Download Club Car DS Pt.1 - Specialty Cartz & Partz

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Transcript 
2001-2002
ILLUSTRATED
PARTS LIST
DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 102189901
EDITION CODE 0801B0602A
USING THE ILLUSTRATED PARTS LIST
∆ WARNING
• This manual is to be used only for identification and ordering of service parts. Be sure to read
and use the maintenance and service manual before attempting any vehicle repairs.
This manual covers all 2001 and 2002 Club Car® DS Tranquility®, DS V-Glide 36-Volt, DS PowerDrive®
System 48™, DS PowerDrive Plus®, and IQ System™ vehicles.
The manual is divided into 16 sections. Sections 1 through 5 pertain to both gasoline and electric vehicles,
sections 6 through 11 pertain to gasoline vehicles only, sections 12 through 15 pertain to electric vehicles
only, and section 16 pertains to tools that are used on all Club Car products. Note that there are two or three
flags on the outside edge of each page. The first flag contains the section number of which that page is a
part. The other flag (or flags) contains either the letter G or E, signifying that the page pertains to either the
gasoline or electric vehicle only, or to both the gasoline and electric vehicles.
Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek.
The Table of Contents lists section numbers, and under them, the individual page titles and numbers to be
found in that section. The index can be used to find specific parts and assemblies. The index is divided into
numerical and alphabetical listings with the page numbers in italic text.
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. Some item
numbers have more than one part number because several configurations of a component are represented
together on one spread.
Note that a part description may be indented. This indention corresponds to a parts assembly level indicated
by the numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part
that is indented to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is
a component of the level 2 part that it is listed under, and a level 4 part is a component of the level 3 part
preceding it. In each case, the part quantity given for a level 2, 3, or 4 part is the quantity used per next
higher level assembly of which it is a component. A part that is not indented is a level 1 part. This means that
the quantity given is the quantity used per the portion of the vehicle illustrated on that particular spread.
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.
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 incurring any obligation or liability whatsoever.
©2001 Club Car, Inc.
Club Car, ArmorFlex, PowerDrive, PowerDrive Plus
and Tranquility are registered trademarks of Club Car, inc.
This manual effective July 24, 2000.
2001/2002 DS Golf Cars Illustrated Parts List
CONTENTS
SECTION 1 – BODY AND TRIM
Body Trim ..........................................................................................................................................
1-3
Front Body .........................................................................................................................................
1-5
Rear Body and Fender – Gasoline Vehicle .......................................................................................
1-7
Rear Body and Fender – Electric Vehicle ..........................................................................................
1-9
Seat Bottom and Armrest ..................................................................................................................
1-11
Seat Back and Bag Hoop – Earlier Style ...........................................................................................
1-13
Seat Back and Bag Hoop – Later Style .............................................................................................
1-15
Canopy ..............................................................................................................................................
1-17
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 .................................................................................................................................
4-3
Brake Pedal and Cable Assembly .....................................................................................................
4-5
Accelerator Pedal Assembly ..............................................................................................................
4-7
SECTION 5 – STEERING, FRONT AND REAR SUSPENSION
Steering Column ................................................................................................................................
5-3
Steering Gear Assembly ....................................................................................................................
5-5
Front Suspension, Upper ...................................................................................................................
5-7
Front Suspension, Lower ...................................................................................................................
5-9
Rear Suspension ...............................................................................................................................
5-11
SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLE
Wiring – Gasoline Vehicle ..................................................................................................................
6-3
Forward/Reverse Shifter Assembly – Gasoline Vehicle ....................................................................
6-5
Electrical Component Box – Gasoline Vehicle ..................................................................................
6-7
Electrical Components, Front Body – Gasoline Vehicle ....................................................................
6-9
Starter/Generator Assembly ..............................................................................................................
6-11
Starter/Generator Mounting ...............................................................................................................
6-13
Battery – Gasoline Vehicle ................................................................................................................
6-15
2001/2002 DS Golf Cars Illustrated Parts List
CONTENTS
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
Engine Mounting ................................................................................................................................
7-15
SECTION 8 – FUEL, INTAKE, AND GOVERNOR SYSTEMS
Fuel System .......................................................................................................................................
8-3
Carburetor Assembly .........................................................................................................................
8-5
Carburetor Installation ........................................................................................................................
8-7
Governor and Accelerator Cables ......................................................................................................
8-9
Intake Duct, Choke, and Air Box Assembly .......................................................................................
8-11
SECTION 9 – EXHAUST SYSTEM
Exhaust System .................................................................................................................................
9-3
SECTION 10 – TORQUE CONVERTER
Drive Clutch ........................................................................................................................................
10-3
Driven Clutch ......................................................................................................................................
10-5
SECTION 11 – UNITIZED TRANSAXLE
Unitized Transaxle – Gear Cases and Brackets ................................................................................
11-3
Unitized Transaxle – F&R Transmission and Gear Reduction ...........................................................
11-5
Unitized Transaxle – Differential and Axles .......................................................................................
11-7
SECTION 12 – ELECTRICAL SYSTEM – ELECTRIC VEHICLE
Electrical Components, Front Body – Electric Vehicle .......................................................................
12-3
Wiring – V-Glide 36-Volt Vehicle ........................................................................................................
12-5
Forward/Reverse Switch – V-Glide 36-Volt Vehicle ...........................................................................
12-7
Wiper Switch – V-Glide 36-Volt Vehicle .............................................................................................
12-9
Resistor and Board Assembly – V-Glide 36-Volt Vehicle ................................................................... 12-11
Batteries, Charger Receptacle, Solenoid – V-Glide 36-Volt Vehicle .................................................. 12-13
Forward/Reverse Switch – PowerDrive System 48 Vehicle ............................................................... 12-15
Batteries, Charger Receptacle – PowerDrive System 48 Vehicle ...................................................... 12-17
Computer, Controller, and Solenoid – PowerDrive System 48 Vehicle ............................................. 12-19
Multi-Step Potentiometer – PowerDrive System 48 and PowerDrive Plus ........................................ 12-21
2001/2002 DS Golf Cars Illustrated Parts List
CONTENTS
Motor Controller Output Regulator (MCOR) ...................................................................................... 12-23
Wiring – PowerDrive System 48 Vehicle with Multi-Step Potentiometer ........................................... 12-25
Wiring – PowerDrive System 48 Vehicle with Motor Controller Output Regulator (MCOR) .............. 12-27
Wiring – PowerDrive Plus Vehicle with Multi-Step Potentiometer ..................................................... 12-29
Wiring – PowerDrive Plus Vehicle with Motor Controller Output Regulator (MCOR) ........................ 12-31
Forward/Reverse Switch, Tow/Run Switch – PowerDrive Plus Vehicle ............................................ 12-33
Batteries, Charger Receptacle – PowerDrive Plus Vehicle ............................................................... 12-35
Solenoids, Energy Displacement Module – PowerDrive Plus Vehicle ............................................... 12-37
Controller, Onboard Computer – PowerDrive Plus Vehicle ............................................................... 12-39
Wiring – IQ System Vehicle with Motor Controller Output Regulator (MCOR) .................................. 12-41
Forward/Reverse Switch, Tow/Run Switch – IQ System Vehicle ...................................................... 12-43
Batteries, Charger Receptacle – IQ System Vehicle ......................................................................... 12-45
Computer, Controller, and Solenoid – IQ System Vehicle ................................................................. 12-47
SECTION 13 – BATTERY CHARGER
Accu-Power Charger, Domestic – V-Glide 36-Volt Vehicle ...............................................................
13-3
Accu-Power Charger, Export, 230-Volt – V-Glide 36-Volt Vehicle ....................................................
13-5
Accu-Power Charger, Export, 100-Volt – V-Glide 36-Volt Vehicle ....................................................
13-7
PowerDrive Charger, Domestic .........................................................................................................
13-9
PowerDrive 2 Charger, Domestic ...................................................................................................... 13-11
PowerDrive Charger, Export .............................................................................................................. 13-13
PowerDrive Charger, European ......................................................................................................... 13-15
SECTION 14 – ELECTRIC MOTOR
Motor – V-Glide 36-Volt Vehicle ........................................................................................................
14-3
Motor – PowerDrive System 48 Vehicle ............................................................................................
14-5
Motor – PowerDrive Plus Vehicle ......................................................................................................
14-7
Motor – IQ System Vehicle ................................................................................................................
14-9
SECTION 15 – TRANSAXLE – ELECTRIC VEHICLE
Transaxle, Type G – Electric Vehicle .................................................................................................
15-3
Transaxle, Type K – Electric Vehicle .................................................................................................
15-5
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
SECTION i – INDEX
2001/2002 DS Golf Cars Illustrated Parts List
BODY AND TRIM
1
G
E
1
G
11
E
Frame
2
3
4
Front Body
Of Car
Center
Dash
Frame
Dash
Dash
TYPICAL
3 PLACES
1
9
10
TYPICAL
2 PLACES
8
7
6
13
5
TYPICAL
2 PLACES
14
12
25
24
23
15
16
22
21
TYPICAL
2 PLACES
22
21
20
19
18
TYPICAL
2 PLACES
21
20
Page 1-2
2001/2002 DS Golf Cars Illustrated Parts List
17
TYPICAL
9 PLACES
BODY TRIM
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
1013344
101660404
101802601
1013343
1015032
1014645
N/A
N/A
N/A
N/A
7973
101708301
7847
1016952
101768202
1010434
1017079
1016379
1016875
7473
1011697
1016876
101706702
1010434
102221201
2
3
QTY
GAS
QTY
ELEC
1
1
1
1
1
1
1
2
1
1
1
1
3
2
2
2
1
9
1
1
1
4
6
4
1
12
2
4
Component, Driver Side Dash, Black .........................................................
Panel, Center Dash, Black .........................................................................
Plug, Hole (V-Glide 36-Volt vehicle only) ....................................................
Component, Passenger Side Dash, Black .................................................
Mat, Floor ...................................................................................................
Kit, Snap Washer, Black (includes items 7 - 10) ........................................
Nut, Speed .............................................................................................
Washer, #10 ...........................................................................................
Screw, #10 Sheet Metal .........................................................................
Cover, Screw Head ................................................................................
Rivet, Aluminum Pop, 3/16 .........................................................................
Kit, Drink Holder (includes items 13 and 14) ..............................................
Screw, Hex Head Cap, 1/4-20 x 3/4 .......................................................
U-Nut, 1/4-20 .........................................................................................
Kit, Bagwell Protector (includes item 16) ...................................................
Fastener, Plastic Barrel ..........................................................................
Kit, Rear Bumper (includes items 18 - 22) .................................................
Bumper, Rear .........................................................................................
Plate, Mounting, Long ............................................................................
Nut, Nylon Lock, 5/16-18 .......................................................................
Washer, Special, 5/16 ............................................................................
Bolt, Phillips Truss Head Shoulder, 3/8-18 x 2 .......................................
Kit, Scuff Guard (includes item 24) ............................................................
Fastener, Plastic Barrel ..........................................................................
Pad, Wear ..................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
2
1
1
1
1
3
2
2
2
1
9
1
1
1
4
6
4
1
12
2
Page 1-3
1
G
E
1
G
E
TYPICAL
2 PLACES
12
10
11
13
TYPICAL
6 PLACES
17
9
7
8
6
18
Club
Car
2
14
TYPICAL
2 PLACES
16
1
5
3
TYPICAL
8 PLACES
4
Page 1-4
TYPICAL
2 PLACES
2001/2002 DS Golf Cars Illustrated Parts List
15
FRONT BODY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
7
7
7
7
7
7
7
7
8
8
8
8
8
8
8
8
8
9
10
11
12
13
14
15
16
17
18
1017080
1016868
7251
7473
1016967
1014198
101692501
101692502
101692504
101692506
101692509
101692510
101692511
101692512
101692513
101693901
101693902
101693904
101693906
101693908
101693909
101693910
101693911
101693912
1011014
1010435
1241
1011017
1011394
101347501
102310701
1015032
7473
102259001
2
3
QTY
GAS
QTY
ELEC
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
6
1
2
8
1
2
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
6
1
2
8
1
2
1
4
Kit, Front Bumper (includes items 2 - 5) .....................................................
Bumper, Front ........................................................................................
Screw, Phillips Truss Head, 5/16-18 x 1 .................................................
Nut, Nylon Lock, 5/16-18 .......................................................................
Rivet, Push Type Blind ...........................................................................
Nameplate – Gold ......................................................................................
Body, Front – Beige ....................................................................................
Body, Front – White ....................................................................................
Body, Front – Gray .....................................................................................
Body, Front – Red ......................................................................................
Body, Front – Royal Blue (Pacific Blue).......................................................
Body, Front – Dark Green ..........................................................................
Body, Front – Black ....................................................................................
Body, Front – Classic Blue (Navy) ..............................................................
Body, Front – Burgundy ..............................................................................
Body, Front with Headlight Opening – Beige ..............................................
Body, Front with Headlight Opening – White ..............................................
