) 6_RED(W57) 18_PINK(W21) TOW SWITCH 18_PINK(W27) FUSE & RECEPTACLE BRACKET ASM 18_GRAY(W65) SONIC WELD 18_YEL(W13) 12 VOLT BATTERIES ON-BOARD D RE F1 F2 BL K A1 GRN MOTOR A2 18_BLK_WHT(W09) 6_BLK(W66) 3 PIN CONNECTOR 10_BLK(W50) 18_LHT_BLU(W10) 10_BLU(W63) 6_GRN(W64) 1 COMPUTER 6_BLK(W55) 6_WHT(W62) 1 6_BLK(W68) 10_BLK(W54) FUSE(101894901) (INCLUDED WITH FUSE & RECEPTACLE ASM) 18_GRAY(W52) 10_ORG(W61) 6_BLK(W69) 1 10_BLK(W51) 18_RED(W26) 18_BRN_WHT(W08) 18_WHT(W22) 18_BRN_WHT(W08) 18_LT_GREEN(W02) 18_RED(W19) 18_GRN_WHT(W30) 10_BLK(W49) 6_BLK(W55) 000412-002 2007 DS Golf Cars Illustrated Parts List Page 12-3 12 G E D See previous two pages for diagram. Page 12-4 2007 DS Golf Cars Illustrated Parts List WIRING ITEM PART NO. DESCRIPTION 1 1 2 101795701 102913301 2 3 QTY 4 Wire Assembly #6 Black ....................................................................................... Wire Harness, Electric, DS, Four 12-Volt Batteries ............................................... 3 1 12 G E D 2007 DS Golf Cars Illustrated Parts List Page 12-5 12 G E TYPICAL 2 PLACES AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED D 13 1 14 12 15 16 7 2 6 OFF ON 18 TYPICAL 2 PLACES 17 000340-001 Page 12-6 2007 DS Golf Cars Illustrated Parts List INSTRUMENT PANEL COMPONENTS ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1012505 1016859 1011229 1012431 1015720 1016849 1016851 N/A 8056 8057 8058 101826201 101830601 101830701 101834502 101851101 101935501 8990 2 3 QTY 4 Keys (set of 2) ....................................................................................................... Kit, Reverse Buzzer (includes items 3 through 11) ............................................... Locknut, #6-32 Whiz ......................................................................................... Washer, #4 Flat ................................................................................................. Screw, #6-32 X 1/2 Hex Washer-Head ............................................................. Screw, #4-24 X 0.33 Pan-Head Machine .......................................................... Buzzer, Reverse (9-48 VDC) ............................................................................ Wire Assembly Black #18 ................................................................................. Screw, #4-40 X 0.75 Round-Head Machine ...................................................... Nut, #4-40 Hex Machine ................................................................................... Lockwasher, #4 Helical Split ............................................................................. Key Switch, On/Off ................................................................................................ Screw and Washer Assembly ............................................................................... Nut, Key Switch ..................................................................................................... Cap, Black Key Switch .......................................................................................... Washer, Key Switch .............................................................................................. Light, Battery ......................................................................................................... Tie Wrap, 8" Nylon ................................................................................................ 1 1 1 2 1 2 1 1 2 2 2 1 2 1 1 1 1 2 Note: Item 2, Reverse Buzzer Kit, contains parts not used in this application. 2007 DS Golf Cars Illustrated Parts List Page 12-7 12 G E D 12 G 5 E D 4 3 1 2 000243-001 Page 12-8 2007 DS Golf Cars Illustrated Parts List MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 1015752 101920101 101936801 102101001 102101101 2 3 QTY 4 Screw, #12-16 X 0.625 Hi-Lo ................................................................................ Kit, 3-Pin Wedge Lock ........................................................................................... Kit, 2-Pin Wedge Lock ........................................................................................... Bar, Drive, Cast ..................................................................................................... MCOR ................................................................................................................... 2007 DS Golf Cars Illustrated Parts List 2 1 1 1 1 Page 12-9 12 G E D 12 G E 3 D 9 11 2 13 12 10 F 8 1 5 24 6 TYPICAL 3 PLACES 19 21 16 17 18 20 ING WARN 15 TOW RUN 7 14 22 4 23 F 25 25 000244-001 Page 12-10 2007 DS Golf Cars Illustrated Parts List FORWARD/REVERSE SWITCH, TOW/RUN SWITCH 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 1012285 101855002 101856002 101908101 101908401 101922501 101932401 101942301 102266601 101920101 N/A N/A N/A 102266701 101932501 102196901 N/A N/A N/A N/A N/A 332 8233 8248 8990 2 3 QTY 4 Screw, 1/4 X 0.625 Hex-Head ............................................................................... Case, FNR Switch ................................................................................................. Switch, Rocker, Single-Pole .................................................................................. Switch Assembly, Tow/Run ................................................................................... Boot, Switch .......................................................................................................... Bracket, Tow/Run Switch Mounting ...................................................................... Kit, 4-Pin Receptacle and Wedge Lock ................................................................. Kit, 3-Pin Wedge Lock ........................................................................................... Wire Assembly, FNR Switch (includes items 10 through 13) ................................ Kit, 3-Pin Wedge Lock ...................................................................................... Wire Assembly, #18 Blue .................................................................................. Wire Assembly, #18 Orange ............................................................................. Wire Assembly, #18 Brown ............................................................................... Wire Assembly, IQDM Port (includes items 15 through 21) .................................. Kit, 4-Pin Wedge Lock ...................................................................................... Dust Cap ........................................................................................................... Connector Mount, Four-Pin ............................................................................... Wire Assembly, #18 Red/Yellow ....................................................................... Wire Assembly, #18 Black/Yellow ..................................................................... Wire Assembly, #18 Blue/Yellow ....................................................................... Wire Assembly, #18 Green/Yellow .................................................................... Washer, 1/4 Type A Narrow Flat ........................................................................... Locknut, 1/4-20 Nylon Insert ................................................................................. Screw, 1/4-20 X 0.75 Truss-Head Machine .......................................................... Tie Wrap, 8" Nylon ................................................................................................ 2007 DS Golf Cars Illustrated Parts List 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 Page 12-11 12 G E D 12 G E 11 TYPICAL 4 PLACES D 1 TYPICAL 2 PLACES TYPICAL 3 PLACES 4 5 6 10 3 8 2 7 9 000369-001 Page 12-12 2007 DS Golf Cars Illustrated Parts List BATTERY CHARGER RECEPTACLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 101801001 101802101 1017705 101796501 101796801 1013061 101894901 N/A N/A N/A 101832001 2 3 QTY 4 Plate, Receptacle Backing .................................................................................... Fuse and Receptacle Assembly (includes items 3 through 10) ............................ Screw, #8 X 5/8 Phillips Pan-Head Type AB ..................................................... Receptacle ........................................................................................................ Fuse Assembly (includes item 6) ...................................................................... Locknut, #10-32 Nylon Insert ....................................................................... Fuse, 3/8-Amp .................................................................................................. Wire Assembly, Sense Lead, Gray ................................................................... Wire Assembly, #10 Red ................................................................................... Wire Assembly, #10 Black ................................................................................ Screw, #7-19 X 0.625 Phillips Pan-Head Tap ....................................................... 2007 DS Golf Cars Illustrated Parts List 1 1 3 1 1 2 1 1 1 1 4 Page 12-13 12 G E D 12 G E D 7 TYPICAL 4 PLACES 3 TYPICAL 8 PLACES 2 1 8 TYPICAL 6 PLACES 4 TYPICAL 3 PLACES TYPICAL 4 PLACES 5 6 FRONT OF VEHICLE 000241-002 Page 12-14 2007 DS Golf Cars Illustrated Parts List BATTERIES, ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 1011697 1014304 1015072 101795701 102511301 102511302 102777401 102832601 2 3 QTY 4 Washer, 5/16 Flat .................................................................................................. Nut, 5/16-18 Stainless-Steel Hex .......................................................................... Locknut, 5/16-18 Nylon Insert ............................................................................... Wire Assembly #6 Black ....................................................................................... Battery, Ventmaster 12-Volt (Wet) ......................................................................... Battery, Ventmaster 12-Volt (Dry, also known as moist) ....................................... Battery Hold-Down ................................................................................................ Bolt, Battery, J- ...................................................................................................... 2007 DS Golf Cars Illustrated Parts List 8 8 8 3 4 4 4 8 Page 12-15 12 G E D 12 G E D 34 17 23 2 TYPICAL 2 PLACES 27 TYPICAL 3 PLACES 18 TYPICAL 2 PLACES 25 24 15 28 26 29 6 7 5 30 33 32 1 1 TYPICAL 2 PLACES TYPICAL 3 PLACES 16 22 31 21 19 TYPICAL 2 PLACES 20 1 F TYPICAL 2 PLACES 10 3 9 11 12 13 TYPICAL 2 PLACES 1 4 TYPICAL 2 PLACES 14 000242-001 Page 12-16 2007 DS Golf Cars Illustrated Parts List COMPUTER, CONTROLLER, AND SOLENOID, 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 1012285 1014288 1014947 1014948 101827801 N/A N/A 8990 101908701 1012528 1013734 N/A N/A N/A 101910401 101932701 101965205 102240501 102240601 101931501 102240701 102240801 **** 102259801 102263601 102263701 102266501 102806201 102806202 102852001 101932601 1242 7174 8990 2 3 QTY 4 Screw, 1/4 X 0.625 Hex-Head ............................................................................... Screw, 5/16-18 X 0.75 Thread-Forming ................................................................ Resistor Assembly ................................................................................................ Diode ..................................................................................................................... Ground Wire Kit, 48-Volt (includes items 6 through 8) .......................................... Compression Lug .............................................................................................. Wire Assembly, Black ....................................................................................... Tie Wrap, 8" Nylon ............................................................................................ Solenoid, 48-Volt (includes items 10 through 14) ................................................. Nut, M8-1.25 Hex .............................................................................................. Lockwasher, 8mm Split ..................................................................................... Solenoid, 48-Volt ............................................................................................... Washer, Lock .................................................................................................... Nut .................................................................................................................... Screw, 5/16-18 X 1.25 Thrd Frm ........................................................................... Kit, 6-Pin Receptacle and Wedge Lock ................................................................. Plate, Component Com Solnd .............................................................................. Bolt, Controller, Terminal ....................................................................................... Cover Assembly, Controller (includes items 20 through 22) ................................. Decal, Component Cover .................................................................................. Cover, Controller ............................................................................................... Gasket, Controller Cover .................................................................................. Extrusion, Cover Support ...................................................................................... Terminal Block ....................................................................................................... Wire Assy, #10 Black ............................................................................................ Screw, #10-24 X 0.75 Phillips, Thread-Forming .................................................... Kit, Connector, IQ Controller ................................................................................. Controller, IQ, 48-volt ............................................................................................ Controller, IQ, 48-volt, Nonstandard ...................................................................... Asm, Obc, Iq, Smt (includes item 31) ................................................................... Kit, 6-Pin Wedge Lock ...................................................................................... Nut, 5/16-18 Hex ................................................................................................... Lockwasher, 5/16 Split .......................................................................................... Tie Wrap, 8" Nylon ................................................................................................ 9 2 1 1 1 1 1 3 1 2 2 1 2 2 2 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 **** Special order item available upon request. 2007 DS Golf Cars Illustrated Parts List Page 12-17 12 G E D 12 G E D ELECTRIC MOTOR 13 G E D 13 G 3 5 6 E THROUGH TYPICAL 2 PLACES 31 21 14 22 26 29 D 30 28 20 TYPICAL 2 PLACES 12 27 24 19 23 16 18 17 31 32 25 TYPICAL 4 PLACES 13 15 1 34 F2 6 F1 1 A A2 4 10 8 11 9 33 2 7 TYPICAL 3 PLACES 000349-001 Page 13-2 2007 DS Golf Cars Illustrated Parts List MOTOR (MODEL 5BC59JBS6365) – ELECTRIC VEHICLE (EARLIER STYLE) 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 1010934 1014201 101920101 102235201 N/A 1017944 1017947 1011280 N/A N/A 1241 1017949 1017950 1017953 102265501 102265701 N/A N/A 102265901 102265601 101942301 N/A 102266001 102267001 102266101 102327801 1011411 N/A 1017948 102251901 N/A 102243403 451 7174 2 3 QTY 4 Screw, 5/16-18 X 1.00 Hex Cap ............................................................................ Screw, 1/4-20 X 2.25 Hex Cap .............................................................................. Kit, 3-Pin Wedge Lock ........................................................................................... Bumper, Drive Unit ................................................................................................ Motor, 48-Volt Shunt-Wound (includes items 6 through 31) .................................. End Shield ......................................................................................................... Hardware Package (includes items 8 through 11) ............................................ Locknut, 5/16-18 ........................................................................................... Insulator Bushing .......................................................................................... Insulated Bushing ......................................................................................... Washer, 5/16 Type A Flat ............................................................................. Screw, #6-32 X 0.480 Hex-Head ...................................................................... Bearing Retainer ............................................................................................... Screw, Bearing Retainer ................................................................................... Stator Shell and Winding ................................................................................... Kit, Bearing and Magnet (includes items 17 and 18) ........................................ Ball Bearing .................................................................................................. Magnet ......................................................................................................... Motor End Shield Asm (includes items 20 through 24) ..................................... Speed Sensor Assembly (includes items 21 and 22) ................................... Kit, 3-Pin Wedge Lock ............................................................................. Sensor, Speed, without Connector .......................................................... End Shield, Motor ......................................................................................... Screw, #8-32 X 0.375 Hex-Head .................................................................. Screw, #10 - 32 X 8.250 .................................................................................... Brush Assembly, Beveled (includes items 27 through 30) ................................ Brush Spring Package (includes item 28) .................................................... Brush Spring ............................................................................................ Brush Rigging ............................................................................................... Brush Kit, Motor ............................................................................................ Armature ........................................................................................................... Lubricant, Moly-Teflon (Single-Use Tube) ............................................................. Lockwasher, 1/4 Helical Split ................................................................................ Lockwasher, 5/16 Split .......................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 3 1 1 1 1 1 4 2 2 4 2 1 2 1 1 1 1 1 1 1 1 1 1 4 1 1 4 1 1 1 1 3 1 Page 13-3 13 G E D 13 G 3 5 6 E THROUGH TYPICAL 2 PLACES 31 20 14 21 27 30 D 31 29 19 TYPICAL 2 PLACES 12 28 23 18 22 15 17 16 26 32 24 TYPICAL 4 PLACES 13 25 1 34 F2 6 F1 1 A A2 4 10 8 11 9 33 2 7 TYPICAL 3 PLACES 000349-002 Page 13-4 2007 DS Golf Cars Illustrated Parts List MOTOR (MODEL 5BC59JBS6365A) – ELECTRIC VEHICLE (LATER STYLE) 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 1010934 1014201 101920101 102235201 102240104 1017944 1017947 1011280 N/A N/A 1241 1017949 1017950 1017953 102265701 N/A N/A 102265901 102265601 101942301 N/A 102266001 102267001 102266101 103325701 N/A 103337601 1011411 N/A 103325501 103325601 102243403 451 7174 2 3 QTY 4 Screw, 5/16-18 X 1.00 Hex Cap ............................................................................ Screw, 1/4-20 X 2.25 Hex Cap .............................................................................. Kit, 3-Pin Wedge Lock ........................................................................................... Bumper, Drive Unit ................................................................................................ Motor, 48-Volt Non-Skew IQ (includes items 6 through 27) .................................. End Shield ......................................................................................................... Hardware Package (includes items 8 through 11) ............................................ Locknut, 5/16-18 ........................................................................................... Insulator Bushing .......................................................................................... Insulated Bushing ......................................................................................... Washer, 5/16 Type A Flat ............................................................................. Screw, #6-32 X 0.480 Hex-Head ...................................................................... Bearing Retainer ............................................................................................... Screw, Bearing Retainer ................................................................................... Kit, Bearing and Magnet (includes items 16 and 17) ........................................ Ball Bearing .................................................................................................. Magnet ......................................................................................................... Motor End Shield Asm (includes items 19 through 23) ..................................... Speed Sensor Assembly (includes items 20 and 21) ................................... Kit, 3-Pin Wedge Lock ............................................................................. Sensor, Speed, without Connector .......................................................... End Shield, Motor ......................................................................................... Screw, #8-32 X 0.375 Hex-Head .................................................................. Screw, #10 - 32 X 8.250 .................................................................................... Stator Shell and Winding ................................................................................... Armature, Non-Skewed ..................................................................................... Brush Assembly, IQ Motor, Non-Skew (includes items 28 through 31) ............. Brush Spring Package (includes item 29) .................................................... Brush Spring ............................................................................................ Brush Rigging, Non-Skew Motor .................................................................. Brush Set, Non-Skew ................................................................................... Lubricant, Moly-Teflon (Single-Use Tube) ............................................................. Lockwasher, 1/4 Helical Split ................................................................................ Lockwasher, 5/16 Split .......................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 3 1 1 1 1 1 4 2 2 4 2 1 2 1 1 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 1 3 1 Page 13-5 13 G E D 13 TYPICAL 2 PLACES G 3 15 E TYPICAL 2 PLACES INCLUDES ALL 4 SPRINGS 22 18 7 D 14 21 TYPICAL 4 PLACES 20 8 19 29 TYPICAL 2 PLACES INCLUDES ALL 4 BRUSHES 10 31 30 TYPICAL 2 PLACES 28 33 11 32 12 13 16 25 TYPICAL 2 PLACES 24 27 23 9 34 36 1 26 17 5 TYPICAL 3 PLACES 4 35 2 000185-001 Page 13-6 2007 DS Golf Cars Illustrated Parts List MOTOR (MODEL EJ4-4001) – 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 1010934 1014201 101920101 102235201 102243403 102705001 102186001 N/A 102186101 102186201 N/A 102186301 102186401 102186701 102186801 102186901 102187001 102187101 N/A N/A N/A N/A 102187201 N/A N/A 102704701 102704801 102704901 101942301 N/A N/A N/A N/A N/A 451 7174 2 3 QTY 4 Screw, 5/16-18 X 1.00 Hex Cap ............................................................................ Screw, 1/4-20 X 2.25 Hex Cap .............................................................................. Kit, 3-Pin Wedge Lock ........................................................................................... Bumper, Drive Unit ................................................................................................ Lubricant, Moly-Teflon (Single-Use Tube) ............................................................. IQ Electric Motor, 48-VDC 3.3 hp (includes items 7 through 34) .......................... Spring Kit, Motor Brush (includes item 8) .......................................................... Spring, Brush, Starter/gen ............................................................................ Brush Box Assembly ......................................................................................... Brush Kit, Motor (includes item 11) ................................................................... Assembly, Brush and Terminal ..................................................................... Ring, 2.24" Internal Retaining ........................................................................... Bearing, Ball ...................................................................................................... End Cap, Motor ................................................................................................. Screw, 1/4-20 X 2.25 Hex-Head Washer .......................................................... Screw, #8-32 X .5 Hex-Head ............................................................................ L-Bracket, Motor ............................................................................................... Hardware Kit, Motor Terminal (includes items 19 through 22) .......................... Bushing, Nylon ............................................................................................. Washer, Nylon Flat ....................................................................................... Washer, Flat, 5/16 Steel ............................................................................... Nut, Brass Hex, 5/16 - 18 ............................................................................. Plate Kit, Motor Cover (includes items 24 and 25) ............................................ Assembly, Cover Plate ................................................................................. Screw, #8-32 x 0.375, Taptite Thread ........................................................... Frame and Field Assembly ............................................................................... Armature Assembly ........................................................................................... Kit, Speed Sensor (includes items 29 through 33) ............................................ Kit, 3-Pin Wedge Lock .................................................................................. Sensor, Motor Speed, ADC .......................................................................... Screw, #8-32, Taptite Thread ....................................................................... Magnet, ADC Motor ...................................................................................... Screw, 1/4-20 x 0.5 ....................................................................................... Bolt, 1/4 - 20 x 0.73 Thread-Forming ................................................................ Lockwasher, 1/4 Helical Split ................................................................................ Lockwasher, 5/16 Split .......................................................................................... 2007 DS Golf Cars Illustrated Parts List 1 3 1 1 1 1 1 4 1 1 2 1 1 1 2 2 1 2 2 2 2 2 1 1 1 1 1 1 1 1 2 1 1 2 3 1 Page 13-7 13 G E D 13 G E D TRANSAXLE – ELECTRIC VEHICLES 14 G E D 14 G REFERENCE MOTOR 6 4 E D 15 23 28 27 29 3 31 5 18 cm 4 . 50 31 16 11 2 31 32 14 20 19 8 22 21 18 30 26 7 2 23 10 cm 3 . 25 12 30 10 9 13 17 17 18 24 25 000223-002 Page 14-2 2007 DS Golf Cars Illustrated Parts List TRANSAXLE – ELECTRIC VEHICLES 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 102771701 1013794 101895401 101895501 101897001 101897201 101897401 101897601 101903601 101903701 101906901 101922101 101923001 101923201 101923501 101923701 101923901 101928701 101972101 101972201 102356601 102356801 102357001 102886301 101922201 102886401 102886501 101922201 102886601 7330 7335 7336 2 3 QTY 4 Transaxle, Electric (includes items 2 through 32) ................................................. Axle Shaft Oil Seal ............................................................................................ Gear Case, Left-Hand ....................................................................................... Gear Case, Passenger-Side ............................................................................. Screw, M8-1.25 X 60mm Hex-Head ................................................................. Breather ............................................................................................................ Screw, M10-1.25 X 25mm ................................................................................. Pin, 11mm OD X 8.5mm ID X 10mm ................................................................ Washer, Thrust .................................................................................................. Washer, Thrust .................................................................................................. Intermediate Shaft Assembly ............................................................................ Pin, 15.99mm X 88.7mm Dowel ....................................................................... Gear, Differential Idler ....................................................................................... Gasket ............................................................................................................... Seal, Lip ............................................................................................................ Shaft, Input ........................................................................................................ Gear, Differential ............................................................................................... Sealant .............................................................................................................. Plug, M14-1.5 X 12mm Magnetic ...................................................................... Plug, M14-1.5 X 12mm Hex .............................................................................. Housing, Differential, 6 Bolt .............................................................................. Gear, Differential Output, 6-Bolt ........................................................................ Screw, Flg Hd M10 X 1.5 X 30 .......................................................................... Axle Assembly, Driver-Side (includes item 25) ................................................. Lug Stud ....................................................................................................... Tube, Axle, Driver-Side ..................................................................................... Axle Assembly, Passenger-Side (includes item 28) .......................................... Lug Stud ....................................................................................................... Tube, Axle, Passenger-Side ............................................................................. Inner Axle, Tube Bearing .................................................................................. Bearing .............................................................................................................. Bearing .............................................................................................................. 2007 DS Golf Cars Illustrated Parts List 1 2 1 1 11 1 6 2 2 2 1 1 2 2 1 1 2 A/R 1 1 1 1 10 1 4 1 1 4 1 2 3 1 Page 14-3 14 G E D 14 G E D BATTERY CHARGER 15 G E D 15 G E 20 12 D 11 15 14 17 13 18 12 6 7 19 8 9 10 5 4 21 11 000291-001 Page 15-2 2007 DS Golf Cars Illustrated Parts List POWERDRIVE 2 BATTERY CHARGER (MODEL 22110), DOMESTIC 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 101802204 101802205 101802206 1012098 101828601 101828801 101828802 101828904 101828905 101828906 102273201 7577 102273301 102273401 102273501 102273601 102273701 102273801 102273901 102274001 CCX8506 2 3 QTY 4 48-V/13-A PowerDrive 2 (9-ft. DC, 6-ft. AC) ......................................................... 48-V/13-A PowerDrive 2 (12-ft. DC, 9-ft. AC) ....................................................... 48-V/13-A PowerDrive 2 (20-ft. DC, 9-ft. AC) (includes items 4 through 21) ........ Bushing, DC Cord ............................................................................................. Relay, 48-Volt .................................................................................................... Cord, AC, 80-Inch (203 cm) .............................................................................. Cord, AC, 108-Inch (274 cm) ............................................................................ PD2 DC Cordset, 113-inch ................................................................................ PD2 DC Cordset, 154-inch ............................................................................... Pd2 Dc Cordset 250 Inch .................................................................................. PD2 Case (includes item 12) ............................................................................ Screw, #10 X 0.50 Phillips Pan-Head ........................................................... PD2 Transformer Asm ...................................................................................... PD2 Heatsink .................................................................................................... PD2 Diode Bridge w/Film .................................................................................. PD2 Wire Asm .................................................................................................. PD2 Fuse Asm .................................................................................................. PD2 Ammeter ................................................................................................... PD2 AC Cord Bushing ...................................................................................... PD2 Handle ....................................................................................................... Circuit Breaker, 15-Amp/120-Volt ...................................................................... 1 1 1 1 1 1 1 1 1 1 1 12 1 1 1 1 1 1 1 1 1 Note: Item 16 not shown. Level 1 Battery Charger part numbers include one AC and one DC cord. They do not include all of the level 2 cords listed. 2007 DS Golf Cars Illustrated Parts List Page 15-3 15 G E D 15 G 9 E D 19 6 8 10 17 9 14 15 16 5 4 C lu b C ar R 11 18 20 12 13 7 000351-001 Page 15-4 2007 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER (MODEL 17930), DOMESTIC 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 101802201 101802202 101802203 1012098 1012101 1015914 1015917 101819701 101828301 101828501 101828601 101828801 101828802 101828901 101828902 101828903 101831101 101914401 7577 CCX8506 2 3 QTY 4 48V/17A PowerDrive (9-ft DC, 6-ft AC Cord) ........................................................ 48V/17A PowerDrive (12-ft DC, 9-ft AC Cord) ...................................................... 48V/17A PowerDrive (20-ft DC, 9-ft AC Cord) (includes items 4 through 20) ....... Bushing, DC Cord ............................................................................................. Fuse Assembly ................................................................................................. Rectifier with Heatsink Assembly ...................................................................... Bushing, AC Cord ............................................................................................. Transformer, Battery Charger ........................................................................... Case Assembly ................................................................................................. Ammeter ........................................................................................................... Relay, 48-Volt .................................................................................................... Cord, AC, 80-Inch (203 cm) .............................................................................. Cord, AC, 108-Inch (274 cm) ............................................................................ Cord, DC, 113-Inch (287 cm) ............................................................................ Cord, DC, 154-Inch (391 cm) ............................................................................ Cord, DC, 250-Inch (635 cm) ............................................................................ Wire Assembly Kit ............................................................................................. Assembly, Voltage Suppressor ......................................................................... Screw, #10 X 0.50 Phillips Pan-Head ............................................................... Circuit Breaker, 15-Amp/120-Volt ...................................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 1 Note: Level 1 Battery Charger part numbers include one AC and one DC cord. They do not include all of the level 2 cords listed. 2007 DS Golf Cars Illustrated Parts List Page 15-5 15 G E D 15 G 19 E D 20 5 12 7 15 18 13 17 16 19 8 9 4 3 C lu b C ar R 14 10 11 6 000352-001 Page 15-6 2007 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER (MODEL 18780), EXPORT 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 101831503 101831504 1012098 1012101 1015914 1015917 101828501 101828901 101828902 101831701 **** 101838201 101838301 101838401 101838501 101838601 101838701 101914401 N/A 7577 2 3 QTY 4 Battery Charger, 48-Volt DC (8.5-ft DC, 6-ft AC) ................................................... Battery Charger, 48-Volt DC (12-ft DC, 9-ft AC) (includes items 3 through 20) .... Bushing, DC Cord ............................................................................................. Fuse Assembly ................................................................................................. Rectifier with Heatsink Assembly ...................................................................... Bushing, AC Cord ............................................................................................. Ammeter ........................................................................................................... Cord, DC, 113-Inch (287 cm) ............................................................................ Cord, DC, 154-Inch (391 cm) ............................................................................ Cord, AC, 80-Inch (203 cm), without Plug ........................................................ Cord, AC, 118-Inch (203 cm), without Plug ....................................................... Transformer, Export Battery Charger ................................................................ Relay, Export Charger ....................................................................................... Circuit Breaker .................................................................................................. Kit, Wire Assembly ............................................................................................ Four-Position Switch ......................................................................................... Mounting Bracket, Relay ................................................................................... Assembly, Voltage Suppressor ......................................................................... Case, Charger ................................................................................................... Screw, #10 X 0.50 Phillips Pan-Head ............................................................... 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 10 **** Special order item available upon request. Note: Level 1 Battery Charger part numbers include one AC and one DC cord. They do not include all of the level 2 cords listed. 2007 DS Golf Cars Illustrated Parts List Page 15-7 15 G E D 15 G 18 E D 19 16 17 14 5 15 11 13 12 9 15 6 7 4 3 C lu b C ar R 10 8 21 20 Page 15-8 000353-001 2007 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER (MODEL 20310), EUROPEAN 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 101956201 101956202 1012098 1012101 1015914 101828901 101828902 101838401 101838601 101973501 101976601 101987501 N/A N/A **** **** **** **** 7577 101958201 101958301 2 3 QTY 4 Battery Charger, 48-Volt w/ 4-Position Switch (8.5-ft DC) ..................................... 1 Battery Charger, 48-Volt w/ 4-Pos. Switch (12-ft DC) (includes items 3 through 19) 1 Bushing, DC Cord ............................................................................................. 1 Fuse Assembly ................................................................................................. 1 Rectifier with Heatsink Assembly ...................................................................... 1 Cord, DC, 113-Inch (287 cm) ............................................................................ 1 Cord, DC, 154-Inch (391 cm) ............................................................................ 1 Circuit Breaker .................................................................................................. 2 Four-Position Switch ......................................................................................... 1 Receptacle, AC Cord ........................................................................................ 1 Ammeter with Mounting Bracket ....................................................................... 1 Relay ................................................................................................................. 1 Wire, Jumper ..................................................................................................... 1 Case, Charger ................................................................................................... 1 Transformer, European Battery Charger ........................................................... 1 Suppressor, AC Voltage .................................................................................... 1 Assembly, Wire ................................................................................................. 1 Limiter, Current ................................................................................................. 1 Screw, #10 X 0.50 Phillips Pan-Head ............................................................... 10 Cord, UK, AC, Battery Charger ............................................................................. 1 Cord, European AC, Battery Charger ................................................................... 1 **** Special order item available upon request. Note: Level 1 Battery Charger part numbers include one AC and one DC cord. They do not include all of the level 2 cords listed. 2007 DS Golf Cars Illustrated Parts List Page 15-9 15 G E D 15 G E D MAINTENANCE AND SERVICE TOOLS 16 G E D 16 G E D Loctite® AC PE CE DA LE L RAT HE O IG R HT 1 2 4 3 7 6 5 8 9 BR EQ A K U E AL C IZ AB AT L IO E N BR AK H EP EI E G DA H L T 15 14 11 10 12 13 CALIBRATION & TEST MODULE INSTRUCTIONS SPEED CONTROL SET POWER SWITCH TO "ON". TEST PEDAL CIRCUIT POT CALIBRATION: SET MODE SWIT CH TO "PO T". CHECK INTERNAL 4.30.03 VOL T SIGNAL BY PRESSING "TEST" BUTTON. CON NECT TEST SOCKET TO POT PLUG, CONNECT GREEN LEAD TO GREEN/ WHITE POT LIMIT SWIT CH LEAD, CONNECT BLUE LEAD TO BATTERY POSITIVE. ILLUMINATION OF THE L.E .D. INDICA TES A CLOSED PEDAL LIMIT SWIT CH, 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 MO TOR SPEED SENSOR PLUG,ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICA TING SPEED SENSOR IS FUNCTIONAL. SEE OPERATING INSTRUCTIONS FOR MORE DETAIL POWER ON OFF R Club Car 16 Page 16-2 MODE SSAM POT 17 2007 DS Golf Cars Illustrated Parts List 18 19 MAINTENANCE AND SERVICE TOOLS ITEM PART NO. QTY DESCRIPTION 1 2 3 DIESEL QTY GAS QTY ELEC 4 G The following tool list includes all tools available from Club Car for maintenance and service procedures for gasoline, electric, and/or diesel vehicles, both past and present models. Be sure to carefully examine the tool list for applicability to your vehicle before ordering. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 101871001 101813202 101641202 101831901 1014305 1011767 1016417 1016416 1012811 1012812 1013582 102555501 102249901 **** **** 101887101 101808401 102562401 102686101 Accelerator Pedal Adjustment Tool ................................................. Adhesive, Guide Ring, 3-Gram Tube .............................................. Arbor ............................................................................................... 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 .................................................. Brake Adjustment Tool (used only on vehicles with manually adjusted mechanical brakes) ........................................... Brake Cable Release Tool .............................................................. Brake Pedal Adjustment Tool Kit (used for the Carryall Electric Industrial Truck only) (includes items 14 and 15)............................. Brake Pedal Adjustment Tool ...................................................... Brake Pedal Tension Tool ........................................................... Calibration Test Module .................................................................. Cam Installation Tool ....................................................................... Charger Bezel Tool ......................................................................... Clutch Removal Tool (for 4x4 vehicles)............................................................................. E D 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. **** 16 Special order item available upon request 2007 DS Golf Cars Illustrated Parts List Page 16-3 16 G G IN N R A W E D 21 24 23 22 27 26 25 20 28 30 29 32 31 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). POWER ON OFF R Club Car PART #17075 33 38 Page 16-4 39 36 35 34 40 2007 DS Golf Cars Illustrated Parts List 41 42 37 43 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 20 21 22 23 24 25 26 27 28 1014510 1014498 1014496 1014497 1014508 1014507 1015524 101809101 102601501 29 102603501 30 102605201 31 102606101 32 102607501 33 34 35 36 37 38 39 40 41 42 43 101831801 101641002 1011273 102773801 102773901 102774101 102774101 102675401 102774201 102774301 102774401 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC 4 Clutch Tool Kit (includes items 21 - 27) ........................................... Clutch Alignment Tool (for pre-unitized transaxle vehicles built prior to 1997 model year) ...................................... Drive Clutch Puller (for Kawasaki engines only) ......................... Drive Clutch Hub Puller (for Kawasaki engines only) ................. Driven Clutch Cam Puller (for Kawasaki engines only) .............. Driven Clutch Puller Plug (for Kawasaki engines only) ............... Drive Clutch Holder Tool Assembly (for Kawasaki engines only) Press Weldment (for Kawasaki engines only) ............................ Drive ClutchFixed Sheave Tool (for 4x4 vehicles).............................................................................. Driven Clutch Spring Compression Base (for use with items 30 and 31) (for 4x4 vehicles) ................................................................ Driven Clutch Spring Compression Collar (for use with items 29 and 31) (for 4x4 vehicles) ................................................................ Driven Clutch Spring Compression Nut (for use with items 29 and 30) (for 4x4 vehicles) ................................................................ Drive Clutch Spider Removal Tool (for 4x4 vehicles).............................................................................. Communication Display Module ..................................................... Compression Gauge and Adapter .................................................. Continuity Tester ............................................................................. Cutter, Valve Seat, #122 .................................................................. Cutter, Valve Seat #115.................................................................... Wrench, T, #505 ............................................................................... Adapter, T-Wrench ........................................................................... Cutter, Valve Seat, 60 Degree (requires item 51) (for Honda GX620 Gasoline Engines) ............................................ Pilot, 6.6 MM .................................................................................... Pilot, 6.62 MM .................................................................................. Pilot, 6.65 MM .................................................................................. G 1 E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 D 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. 2007 DS Golf Cars Illustrated Parts List 16 Page 16-5 16 G E D 44 45 46 47 48 49 50 51 2 56 57 3 54 52 53 58 Page 16-6 2007 DS Golf Cars Illustrated Parts List 59 60 61 Liquid Gasket 55 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 44 45 46 47 48 49 1012151 1016627 102669901 1016418 101933101 102169401 50 51 52 1011478 1013593 102248803 53 102248804 54 55 56 57 58 59 59 59 59 59 59 59 59 59 59 60 61 102251501 102241502 102241501 101928701 102243402 101997201 101997207 101997212 101997211 101997205 101997209 101997204 101997203 101997206 101997202 102562301 102587201 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC 1 1 1 4 Dry Moly Lubricant .......................................................................... Flywheel Puller Kit (for Kawasaki Engines) .................................... Gauge, Carburetor Float Level (for Honda GX620 Gasoline Engines) ............................................ Gear Yoke ....................................................................................... Governor Shaft Installation Tool (for Kawasaki Engine Vehicles) ... Hydraulic Brake Adjuster (for Turf/CA 272/472, Pioneer/XRT 1200, Bobcat 2100, HUV 4213) ................................................................ Hydrometer ..................................................................................... Internal Retaining Ring Pliers .......................................................... IQ Display Module (IQDM) Kit (for IQ System vehicles only) .......... (includes items 54 and 55) IQ Display Module (IQDM-P) Kit (for IQ System vehicles only) ....... (includes items 54 and 55) Adaptor, Cable ............................................................................ IQDM Series 2 Cable .................................................................. IQDM Series 1 Cable (replacement) ............................................... Liquid Gasket (transaxle case) ....................................................... Moly-Teflon Lubricant (4-oz. (113-gram) tube) ................................ Paint, Touch-Up – Beige* ................................................................ Paint, Touch-Up – Black* ................................................................ Paint, Touch-Up – Burgundy* .......................................................... Paint, Touch-Up – Classic Blue (Navy)* .......................................... Paint, Touch-Up – Dark Gray* ......................................................... Paint, Touch-Up – Dark Green* ...................................................... Paint, Touch-Up – Gray* ................................................................. Paint, Touch-Up – Red* .................................................................. Paint, Touch-Up – Royal Blue (Pacific Blue)* ................................. Paint, Touch-Up – White* ................................................................ Paint, Precedent Underbody – Gray ................................................ Paint Pen, Touch-Up, Precedent Underbody – 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 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. * Item 59 is not for use on Surlyn® body material, which is used on Precedent vehicles. 2007 DS Golf Cars Illustrated Parts List G E 1 1 1 1 16 Page 16-7 D 16 G E D 63 62 66 65 64 Safety First Never use a vehicle that is unsafe. Inspect each day. Inspect GOOD NEED(S) ATTENTION • Brakes • Park Brake • Steering • Accelerator • F & R Selector • Reverse Buzzer • Key Switch • Speeds • Tires • Bag Straps and Buckles Other Mechanical Problems • Unusual Noise • Will Not Run • Stopped on Course • Other: • • • Damage • Right Side • Left Side • Front • Rear • Other: ______________ No Damage NEED(S) ATTENTION Cleanliness • Seats • Floor Mat • Dash Compartments • Bag Well • Beverage Holders • Overall Appearance: ___________________ Date: _____________ Inspected By: _________________ Car No. ___________ (Over) CCI 1018231 69 68 67 71 70 72 AM10753 ON OFF STR SPK MAX MIN GAS DSL GAS/DIESEL TACHOMETER 73 77 Page 16-8 82 2007 DS Golf Cars Illustrated Parts List 76 75 74 83 84 85 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 62 63 64 65 66 67 68 69 1016414 1016415 102668801 1012549 1012560 101823101 1012809 102330901 70 71 72 73 74 75 76 77 78 1014264 1014259 102061201 AM10753 AM10771 1014162 1014161 1014115 101611003 79 AM11804 80 AM11805 81 82 83 84 85 AM1220301 1016413 102674601 101641201 102674401 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC 4 Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) . Piston Ring Pliers (for Kawasaki Engines) ...................................... Puller, Special Use (for Kubota D722 Diesel Engines) .................... Retaining Ring Pliers, 45° External ................................................. Retaining Ring Pliers, 90° Internal .................................................. Safety First Card (50 per pack) ....................................................... Seal Puller ....................................................................................... Spanner Wrench (for coil over shock front suspension vehicles only) ............................................................... Steering Column Bearing Press Tool .............................................. Steering Column Retaining Ring Tool ............................................. Steering Wheel Puller Tool .............................................................. Tachometer (includes gasoline engine pick up lead only) ............... Tachometer Diesel Probe (for use with item 73) ............................. Transaxle Axle Seal Tool ................................................................. Transaxle Pinion Seal Tool .............................................................. Transmission Tool Kit ...................................................................... Tune-Up Kit, All OHV (for Kawasaki Engines) (includes air filter, spark plug, oil filter, fuel filters) (not shown) .................................... Tune-Up Kit, Gx620 (for Honda Engines) (includes air filter, spark plug, oil filter, fuel filters) (not shown) .................................... Tune-Up Kit, D722 (for Kubota Engines) (includes air filter, oil filter, fuel filters, water separator filter) (not shown) .................... Tune-Up Kit, Precedent (for FE290/350 Engines) (includes air filter, spark plug, oil filter, fuel filters) (not shown) ........................... Valve Clearance Adjuster Screw Holder (for FE290 engines only) . Valve Guide Driver (for Honda GX620 Gasoline Engines) ............................................ Valve Guide Reamer (FE290, FE350, and FE400 only) .................. Valve Guide Reamer, 6.6 mm (for Honda GX620 Gasoline Engines) ............................................ G 1 1 1 1 1 1 1 1 1 1 1 E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2007 DS Golf Cars Illustrated Parts List 16 1 1 1 1 1 Page 16-9 D 16 G E D 86 87 - 45 45 88 89 + WAVETEK V 5XL 1000 V OFF 500 200 200 20 200 2m 2 200 m 20 m 200 m 2000 k 200k 20k V ! MAX 1000 --750V 90 Page 16-10 200 A 2k ! COM 200nA FUSED 91 2007 DS Golf Cars Illustrated Parts List 92 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 86 87 88 89 90 91 92 1016552 1016551 1016553 1016554 101641101 1011480 102570401 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC 4 Valve Seat Cutter Guide .................................................................. Valve Seat Cutter T-Wrench ............................................................ Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) Valve Seat Cutter, 45°/30° (35 mm diameter) ................................. Valve Spring Compressor ................................................................ Volt Ohm Meter ............................................................................... Tool, Tensioning, Starter Generator (For Precedent vehicles) ........ 1 2007 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 16 G E D 1 Page 16-11 INDEX Part Number and Page AM10753 AM10771 AM10079 AM10080 AM10081 AM10419 AM10682 AM10724 CCX8506 16-9 16-9 6-9 11-5 11-5 10-7 2-3 7-5 15-3, 15-5 183 8-15, 10-3, 11-3 324 1-19 332 1-11, 1-13, 1-15, 1-19, 8-13, 9-3, 11-11, 12-11 334 4-9, 4-11, 5-3, 5-7, 7-15 357 5-11, 10-3 451 9-3, 13-3, 13-5, 13-7 705 6-13, 7-15 706 5-11 808 10-3 1028 1-17, 4-5 1032 4-5 1035 4-7, 5-7, 5-9 1241 1-3, 1-17, 4-5, 4-7, 4-9, 4-11, 6-7, 6-13, 6-15, 9-3, 13-3, 13-5 1242 4-7, 6-7, 6-13, 12-17 1308 5-9 1606 8-15 1620 1-7 1624 4-9, 4-11, 5-7, 5-11 2402 5-9 7048 5-13 7173 6-13, 6-15 7174 5-3, 6-13, 8-11, 9-3, 12-17, 13-3, 13-5, 13-7 7251 1-3 727102 2-3 7310 2-3 7330 11-7, 14-3 7335 11-5, 14-3 7336 14-3 7473 1-3, 1-5, 1-17, 4-5, 4-7, 4-9, 4-11, 6-7, 6-13, 6-15 7479 1-15, 1-17 7539 5-9 7540 5-7, 5-9 7555 5-7, 5-9 7569 5-17 7577 15-3, 15-5, 15-7, 15-9 7602 5-7, 5-9 7716 4-5, 4-9, 4-11 7818 1-17, 6-7 7847 1-9, 1-13, 9-3 7893 6-7, 11-11 7973 1-7 8056 6-9, 12-7 6-7, 6-9, 11-9, 12-7 6-7, 6-9, 11-9, 12-7 8067 5-13 8233 1-13, 1-15, 1-19, 4-9, 4-11, 8-3, 11-3, 11-9, 11-11, 12-11 8248 1-13, 1-15, 8-3, 11-9, 12-11 8251 1-13, 1-15, 11-11 8418 1-17 8450 10-3 8717 6-7, 11-3, 11-9 8745 5-11 8754 4-9, 4-11, 5-3, 5-7, 5-9, 5-11, 5-15, 5-17, 6-13 8755 5-11, 5-15, 5-17 8861 5-9 8990 5-7, 6-7, 12-7, 12-11, 12-17 1010124 5-11 1010138 5-9 1010145 5-15, 5-17 1010150 5-11 1010200 5-11 1010219 5-9 1010413 1-17 1010434 1-5, 1-17 1010435 1-3 1010543 1-11 1010577 7-15 1010805 4-5 1010829 4-7 1010850 4-3 1010877 4-5 8057 8058 1010878 1010921 1010927 1010932 1010933 1010934 1010954 1010974 1010984 1011014 1011017 1011019 1011084 1011229 1011273 1011280 1011291 1011382 1011394 1011402 1011411 1011415 1011418 1011466 1011478 4-5 1-17, 4-5 4-5 4-5 4-5 6-15, 13-3, 13-5, 13-7 6-7, 11-3, 11-9 5-17 2-3 1-3 1-3 1-7 4-13 6-9, 12-7 16-5 13-3, 13-5 11-7 1-7 1-3 4-5 13-3, 13-5 5-15, 5-17 4-5 4-3 16-7 1011480 1011652 1011694 1011697 1011700 16-11 1-11 4-9, 4-11 1-5, 5-3, 8-9, 8-11, 12-15 4-9, 4-11 1011734 4-13 1011767 16-3 1011779 4-7 101187702 4-5 1011930 5-7, 5-9 1011988 8-3 1012030 5-11 1012047 1-13, 1-15 1012098 15-3, 15-5, 15-7, 15-9 1012101 15-5, 15-7, 15-9 1012151 16-7 1012159 1-15 1012180 5-15, 5-17 1012181 5-15, 5-17 1012182 5-15, 5-17 1012285 8-11, 11-3, 11-11, 12-11, 12-17 1012295 6-7 1012303 5-11, 5-15, 5-17 1012304 5-15 1012324 5-15 1012328 6-15 1012333 11-11 1012382 6-5 1012412 1-13, 1-15 1012431 6-7, 6-9, 11-9, 12-7 1012466 5-3 1012467 5-7 1012505 6-9, 12-7 1012528 9-3, 12-17 1012549 16-9 1012560 16-9 1012565 5-5 1012566 5-5 1012571 7-15 1012594 11-9 1012604 5-3 1012605 5-3 1012649 8-3 1012711 11-3 1012714 11-5 1012740 11-5 1012741 11-5 1012747 11-5 1012748 11-5 1012752 11-3 1012809 16-9 1012811 16-3 1012812 16-3 1012830 6-13, 8-11, 9-3 1012836 10-7 1012896 11-3 2007 DS Golf Cars Illustrated Parts List Page i-1 INDEX 1012981 7-5 1012987 11-9 1013001 6-11 1013003 6-11 1013005 6-11 101301102 6-11 1013032 1-13, 1-15 1013035 5-7 1013042 5-7 1013044 5-7 1013051 5-7 1013052 5-7 1013061 11-3, 12-13 1013164 5-15, 5-17 1013207 5-17 1013343 1-7 1013344 1-7 1013494 1-7 1013531 4-7 1013582 16-3 1013587 11-9 1013589 6-7, 11-9 