Body, Front with Headlight Opening – Gray ...............................................
Body, Front with Headlight Opening – Red ................................................
Body, Front with Headlight Opening – Royal Blue (Pacific Blue) ................
Body, Front with Headlight Opening – Dark Green ....................................
Body, Front with Headlight Opening – Black ..............................................
Body, Front with Headlight Opening – Classic Blue (Navy) .......................
Body, Front with Headlight Opening – Burgundy .......................................
Trim, Front Body .........................................................................................
Screw, Round-Head Square-Neck, 5/16-18 x 1 .........................................
Washer, Flat, 5/16 ......................................................................................
Screw, Flange Lock ....................................................................................
T-Nut, Slab Base (package of 4) ................................................................
Bumper, Side Guard Trim ...........................................................................
Screw, Hex Washer-Head, #8-18 x 3/8 .......................................................
Mat, Floor ...................................................................................................
Nut, Nylon Lock, 5/16-18 ............................................................................
Emblem, IR, Golf Car (for 2002 vehicles) ...................................................
2001/2002 DS Golf Cars Illustrated Parts List
Page 1-5
1
G
E
1
G
7
E
4
FRONT SEAT
SUPPORT
VERTICAL
STRUT
TYPICAL
2 PLACES
1
5
TYPICAL
2 PLACES
1
8
1
5
2
6
17
6
TYPICAL
2 PLACES
9
15
10
16
14
TYPICAL
2 PLACES
11
5
1
13
6
TYPICAL
2 PLACES
TYPICAL
EACH SIDE
OF VEHICLE
TYPICAL
EACH SIDE
OF VEHICLE
Page 1-6
2001/2002 DS Golf Cars Illustrated Parts List
3
12
6
TYPICAL
2 PLACES
REAR BODY AND FENDER – GASOLINE VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
7
8
9
9
9
9
9
9
9
9
9
10
10
10
10
10
10
10
10
10
11
12
13
14
15
16
17
8251
101904101
1014306
1012412
332
8233
1013032
1013140
1015525
101692601
101692602
101692604
101692606
101692609
101692610
101692611
101692612
101692613
101696208
101696209
101696211
101696213
101696215
101696216
101696219
101696220
101696221
1017748
1012047
7847
1017936
1017141
1015032
102221201
2
3
QTY
4
Screw, Phillips Head, 1/4-20 x 1 ...........................................................................
Plate, Body Kick ....................................................................................................
Washer, Flat, Type B, 1/4 ......................................................................................
Plate, Body Hinge .................................................................................................
Washer, Flat, 1/4 ...................................................................................................
Nut, Nylon Lock, 1/4-20 .........................................................................................
Door, Access – Black ............................................................................................
Door, Access – Beige ............................................................................................
Nut, Blind, 1/4-20 ..................................................................................................
Body – Beige .........................................................................................................
Body – White .........................................................................................................
Body – Gray ..........................................................................................................
Body – Red ...........................................................................................................
Body – Royal Blue (Pacific Blue) ...........................................................................
Body – Dark Green ...............................................................................................
Body – Black .........................................................................................................
Body – Classic Blue (Navy) ...................................................................................
Body – Burgundy ..................................................................................................
Body with Taillight Opening – Beige ......................................................................
Body with Taillight Opening – White ......................................................................
Body with Taillight Opening – Gray .......................................................................
Body with Taillight Opening – Red ........................................................................
Body with Taillight Opening – Royal Blue (Pacific Blue) ........................................
Body with Taillight Opening – Dark Green ............................................................
Body with Taillight Opening – Black ......................................................................
Body with Taillight Opening – Classic Blue (Navy) ................................................
Body with Taillight Opening – Burgundy ................................................................
Clip, Body Keeper .................................................................................................
Screw, Self-Tapping, #8-32 x 3/8 ..........................................................................
Screw, Hex Head Cap, 1/4-20 x 3/4 ......................................................................
Fender, Inner .........................................................................................................
Support, Front Body ..............................................................................................
Mat, Floor ..............................................................................................................
Pad, Wear .............................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
10
1
2
2
10
12
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
4
2
1
1
2
Page 1-7
1
G
E
1
G
TYPICAL
2 PLACES
4
E
17
1
FRONT SEAT
SUPPORT
VERTICAL
STRUT
1
5
5
20
TYPICAL
2 PLACES
6
18
6
2
TYPICAL
2 PLACES
3
15
16
19
TYPICAL
2 PLACES
13
7
9
14
11
Page 1-8
8
6
10
12
5
1
TYPICAL
EACH SIDE
OF VEHICLE
2001/2002 DS Golf Cars Illustrated Parts List
TYPICAL
EACH SIDE
OF VEHICLE
6
1
REAR BODY AND FENDER – ELECTRIC VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
15
15
15
15
15
15
16
16
16
16
16
16
16
16
16
17
17
18
19
20
8251
101904101
1017141
1012412
332
8233
1017936
1014306
1017814
1012159
7479
1017815
1017748
1012047
101693301
101693302
101693304
101693306
101693309
101693310
101693311
101693312
101693313
101696201
101696202
101696204
101696206
101696217
101696218
101696222
101696223
101696224
1013032
1013140
1015525
1015032
102221201
2
3
QTY
4
Screw, Phillips Head, 1/4-20 x 1 ...........................................................................
Plate, Body Kick ....................................................................................................
Support, Front Body ..............................................................................................
Plate, Body Hinge .................................................................................................
Washer, Flat, 1/4 ...................................................................................................
Nut, Nylon Lock, 1/4-20 .........................................................................................
Fender, Inner .........................................................................................................
Washer, Flat, Type B, 1/4 ......................................................................................
Spacer, 1-7/8 .........................................................................................................
Screw, Hex Head Cap, 1/4-20 x 2-3/4 ...................................................................
Screw, Hex Head Cap, 1/4-20 x 1-1/4 ...................................................................
Spacer, 1/2 ............................................................................................................
Clip, Body Keeper .................................................................................................
Screw, Self-Tapping, #8-32 ...................................................................................
Body – Beige .........................................................................................................
Body – White .........................................................................................................
Body – Gray ..........................................................................................................
Body – Red ...........................................................................................................
Body – Royal Blue (Pacific Blue)............................................................................
Body – Dark Green ...............................................................................................
Body – Black .........................................................................................................
Body – Classic Blue (Navy)....................................................................................
Body – Burgundy ..................................................................................................
Body with Taillight Opening – Beige ......................................................................
Body with Taillight Opening – White ......................................................................
Body with Taillight Opening – Gray .......................................................................
Body with Taillight Opening – Red ........................................................................
Body with Taillight Opening – Royal Blue (Pacific Blue) ........................................
Body with Taillight Opening – Dark Green ............................................................
Body with Taillight Opening – Black ......................................................................
Body with Taillight Opening – Classic Blue (Navy) ................................................
Body with Taillight Opening – Burgundy ................................................................
Door, Access – Black ............................................................................................
Door, Access – Beige ............................................................................................
Nut, Blind, 1/4-20 ..................................................................................................
Mat, Floor ..............................................................................................................
Pad, Wear .............................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
10
1
1
2
10
12
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
Page 1-9
1
G
E
1
TYPICAL
2 PLACES
G
10
E
5
4
7
TYPICAL
8 PLACES
TYPICAL
8 PLACES
1
2
3
TYPICAL
2 PLACES
REFERENCE
REAR BODY AND
FENDER
Page 1-10
8
9
TYPICAL
4 PLACES
2001/2002 DS Golf Cars Illustrated Parts List
6
TYPICAL
8 PLACES
SEAT BOTTOM AND ARMREST
ITEM
PART NO.
DESCRIPTION
1
1
1
1
1
2
2
2
2
3
4
5
6
7
8
9
10
102174201
102174202
102174204
102174205
101998201
101998202
101998204
101998205
1010543
101987601
101985501
1016916
332
1011652
101954301
101998501
2
3
QTY
GAS
QTY
ELEC
1
1
1
1
1
1
1
1
12
1
1
8
8
2
4
2
1
1
1
1
1
1
1
1
12
1
1
8
8
2
4
2
4
Assembly, Seat Bottom – Buff (includes items 2 and 3) ............................
Assembly, Seat Bottom – White (includes items 2 and 3) ..........................
Assembly, Seat Bottom – Black (includes items 2 and 3) ..........................
Assembly, Seat Bottom – Gray (includes items 2 and 3) ...........................
Cover, Vinyl Seat Bottom – Buff .............................................................
Cover, Vinyl Seat Bottom – White ..........................................................
Cover, Vinyl Seat Bottom – Black ...........................................................
Cover, Vinyl Seat Bottom – Gray ............................................................
Insert, Wood ...........................................................................................
Armrest, Driver Side ...................................................................................
Armrest, Passenger Side ...........................................................................
Screw, Hex Head Cap, 1/4-20 x 1-1/2 ........................................................
Washer, Flat, Type A ..................................................................................
Plate, Seat Hinge, Stainless Steel .............................................................
Screw, Hex Head Cap, 1/4-20 x 3/4 (with patch) .......................................
Gasket, Seat ..............................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
Page 1-11
1
G
E
1
G
7
EARLIER STYLE
E
8
9
TYPICAL
2 PLACES
10
2
3
1
13
11
4
12
TYPICAL
2 PLACES
5
15
TYPICAL
4 PLACES
22
16
17
18
6
17
21
23
20
9
21
TYPICAL 2 PLACES
14
19
TYPICAL 2 PLACES
ON EACH SIDE OF VEHICLE
Page 1-12
17
TYPICAL 2 PLACES
2001/2002 DS Golf Cars Illustrated Parts List
SEAT BACK AND BAG HOOP – EARLIER STYLE
ITEM
PART NO.
QTY
GAS
DESCRIPTION
1
2
3
QTY
ELEC
4
G
This manual includes two seat back styles. Not all parts are
interchangeable, so it is important to identify the correct seat back
style for your vehicle.
Earlier and later seat back styles can be distinguished most easily by
differences in the sweater basket design.
Before ordering parts from this page, compare your vehicle’s sweater
basket to those shown on pages 1-12 and 1-14. Order from the page that
corresponds to the sweater basket style of your vehicle.
1
1
1
1
2
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
E
102076601
102076602
102076604
102076605
102060501
102060502
102060504
102060505
102058901
102059901
102076701
101910401
1010921
1015075
7473
1013935
1010434
1010413
1013754
1017774
101707206
8418
1015075
1014482
8233
7479
1241
7818
102242401
Assembly, Seat Back – Buff (includes item 2) ............................................
Assembly, Seat Back – White (includes item 2) .........................................
Assembly, Seat Back – Black (includes item 2) .........................................
Assembly, Seat Back – Gray (includes item 2) ...........................................
Cover, Vinyl, Seat Back – Buff ...............................................................
Cover, Vinyl, Seat Back – White .............................................................
Cover, Vinyl, Seat Back – Black .............................................................
Cover, Vinyl, Seat Back – Gray ..............................................................
Cap, Seat Back – Black ..............................................................................
Weldment, Support, Seat Back ..................................................................
Screw, SEMS (with Patch) 1/4-20 x 1-3/4 ..................................................
Screw, Self-Tapping, 5/16-18 x 1-1/4 .........................................................
Screw, Cap Hex Head, 5/16-18 x 2-1/2 ......................................................
Washer, Flat, 5/16 ......................................................................................
Nut, Nylon Lock, 5/16-18 ............................................................................
Assembly, Bag Hoop (includes items 11 - 13) ...........................................
Fastener, Plastic Barrel ..........................................................................
Strap, Bag ..............................................................................................
Buckle, Bag Strap ..................................................................................
Spacer, Body ..............................................................................................
Kit, Sweater Basket (includes items 16 - 20) .............................................
Screw, Phillips Truss Head, 1/4-20 x 1-1/2 .............................................
Washer, Flat, 5/16 ..................................................................................
Spacer, Nylon .........................................................................................
Nut, Nylon Lock, 1/4-20 .........................................................................
Screw, Hex Head Cap, 1/4-20 x 1-1/4.....................................................
Washer, Flat, 5/16 ......................................................................................
Screw, Round-Head Square-Neck, 5/16-18 x 1-1/2 ...................................
Nut, Nylon Insert with Cap, 1/4-20 ..............................................................
1
1
1
1
1
1
1
1
1
2
4
4
2
4
4
1
2
1
2
4
1
1
4
1
2
2
6
2
1
1
1
1
1
1
1
1
1
1
2
4
4
2
4
4
1
2
1
2
4
1
1
4
1
2
2
6
2
1
102237903
Kit, Seat Back Retrofit (not shown) converts the earlier style seat back
to the later style back (includes items 3, 4, and 5 on page 1-15) ...............
1
1
2001/2002 DS Golf Cars Illustrated Parts List
1
Page 1-13
1
G
7
LATER STYLE
E
8
TYPICAL
2 PLACES
9
10
2
3
1
13
11
4
12
TYPICAL
2 PLACES
15
5
TYPICAL
4 PLACES
22
16
17
18
6
17
21
23
20
9
21
TYPICAL 2 PLACES
14
19
TYPICAL 2 PLACES
ON EACH SIDE OF VEHICLE
Page 1-14
17
TYPICAL 2 PLACES
2001/2002 DS Golf Cars Illustrated Parts List
SEAT BACK AND BAG HOOP – LATER STYLE
ITEM
PART NO.
QTY
GAS
DESCRIPTION
1
2
3
QTY
ELEC
4
G
This manual includes two seat back styles. Not all parts are
interchangeable, so it is important to identify the correct seat back
style for your vehicle.
Earlier and later seat back styles can be distinguished most easily by
differences in the sweater basket design.
Before ordering parts from this page, compare your vehicle’s sweater
basket to those shown on pages 1-12 and 1-14. Order from the page that
corresponds to the sweater basket style of your vehicle.
1
1
1
1
2
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
E
102238301
102238302
102238304
102238305
102060501
102060502
102060504
102060505
102237001
102236601
102236703
101910401
1010921
1015075
7473
1013935
1010434
1010413
1013754
1017774
102076701
8418
1015075
1014482
8233
7479
1241
7818
102242401
Assembly, Seat Back – Buff (includes items 2 and 3) ................................
Assembly, Seat Back – White (includes items 2 and 3) .............................
Assembly, Seat Back – Black (includes items 2 and 3) ..............................
Assembly, Seat Back – Gray (includes items 2 and 3) ...............................
Cover, Vinyl, Seat Back – Buff ...............................................................
Cover, Vinyl, Seat Back – White .............................................................
Cover, Vinyl, Seat Back – Black .............................................................
Cover, Vinyl, Seat Back – Gray ..............................................................
Cap, Seat Back – Black .........................................................................
Weldment, Support, Seat Back ..................................................................
Basket, Sweater .........................................................................................
Screw, Self-Tapping, 5/16-18 x 1-1/4 .........................................................
Screw, Cap Hex Head, 5/16-18 x 2-1/2 ......................................................
Washer, Flat, 5/16 ......................................................................................
Nut, Nylon Lock, 5/16-18 ............................................................................
Assembly, Bag Hoop (includes items 11 - 13) ...........................................
Fastener, Plastic Barrel ..........................................................................
Strap, Bag ..............................................................................................
Buckle, Bag Strap ..................................................................................
Spacer, Body ..............................................................................................
Screw, SEMS (with Patch) 1/4-20 x 1-3/4 ..................................................
Screw, Phillips Truss Head, 1/4-20 x 1-1/2 .................................................
Washer, Flat, 5/16 ......................................................................................
Spacer, Nylon .............................................................................................
Nut, Nylon Lock, 1/4-20 ..............................................................................
Screw, Hex Head Cap, 1/4-20 x 1-1/4.........................................................
Washer, Flat, 5/16 ......................................................................................
Screw, Round-Head Square-Neck, 5/16-18 x 1-1/2 ...................................
Nut, Nylon Insert with Cap, 1/4-20 ..............................................................
1
1
1
1
1
1
1
1
1
2
1
4
2
4
4
1
2
1
2
4
4
1
4
1
2
2
6
2
1
1
1
1
1
1
1
1
1
1
2
1
4
2
4
4
1
2
1
2
4
4
1
4
1
2
2
6
2
1
102237903
Kit, Seat Back Retrofit (not shown) converts the earlier style seat back
to the later style back (includes items 3, 4, and 5) .....................................
1
1
2001/2002 DS Golf Cars Illustrated Parts List
1
Page 1-15
1
G
TYPICAL 2
PLACES
E
TYPICAL 2 PLACES
6
3
REF.
11
4
6
REF.
7
7
4
3
5
REFERENCE
SEAT BACK
SUPPORT
WELDMENT
1
4
REF.
F
NT O
FRO LE
IC
VEH
8
9
9
12
10
TYPICAL 2
PLACES
2
Page 1-16
2001/2002 DS Golf Cars Illustrated Parts List
CANOPY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
11
12
102099101
102155501
102063901
102065501
102064601
102076701
101835601
324
332
8233
102061301
102061302
102198301
2
3
QTY
GAS
QTY
ELEC
2
1
1
1
1
8
8
2
4
2
1
1
2
2
1
1
1
1
8
8
2
4
2
1
1
2
4
Screw, SEMS (with patch) 5/16-18 x 1........................................................
Kit, Support (includes items 3 - 10) ............................................................
Weldment, Windshield ...........................................................................
Support, Rear Canopy (driver side) .......................................................
Support, Rear Canopy (passenger side) ...............................................
Screw, Sems, (with patch) 1/4-20 x 1-3/4 ...............................................
Nut, Flange, 1/4-20 ................................................................................
Screw, Hex Head Cap, 1/4-20 x 2-1/2 ....................................................
Washer, Flat, 1/4 ....................................................................................
Nut, Lock, 1/4-20 ....................................................................................
Canopy – White ..........................................................................................
Canopy – Beige ..........................................................................................
Pad, Mounting (windshield frame)...............................................................
2001/2002 DS Golf Cars Illustrated Parts List
Page 1-17
1
G
E
1
G
E
WHEELS AND TIRES
2
G
E
2
G
E
1
2
3
4
5
STANDARD
TREAD
Page 2-2
PREMIUM
TREAD
2001/2002 DS Golf Cars Illustrated Parts List
EXTRA
TRACTION
WHEELS AND TIRES
ITEM
PART NO.
QTY
GAS
QTY
ELEC
Nut, Lug .....................................................................................................
Assembly, Wheel (beige) and Standard Tread Tire (18 x 8.50 - 8) .............
Assembly, Wheel (beige) and Premium Tread Tire
(18 x 8.50 - 8) (Carlisle®) ...........................................................................
Assembly, Wheel (beige) and Extra Traction Tire,
6-Ply Rated (18 x 8.50 - 8) .........................................................................
Assembly, Wheel (beige) and Performance Grade Tread Tire
(18 x 8.50 - 8) (Duro®) ...............................................................................
Assembly, Wheel (beige) and Premium Grade Tire
16
4
16
4
4
4
4
4
4
4
(18 x 8.50 - 8) (Kenda®) ..............................................................................
Assembly, Wheel (white) and Standard Tread Tire (18 x 8.50 - 8) .............
Assembly, Wheel (white) and Premium Tread Tire
(18 x 8.50 - 8) (Carlisle) .............................................................................
Assembly, Wheel (white) and Extra Traction Tire,
6-Ply Rated (18 x 8.50 - 8) .........................................................................
Assembly, Wheel (white) and Performance Grade Tread Tire
(18 x 8.50 - 8) (Duro) .................................................................................
Assembly, Wheel (white) and Premium Grade Tire
(18 x 8.50 - 8) (Kenda) ................................................................................
Wheel Rim – Beige ....................................................................................
Wheel Rim – White ....................................................................................
Tire, Unmounted, Standard Tread (18 x 8.50 - 8) .......................................
Tire, Unmounted, Performance Grade Tread (Duro) ..................................
Tire, Unmounted, Premium Tread (18 x 8.50 - 8) (Carlisle) .......................
Tire, Unmounted, Extra Traction, 6-Ply Rated (18 x 8.50 - 8) ....................
Stem, Valve ................................................................................................
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
DESCRIPTION
1
1
2
2
1010984
101570501
101570502
2
101570507
2
2
101570508
101570513
2
2
101651401
101651402
2
101651407
2
101651408
2
101651413
3
3
4
4
4
4
5
1015707
1014771
727102
101567201
101567202
101769302
7310
2
3
4
2001/2002 DS Golf Cars Illustrated Parts List
Page 2-3
2
G
E
2
G
E
DECALS
3
G
E
3
WARNING
G
E
OFF
ROLLOVER OR FALLING OFF MAY CAUSE DEATH.
• 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.
ON
OPERATING INSTRUCTIONS
KEY SWITCH
DECAL
2
3
CCI 1019606-01
DRIVER / PASSENGER
WARNING DECAL
1
• 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, firmly depress park brake until it locks.
• Place forward and reverse switch in neutral position.
Turn key “OFF” and remove key when not in use.
CCI 1016216-01
OPERATING INSTRUCTIONS
DECAL
WARNING
CAN CAUSE SEVERE INJURY
Rotating parts
HOT
manifold & muffler
KEEP CLEAR
WARNING
•
•
•
•
•
CCI 1019605-01
ROTATING PARTS AND
HOT MANIFOLD DECAL
GASOLINE EXPLOSION / FIRE.
CAN CAUSE SEVERE INJURY OR DEATH.
NO SMOKING, SPARKS, OR OPEN FLAME.
STOP ENGINE, ALLOW TO COOL BEFORE REFUELING.
TURN FUEL VALVE (
) ON DURING OPERATION.
(
) OFF DURING STORAGE OR TRANSPORT. CCI 1015476-01
(ON STARTER/GENERATOR
AND ENGINE)
5
GASOLINE WARNING DECAL
(ON VEHICLE FRAME NEAR FUEL TANK)
4
INGERSOLL-RAND DECAL
(ON BODY PANEL)
(FOR 2001 VEHICLES ONLY)
7
6
FRAME GROUND AND
GOVERNOR WARNING DECAL
(ON VEHICLE FRAME NEAR BATTERY)
WARNING
Negative frame ground. Can cause severe injury.
Do not contact positive (+) battery post or cable to frame.
Disconnect negative battery lead first.
WARNING
Excessive speed.
Can cause severe injury or death.
Do not tamper with engine governor adjustment.
CCI 1019152-01
Page 3-2
2001/2002 DS Golf Cars Illustrated Parts List
DECALS – GASOLINE VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
101960601
101825101
101621601
101547601
101960501
101915201
101952401
2
3
QTY
4
Decal, Driver/Passenger Warning .........................................................................
Decal, Key Switch .................................................................................................
Decal, Operating Instructions ................................................................................
Decal, Gasoline Warning ......................................................................................
Decal, Rotating Parts and Hot Manifold Warning ..................................................
Decal, Frame Ground and Governor Warning .......................................................
Decal, Ingersoll-Rand – Gold (for 2001 vehicles only) ..........................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
2
1
2
Page 3-3
3
G
E
3
E
OFF
WARNING
ROLLOVER OR FALLING OFF MAY CAUSE DEATH.
• 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.
ON
OPERATING INSTRUCTIONS
KEY SWITCH DECAL
2
3
CCI 101960601
DRIVER / PASSENGER
WARNING DECAL
1
• 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, firmly depress park brake until it locks.
• Place forward and reverse switch in neutral position.
Turn key “OFF” and remove key when not in use.
CCI 1016216-01
OPERATING INSTRUCTIONS
DECAL
ELECTRICAL COMPONENT DECAL
(ON SPEED CONTROLLER COVER
IQ SYSTEM VEHICLE ONLY)
4
NOTICE
MOTOR BRAKING DECAL
(POWERDRIVE PLUS VEHICLES ONLY)
IMPORTANT
NOTICE
VEHICLE EQUIPPED TO
LIMIT DOWNHILL SPEED
•
•
•
•
Maximum vehicle speed is limited during downhill operation
with accelerator pedal depressed.
Vehicle will brake gently when accelerator pedal is released.
System is activated only when tow switch is in the "RUN"
position.
When towing vehicle, tow switch must be in the "TOW" position.
9
CCI 1019599-01
NOTICE
(IQ SYSTEM VEHICLES ONLY)
IMPORTANT
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.
• 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.
• When towing vehicle, tow switch must be in the "TOW" position.
101959902
• DO NOT OPERATE VEHICLE
WITHOUT COVER IN PLACE.
• DO NOT DIRECT WATER
STREAM AT THIS SWITCH.
CCI 1016109-01
POTENTIOMETER CAUTION DECAL
(ON WIPER SWITCH COVER INSIDE
BATTERY COMPARTMENT)
6
WARNING
HOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS.
RESISTOR WARNING DECAL
5
(ON FRAME UNDER SEAT ON
V-GLIDE 36 VOLT VEHICLE)
(ON MOUNTING PLATE UNDER ACCESS PANEL
ON POWERDRIVE PLUS VEHICLE EQUIPPED
WITH A DB SOLENOID AND COIL)
Club
Car
TOW/RUN SWITCH WARNING DECAL
7
(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 INJURY.
8
CCI 101908601
(POWERDRIVE PLUS AND IQ SYSTEM VEHICLES)
Page 3-4
F N
G
2001/2002 DS Golf Cars Illustrated Parts List
INGERSOLL-RAND DECAL
(ON BODY PANEL)
(FOR 2001 VEHICLES ONLY)
DECALS – ELECTRIC VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
4
5
6
7
8
9
101960601
101825101
101621601
101959901
101959902
1013496
101610901
101952401
101908601
101931501
2
3
QTY
4
Decal, Driver/Passenger Warning .........................................................................
Decal, Key Switch .................................................................................................