1013590 11-9 1013591 11-9 1013593 16-7 1013609 1013687 1013692 1013700 1013734 1013746 1013754 1013759 1013768 1013769 1013770 1013771 1013772 1013773 1013774 1013787 1013792 1013794 1013861 1013869 1013870 1013871 1013876 1013924 1013935 1013983 1014007 1014049 1014050 1014051 1014052 Page i-2 6-7 8-3 8-3 8-11 9-3, 12-17 8-3, 8-5, 8-9 1-17 11-3 11-7 11-7 11-7 11-7 11-7 11-7 11-7 11-7 11-7 11-7, 14-3 5-3 4-5 4-5 4-9, 4-11 4-5 4-3, 7-15 1-17 1-5 4-9, 4-11, 11-3 10-3 10-3 10-3 10-3 1014055 1014056 1014057 1014058 1014059 1014062 1014063 1014065 1014070 1014072 1014078 1014080 1014089 1014115 1014116 1014119 1014125 1014126 1014145 1014153 1014161 1014162 1014193 1014198 1014201 1014207 1014211 1014212 1014213 1014214 1014216 1014217 1014235 1014259 1014264 1014276 1014287 1014288 1014289 1014304 1014305 1014306 1014375 1014453 1014454 1014482 1014496 1014497 1014498 1014507 1014508 1014510 1014523 1014524 1014555 1014645 10-3 10-3 10-3 10-3 10-3 10-3 10-3 6-7, 10-3, 11-9 10-7 10-7 10-7 10-7 11-9 16-9 8-3 6-7 5-3 5-3 6-7, 11-9 4-3 16-9 16-9 1014727 1014771 1014807 1014808 1014928 1014947 1014948 1015032 11-7 3-3, 3-5 13-3, 13-5, 13-7 11-7 5-3 5-3 1015405 6-7 1015426 8-13 101547601 3-3 1015524 16-5 1015525 1-13, 1-15 1015545 5-3 1015583 5-11, 5-15, 5-17 1015597 5-7, 5-9, 5-13 1015649 7-3 101570501 2-3 101570507 2-3 101570512 2-3 101570513 2-3 1015707 2-3 1015720 6-9, 12-7 1015737 6-5, 6-7 1015741 6-7 1015752 6-7, 8-13, 12-9 1015814 9-3 101584502 8-11 1015878 6-7 1015914 15-5, 15-7, 15-9 1015917 15-5, 15-7 1015920 6-5, 6-13 1015932 6-13 1015969 7-3 1016003 8-3, 8-5 1016074 6-13 1016103 8-9 101611003 16-9 5-3 5-3 5-3 5-3 5-9 16-9 16-9 5-11 10-3 5-3, 6-15, 10-3, 12-17 6-11 12-15 16-3 1-13, 1-15 6-15 10-3 10-7 1-17 16-5 16-5 16-5 16-5 16-5 16-5 8-3 8-3 5-15, 5-17 1-7 2007 DS Golf Cars Illustrated Parts List 11-9 2-3 6-7, 11-9 6-7 8-3 12-17 6-7, 12-17 1-13, 1-15 101503202 1-7 1015064 11-9 1015072 12-15 1015075 1-3, 1-17 1015137 8-3, 8-5, 8-9 1015139 8-3, 8-5 1015143 8-3, 8-5 1015188 8-3, 8-5 101524001 6-13 1015330 7-9, 9-3 1015332 6-5, 7-3 1015371 6-7 1015372 6-7 1015373 6-7 1016154 1016156 1016181 5-5 5-5 5-3 1016183 5-3 INDEX 1016201 10-3, 11-9 1016203 10-5 1016214 5-5 101621601 3-3, 3-5 1016219 5-5 1016263 5-3 1016269 5-3 1016289 10-3 1016337 11-5 1016338 11-5 1016341 11-3 1016342 11-9 1016346 5-9 1016349 5-9 1016350 5-9 1016353 5-9 1016379 1-5 1016384 5-11 1016385 5-9 1016450 7-9 1016451 7-9 1016452 7-9 1016453 7-11 1016454 7-11 1016455 7-5 1016456 7-3, 7-5, 7-11 1016457 7-7 1016458 7-9, 7-11 101645901 7-13 101645902 7-13 101645903 7-13 1016460 7-13 101646101 7-13 101646102 7-13 101646103 7-13 1016467 7-7 1016469 7-13 1016470 7-13 1016386 5-11 1016387 5-11 1016389 5-11 101641002 16-5 101641101 16-11 101641201 16-9 101641202 16-3 1016413 16-9 1016414 16-9 1016415 16-9 1016416 16-3 1016417 16-3 1016418 16-7 101642572 8-7 101642575 8-7 101642578 8-7 101642580 8-7 101642582 8-7 1016429 7-7 1016430 7-9 1016431 7-9 1016471 1016472 1016473 1016432 1016435 1016436 1016437 1016438 1016439 1016440 1016441 1016442 1016443 1016444 1016445 1016446 1016447 1016448 1016449 7-7, 11-3 7-7 7-9 8-7 8-9 8-9 7-9, 8-9 8-9 7-9 7-3 8-9 7-5 7-9, 7-11 7-9 7-9 7-9 7-9 7-11 7-7 1016474 7-9 101647501 7-13 101647502 7-13 1016479 7-9 1016480 8-9 101648102 8-9 101648203 7-7 1016483 7-9 1016484 7-7 1016486 8-7 1016489 7-9 101649002 8-9 1016493 7-5 1016494 7-11 1016496 7-11 1016497 7-5 1016499 8-7 1016501 8-7 1016502 7-7 1016505 7-5 1016506 7-11 1016507 7-3 1016509 7-13 1016510 7-11 1016513 11-3 101651401 2-3 101651407 2-3 101651412 2-3 101651413 2-3 1016516 7-13 1016517 7-9 1016519 7-9 1016520 7-11 1016521 7-11 1016523 7-9 1016524 7-3 1016525 7-3 1016526 7-3 1016531 7-3 1016532 7-13 1016533 7-13 1016535 7-11 1016536 7-3 1016537 7-7 1016538 7-11 1016539 7-3 1016541 7-13 1016542 7-9 1016544 7-5, 7-9, 7-11 1016545 7-9 1016546 8-11 1016547 7-3, 7-13, 8-9 1016548 7-5 1016549 7-9 101655001 7-13 101655002 7-13 101655003 7-13 101655004 7-13 101655005 7-13 101655006 7-13 101655007 7-13 101655008 7-13 101655009 7-13 1016551 16-11 1016552 16-11 1016553 16-11 1016554 16-11 1016558 7-13 1016559 7-13 1016560 7-9 1016561 7-5 1016562 7-5, 7-13 1016563 7-9 1016564 7-11 1016565 7-11 1016566 7-9 1016567 7-11 1016568 7-13 1016569 7-9 1016570 7-7 1016571 7-13 1016572 8-9 1016576 7-7 1016578 7-5 1016579 7-5 1016580 7-13 1016581 7-7 1016582 8-9 1016583 7-9 1016584 7-11 2007 DS Golf Cars Illustrated Parts List Page i-3 INDEX 1016585 8-7 1016586 7-5 1016587 7-5 1016588 7-5 101660404 1-7 1016622 5-3 1016627 16-7 1016630 6-9 1016663 5-5 1016672 11-7 1016801 10-3 1016849 6-9, 12-7 1016851 6-9, 12-7 1016859 6-9, 12-7 1016868 1-3 1016874 1-5 1016875 1-5 1016876 1-5 1016883 6-13 1016916 1-11 101692501 1-3 101692502 1-3 101692504 1-3 101692506 1-3 101692509 1-3 101692510 1-3 101692511 1-3 101692512 1-3 101692513 1-3 101692514 1-3 101692515 1-3 101692601 1-13 101692602 1-13 101692604 1-13 101692606 1-13 101692609 1-13 101692610 1-13 101692611 1-13 101692612 1-13 101692613 1-13 101693301 1-15 101693302 1-15 101693304 1-15 101693306 1-15 101693309 1-15 101693310 1-15 101693311 1-15 101693312 1-15 101693313 1-15 101693901 1-3 101693902 1-3 101693904 1-3 101693906 1-3 101693908 1-3 101693909 1-3 101693910 1-3 Page i-4 101693911 1-3 101693912 1-3 101693913 1-3 101693914 1-3 1016947 11-9 1016952 1-9 101696201 1-15 101696202 1-15 101696204 101696206 101696208 101696209 101696211 101696213 101696215 101696216 101696217 101696218 101696219 1-15 1-15 1-13 1-13 1-13 1-13 1-13 1-13 1-15 1-15 1-13 101696220 101696221 101696222 1-13 1-13 1-15 101696223 1-15 101696224 1-15 1016967 1-3 1017029 4-5 101706702 1-5 1017079 1-5 1017080 1-3 1017082 11-3 101708301 1-9 1017141 1-13, 1-15 1017203 8-3 1017221 7-3 1017226 5-3 1017231 11-3 1017266 5-9 1017273 5-5 1017327 10-7 1017378 4-9, 4-11 1017380 4-9, 4-11 1017424 4-9, 4-11 1017448 7-5 1017455 7-5 1017456 7-7 1017461 8-7 1017466 8-9 1017507 7-7 101768202 1-5 1017686 10-7 1017689 9-3 101769302 2-3 1017696 4-9, 4-11 1017705 12-13 1017748 1-13, 1-15 1017774 1-17 2007 DS Golf Cars Illustrated Parts List 1017814 1-15 1017815 1-15 101791101 4-3 1017936 1-13, 1-15 1017944 13-3, 13-5 1017947 13-3, 13-5 1017948 13-3 1017949 13-3, 13-5 1017950 13-3, 13-5 1017953 13-3, 13-5 101795701 12-5, 12-15 101796201 4-9, 4-11 101796501 12-13 101796801 12-13 101801001 12-13 101802101 12-13 101802201 15-5 101802202 15-5 101802203 15-5 101802204 15-3 101802205 15-3 101802206 15-3 101804301 101805701 101808401 8-13 8-15 16-3 101809101 101811401 101811501 101811901 101812301 101813001 101813202 101815501 101815502 101816301 101816501 101816502 101817401 101818801 101819701 101820201 101821301 101821501 101823101 101823201 101823301 101823302 101823801 101823901 101824001 101824002 101824401 16-5 8-15 8-15 8-13 8-13 8-13 16-3 4-3 4-3 4-3 4-3 4-3 4-9, 4-11 4-9 15-5 8-9 6-7 8-13 16-9 4-3 4-3 4-3 4-3 4-3 4-3 4-3 8-3, 8-5 3-3, 3-5 12-7 6-9 7-15 101825101 101826201 101826301 101827101 INDEX 101828902 101828903 101828904 101828905 101828906 101830601 101830701 101831101 101831503 101831504 101831701 101831801 101831901 101832001 101832101 101832202 101832302 101832701 101833201 101833401 101833601 101833701 101833902 6-7 12-17 15-5 15-5, 15-7 15-3, 15-5 15-3, 15-5 15-3, 15-5 15-5, 15-7, 15-9 15-5, 15-7, 15-9 15-5 15-3 15-3 15-3 6-9, 12-7 6-9, 12-7 15-5 15-7 15-7 15-7 16-5 16-3 12-13 7-15 8-11 8-11 7-15 7-15 10-7 11-3 6-11 10-3 101834001 101834502 101834601 101834801 101835601 101836201 101837101 101837301 101838201 10-7 6-9, 12-7 7-15 11-3 1-19 10-7 8-13 6-5, 6-13 15-7 101871001 101874901 101875001 101875101 101875201 101875301 101875401 101875501 101875601 101875701 101875802 101876001 101876202 101876301 101876402 101876501 101877601 101877701 101878101 101878201 101878302 101879001 101879401 101879501 101879601 101879701 101879801 101879901 101880001 101880101 101880201 101880301 101881101 101881701 101884801 101886101 101887101 101887601 101889301 101889401 101838301 101838401 101838501 101838601 101838701 101850301 101851101 101855002 101855801 101856002 101856102 101856201 101859301 101861901 101862001 101869302 15-7 15-7, 15-9 15-7 15-7, 15-9 15-7 8-15 6-9, 12-7 12-11 11-11 12-11 6-7 8-15 9-3 4-9, 4-11 4-11 6-11 101890001 101890101 101890201 101890501 101890601 101890901 101891001 101891301 101891401 101891501 101891601 101891901 101892001 101892201 101892301 101892401 101827601 101827801 101828301 101828501 101828601 101828801 101828802 101828901 16-3 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 4-5 5-7 6-11 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 7-5 8-13 7-15 11-3 16-3 7-3, 8-9 6-5, 6-7 11-5 11-5 11-3 11-3 11-3 11-3 11-7 11-7 11-3 11-7 11-7 11-5 11-5 11-5 11-5 11-5 11-5 101892501 101892601 11-5 11-5 101892701 101892901 101893201 11-7 11-3 11-5 101893801 101893901 101894901 11-3 11-5 12-13 101895401 101895501 101896501 101896901 101897001 101897201 101897401 101897601 101898001 101900801 101900901 101903101 101903601 101903701 101904101 101905601 101906901 101908101 101908401 101908601 101908701 101909201 101909301 101909401 101909501 101909701 101910401 101910501 101912401 101914401 101915201 101915401 101915501 101915601 101915701 101915801 101916501 101916701 101921501 101922101 101922201 14-3 14-3 6-11 8-3, 8-5 14-3 14-3 14-3 14-3 6-15 4-7, 5-15 6-9 5-11 14-3 14-3 1-13, 1-15 8-7 14-3 12-11 12-11 3-5 12-17 7-5 7-5 7-5 7-5 7-3 1-17, 12-17 11-7 4-13 15-5, 15-7 3-3 7-11 7-13 7-3 7-5 7-5 10-3 6-13, 10-3 8-13 8-15 12-9, 12-11, 13-3, 13-5, 13-7 8-13 14-3 14-3 101922301 101922501 101923001 7-13 12-11 14-3 101923201 14-3 101917601 101917701 101920101 2007 DS Golf Cars Illustrated Parts List Page i-5 INDEX 101923501 101923701 101923901 101925701 101926901 101927101 101927201 101927301 101927501 101927601 101927701 101927901 101928001 101928101 101928301 101928601 101928701 101929801 101931501 101932401 101932501 101932601 14-3 14-3 14-3 8-13 11-3 11-3 11-3 11-3 11-5 11-5 11-5 11-5 11-5 11-5 11-7 11-3 11-3, 14-3, 16-7 10-3 3-5, 12-17 12-11 12-11 12-17 101932701 101933101 101935501 101936801 101939901 101942301 101951501 101953101 101953901 101954301 101956201 101956202 101958101 101958201 101958301 101959902 101960501 101960601 101971301 101972001 101972002 101972003 101972004 101972005 101972006 101972007 101972009 101972011 101972012 101972101 12-17 16-7 12-7 12-9 6-11 12-11, 13-3, 13-5, 13-7 11-11 4-7 7-3 1-11 15-9 15-9 8-15 15-9 15-9 3-5 3-3 3-3, 3-5 7-15 12-17 4-9, 4-11 8-13 16-7 16-7 16-7 16-7 16-7 16-7 16-7 16-7 16-7 16-7 14-3 101972201 14-3 101963401 101965205 101966901 Page i-6 101972801 101973101 101973201 101973501 101976601 101979101 101980801 101980901 101981001 101984801 8-13 8-7 8-7 15-9 15-9 11-9 11-5 11-5 11-5 5-3 101985502 101987501 101987602 1-11 15-9 1-11 101987701 101990801 101998211 8-3 4-7 1-11 101998212 101998214 101998215 101998501 102003201 102022101 102026001 102031901 102045901 102060511 102060512 102060514 1-11 1-11 1-11 1-11 8-3 4-7 4-9, 4-11 11-7 11-3, 11-11 1-17 1-17 1-17 102060515 102061201 102061301 102061302 102063901 102064601 102065501 102065901 102076701 102099101 102101001 102101101 102155501 102169401 102174201 102174202 102174204 102174205 1-17 16-9 1-19 1-19 1-19 1-19 1-19 7-15 1-17, 1-19 1-19 12-9 12-9 1-19 16-7 1-11 1-11 1-11 1-11 102186001 102186101 102186201 13-7 13-7 13-7 102186301 102186401 102186701 102186801 102186901 102187001 102187101 13-7 13-7 13-7 13-7 13-7 13-7 13-7 2007 DS Golf Cars Illustrated Parts List 102187201 102196901 102198301 102221201 102235201 102236601 102236703 102237001 102238301 102238302 102238304 102238305 102240104 102240501 102240601 102240701 102240801 102241501 102241502 102242101 102242401 102243402 102243403 102248803 102249901 102251501 102251901 102259801 102263601 102263701 102265501 102265601 102265701 102265901 102266001 102266101 102266501 102266601 102266701 102267001 102273201 102273301 102273401 102273501 102273601 102273701 102273801 102273901 102274001 102278001 102304701 102310701 102323101 102323201 102327801 102330901 13-7 12-11 1-19 1-5, 1-13, 1-15 13-3, 13-5, 13-7 1-17 1-17 1-17 1-17 1-17 1-17 1-17 13-5 12-17 12-17 12-17 12-17 16-7 16-7 10-7 1-17 16-7 13-3, 13-5, 13-7 16-7 16-3 16-7 13-3 12-17 12-17 12-17 13-3 13-3, 13-5 13-3, 13-5 13-3, 13-5 13-3, 13-5 13-3, 13-5 12-17 12-11 12-11 13-3, 13-5 