Decal, Operating Instructions ................................................................................
Decal, Motor Braking (PowerDrive Plus vehicle) ...................................................
Decal, Motor Braking (IQ System vehicle) ............................................................
Decal, Resistor Warning (V-Glide 36-Volt and
PowerDrive Plus vehicles) .....................................................................................
Decal, Potentiometer Caution ...............................................................................
Decal, Ingersoll-Rand – Gold (for 2001 vehicles only) ...........................................
Decal, Tow/Run Switch (PowerDrive Plus and IQ System vehicles) .....................
Decal, Electrical Component Cover (IQ System vehicle) ......................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
2
1
1
Page 3-5
3
G
E
3
G
E
BRAKES, PEDAL,
AND CABLE ASSEMBLIES
4
G
E
4
G
10
6
E
TYPICAL 4
PLACES
TYPICAL 4
PLACES
11
1
8
18
6
TYPICAL 2
PLACES
7
7
TYPICAL 2
PLACES
4
3
2
13
9
12
15
14
5
17
ELECTRIC
VEHICLE
16
GASOLINE
VEHICLE
SEE REAR SUSPENSION–
SECTION 6 FOR MOUNTING
Page 4-2
2001/2002 DS Golf Cars Illustrated Parts List
BRAKE ASSEMBLY
ITEM
PART NO.
DESCRIPTION
1
1
1
2
2
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
101823301
101823302
101824001
101824002
101816501
101816502
101823901
101823801
1010850
101823201
1011466
101816301
101815501
101815502
1013924
1014153
102022101
1010829
1035
1011779
101900801
1013207
101791101
2
3
QTY
GAS
QTY
ELEC
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
8
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
8
2
2
2
2
4
Cluster, Brake, Passenger Side (includes items 1 - 9) ...............................
Cluster, Brake, Driver Side (includes items 1 - 9) ......................................
Assembly, Backing Plate, Passenger Side (includes items 2 - 4) ..........
Assembly, Backing Plate, Driver Side (includes items 2 - 4) ..................
Mechanism, Adjusting, Passenger Side ............................................
Mechanism, Adjusting, Driver Side ...................................................
Washer ..............................................................................................
Washer, Plate ....................................................................................
Cover, Dust ............................................................................................
Package, Brake Shoe (four pieces) ........................................................
Kit, Shoe Retainer (four pieces) .............................................................
Package, Brake Spring (four pieces) ......................................................
Assembly, Lever, Passenger Side ..........................................................
Assembly, Lever, Driver Side ..................................................................
Nut, Hex Head Lock, Grade 8, 5/16-24 ......................................................
Bolt, Brake Cluster Mounting, Grade 8, 5/16-24 x 7/8 ...............................
Kit, Brake Cable (includes items 13 -15) ....................................................
Pin, Clevis, 5/16 .....................................................................................
Pin, Cotter, 3/32 x 1 ...............................................................................
E-Clip, 1/2 ..............................................................................................
Hanger, Brake Cable (gasoline vehicle only) .............................................
Hanger, Brake Cable (electric vehicle only) ...............................................
Drum, Brake ...............................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
2
2
2
Page 4-3
4
G
E
4
G
E
ON
OFF
TYPICAL
2 PLACES
26
24
25
28
27
10
8
OP
T
S
TYPICAL
4 PLACES
FLOORBOARD
REMOVED
FOR CLARITY
13
5
22
21
17
18
16
15
20
25
11
19
14
9
TYPICAL
4 PLACES
SERVICE PART
BRAKE PEDAL HAS
SECOND WELDMENT
16
23
12
TYPICAL
2 PLACES
TYPICAL
2 PLACES
2
TYPICAL
4 PLACES
3
4
29
1
6
Page 4-4
7
5
2
2001/2002 DS Golf Cars Illustrated Parts List
BRAKE PEDAL AND CABLE ASSEMBLY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
101990801
1241
1013531
1010921
7473
102022101
1011779
101878201
7716
1013869
1010878
1028
101953101
101953001
7473
101187702
N/A
1017029
1010877
1010805
1010932
1010933
1010927
1011402
1011418
1032
8626
1013876
1013870
1242
2
3
QTY
GAS
QTY
ELEC
1
5
1
4
5
2
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
4
5
2
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
1
4
Equalizer ....................................................................................................
Washer, Flat, 5/16 ......................................................................................
Spring, Brake Return .................................................................................
Screw, Hex Head Cap, 5/16-18 x 2-1/2 ......................................................
Nut, Nylon Lock, 5/16-18 ............................................................................
Kit, Brake Cable (includes item 7, and Items 13 and 14 on page 4-3) .......
E-Clip, 1/2 ..............................................................................................
Kit, Brake Pedal (includes items 9 and 10) ................................................
Screw, Slotted Hex Washer Head, #10-16 x 1/2 ....................................
Pad, Brake Pedal ...................................................................................
Bumper, Rubber .........................................................................................
Nut, Hex, 1/4-20 .........................................................................................
Rod, Equalizer ............................................................................................
Bolt, Hex Head Shoulder, 3/8 x 1 ...............................................................
Nut, Nylon Lock, 5/16-18 ............................................................................
Kit, Park Brake Latch (includes items 16 - 20 and Item 25 on Page 4-7) ...
Rod And Pawl ........................................................................................
Pin, Cotter, 7/64 x 1/2 ............................................................................
Nut, Push, 5/16 ......................................................................................
Sleeve, Park Brake Rod .........................................................................
Joint, Ball, 1/4-28 ...................................................................................
Spring, Park Brake Torsion .........................................................................
Spacer, Park Brake ....................................................................................
Package, Brake Mounting Block (contains upper and lower
for driver and passenger sides) ..................................................................
Kit, Park Brake Pedal (includes items 25 - 28) ...........................................
Bushing, Nylon .......................................................................................
Screw, Slotted Hex Washer Head, #10-16 x 1/2 ....................................
Nut, Push, 3/8 ........................................................................................
Pad, Park Brake .....................................................................................
Nut, Hex, 5/16-18 .......................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
Page 4-5
4
G
E
4
G
E
2
GO
1
8
5
20
10
11
12
TYPICAL
4 PLACES
13
3
5
9
4
8
19
18
6
14
17
17
18
19
TYPICAL
4 PLACES
21
22
23
7
TYPICAL
4 PLACES
24
20
23
OFF ON
25
Page 4-6
2001/2002 DS Golf Cars Illustrated Parts List
15
16
ACCELERATOR PEDAL ASSEMBLY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
8
9
10
11
12
13
14
15
16
17
1017696
1013871
7716
1624
334
102026001
1011700
101818801
101862001
1017424
101966901
101817401
101796201
1017378
1017380
1241
7473
101871901
17
101912401
18
19
20
21
22
23
24
1011084
1011734
8754
8233
1014007
1011694
101861901
101187702
N/A
25
2
3
QTY
GAS
QTY
ELEC
1
1
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
Sub-Assembly, Accelerator Pedal (includes Items 2 and 3) .......................
Pad, Accelerator Pedal ...........................................................................
Screw, Slotted Hex Washer Head, #10-16 x 1/2 ....................................
Screw, Hex Cap, 3/8-16 x 1-1/2 .................................................................
Washer, Flat, 3/8 ........................................................................................
Kit, Accelerator Pivot Rod (includes Item 7) ...............................................
Spacer ....................................................................................................
Stud, Ball (for all vehicles except those equipped with MCOR) ..................
Screw, Hex Head Cap, 1/4-20 x 1-3/8 (MCOR vehicles) ............................
Bearing, Pivot Support ...............................................................................
Nut, Flange, 1/4-28 ....................................................................................
Retainer, Spring .........................................................................................
Spring, Return ............................................................................................
Cup, Spring ................................................................................................
Bumper, Return Spring ..............................................................................
Washer, Flat, 5/16 ......................................................................................
Nut, Nylon Lock, 5/16-18 ............................................................................
Assembly, Accelerator Rod (PowerDrive System 48
vehicles equipped with multi-step potentiometers and
all V-Glide 36-Volt vehicles) (includes items 18 and 19)..............................
Assembly, Accelerator Rod (gasoline vehicle only)
(includes items 18 and 19) .........................................................................
Nut, UNF Hex Jam, 1/4-28 .....................................................................
Joint, Spring-Loaded Ball .......................................................................
Nut, Nylon Lock, 3/8-16 ..............................................................................
Nut, Nylon Lock, 1/4-20 ..............................................................................
Washer, Flat, Type B, 1/4 ...........................................................................
Support, Accelerator Pivot Rod ..................................................................
Screw, Hex Cap, 1/4-20 x 1-1/8 .................................................................
Kit, Park Brake Latch (includes item 25, and items 16 - 20 on page 4-5) ..
Ratchet, Park Brake ...............................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
2
2
2
4
4
2
4
1
1
2
2
2
4
4
2
4
1
1
Page 4-7
4
G
E
4
G
E
STEERING,
FRONT AND REAR SUSPENSION
5
G
E
5
30
G
E
26
28
27
23
29
21
25
19
20
24
17
22
12
18
15
18
13
16
5
14
17
21
19
TYPICAL 2
PLACES
9
20
7
7
8
TYPICAL 2
PLACES
6
2
TYPICAL
3 PLACES
3
4
1
Page 5-2
2001/2002 DS Golf Cars Illustrated Parts List
TYPICAL 2
PLACES
11
10
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
2
3
QTY
4
1013861
1017226
7174
101984801
1016663
1016269
334
1016183
8754
1014288
1011697
102278001
1016181
1012605
1012604
1014217
1014125
1014213
1014126
1015545
1016622
1014214
1016263
1016156
1017273
1016219
1012565
1012566
1016214
1016154
Joint, Compound Steering (includes items 2 and 3) .............................................
Screw, Hex Head Cap, M8 x 1.25 x 30 mm ......................................................
Washer, Lock, 5/16 ...........................................................................................
Kit, Steering Column Mounting Bracket ................................................................
Screw, Phillips, Type A, #12-11 x 5/8 ....................................................................
Screw, Hex Washer Head Thread-Forming, 5/16-18 x 2 .......................................
Washer, Flat, 3/8 ...................................................................................................
Screw, Hex Head Cap, 3/8-16 x 7 .........................................................................
Nut, Nylon Lock, 3/8-16 .........................................................................................
Screw, Hex Washer Head Thread-Forming, 5/16-18 x 3/4 ....................................
Washer, Flat, 5/16 .................................................................................................
Boot, Steering Column ..........................................................................................
Assembly, Steering Column (includes items 14 - 22) ............................................
Ring, Retaining .................................................................................................
Washer, Steel, 5/8 .............................................................................................
Spring, Compression ........................................................................................
Wedge ...............................................................................................................
Assembly, Bearing ............................................................................................
Seat, Bearing ....................................................................................................
Shaft, Steering Column .....................................................................................
Column, Aluminum Steering .............................................................................
Ring, Retaining .................................................................................................
Cover, Steering Column ........................................................................................
Wheel, Steering ....................................................................................................
Nut, Nylon Lock, 5/8-18 .........................................................................................
Assembly, Scorecard Plate (includes items 27 - 30) .............................................
Screw, Round Head, #12-14 x 1 .......................................................................
Spring, Tapered Compression ...........................................................................
Grip, Pencil ........................................................................................................
Clip, Scorecard ..................................................................................................
1
3
3
1
2
2
4
2
2
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
2
2
1
1
1014216
Kit, Steering Column Rebuild (not shown) ............................................................
A/R
2001/2002 DS Golf Cars Illustrated Parts List
Page 5-3
5
G
E
5
G
23
28
22
1
E
2
25
3
4
27
26
21
24
11
10
9
8
5
7
6
12
29
13
14
30
TYPICAL
3 PLACES
31
TYPICAL
3 PLACES
19
16
17
18
2
Page 5-4
2001/2002 DS Golf Cars Illustrated Parts List
20
15
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
101878302
1013035
8990
101880201
101880301
N/A
N/A
N/A
101879401
101879901
1013051
1013052
101879701
101879801
1013044
N/A
N/A
101879501
101879601
101880001
101880101
1035
7540
1015597
7602
1011930
7555
1012467
1013042
1624
334
8754
2
3
QTY
4
Assembly, Steering Gear Box (includes items 1 - 20) ...........................................
Seal, Dust, Passenger Side ..............................................................................
Tie, Wire ............................................................................................................
Assembly, Inner Ball Joint .................................................................................
Washer, Tab ......................................................................................................
Box, Steering Gear ...........................................................................................
Bearing, Lower Pinion .......................................................................................
Pinion, Steering .................................................................................................
Bearing, Upper Pinion .......................................................................................
Ring, C-Type Stop .............................................................................................
Ring, Snap ........................................................................................................
Seal, Dust, Steering Pinion ...............................................................................
Guide, Steering Rack ........................................................................................
Spring, Yoke ......................................................................................................
Nut, Lock, Rack Screw ......................................................................................
Screw, Rack Guide ............................................................................................