15-3 15-3 15-3 15-3 15-3 15-3 15-3 15-3 15-3 5-3 7-9 1-5 4-5 4-5 13-3 16-9 INDEX 102336001 102336101 102353201 102353301 102353401 102354103 102354203 102355301 102356601 102356801 102357001 102357701 102453001 102453101 102511301 102511302 102540301 102555501 102562401 102569304 102570401 102601501 102603501 102605201 102606101 102607501 102668801 102669901 102674001 102674101 102674201 102674401 102674601 102675001 102675101 102675201 102675301 102675401 102686101 102704701 102704801 102704901 102705001 102706401 102711201 102771701 102777401 102806201 102806202 102832601 102852001 102886301 102886401 102886501 102886601 8-11 8-11 5-13 5-13 5-13 5-13 5-13 6-15 14-3 14-3 14-3 5-13 11-5 11-5 12-15 12-15 7-15 16-3 16-3 2-3 16-11 16-5 16-5 16-5 16-5 16-5 16-9 16-7 16-5 16-5 16-5 16-9 16-9 16-5 16-5 16-5 16-5 16-5 16-3 13-7 13-7 13-7 13-7 5-15, 5-17 6-7 14-3 12-15 12-17 12-17 12-15 12-17 14-3 14-3 14-3 14-3 102913301 12-5 103325501 103325601 103325701 103337601 13-5 13-5 13-5 13-5 A AC cord 15-3, 15-5, 15-7, 15-9 AC cord bushing 15-3 AC cord receptacle 15-9 accelerator bracket and bearing assembly 4-9, 4-11 accelerator cable 8-11 accelerator pedal 4-9, 4-11 accelerator pedal adjustment tool 16-3 accelerator pivot rod 4-9, 4-11 accelerator return spring 4-9, 4-11 accelerator rod 4-13 adapter cable (IQDM) 16-7 adhesive, guide ring 16-3 adjuster hydraulic brake 16-7 air box 8-13 air box top 8-13 air duct assembly 8-15 air filter 8-13 air intake hose 8-13 ammeter 15-3, 15-5, 15-7, 15-9 A-plate strap 5-9 A-plate, delta 5-9 arbor 16-3 arm governor 11-3 pivot 11-3 rocker 7-9 armature 6-11, 13-3, 13-5, 13-7 armrest 1-11 assembly accelerator bracket and bearing 4-9, 4-11 accelerator pivot rod 4-9, 4-11 air box 8-13 air box top 8-13 air duct 8-15 armature 6-11 axle 11-7 bearing, steering shaft 5-3 brake lever 4-3 brush connector 6-11 brush holder 6-11 carburetor 8-7 connecting rod 7-13 delta A-plate 5-9 delta shock and gear support 5-9 drive hub 10-3 driven clutch 10-7 driven clutch fixed-face 10-7 field coil 6-11 float 8-7 Forward/Reverse shifter 11-9 frame and field (motor) 13-7 fuel tank vent 8-3, 8-5 governor 11-5 idle screw 8-7 inner ball joint 5-7 kingpin 5-11 moveable-face 10-3, 10-7 pilot air screw 8-7 ratchet 4-5 score card plate 5-5 secondary clutch weight 10-3 steering shaft 5-3 steering wheel 5-5 axle 11-7, 14-3 axle shaft oil seal 11-7, 14-3 axle tube 14-3 B backing plate, brake 4-3 bag hoop 1-17 bag strap assembly 1-17 bag strap buckle 1-17 bag well protector 1-5 ball joint 4-5, 4-13, 5-7, 5-9, 11-11 ball joint, left-hand thread 5-7, 5-9 ball stud 6-7, 11-3, 11-9 ball, shifter 11-5 ball, steel pressure relief 7-7 band, RPM limiter mount 7-5 bar, drive 12-9 barb, vent 8-3, 8-5 barrel, plastic 1-5, 1-17 basket, sweater 1-17 battery charger 15-3, 15-5, 15-7, 15-9 battery charger case 15-3, 15-5, 15-7, 15-9 battery charger handle 15-3 battery charger transformer 15-3, 15-5, 15-7, 15-9 battery clamp 6-15 battery discharge machine 16-3 battery hold-down, 12-volt 12-15 battery terminal protector spray 16-3 battery thermometer 16-3 battery warning light 12-7 battery, 12-volt 6-15 battery, 12-volt, Trojan T1275, moist 12-15 battery, 12-volt, Trojan T1275, wet 12-15 bearing 14-3 ball (motor) 13-7 ball (steering pinion) 5-7 idler 10-3 inner axle tube 11-7, 14-3 2007 DS Golf Cars Illustrated Parts List Page i-7 INDEX lower pinion (steering) 5-7 needle 11-5 outer axle tube 11-7 pivot support 4-9, 4-11 steering shaft 5-3 thrust 5-11 bearing and oil seal remover 16-3 bearing driver set 16-3 bearing puller 16-3 bearing puller wedge 16-3 bearing retainer 13-3, 13-5 bearing seal 5-3 bearing seat 5-3 bell crank 6-7, 11-9 bellows 5-7 belt, drive 10-5 belt, starter/generator 6-13, 10-3 beverage holder 1-9 block, brake-mounting 4-5 block, fuse 6-7 body kick plate 1-13, 1-15 body, front 1-3 body, rear 1-13, 1-15 bolt, J- 12-15 boot, steering column 5-3 boot, switch 12-11 bottom, air box 8-13 box air 8-13 electrical component 6-7 steering gear 5-7 bracket 7-3 accelerator cable 8-11 adjustable starter/generator 6-13 governor cable 8-11 muffler mounting 9-3 oil filter mount 7-7 oil level switch 7-11 relay mounting 15-7 RPM limiter 7-5 shifter 11-3, 11-11 shock absorber 5-15, 5-17 shock mounting 5-15, 5-17 snubber 7-15 starter/generator mounting 6-13 steering column 5-3 steering column mounting 5-3 throttle spring return 8-9 Tow/Run switch 12-11 brake adjusting mechanism 4-3 brake adjustment tool 16-3 brake backing plate 4-3 brake cable 4-7 brake cable equalizer 4-7 brake cable hanger 4-7, 5-15, 5-17 brake cable release tool 16-3 Page i-8 brake cluster 4-3 brake drum 4-3 brake lever 4-3 brake mounting block 4-5 brake pedal 4-5 brake pedal adjustment tool 16-3 brake pedal pad 4-5 brake pedal tension tool 16-3 brake return spring 4-7 brake self-adjusting mechanism 4-3 brake shoe 4-3 brake spring 4-3 breaker, circuit 15-3, 15-5, 15-7, 15-9 breather 11-3, 14-3 brush 13-3, 13-5, 13-7 brush and screw set 6-11 brush box assembly 13-7 brush connector 6-11 brush holder 6-11 brush inspection port cover 6-11 brush port cover 6-11 brush rigging 13-3, 13-5, 13-7 brush spring 13-3, 13-5, 13-7 brush spring set 6-11 buckle, bag strap 1-17 bumper drive unit (motor) 13-3, 13-5, 13-7 front 1-3 front, kit 1-3 rear 1-5 rubber 4-5 side trim 1-5 spring return 4-9, 4-11 bumper mounting 1-5 bushing 10-3 AC cord 15-3 bronze 5-13 nylon 4-5 spindle 5-13 steel 5-11, 5-15, 5-17 urethane 5-9, 5-11, 5-15, 5-17 button, choke 8-15 button, drive 10-7 buzzer, reverse 6-9, 12-7 C cable accelerator brake 4-7 FNR shifter 8-11 11-11 governor 8-11 IQDM 16-7 transmission 11-11 cable retainer 11-11 calibration test module cam 2007 DS Golf Cars Illustrated Parts List 16-3 driven clutch 10-7 electrical component box 6-7 neutral lockout 11-9 cam installation tool 16-3 camshaft 7-11 canopy 1-19 canopy support 1-19 cap dust 12-11 fuel tank 8-3, 8-5 key switch 6-9, 12-7 spark plug 7-5 carburetor 8-7 carburetor float level tool 16-7 carburetor insulator 8-9 carburetor mounting gasket 8-9 card, safety first 16-9 case battery charger 15-3, 15-5, 15-7, 15-9 differential gear 11-7 FNR switch 12-11 gear 11-3, 14-3 rocker 7-9 charger bezel tool 16-3 charger, battery 15-3, 15-5 choke button 8-15 choke lever 8-15 choke lever guide 8-15 choke positioner 8-15 choke valve 8-13 circuit breaker 15-3, 15-5, 15-7, 15-9 clamp battery 6-15 cable retaining 8-11 hose 8-3, 8-5, 8-9, 8-13 muffler hose 9-3 clevis, upper delta 5-11 clip, score card 5-5 cluster idler gear 11-5 cluster, brake 4-3 clutch alignment tool 16-5 clutch pulley 10-3 clutch removal tool 16-3 clutch repair kit 10-7 clutch tool kit 16-5 clutch weight 10-3 clutch, drive 10-3 clutch, driven 10-7 coil, field 6-11 coil, ignition 7-5 collet 7-9 column, steering 5-3 communication display module 16-5 component box, electrical 6-7 compression gauge 16-5 compression lug 12-17 INDEX compression spring 8-15 compressor, piston ring 16-9 compressor, valve spring 16-11 connecting rod 7-13 connector, a- 6-11 connector, four-pin 12-11 connector, speed controller 12-17 continuity tester 16-5 controller cover 12-17 controller cover gasket 12-17 controller, motor speed 12-17 cord connector 7-11 cord set, DC 15-3 cord, AC 15-3, 15-5, 15-7, 15-9 cord, DC 15-5, 15-7, 15-9 counterbalance guide shaft 7-13 counterbalance weight 7-13 cover brush inspection port 6-11 brush port 6-11 controller 12-17 crankcase 7-11 dust 4-3, 5-3 electrical box 6-7 oil pump 7-7 screw head 1-7 steering column tube 5-3 cover plate 13-7 cowl 1-3 crank, bell 11-9 crankcase 7-13 crankcase cover gasket 7-9, 7-11 crankcase vent tube 8-9 crankshaft 7-13 crankshaft seal 7-11 crankshaft shim 7-13 C-type stop ring 5-7 cup holder 1-9 cup, spring 4-9, 4-11 current limiter 15-9 cushion, shock absorber 5-15, 5-17 cutter, valve seat 16-5, 16-11 D damper, RPM limiter 7-5 dash component 1-7 dash panel 1-7 DC cord 15-5, 15-7, 15-9 DC cord set 15-3 decal component cover 3-5, 12-17 dash warning 3-3, 3-5 driver/passenger 3-3 frame ground 3-3 motor braking 3-5 on/off 3-3, 3-5 operating instructions 3-3, 3-5 rotating parts 3-3 Tow/Run switch warning 3-5 delta A-plate 5-9 delta A-plate sub-assembly 5-9 delta shock and gear support 5-9 DF-terminal insulator 6-11 diesel tachometer probe 16-9 differential drive unit 14-3 differential gear 11-7, 14-3 differential gear case 11-7 differential housing 14-3 differential idler gear 11-7 differential pin 11-7 diode 6-7, 12-17 diode, rectifier 15-3 dipstick 7-3 door, access 1-13, 1-15 drain plug 7-7 drain plug gasket 7-7, 11-3 drink holder 1-9 drive bar 12-9 drive belt 10-5 drive button 10-7 drive clutch 10-3 drive clutch button 10-3 drive clutch fixed sheave tool 16-5 drive clutch fixed-face 10-3 drive clutch holder tool 16-5 drive clutch hub puller 16-5 drive clutch puller 16-5 drive clutch spider removal tool 16-5 drive clutch spring 10-3 drive clutch weight 10-3 drive hub 10-3 drive unit bumper 13-3, 13-5, 13-7 driven clutch 10-7 driven clutch button 10-7 driven clutch cam 10-7 driven clutch cam puller 16-5 driven clutch fixed-face assembly 10-7 driven clutch puller plug 16-5 driven clutch spring compression base tool 16-5 driven clutch spring compression collar tool 16-5 driven clutch spring compression nut tool 16-5 driver, drive clutch 10-3 drum, brake 4-3 dry moly lubricant 16-7 dust cap 12-11 dust cover 4-3, 5-3 E eccentric adjustment screw 5-11 E-clip 4-7 electrical box cover 6-7 electrical component box 6-7 end bell, commutator 6-11 end bell, output shaft 6-11 end cap, motor 13-3, 13-5, 13-7 end shield motor 13-3, 13-5 engine 7-3 engine mounting plate 7-15 engine shroud 7-3 engine valve spring 7-9 equalizer rod 4-7 equalizer, brake cable 4-7 exhaust system 9-3 exhaust valve 7-9 extrusion 12-17 F face, moveable 10-3, 10-7 fan housing 7-3 fan shroud 7-3 fan, flywheel 7-5 fender, inner 1-13, 1-15 field coil 6-11 field coil housing 6-11 fill plug 11-3 filter air 8-13 fuel 8-3 oil 7-7 fitting, thread-forming grease 5-7, 5-9, 5-13 fixed-face, drive clutch 10-3 fixed-face, driven clutch 10-7 float 8-7 floor mat 1-7, 1-13, 1-15 flywheel 7-5 flywheel fan plate 7-5 flywheel puller 16-7 FNR handle 11-9 FNR shifter base 11-9 FNR shifter cable 11-11 FNR switch case 12-11 foam, seat 1-11 fork, shift 11-5 Forward/Reverse shifter 11-9 frame and field assembly (motor) 13-7 front body 1-3 front body support 1-13, 1-15 front bumper 1-3 front bumper kit 1-3 front hub 5-13 front shock absorber 5-9 2007 DS Golf Cars Illustrated Parts List Page i-9 INDEX front spring retainer plate 5-11 F-terminal hardware 6-11 f-terminal insulator 6-11 fuel filter 8-3 fuel line 8-3, 8-5, 8-9 fuel pump, impulse 8-3 fuel tank 8-3, 8-5 fuel tank strap 8-3 fuel tank vent 8-3, 8-5 fuse 12-13, 15-5, 15-7, 15-9 10-amp 6-7 3/8-amp 12-13 charger 15-3 fuse block 6-7 G gasket 14-3 carburetor mounting 8-7, 8-9 controller cover 12-17 crankcase cover 7-9, 7-11 drain plug 7-7, 11-3 exhaust 7-9, 9-3 head 7-9 insulator 7-9, 8-9 liquid 11-3, 14-3, 16-7 oil pump 7-7 rocker case 7-9 seat 1-11 gasket kit, FE290 7-9 gauge, compression 16-5 gear case 11-3, 14-3 cluster idler 11-5 differential 11-7, 14-3 differential idler 11-7, 14-3 differential output 14-3 helical 7-13, 11-5, 11-7 spur 7-13, 11-5 synchro 11-5 gear yoke 16-7 governor 11-5 governor arm 11-3 governor cable 8-11 governor cable bracket 8-11 governor shaft installation tool 16-7 governor shield 8-9 grip, pencil 5-5 grommet 8-3, 8-5 guide choke lever 8-15 intake valve 7-9 valve seat cutter 16-11 guide ring adhesive 16-3 Page i-10 H handle, battery charger 15-3 handle, FNR 11-9 hanger, brake cable 4-7, 5-15, 5-17 hardware, F-terminal 6-11 harness, wire 6-5, 6-7, 12-5 head gasket 7-9 head, FE290 7-9 heatsink 15-3 heatsink and rectifier 15-5, 15-7, 15-9 helical gear 7-13, 11-5, 11-7 hill brake rod 4-5 hill brake weld assembly 4-5 hinge plate 1-11, 1-13, 1-15 hold-down, battery, 12-volt 12-15 holder, cup 1-9 hose, air intake 8-13 housing 2-pin 12-9 3-pin 12-9, 12-11, 13-3, 13-5, 13-7 4-pin 12-11 6-pin 12-17 differential 14-3 fan 7-3 field coil 6-11 hub 5-13 hub and spindle 5-13 hub, front 5-13 hub, synchronizer clutch 11-5 hubcap 5-13 hydraulic brake adjuster 16-7 hydrometer 16-7 joint ball 4-5, 4-13, 5-9, 11-11 left-hand thread ball 5-7, 5-9 K key crankshaft 7-5, 7-13 driven clutch 