Rack, Steering ..................................................................................................
Washer, Stop .....................................................................................................
Ring, C-Type Stop .............................................................................................
Seal, Dust, Driver Side ......................................................................................
Ring, Retaining .................................................................................................
Pin, Cotter, 3/32 x 1 ..............................................................................................
Ball Joint, Left-Hand Thread (includes items 23, 24 and 25) ................................
Fitting, Thread-Forming Grease, 1/4-28 ............................................................
Nut, Hex Slotted, 3/8-24 ....................................................................................
Boot, Dust ..........................................................................................................
Nut, Hex, Left-Hand Thread, 1/2-20 ......................................................................
Link, Rack and Pinion Drag ...................................................................................
Nut, Hex, M12 x 1.75 ............................................................................................
Screw, Hex Head Cap, 3/8-16 x 1-1/2 ...................................................................
Washer, Flat, 3/8 ...................................................................................................
Nut, Nylon Lock, 3/8-16 .........................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
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
1
1
3
3
3
Page 5-5
5
G
E
5
TYPICAL
2 PLACES
G
5
8
E
REFERENCE
STEERING GEAR
15
14
TYPICAL 4
PLACES
7
21
5
10
12
15
11
9
13
2
16
18
19
TYPICAL
2 PLACES
5
10
4
2
3
2
18
5
TYPICAL
2 PLACES
2
4
1
2
20
6
TYPICAL 4
PLACES
17
TYPICAL
2 PLACES
22
Page 5-6
2001/2002 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
1016353
1016346
1016350
1016349
8754
1010200
1308
8861
1010138
2402
1010219
7555
7540
7539
1015597
1011930
7602
1017266
1014235
1010124
1016385
1035
2
3
QTY
4
Assembly, Delta A-Plate (includes items 2, 3 and 4) ............................................
Bushing, Urethane ............................................................................................
Sleeve, Delta Outer ...........................................................................................
Sleeve, Delta Inner ............................................................................................
Nut, Nylon Lock, 3/8-16 .........................................................................................
Screw, Hex Head Cap, 3/8-16 x 4-1/4 ...................................................................
Nut, Hex, 1/2-20 ....................................................................................................
Screw, Hex Head Cap, 3/8-16 x 1-3/4 ...................................................................
Nut, Dimpled Lock, 3/8-16 .....................................................................................
Screw, Hex Head Cap, 3/8-16 x 2-1/4 ...................................................................
Rod, Tie .................................................................................................................
Nut, Hex, Left-Hand Thread, 1/2-20 ......................................................................
Ball Joint, Left-Hand Thread (includes items 15, 16 and 17) ................................
Ball Joint (includes items 15, 16 and 17) ..............................................................
Fitting, Thread-Forming Grease, 1/4-28 ............................................................
Boot, Dust .........................................................................................................
Nut, Slotted Hex, 3/8-24 ....................................................................................
Strap, A-Plate ........................................................................................................
Shock Absorber, Front ..........................................................................................
Plate, Spring Mounting ..........................................................................................
Assembly, Delta Shock and Gear Support ............................................................
Pin, Cotter, 3/32 x 1 ..............................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
2
6
1
2
10
4
1
2
2
4
1
1
1
1
1
1
1
1
2
3
1
3
Page 5-7
5
G
E
5
G
E
REFERENCE
STEERING GEAR
ASSEMBLY
15
17
PASSENGER
SIDE ONLY
2
14
16
18
3
29
TYPICAL
4 PLACES
5
25
1
TYPICAL
4 PLACES
DRIVER
SIDE ONLY
24
26
11
14
20
4
23
27
21
19
7
12
10
8
26
9
TYPICAL
4 PLACES
6
30
28
31
Page 5-8
2001/2002 DS Golf Cars Illustrated Parts List
10
22
13
FRONT SUSPENSION, LOWER
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1010348
1010347
8067
7048
1015597
1012030
8745
706
1011892
1011393
1011304
1013135
1011887
8754
1016387
1016384
101903101
1010150
1016389
1010984
1010005
7840
7910
8755
1016386
1015583
1012303
1014276
1624
357
706
2
3
QTY
4
Assembly, Spindle, Driver Side (includes items 3, 4 and 5) ..................................
Assembly, Spindle, Passenger Side (includes items 3, 4 and 5) ..........................
Bushing, Bronze Spindle ...................................................................................
Bushing, Bronze ................................................................................................
Fitting, Grease, 1/4-28 ......................................................................................
Spring, Tapered Leaf .............................................................................................
Assembly, Eccentric ..............................................................................................
Nut, Hex, 3/8-16 ....................................................................................................
Assembly, Hub (includes items 10 - 13) ................................................................
Package, Hub Bearing ......................................................................................
Stud, Lug, 1/2-20 ..............................................................................................
Seal, Double Lip ................................................................................................
Cover, Dust .......................................................................................................
Nut, Nylon Lock, 3/8-16 .........................................................................................
Screw, Hex Head Cap, 3/8-16 x 2-3/4 ...................................................................
Clevis, Upper Delta ...............................................................................................
Nut, Nylon Lock, 1/2-20 .........................................................................................
Bearing, Thrust ......................................................................................................
Washer, Kingpin Wave ..........................................................................................
Nut, Lug ................................................................................................................
Washer, Flat, 3/4 ...................................................................................................
Nut, Hex Slotted, 3/4-16 ........................................................................................
Pin, Cotter, 5/32 x 1 ..............................................................................................
Screw, Hex Head Cap, 3/8 - 16 x 3-3/8 .................................................................
Kingpin ..................................................................................................................
Bushing, Urethane ................................................................................................
Bushing, Steel .......................................................................................................
Plate, Front Spring Retainer ..................................................................................
Screw, Hex Head Cap, 3/8-16 x 1-1/2 ...................................................................
Washer, Lock, 3/8 .................................................................................................
Nut, Hex, 3/8-16 ....................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
1
2
2
4
1
1
4
2
2
2
2
2
8
2
2
2
2
2
4
2
1
4
4
4
Page 5-9
5
G
E
5
G
BRAKE CABLE
HANGER MOUNTING—
GASOLINE VEHICLE ONLY
E
TYPICAL ON
EACH SIDE
OF VEHICLE
17
TYPICAL ON
EACH SIDE
OF VEHICLE
BRAKE CABLE
HANGER MOUNTING—
ELECTRIC VEHICLE ONLY
16
4
14
3
14
2
11
4
1
3
4
7
12
2
1
6
14
2
9
15
4
10
3
13
10
8
TYPICAL 2
PLACES
9
5
Page 5-10
2001/2002 DS Golf Cars Illustrated Parts List
4
REAR SUSPENSION
ITEM
PART NO.
1
1
1
2
3
4
5
6
7
8
9
10
11
12
12
13
14
15
15
16
17
1012304
7569
8754
1012303
1015583
1010145
1013164
1014236
1011415
N/A
N/A
1012180
1012324
1010974
1014555
8755
1012182
1012181
101900801
1013207
QTY
GAS
DESCRIPTION
2
3
QTY
ELEC
4
Shackle, Rear Spring (gasoline vehicle) ....................................................
Shackle, Rear Spring (electric vehicle) (not shown) ..................................
Nut, Nylon Lock, 3/8-16 ..............................................................................
Bushing, Steel ............................................................................................
Bushing, Urethane .....................................................................................
Nut, UNF Hex, 3/8-24 .................................................................................
Kit, Shock Absorber (includes items 7, 9, and 10) .....................................
Shock Absorber, Rear ............................................................................
Kit, Shock Absorber Cushion (includes 2 each of items 9 and 10) .............
Retainer, Shock Absorber Cushion ........................................................
Cushion, Shock Absorber ......................................................................
U-Bolt .........................................................................................................
Spring, Rear Leaf (gasoline vehicle) ..........................................................
Spring, Rear Leaf (electric vehicle) ............................................................
Nut, Nylon Lock, 7/16-24 ............................................................................
Screw, Hex Head Cap, 3/8-16 x 3-3/8 ........................................................
Pad, Spring, Driver Side .............................................................................
Pad, Spring, Passenger Side .....................................................................
Hanger, Brake Cable (gasoline vehicle) .....................................................
Hanger, Brake Cable (electric vehicle) .......................................................
2001/2002 DS Golf Cars Illustrated Parts List
G
4
6
6
12
4
1
2
4
8
8
2
2
4
6
1
1
2
5
4
6
6
12
4
1
2
4
8
8
2
2
4
6
1
1
2
Page 5-11
E
5
G
E
ELECTRICAL SYSTEM –
GASOLINE VEHICLE
6
G
E
6
G
14
4
3
E
13
FORWARD / REVERSE
ASSEMBLY
CK
B LA
FRAME
GROUND
RED
TE
WH I
R
E
WHIT
LIMIT
SWITCHES
E
CK
B LA
2
N
O RA
KEY
SWITCH
1
3
LOW
BLA
GE
RED
/ WH
GR
ITE
CK
5
OIL
LIGHT
2
RED / WHITE
WH
BL A
E
WHIT
REVERSE
BUZZER
RED
ITE
/ WH
BLA
ITE/
LIMIT
SWITCHES
CK
BLA EEN
GR
ORA
CK
6
15
NGE
7
WH I
CK
CK
BLA
TE /
4
E
WHIT
CK
BL A
BL U
E
FRAME
GROUND
SOLENOID
RE D
E
BLU
RED
WHITE / BLACK
RED ITE
WH
RE D
VOLTAGE
REGULATOR
R ED
O RA
NGE
YELLOW
RED
BLACK
FUSE
BLOCK
17
8
16
IRE
E
ND W
WIR
ROU
G
UND
IDED
GRO
D
E
BRA
ID
K
LAC
BRA
E/B
WHIT
TE
WH I
18
STARTER /
GENERATOR
F2
DF
A1
9
F1
A2
YELLOW
WHITE
BLACK
BATTERY
ENGINE
YE L L O W
OIL
SENDING
UNIT
/ BLACK
BLACK
YELLO
YELLOW W
BLA C K
10
12
YELLOW
YELLOW
N
EE
GR
RPM LIMITER
WHITE
FRAME
GROUND
19
11
Page 6-2
1
E EN
LOW
1
WHITE
BLUE
2
M-
M+
E
WHIT
ED /
YE L
YEL
BL U
K
C
A
/ BL
2001/2002 DS Golf Cars Illustrated Parts List
WIRING – GASOLINE VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
101889302
N/A
N/A
N/A
N/A
N/A
N/A
1015769
N/A
N/A
1014119
N/A
1012382
N/A
N/A
N/A
1015920
1015737
1015332
101837301
2
3
QTY
4
Wire Harness (includes items 1 - 11) ....................................................................
Wire Assembly, #18 Red/White .........................................................................
Wire Assembly, #18 Yellow ................................................................................
Wire Assembly, #18 Yellow and #16 Blue ..........................................................
Wire Assembly, #18 White/Black and #18 White ...............................................
Wire Assembly, #18 Green ...............................................................................
Wire Assembly, #18 Black .................................................................................
Wire Assembly, #6 White ..................................................................................
Wire Assembly, #16 Red and #16 Orange ........................................................
Wire Assembly, #16 Yellow ................................................................................
Wire Assembly, #6 Red .....................................................................................
Wire Assembly, #18 Yellow ................................................................................
Wire Assembly, #6 Black .......................................................................................
Wire Assembly, #18 Black .....................................................................................
Wire Assembly, #18 Black (part of reverse buzzer kit) ..........................................
Wire Assembly, #16 Orange (part of the electrical component box) .....................
Wire Assembly, #6 Braided Ground ......................................................................
Wire Assembly, #10 Red (part of the electrical component box) ..........................
Wire Assembly, #10 Braided Ground ....................................................................
Wire Assembly, #6 Green .....................................................................................
2001/2002 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
Page 6-3
6
G
E
6
G
22
23
E
TYPICAL 4
PLACES
2
21
3
24
4
9
1
5
6
NC
NO
M
CO
25
26
8
8
2
11
13
10
12
14
20
19
7
27
18
16
17
15
28
20
19
24
29
Clu
b
Ca
r
30
Page 6-4
2001/2002 DS Golf Cars Illustrated Parts List
TYPICAL 3
PLACES
FORWARD/REVERSE SHIFTER ASSEMBLY –
GASOLINE VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1016947
1012594
8057
1012431
101979101
1014807
8058
1013591
1014145
1014727
1016342
1014089
1014065
1013590
1013589
8717
1013587
1010954
101951501
7893
1012333
1013198
1012987
8248
8233
1016201
8251
101855801
332
101922601
1012285
2
3
QTY
4
Assembly, Forward/Reverse Shifter (includes items 1 - 17) ..................................
Screw, Machine, #4-40 x 1-1/2 ..........................................................................
Nut, Hex Head, #4-40 .......................................................................................
Washer, Flat, #4 ................................................................................................
Switch, Limit ......................................................................................................
Switch, Limit ......................................................................................................
Washer, Lock, #4 ..............................................................................................
Pin, Roll, 1/8 ......................................................................................................
Bushing, Bronze ................................................................................................
Washer, Nylon Flat, #4 ......................................................................................
Base, Forward/Reverse Shifter .........................................................................
Kit, Neutral Lockout Cam (includes item 12) .....................................................
Washer, Flat .................................................................................................
Spring, Forward/Reverse Cam ..........................................................................
Ring, Retaining .................................................................................................
Nut, Nylon Lock, 1/4-28 ....................................................................................
Weldment, Forward/Reverse Bell Crank ...........................................................
Stud, Ball, 1/4-28 x 1/4 ......................................................................................
Cable, Transmission (includes items 19 and 20) ...................................................
Nut, Hex, #10-32 ...............................................................................................
Joint, Ball ..........................................................................................................
Screw, Phillips Oval Countersunk Machine, #8-32 x 5/8 .......................................
Handle, Forward/Reverse Switch ..........................................................................
Screw, Phillips Truss Head, 1/4-20 x 3/4 ...............................................................
Nut, Nylon Lock, 1/4-20 .........................................................................................
Washer, Wave, 3/8 ................................................................................................
Screw, Phillips Head, 1/4-20 x 1 ............................................................................
Retainer, Cable .....................................................................................................
Washer, Flat, 1/4 ...................................................................................................
Bracket, Transmission Cable Support ...................................................................
Screw, Thread Rolling, 1/4-20 x 5/8 ......................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
2
4
4
1
1
2
1
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
4
8
1
4
1
4
1
3
Page 6-5
6
G
E
6
G
2
1
E
10
TYPICAL 2
PLACES
11
REFERENCE
ACCELERATOR CABLE
12
3
13
ORANGE WIRE
ASSEMBLY
19
15
10
TYPICAL 2
PLACES
20
14
17
TYPICAL 2
PLACES
4
2
18
TYPICAL 2
PLACES
5
16
TYPICAL 2
PLACES
29
21
10
22
23
26
5
25
TO FRAME
GROUND
6
FRO
NT
VEH OF
ICLE
REFERENCE
ACCELERATOR ROD
8
28
Page 6-6
27
9
2001/2002 DS Golf Cars Illustrated Parts List
2
TYPICAL 2
PLACES
7
TYPICAL 2
PLACES
24
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
101992601
1015372
1015752
1013589
1015373
1014145
1014065
1010954
101821301
8717
8057
8058
1014807
1014808
1012431
N/A
1015878
101856102
1015777
7893
1242
1013609
1012295
1015737
1015741
1015371
1015405
1241
7473
7818
2
3
QTY
4
Box, Electrical Component, Complete (includes items 1 - 25) ...............................
Cover, Electrical Component Box .....................................................................
Screw, Hi-Lo, #12-16 x 5/8 ................................................................................
Ring, Retaining .................................................................................................
Cam, Electrical Box ...........................................................................................
Bushing, Bronze ................................................................................................
Washer, Flat ......................................................................................................
Stud, Ball, 1/4-28 ..............................................................................................
Assembly, Bell Crank and Shaft ........................................................................
Nut, Nylon Lock, 1/4-28 ....................................................................................
Nut, Hex, #4-40 .................................................................................................
Washer, Lock, #4 ..............................................................................................
Switch, Limit ......................................................................................................
Switch, Limit ......................................................................................................
Washer, Flat, #4 ................................................................................................
Wire Assembly, #16 Orange .............................................................................
Screw, Hex Head Machine, #4-40 x 1-5/8 .........................................................
Screw, Hex Washer Head Hi-Lo, 1/4-15 x 1-1/2 ................................................
Assembly, Voltage Regulator ............................................................................
Nut, Hex, #10-32 ...............................................................................................
Nut, Hex, 5/16-18 ..............................................................................................
Solenoid, 12-Volt ...............................................................................................
Fuse, 10-Amp ...................................................................................................
Wire Assembly, #10 Red ...................................................................................
Block, Fuse .......................................................................................................
Box, Electrical Component ................................................................................
Screw, Round-Head Square-Neck, 5/16-18 x 2 ....................................................
Washer, Flat, 5/16 .................................................................................................
Nut, Nylon Lock, 5/16-18 .......................................................................................
Screw, Round-Head Square-Neck, 5/16-18 x 1-1/2 ..............................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
5
1
1
2
1
1
1
1
4
2
1
1
2
1
2
1
1
2
2
1
1
1
1
1
1
2
2
1
Page 6-7
6
G
E
6
G
E
5
AS SEEN
FROM FRONT
DRIVER SIDE
OF VEHICLE,
BODY
REMOVED
6
M-
1
2
M+
10
ON
OFF
11
4
2
1
8
7
9
TYPICAL
4 PLACES
3
OFF ON
13
14
TYPICAL
3 PLACES
Page 6-8
2001/2002 DS Golf Cars Illustrated Parts List
12
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
1016859
1016849
1016851
N/A
1011229
1015720
101830601
101826301
101851101
101830701
101834502
1012505
1016630
101900901
2
3
QTY
4
Kit, Reverse Buzzer (includes items 2, 3 and 4) ...................................................
Screw, Pan Head Hi-Lo, #4-24 x 5/16 ...............................................................
Buzzer, Reverse ................................................................................................
Wire Assembly, #18 Black .................................................................................
Nut, K Lock, #6-32 ................................................................................................
Screw, Hex Washer Head, #6-32 x 1/2 .................................................................
Assembly, Screw and Washer ...............................................................................
Switch, Key ...........................................................................................................
Washer ..................................................................................................................
Nut, Key Switch .....................................................................................................
Cap, Key Switch (black) ........................................................................................
Key (pair) ...............................................................................................................
Light, Oil Warning ..................................................................................................
Retainer, Harness .................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
2
1
1
1
1
4
1
1
1
1
1
1
3
Page 6-9
6
G
E
6
G
24
TYPICAL
2 PLACES
E
TYPICAL
3 PLACES
TYPICAL
4 PLACES
15
26
27
TYPICAL
2 PLACES
30
21
14
TYPICAL
2 PLACES
29
28
TYPICAL
4 PLACES
TYPICAL
2 PLACES
AT F1 AND
F2 TERMINALS
TYPICAL
4 PLACES
22
18
17
20
19
23
TYPICAL
2 PLACES
AT A1 AND
A2 TERMINALS
DF
TERMINAL
16
25
TYPICAL
2 PLACES
12
11
8
1
TYPICAL
3 PLACES
7
5
9
10
2
3
4
6
13
Page 6-10
2001/2002 DS Golf Cars Illustrated Parts List
31
STARTER/GENERATOR ASSEMBLY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
101833701
101875201
101875101
101875001
1013001
1013005
101939901
1013003
101876501
N/A
N/A
N/A
101896501
101874901
101875301
101875401
101875501
101875601
101877601
101875701
101877701
101301102
101878101
101876001
101876301
1017653
101876402
101879001
101869302
101876202
101875802
1014289
2
3
QTY
4
Starter/Generator (clockwise rotation) (includes items 1 - 30) ..............................
Housing, Field Coil ............................................................................................
Assembly, Armature (includes items 3 - 6) ........................................................
Retainer, Bearing .........................................................................................
Ball Bearing, Output Shaft ............................................................................
Commutator, Ball Bearing ............................................................................
Spacer, 5/16 .................................................................................................
Key, Woodruff ....................................................................................................
Kit, Pulley Nut and Screw (includes items 9 - 12) .............................................
Washer, Lock, M14 .......................................................................................
Nut, Hex, M14 x 2 .........................................................................................
Screw, Cross-Recessed, M5 x .8 x 18 mm ..................................................
Screw, Cross-Recessed, M5 x .8 x 16 mm (with lock washer) .....................
End Bell, Output Shaft ......................................................................................
Set, Pole (set of 4) ............................................................................................
Screw, Pole Piece (set of 4) ..............................................................................
Coil, Field ..........................................................................................................
Insulator, F Terminal ..........................................................................................
Package, Terminal Hardware (F1 and F2) ........................................................
Insulator, DF Terminal .......................................................................................
Package, Terminal Hardware (DF) ....................................................................
Holder, Brush (includes item 22) .......................................................................
Spring, Brush ...............................................................................................
Package, Terminal Hardware (A1 and A2) ........................................................
Cover, Brush Inspection Port (Set of 4) (includes item 25) ...............................
Cover, Brush Inspection Port, with Drain ......................................................
End Bell, Commutator .......................................................................................
Bolt, Clamp, M6 x 1 x 180 mm ..........................................................................
Package, Brush (includes 4 brushes, 4 screws, 4 washers) .............................
Connector, Brush ..............................................................................................
A Connector (set of 2) .......................................................................................
Pulley ....................................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
1
1
2
2
1
1
1
4
2
1
1
1
2
1
2
1
1
Page 6-11
6
G
E
6
G
E
FRAME
CONNECTION
17
16
15
14
AS VIEWED FROM
DRIVER SIDE
OF VEHICLE
A1 TERMINAL
F1
TERMINAL
A2 TERMINAL
TYPICAL
2 PLACES
7
5
13
8
9
6
8
9
1
2
F2
DF
3
4
12
9
AS VIEWED FROM
PASSENGER SIDE OF VEHICLE
11
10
Page 6-12
2001/2002 DS Golf Cars Illustrated Parts List
STARTER/GENERATOR MOUNTING
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
101833701
101524001
101916701
1016883
8754
1015075
705
1012830
7174
1016074
1015932
1242
101837301
1015920
7473
1241
7173
2
3
QTY
4
Starter/Generator (clockwise rotation) ..................................................................
Bracket, Mounting, FE290 .....................................................................................
Belt, Starter/Generator ..........................................................................................
Bracket, Adjusting .................................................................................................
Nut, Nylon Lock, 3/8-16 .........................................................................................
Washer, Flat, 5/16 .................................................................................................
Screw, Hex Head Cap, 3/8-16 x 1-1/4 ...................................................................
Screw, Hex Head Cap, M8 x 1.25 x 22 mm ..........................................................
Washer, Lock, 5/16 ...............................................................................................
Screw, Torx Head, M8 x 1.25 x 18 mm ..................................................................
Screw, Round-Head Square-Neck, 5/16-18 x 1 ....................................................
Nut, Hex, 5/16-18 ..................................................................................................
Wire Assembly, #6 Green .....................................................................................
Wire Assembly, #6 Braided Ground ......................................................................
Nut, Nylon Lock, 5/16-18 .......................................................................................
Washer, Flat, 5/16 .................................................................................................
Screw, Hex Head Cap, 5/16-18 x 3/4 ....................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
2
1
2
2
3
1
1
1
1
1
1
1
1
Page 6-13
6
G
E
6
G
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
1
E
2
3
4
5
TO NEGATIVE
BATTERY POST
TERMINAL
6
9
7
8
7
8
Page 6-14
AS SEEN FROM
DRIVER SIDE
OF VEHICLE
2001/2002 DS Golf Cars Illustrated Parts List
BATTERY – GASOLINE VEHICLE
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
1012328
1014374
1014375
1010934
101898001
7173
1241
7473
1014288
2
3
QTY
4
Battery, 12-Volt ......................................................................................................
Spacer, Battery Terminal Bolt ................................................................................
Screw, Hex Head Cap, Stainless Steel, 3/8-16 x 1/2 ............................................
Screw, Hex Head Cap, 5/16-18 x 1 .......................................................................
Clamp, Battery ......................................................................................................
Screw, Hex Head Cap, 5/16-18 x 3/4 ....................................................................
Washer, Flat, 5/16 .................................................................................................
Nut, Nylon Lock, 5/16-18 .......................................................................................
Screw, Thread-Forming, 5/16-18 x 3/4 ..................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
2
2
1
1
1
2
2
1
Page 6-15
6
G
E
6
G
E
FE290 ENGINE
7
G
E
7
G
E
REF.
1
TYPICAL 6 PLACES
FOR ITEM 9
8
3
REF.
2
4
9
TYPICAL 4
PLACES
FOR ITEM 18
17
4
TYPICAL 4
PLACES
FOR ITEM 3
7
6
TYPICAL 2
PLACES
CARBURETOR
REMOVED
FOR CLARITY
18
2
5
TYPICAL 2
PLACES
1
15
5
10
TYPICAL 3 PLACES
FOR ITEM 10
4
16
14
12
11
4
TYPICAL 2
PLACES
Page 7-2
2001/2002 DS Golf Cars Illustrated Parts List
13
FE290 ENGINE – SHROUDS AND BRACKETS
ITEM
PART NO.
DESCRIPTION
1
101953901
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1016507
1016512
1016524
1016456
1016547
101909701
1016526
1017221
101915601
1016525
1016443
1016539
1016536
1016531
101887601
1015332
1015969
1015649
2
3
QTY
4
FE290 OHV Gasoline Engine (clockwise rotation) with Carburetor
(does not include items 15 through 18) .................................................................
Bolt, 2-Ended, M6 x 1 x 29 mm .........................................................................