10-7 On/Off 6-9, 12-7 square 10-7 starter/generator 6-11 woodruff 11-3 key switch 6-9 key switch cap 6-9, 12-7 key switch, On/Off 12-7 kick plate, body 1-13, 1-15 kingpin 5-11 kit 2-pin housing 12-9 3-pin housing 12-9, 12-11, 13-3, 13-5, 13-7 4-pin housing 12-11 6-pin housing 12-17 accelerator pivot rod 4-9, 4-11 brake cable 4-7 brake pedal 4-5 brake pedal adjustment tool 16-3 brake shoe retainer 4-3 clutch repair 10-7 differential gear case 11-7 drive clutch button 10-3 drive clutch weight 10-3 driven clutch button 10-7 front hub replacement 5-13 impulse fuel pump rebuild 8-3 IQ display module (IQDM) 16-7 magnet and bearing 13-3, 13-5 motor brush 13-7 motor brush spring 13-7 motor cover plate 13-7 motor speed sensor 13-7 motor terminal hardware 13-7 neutral lockout cam 11-9 park brake latch 4-5 I idle screw assembly 8-7 idler bearing 10-3 idler gear, differential 14-3 ignition coil 7-5 inner frame snubber 7-15 input shaft 14-3 insert, synchronizer 11-5 instrument panel 1-7 insulator gasket 7-9, 8-9 insulator, carburetor 8-9 intake pipe 8-9 intake valve 7-9 intermediate shaft 14-3 intermediate steering shaft 5-3 internal retaining ring pliers 16-7 IQ display module (IQDM) 16-7 J J-bolt 12-15 jet, main 8-7 jet, pilot 8-7 2007 DS Golf Cars Illustrated Parts List park brake pedal 4-5 reverse buzzer 6-9, 12-7 shock absorber 5-15, 5-17 shock absorber cushion 5-15, 5-17 steering column rebuild 5-3 tune-up 16-9 L latch, air box 8-13 latch, park brake 4-5 L-bracket, motor 13-7 leaf spring 5-11, 5-15, 5-17 INDEX lever change 11-3 choke 8-13, 8-15 transmission shifter 11-3 light battery warning 12-7 oil 6-9 limit switch 6-7, 11-9 limiter current 15-9 RPM 7-5 line, fuel 8-3, 8-5, 8-9 link, rack and pinion drag 5-7 liquid gasket 11-3, 14-3, 16-7 low oil warning light 6-9 lubricant, dry moly 16-7 lubricant, moly-teflon 13-3, 13-5, 13-7, 16-7 lug nut 2-3 lug stud 5-13, 11-7, 14-3 lug, compression 12-17 M magnet and bearing kit 13-3, 13-5 magnet, speed sensor 13-3, 13-5, 13-7 main jet 8-7 main nozzle 8-7 mat, floor 1-7, 1-13, 1-15 MCOR 12-9 mechanism, brake adjusting 4-3 meter, volt ohm 16-11 module calibration test 16-3 communication display 16-5 moly-teflon lubricant 16-7 motor 48-volt 13-5 48-volt IQ 13-3, 13-7 motor armature 13-3, 13-5 motor brush 13-3, 13-5 motor brush kit 13-7 motor brush spring kit 13-7 motor bumper 13-3, 13-5, 13-7 motor end cap 13-3, 13-5, 13-7 motor end shield 13-3, 13-5 motor L-bracket 13-7 motor magnet, speed sensor 13-3, 13-5, 13-7 motor speed controller 12-17 motor speed sensor 13-3, 13-5, 13-7 motor speed sensor kit 13-7 motor stator shell and winding 13-3, 13-5 motor terminal hardware kit 13-7 mounting block, brake 4-5 moveable-face 10-3, 10-7 muffler hose clamp 9-3 N nameplate kit, amber 3-3, 3-5 needle bearing 11-5 neutral lockout cam 11-9 nozzle, main 8-7 nut, lug 2-3 O oil filler tube 7-3 oil filter 7-7 oil filter mount bracket 7-7 oil filter screen 7-11 oil filter screen plate 7-11 oil level sensor 7-11 oil level switch bracket 7-11 oil pump and rotor 7-7 oil pump cover 7-7 oil pump gasket 7-7 oil pump plate 7-7 oil seal 7-9, 7-13, 11-3, 11-5 oil warning light, low 6-9 O-ring 7-3, 7-9, 7-11, 7-13 spark 7-5 pole set 6-11 positioner, choke P pad accelerator pedal 4-9, 4-11 brake pedal 4-5 park brake 4-5 wear 1-5, 1-13, 1-15 paint, touch-up 16-7 park brake latch 4-5 park brake pedal 4-5 park brake rod sleeve 4-5 park brake spacer 4-5 park brake torsion spring 4-5 pawl 4-5 pedal, accelerator 4-9, 4-11 pedal, brake 4-5 pedal, park brake 4-5 pencil grip 5-5 pilot air screw 8-7 pilot jet 8-7 pin, differential 11-7 pin, piston 7-13 pinion, steering 5-7 pipe, intake 8-9 piston 7-13 piston ring 7-13 piston ring compressor 16-9 piston ring pliers 16-9 pivot arm 11-3 pivot support bearing 4-9, 4-11 plate backing (brake) 4-3 bumper mounting 1-5 cover 13-7 engine mounting 7-15 flywheel fan 7-5 front spring retainer 5-11 hinge 1-11, 1-13, 1-15 oil filter screen 7-11 oil pump 7-7 receptacle backing 12-13 score card 5-5 shackle 5-17 spring mounting 5-11 thrust 11-5, 11-7 pliers internal retaining ring 16-7 piston ring 16-9 retaining ring 16-9 plug 4-pin 12-11 6-pin 12-17 drain 7-7 driven clutch puller 16-5 fill 11-3 8-15 press weldment 16-5 protector spray, battery terminal puller bearing 16-3 clutch 16-3 drive clutch 16-5 drive clutch hub 16-5 driven clutch cam 16-5 flywheel 16-7 seal 16-9 special use tool 16-9 pulley clutch 10-3 starter-generator 6-11 pump, impulse fuel 8-3 push rod 7-9 16-3 R rack and pinion drag link 5-7 rack guide pressure spring 5-7 rack, steering 5-7 ratchet, park brake 4-5 reamer, valve guide 16-9 rear bumper 1-5 rear shock absorber 5-15, 5-17 rear spring shackle 5-15 receptacle 12-13 receptacle backing plate 12-13 receptacle, AC cord 15-9 rectifier diode 15-3 rectifier with heatsink 15-5, 15-7, 15-9 2007 DS Golf Cars Illustrated Parts List Page i-11 INDEX regulator, voltage 6-7 relay 15-7, 15-9 relay mounting bracket 15-7 relay, 48-volt 15-3, 15-5 remover, bearing and oil seal 16-3 resistor assembly 12-17 retainer accelerator pedal spring 4-9, 4-11 bearing 13-3, 13-5 brake shoe 4-3 cable 11-11 shock absorber cushion 5-15, 5-17 spring (drive clutch) 10-3 valve spring 7-9 retaining ring 5-3 retaining ring pliers 16-9 return spring bumper 4-9, 4-11 reverse buzzer 6-9, 12-7 rigging, brush 13-3, 13-5 rim, wheel, white 2-3 ring piston 7-13 retaining 5-3, 6-7, 10-3, 10-7, 11-9 snap 5-7, 7-9, 7-13 spiral backup 10-3 synchronizer 11-5 ring, C-type stop 5-7 rivet, blind push 1-3 rocker arm 7-9 rocker case 7-9 rocker case gasket 7-9 rocker shaft 7-9 rocker switch 12-11 rod accelerator 4-13 accelerator pivot 4-9, 4-11 connecting 7-13 crankshaft 7-13 equalizer 4-7 hill brake 4-5 push 7-9 shift 11-5 tie 5-9 rotor, oil pump and 7-7 RPM limiter 7-5 RPM limiter bracket 7-5 RPM limiter damper 7-5 RPM limiter mount band 7-5 S safety first card 16-9 score card clip 5-5 score card plate 5-5 screen, oil filter 7-11 screw, eccentric adjustment 5-11 screw, valve clearance adjuster 16-9 Page i-12 scuff guard kit, rear body 1-5 seal bearing 5-3 crankshaft 7-11 intake 8-13 lip 14-3 oil 7-9, 7-13, 11-3, 11-5, 11-7, 14-3 steering pinion dust 5-7 vertical socket dust 5-7, 5-9 seal puller 16-9 sealant 11-3, 14-3 seat spring 7-9 valve 7-7 seat back 1-17 seat back cap 1-17 seat bottom assembly 1-11 seat cover, vinyl 1-11 seat foam 1-11 seat gasket 1-11 seat, bearing 5-3 sensor, motor speed 13-3, 13-5, 13-7 sensor, oil level 7-11 sensor, speed 13-3, 13-5 set, brush and screw 6-11 set, pole 6-11 shackle plate 5-17 shackle, rear spring 5-15 shaft change 11-3 counterbalance guide 7-13 input 14-3 intermediate 14-3 intermediate steering 5-3 rocker 7-9 transmission 11-5 shield, governor 8-9 shift fork 11-5 shift rod 11-5 shifter base, FNR 11-9 shifter bracket 11-3, 11-11 shim, crankshaft 7-13 shock absorber cushion 5-15, 5-17 shock absorber cushion retainer 5-15, 5-17 shock absorber, front 5-9 shock absorber, rear 5-15, 5-17 shock mounting bracket 5-15, 5-17 shoe, brake 4-3 shroud, engine 7-3 shroud, fan 7-3 sleeve delta A-plate 5-9 governor 11-5 park brake rod 4-5 synchronizer 11-5 snap ring 5-7, 7-9, 7-13 2007 DS Golf Cars Illustrated Parts List snubber bracket 7-15 snubber, inner frame 7-15 socket 5-7, 5-9 solenoid, 12-volt 6-7 solenoid, 48-volt 12-17 spacer accelerator pivot rod 4-9, 4-11 park brake 4-5 spanner wrench 16-9 spark plug 7-5 spark plug cap 7-5 speed controller 12-17 speed controller connector 12-17 speed controller cover gasket 12-17 speed sensor 13-3, 13-5, 13-7 speed sensor magnet 13-3, 13-5, 13-7 speed sensor, motor 13-3, 13-5, 13-7 spindle 5-13 spindle and hub 5-13 spiral backup ring 10-3 spray, battery terminal protector 16-3 spring accelerator return 4-9, 4-11 brake 4-3 brake return 4-7 brush 6-11, 13-3, 13-5, 13-7 compression 5-5, 8-15 drive button 10-3 drive clutch 10-3 driven clutch 10-7 engine valve 7-9 extension return 8-13 forward/reverse cam 11-9 leaf 5-11, 5-15, 5-17 park brake torsion 4-5 rack guide pressure 5-7 shifter 11-5 steering shaft compression 5-3 synchronizer 11-5 throttle return 8-9 spring cup 4-9, 4-11 spring mounting plate 5-11 spur gear 7-13, 11-5 starter/generator 6-11 starter/generator belt 6-13, 10-3 starter/generator mounting bracket 6-13 starter/generator pulley 6-11 stator shell and winding 13-3, 13-5 steel bushing 5-11, 5-15, 5-17 steel pressure relief ball 7-7 steering column 5-3 steering column bearing press tool 16-9 steering column retaining ring tool steering gear box 5-7 steering pinion 5-7 steering pinion dust seal 5-7 16-9 INDEX steering rack 5-7 steering shaft assembly 5-3 steering shaft column 5-3 steering shaft compression spring 5-3 steering wheel 5-5 steering wheel puller tool 16-9 stem, valve 2-3 stiffener, flywheel side 7-15 strap, A-plate 5-9 strap, fuel tank 8-3 stud 7-15 ball 6-7, 11-3, 11-9 lug 5-13, 11-7, 14-3 support yoke (steering) 5-7 support, front body 1-13, 1-15 suppressor, voltage 15-5, 15-7, 15-9 sweater basket 1-17 switch four-position 15-7, 15-9 key 6-9, 12-7 limit 6-7, 11-9 rocker 12-11 Tow/Run 12-11 switch rubber boot 12-11 synchro gear 11-5 synchronizer clutch hub 11-5 synchronizer insert 11-5 synchronizer sleeve 11-5 synchronizer spring 11-5 system, exhaust 9-3 T 12-volt battery 6-15 12-volt solenoid 6-7 tachometer 16-9 tachometer probe, diesel tank, fuel 8-3, 8-5 tappet 7-11 16-9 terminal block 12-17 tester, continuity 16-5 thermometer, battery 16-3 thread-forming grease fitting 5-7, 5-9, 5-13 throttle return spring 8-9 throttle spring return bracket 8-9 thrust bearing 5-11 thrust plate 11-5, 11-7 tie rod 5-9 tie wrap 5-7, 6-7, 12-7, 12-11, 12-17 tire 2-3 tire and wheel assembly 2-3 tool accelerator pedal adjustment 16-3 belt tensioning, starter/generator 16-11 brake adjustment 16-3 brake cable release 16-3 brake pedal adjustment 16-3 brake pedal tension 16-3 cam installation 16-3 exhaust 7-9 fuel pickup tube carburetor float level 16-7 charger bezel 16-3 clutch alignment 16-5 cT-wrench 16-5 drive clutch fixed sheave 16-5 drive clutch holder 16-5 drive clutch spider removal 16-5 driven clutch spring compression base 16-5 driven clutch spring compression collar 16-5 driven clutch spring compression nut 16-5 governor shaft installation 16-7 puller, special use 16-9 steering column bearing press 16-9 steering column retaining ring 16-9 steering wheel puller 16-9 transaxle axle seal 16-9 transaxle pinion seal 16-9 transmission 16-9 valve guide driver 16-9 valve seat cutter 16-5 tool kit, clutch 16-5 touch-up paint 16-7 Tow/Run switch 12-11 Tow/Run switch bracket 12-11 transaxle 14-3 transaxle axle seal tool 16-9 transaxle housing 14-3 transaxle pinion seal tool 16-9 transaxle, unitized 11-3 transformer, battery charger 15-3, 15-5, 15-7, 15-9 transmission cable 11-11 transmission shaft 11-5 transmission tool 16-9 trim cowl 1-3 tube crankcase vent 8-9 oil filler 7-3 tune-up kit 16-9 T-wrench tool 16-5 8-3, 8-5 intake 7-9 reed 7-9 valve clearance adjuster screw 16-9 valve guide driver tool 16-9 valve guide reamer 16-9 valve guide, intake 7-9 valve seat 7-7 valve seat cutter 16-5, 16-11 valve seat cutter guide 16-11 valve seat cutter tool 16-5 valve seat t-wrench 16-11 valve spring compressor 16-11 valve spring retainer 7-9 valve stem 2-3 vent barb 8-3, 8-5 vertical socket dust seal 5-7, 5-9 volt ohm meter 16-11 voltage regulator 6-7 voltage suppressor 15-5, 15-7, 15-9 W warning light, low oil 6-9 wear pad 1-5, 1-13, 1-15 wedge, bearing puller 16-3 weight clutch 10-3 counterbalance 7-13 secondary clutch 10-3 weldment press 16-5 wheel 2-3 wheel and tire assembly 2-3 wheel rim, white 2-3 wheel, steering 5-5 windshield frame 1-19 windshield frame pad 1-19 wire harness 6-5, 6-7, 12-5 woodruff key 11-3 wrap, tie 5-7, 6-7, 12-7, 12-11, 12-17 wrench, spanner 16-9 Y yoke, gear 16-7 yoke, support (steering) 5-7 U u-bolt 5-15, 5-17 unitized transaxle 11-3 upper delta clevis 5-11 urethane bushing 5-9, 5-11, 5-15, 5-17 V valve choke 8-13 2007 DS Golf Cars Illustrated Parts List Page i-13 Club Car NOTES R 2007 ILLUSTRATED PARTS LIST Club Car, Inc. P.O. Box 204658 Augusta, GA 30917-4658 USA Web www.clubcar.com Phone 1.706.863.3000 1.800.ClubCar Int’l +1 706.863.3000 Fax 1.706.863.5808 CARRYALL 295 AND XRT 1550 GASOLINE/DIESEL VEHICLES MANUAL NUMBER 103209010 EDITION CODE 0906A00000