Washer, Flat, 6 mm ...........................................................................................
Shroud, Engine, FE290 .....................................................................................
Bolt, Flanged, M6 x 1 x 12 mm .........................................................................
Nut, Flange, M6 x 1 ...........................................................................................
Bolt, 2-Ended, M6 x 1 x 27 mm .........................................................................
Shroud, Engine, FE290 (lower) .........................................................................
Bolt, 2-Ended, M6 x 1 x 46 mm .........................................................................
Housing, Fan .....................................................................................................
Shroud, Engine, FE290 (Upper) .......................................................................
Bracket ...............................................................................................................
O-Ring ...............................................................................................................
Tube, Oil Filler, FE290 .......................................................................................
Dipstick .............................................................................................................
Nut, Nylon Lock, M6 x 1 ........................................................................................
Wire Assembly, #10 Braided Ground ....................................................................
Screw, Pan Head, M6 x 1 x 14 mm .......................................................................
Shroud, Fan ..........................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
7
G
1
1
1
1
15
3
2
1
1
1
1
1
1
1
1
1
1
4
1
Page 7-3
E
7
G
E
11
12
13
10
9
8
TYPICAL 2
PLACES
7
19
18
16
24
23
1
2
22
21
17
25
TYPICAL 3
PLACES
20
3
15
14
TYPICAL 2
PLACES
5
4
6
Page 7-4
2001/2002 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
101915701
101915801
1017448
1016548
1016505
1017455
1016562
1016455
101909201
1016578
1016588
1016493
101881101
1016456
1012981
1016579
1016586
101909401
1016445
101909501
1016497
1016544
1016561
1016587
101909301
2
3
QTY
4
Flywheel ............................................................................................................
Fan, Flywheel, Gray ..........................................................................................
Screw, Flanged Hex Head, M6 x 1 x 10 mm .....................................................
Washer, Flat, 16 mm .........................................................................................
Nut, Hex, M16 x 1.5 ..........................................................................................
Plate, Flywheel Fan ...........................................................................................
Key ....................................................................................................................
Bolt, Flanged, M5 x.8 x 25 mm .........................................................................
Coil, Ignition (with internal igniter) .....................................................................
Grommet ...........................................................................................................
Tube, 7 mm x 70 mm ........................................................................................
Assembly, Plug Cap ..........................................................................................
Plug, Spark, OHV ..............................................................................................
Bolt, Flanged, M6 x 1 x 12 mm .........................................................................
Clamp ................................................................................................................
Band, RPM Limiter Mount .................................................................................
Damper, RPM Limiter ........................................................................................
Limiter, RPM, OHV ............................................................................................
Bracket, RPM Limiter ........................................................................................
Clamp ................................................................................................................
Screw, Cross Pan Head, M5 x.8 x 8 mm ..........................................................
Screw, Cross Pan Head Self-Tapping, M5 x.8 x 12 mm ...................................
Clamp ................................................................................................................
Clamp ................................................................................................................
Wire, Lead .........................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
3
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
Page 7-5
7
G
E
7
G
E
5
15
14
TYPICAL 2
PLACES
13
4
12
11
10
9
3
TYPICAL 2
PLACES
7
2
6
1
Page 7-6
2001/2002 DS Golf Cars Illustrated Parts List
8
TYPICAL 6
PLACES
FE290 ENGINE – OIL CIRCULATION
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1016467
1016502
1016457
1017507
1016570
1016576
1016432
1017456
1016484
1016435
1016473
101648203
1016429
1016537
1016581
2
3
QTY
4
Oil Filter .............................................................................................................
Bracket, Oil Filter ...............................................................................................
Bolt, Flanged Hex Head, M6 x 1 x 40 mm ........................................................
Plug ...................................................................................................................
O-Ring, Oil Filter Mount ....................................................................................
Plug, Drain, FE290 ............................................................................................
Gasket, Drain Plug ............................................................................................
Screw, Flanged Hex Head, M6 x 1 x 12 mm .....................................................
Cover, Pump .....................................................................................................
Gasket, Oil Pump ..............................................................................................
Plate, Oil Pump .................................................................................................
Pump, Oil and Rotor ..........................................................................................
Seat, Valve ........................................................................................................
Ball, Steel, Pressure Relief ...............................................................................
Spring ................................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
2
2
1
1
1
6
1
1
1
1
1
1
1
Page 7-7
7
G
E
7
G
E
5
6
7
TYPICAL 2
PLACES
8
9
10
14
1
15
2
12
13
EXHAUST
16
18
INTAKE
19
17
20
22
11
TYPICAL 2
PLACES
AT EXHAUST
CONNECTION
TYPICAL 2
PLACES
21
3
4
TYPICAL 2
PLACES
23
25
26
24
TYPICAL 2
PLACES
Page 7-8
27
TYPICAL 6
PLACES
28
2001/2002 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
2
3
QTY
4
1016442
1016436
1016583
1016569
1016545
1016542
1016451
1016450
1016449
1016523
1016431
1016560
1016519
1016479
1016566
1016448
1016447
1016544
1016474
1016483
1016563
1016489
1016452
1016471
1016549
1016517
1016458
1016430
Case, Rocker ....................................................................................................
Gasket, Rocker Case ........................................................................................
Bolt, Flanged, M6 x 1 x 35 mm .........................................................................
O-Ring ...............................................................................................................
Nut, Hex, M5 x .8 ..............................................................................................
Screw, Stud, M5 x .8 .........................................................................................
Arm, Rocker ......................................................................................................
Collet..................................................................................................................
Retainer, Valve Spring .......................................................................................
Spring, Engine Valve .........................................................................................
Assembly, Cylinder Head, OHV (includes items 12 and 13) .............................
Ring, Snap ....................................................................................................
Guide, Valve .................................................................................................
Seat, Spring ......................................................................................................
Seal, Valve ........................................................................................................
Valve, Exhaust ..................................................................................................
Valve, Intake ......................................................................................................
Screw, Cross Pan Head Self-Tapping, M5 x .8 x 12 mm ..................................
Plate ..................................................................................................................
Valve .................................................................................................................
Pin .....................................................................................................................
Bolt, Stud, M8 x 1.25 x 29 mm ..........................................................................
Shaft, Rocker ....................................................................................................
Rod, Push .........................................................................................................
Washer, Flat, M12 .............................................................................................
Circlip, Type E ...................................................................................................
Bolt, Flanged, M8 x 1.25 x 45 mm ....................................................................
Gasket, Head ....................................................................................................
1
1
2
2
2
2
2
4
2
2
1
2
2
2
2
1
1
1
1
1
2
2
1
2
1
1
6
1
102304701
Kit, Gasket, FE290 (not shown)(contains one each of all internal gaskets for
the FE290 engine) .............................................................................................
1
2001/2002 DS Golf Cars Illustrated Parts List
Page 7-9
7
G
E
7
G
E
TYPICAL 2
PLACES
5
1
CLAMP
ONLY
2
4
3
6
18
17
16
15
14
7
13
TYPICAL 2
PLACES
TYPICAL 3
PLACES
12
11
TYPICAL 2
PLACES
10
20
19
9
TYPICAL 6
PLACES
8
TYPICAL 2
PLACES
Page 7-10
2001/2002 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
1016535
1016538
1016506
1016544
1016564
1016565
1016567
1016584
1016458
1016520
1016446
1016456
1016510
1016494
1016496
1016454
1016472
1016521
101915401
1016453
2
3
QTY
4
Connector, Cord ................................................................................................
O-Ring ...............................................................................................................
Clamp ................................................................................................................
Screw, Cross Pan Head Self-Tapping, M5 x.8 x 12 mm ...................................
Pin .....................................................................................................................
Bearing, Ball ......................................................................................................
Seal, Crankshaft ...............................................................................................
Bolt, 2-Ended, M8 x 1.25 x 69 mm ....................................................................
Bolt, Flanged, M8 x 1.25 x 45 mm ....................................................................
Cover, Crankcase ..............................................................................................
Gasket, Crankcase Cover .................................................................................
Bolt, Flanged, M6 x 1 x 12 mm .........................................................................
Bracket, Oil Level Switch ...................................................................................
Sensor, Oil Level ...............................................................................................
Screw, Cross Pan Head, M4 x.7 x 8 mm ..........................................................
Bolt, Flanged, M5 x.8 x 8 mm ...........................................................................
Plate, Oil Filter Screen ......................................................................................
Screen, Oil Filter ...............................................................................................
Camshaft, Complete .........................................................................................
Tappet ...............................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
2
1
1
2
6
1
1
2
1
1
3
2
1
1
1
2
Page 7-11
7
G
E
7
G
E
6
3
4
1
2
8
TYPICAL 2
PLACES
3
5
7
7
9
14
16
12
13
12
17
13
TYPICAL 4
PLACES
11
20
TYPICAL 4
PLACES
10
15
19
18
Page 7-12
21
2001/2002 DS Golf Cars Illustrated Parts List
FE290 ENGINE – CRANKCASE AND CRANKSHAFT
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
5
5
6
6
6
7
7
8
9
10
11
12
13
14
15
15
15
15
15
15
15
15
15
16
17
18
19
20
21
1016568
101915501
1016558
1016460
101645901
101645902
101645903
101646101
101646102
101646103
101647501
101647502
1016509
101922301
1016533
1016532
1016516
1016580
1016562
101655001
101655002
101655003
101655004
101655005
101655006
101655007
101655008
101655009
1016559
1016541
1016547
1016470
1016571
1016469
2
3
QTY
4
Seal, Oil ............................................................................................................
Crankcase, OHV ...............................................................................................
Ring, Snap ........................................................................................................
Pin, Piston .........................................................................................................
Piston, Standard ...............................................................................................
Piston, .25 mm Oversized .................................................................................
Piston, .50 mm Oversized .................................................................................
Ring Set, Piston, Standard ................................................................................
Ring Set, Piston, .25 mm Oversized .................................................................
Ring Set, Piston, .50 mm Oversized .................................................................
Assembly, Connecting Rod, Standard (includes 2 each of item 8) ...................
Assembly, Connecting Rod, .50 mm Undersized
(includes 2 each of item 8) ................................................................................
Screw, Hex Head Cap, M7 x 1 x 36 mm ...........................................................
Crankshaft, FE290 (left-hand thread)
(includes items 10, 11 and one each of item 12) ..............................................
Gear, Helical .................................................................................................
Gear, Spur ....................................................................................................
Assembly, Rod (includes one each of item 13) ............................................
Bearing, Plain ..........................................................................................
Key ....................................................................................................................
Shim, Crankshaft, 1.13 mm Thick .....................................................................
Shim, Crankshaft, 1.18 mm Thick .....................................................................
Shim, Crankshaft, 1.23 mm Thick .....................................................................
Shim, Crankshaft, 1.28 mm Thick .....................................................................
Shim, Crankshaft, 1.33 mm Thick .....................................................................
Shim, Crankshaft, 1.38 mm Thick .....................................................................
Shim, Crankshaft, 1.43 mm Thick .....................................................................
Shim, Crankshaft, 1.48 mm Thick .....................................................................
Shim, Crankshaft, 1.53 mm Thick .....................................................................
Spacer ...............................................................................................................
Bolt, Stud, M6 x 1 x 22 mm ...............................................................................
Nut, Flanged, M6 x 1 .........................................................................................
Shaft, Counterbalance Guide ............................................................................
O-Ring ...............................................................................................................
Weight, Counterbalance ...................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
A/R
1
4
4
1
1
1
Page 7-13
7
G
E
7
G
FR
O
VE NT O
HIC F
LE
E
REFERENCE
ENGINE
SECTION 7
TYPICAL
2 PLACES
TYPICAL
4 PLACES
8
Clu
bC
ar
5
1
6
2
TYPICAL
2 PLACES
2
3
7
4
10
TYPICAL
4 PLACES
11
TYPICAL
4 PLACES
12
Clu
bC
a
r
TYPICAL
2 PLACES
13
5
6
TYPICAL
4 PLACES
Page 7-14
2001/2002 DS Golf Cars Illustrated Parts List
REFERENCE
UNITIZED TRANSAXLE—
SECTION 11
9
ENGINE MOUNTING
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
1012164
1013924
101834601
101827101
101833001
101884801
101833301
101833201
101832101
101832901
1012571
101855901
101832701
2
3
QTY
4
Snubber .................................................................................................................
Nut, Hex Lock, 5/16-24, UNF ................................................................................
Bracket, Snubber ...................................................................................................
Plate, Mounting .....................................................................................................
Nut, Flange, M8 x 1.25 ..........................................................................................
Screw, Hex Washer, 5/16-24 x 7/8 ........................................................................
Screw, Hex Head Cap, M10 x 1.25 x 30 mm ........................................................
Stud, M8 x 1.25 x 60 mm .......................................................................................
Spacer ...................................................................................................................
Nut, Flange, M10 x 1.25 ........................................................................................
Washer, Heavy Flat, 5/16 ......................................................................................
Screw, Hex Head Cap, M8 x 1.25 x 43 mm ..........................................................
Stiffener, Flywheel Side .........................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
6
1
1
6
6
4
2
2
4
4
4
1
Page 7-15
7
G
E
7
G
E
FUEL, INTAKE,
AND GOVERNOR SYSTEMS
8
G
E
8
G
8
7
4
5
7
3
E
2
6
10
5
11
9
5
1
17
ENGINE REMOVED
FOR CLARITY
19
21
18
20
21
21
SEE ITEM SIX
ABOVE
21
19
12
13
21
21
19
14
23
16
15
19
19
5
21
20
21
21
TO ENGINE CRANKCASE
Page 8-2
22
2001/2002 DS Golf Cars Illustrated Parts List
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
1016003
1015188
1015143
1015139
1015137
101896901
1013746
101824401
101824401
1014928
1013746
1014523
1014524
1017203
101987701
8233
1014116
1011988
1013692
102003201
1012649
8248
1013687
2
3
QTY
4
Kit, Fuel Tank (includes items 2 - 8) ......................................................................
1
Cap, Fuel Tank, Nonvented ...............................................................................
1
Assembly, Fuel Tank Vent ..................................................................................
1
Grommet, Insulation ..........................................................................................
1
Line, Bulk Vent (available by the foot) ............................................................... A/R
Valve, Fuel Pickup Tube with Shut-Off ..............................................................
1
Clamp, Hose .....................................................................................................
2
Barb, Vent ..........................................................................................................
1
Barb, Vent ..............................................................................................................
1
Assembly, Rear Fuel Strap ....................................................................................
1
Clamp, Hose .........................................................................................................
2
Pump, Fuel Impulse ...............................................................................................
1
Rebuild Kit, Fuel Impulse Pump ............................................................................
1
Screw, Round-Head Square-Neck, 1/4-20 x 1 ......................................................
2
Clamp, Plastic .......................................................................................................
1
Nut, Nylon Lock, 1/4-20 .........................................................................................
2
Nut, U-Type Speed, 1/4-20 ...................................................................................
2
Screw, Phillips Truss Head, 1/4-20 x 2 ..................................................................
1
Line, Bulk Fuel (available by the foot) ................................................................... A/R*
Filter, Fuel ..............................................................................................................
2
Clamp, Hose (red) .................................................................................................
9
Screw, Phillips Truss Head, 1/4-20 x 3/4 ...............................................................
1
Clamp, Hose, 3/8 ..................................................................................................
1
* The total fuel line length for the DS Golf Car is 47 inches (119.4 cm).
2001/2002 DS Golf Cars Illustrated Parts List
Page 8-3
8
G
E
8
G
E
2
3
1
4
5
8
6
9
7
10
11
Page 8-4
2001/2002 DS Golf Cars Illustrated Parts List
CARBURETOR ASSEMBLY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
101905601
1016501
N/A
101973101
1016486
101973201
7
7
7
7
7
8
9
10
11
101642582
101642580
101642578
101642575
101642572
1016437
1017461
1016499
1016585
2
3
QTY
4
Assembly, Carburetor (includes items 2 - 11) .......................................................
Assembly, Idle Screw ........................................................................................
Assembly, Pilot Air Screw ..................................................................................
Jet, Pilot, #40 ....................................................................................................
Assembly, Float .................................................................................................
Nozzle, Main .....................................................................................................
Standard Jetting:
Jet, Main, 0 - 3,000 feet ....................................................................................
Jet, Main, 3,000 - 5,000 feet .................................................................................
Jet, Main, 5,000 - 8,000 feet .................................................................................
Jet, Main, 8,000 - 10,000 feet ...............................................................................
Jet, Main, 10,000 Feet and Above ........................................................................
Gasket, Float Chamber .....................................................................................
Assembly, Float Chamber (includes item 10) ....................................................
Assembly, Screw ..........................................................................................
Assembly, Bolt ...................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
A/R
A/R
A/R
A/R
1
1
1
1
Page 8-5
8
G
E
8
G
7
E
6
5
1
2
3
4
8
9
12
10
14
12
11
15
13
16
17
TYPICAL
2 PLACES
Page 8-6
18
2001/2002 DS Golf Cars Illustrated Parts List
CARBURETOR INSTALLATION
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1016440
101648102
1016439
1016444
101820201
1011697
101887601
1016441
1016582
101905601
1013746
1017466
1015137
1016572
1016438
1016480
101649002
1016547
2
3
QTY
4
Gasket, Insulator ...................................................................................................
Insulator, Carburetor .............................................................................................
Gasket, Carburetor Insulator to Throttle Bracket ...................................................
Bracket, Throttle ....................................................................................................
Guard, Governor ...................................................................................................
Washer, Flat, 5/16 .................................................................................................
Nut, Nylon Lock, M6 x 1 ........................................................................................
Gasket, Throttle Bracket to Carburetor ..................................................................
Spring, Throttle Return ..........................................................................................
Assembly, Carburetor ............................................................................................
Clamp, Hose (gray) ...............................................................................................
Clamp, Hose (bronze) ...........................................................................................
Line, Bulk Vent (available by the foot) ...................................................................
Tube, Crankcase Vent ............................................................................................
Gasket, Carburetor to Intake Manifold ..................................................................
Pipe, Intake ...........................................................................................................
Screw, 2-Ended Stud, M6 x 1 x 90 mm .................................................................
Nut, Flanged, M6 x 1 .............................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
1
1
1
1
2
A/R
1
1
1
2
2
Page 8-7
8
G
E
8
7
G
E
6
5
3
4
TYPICAL
2 PLACES
1
2
7
8
9
7
8
12
10
13
14
6
9
11
Page 8-8
2001/2002 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
12
13
14
101832501
101832401
1013700
1016546
101832301
1012285
1016202
1015408
1014413
101832201
1015845
101903501
7174
1011697
2
3
QTY
4
Cable, Accelerator .................................................................................................
Cable, Governor ....................................................................................................
Clamp, Cable Retaining ........................................................................................
Nut, Flanged Hex, M8 x 1.25 ................................................................................
Bracket, Accelerator Support ................................................................................
Screw, Thread-Rolling, 1/4-20 x 5/8 ......................................................................
E-Ring ....................................................................................................................
Pin, Governor Cable Clevis ...................................................................................
Pin, Hair Spring Cotter, 1/8 I.D. x 5/8 ....................................................................
Bracket, Support ....................................................................................................
Bracket, Governor Cable Engine ...........................................................................
Screw, Hex Head Cap, M8 x 1.25 x 24 mm ..........................................................
Washer, Lock, 5/16 ...............................................................................................
Washer, Flat, 5/16 .................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
2
2
1
4
3
2
2
1
1
1
1
1
Page 8-9
8
G
E
8
G
REFERENCE
CARBURETOR
E
1
TYPICAL
2 PLACES
17
18
5
15
6
16
2
3
15
TYPICAL
3 PLACES
4
17
10
19
20
7
21
22
8
9
11
12
13
25
26
26
14
TYPICAL
3 PLACES
14
14
23
24
14
Page 8-10
2001/2002 DS Golf Cars Illustrated Parts List
INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
101821501
101804301
101881701
101925701
101972801
101813001
101917601
N/A
N/A
N/A
101812301
1015426
101811901
101921501
183
101971301
101837101
101850301
101917701
101805701
101811501
101856201
101811401
332
1015752
101958101
1606
101971001
2
3
QTY
4
Assembly, Air Box (includes items 1 - 13) ..............................................................
Screw, Hi-Lo Hex Head, #8-1/2 .........................................................................
Washer, Stainless Steel, #8 ..............................................................................
Latch, Wire ........................................................................................................
Assembly, Air Box Top (includes items 5 - 10) ..................................................
E-Clip ............................................................................................................
Lever, Choke ................................................................................................
O-Ring, 5/16 (red) ........................................................................................
O-Ring, 3/8 (green) ......................................................................................
Valve, Choke ................................................................................................
Spring, Return ..............................................................................................
Filter, Air ............................................................................................................
Bottom, Air Box .................................................................................................
Seal, Intake .......................................................................................................
Washer, Flat, #10 ..................................................................................................
Clamp, Hose (air Intake) .......................................................................................
Hose, Intake ..........................................................................................................
Screw, Hi-Lo, #12 x 1/2 .........................................................................................
Positioner, Choke ..................................................................................................
Assembly, Choke Button (includes items 20, 21 and 22) ......................................
Guide, Choke Lever ..........................................................................................
Spring, Compression ........................................................................................
Lever, Choke .....................................................................................................
Washer, Flat, 1/4 ....................................................................................................
Screw, Hi-Lo, #12-16 x 5/8 ....................................................................................
Assembly, Air Duct ................................................................................................
Rivet, Pop, 3/16 .....................................................................................................
Air Duct Repair Kit (not shown) .............................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
2
2
2
1
1
1
1
1
1
1
1
1
1
4
2
1
4
1
1
1
1
1
3
3
1
2
A/R
Page 8-11
8
G
E
8
G
E
EXHAUST SYSTEM
9
G
E
9
G
TYPICAL 2
PLACES
E
10
11
7
8
6
9
12
5
4
3
TYPICAL 2
PLACES
1
2
REFERENCE
ENGINE MOUNTING
SECTION 7
Page 9-2
2001/2002 DS Golf Cars Illustrated Parts List
EXHAUST SYSTEM
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
11
12
101859301
1015814
332
451
7847
1017689
1012830
7174
1015075
1012528
1013734
1015330
2
3
QTY
4
System, Exhaust ...................................................................................................
Bracket, Muffler Mounting .....................................................................................
Washer, Flat, 1/4 ...................................................................................................
Washer, Lock, 1/4 .................................................................................................
Screw, Hex Head, 1/4-20 x 3/4 .............................................................................
Clamp, Muffler .......................................................................................................
Screw, Hex Head Cap, M8 x 1.25 x 22 mm ..........................................................
Washer, Lock, 5/16 ...............................................................................................
Washer, Flat, 5/16 .................................................................................................
Nut, Hex, M8 x 1.25 ..............................................................................................
Washer, Lock, 8 mm .............................................................................................
Gasket, Exhaust ....................................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
2
2
2
1
1
1
1
2
2
1
Page 9-3
9
G
E
9
G
E
TORQUE CONVERTER 10
G
E
10
G
E
1
2
3
8
4
5
12
6
12
7
11
14
TYPICAL
3 PLACES
(ONE SPRING
PER CLUTCH)
9
10
17
16
19
18
Page 10-2
2001/2002 DS Golf Cars Illustrated Parts List
15
13
DRIVE CLUTCH
ITEM
PART NO.
DESCRIPTION
1
1
2
3
4
5
6
7
8
9
10
101833902
1016801
101929801
1014049
1014050
1014051
1016289
1014057
1014059
101925601
1014453
11
12
13
14
15
16
17
18
19
1014058
1014056
1014052
N/A
1014055
1016203
101916701
101916501
1017328
2
3
QTY
4
Assembly, Drive Clutch (includes items 1 - 15) .....................................................
Kit, Drive Clutch Weight ....................................................................................
Assembly, Fixed Face .......................................................................................
Bearing, Idler .....................................................................................................
Retainer, Spring ................................................................................................
Spring, Drive Clutch – Black .............................................................................
Spacer, Fixed Face Shaft ..................................................................................
Ring, Retaining .................................................................................................
Assembly, Drive Hub .........................................................................................
Plug, Drive Clutch .............................................................................................
Kit, Drive Clutch Button (includes one spring and three each of
the screw, washer, and button) .........................................................................
Washer, Thrust ..................................................................................................
Ring, Spiral Back-Up .........................................................................................
Assembly, Moveable Face (includes items 14 and 15) ......................................
Bushing ........................................................................................................
Retainer ........................................................................................................
Belt, Drive ..............................................................................................................
Belt, Starter/Generator ..........................................................................................
Screw, Hex Head Cap, 3/8-24 x 5-1/2 (left-hand threads) ....................................
Washer, Drive Clutch – Green ..............................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Page 10-3
10
G
E
10
8
G
7
E
5
4
3
TYPICAL 3
PLACES
6
2
9
12
11
1
10
Page 10-4
2001/2002 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
101834001
1014080
1014078
1017686
101836201
1014454
1014072
1014070
101833401
1016203
102242101
102155801
2
3
QTY
4
Assembly, Driven Clutch (includes items 2 - 8) .....................................................
Ring, Retaining .................................................................................................
Key ....................................................................................................................
Cam ..................................................................................................................
Spring – Green ..................................................................................................
Kit, Driven Clutch Button (includes 3 screws and 3 buttons) .............................
Assembly, Moveable Face with Bushing ...........................................................
Face, Fixed ........................................................................................................
Key, Square Transmission .....................................................................................
Belt, Drive ..............................................................................................................
Screw, Hex Head Cap, Thread-Locking Patch, 5/16-18 x 3/4 ...............................
Washer, Driven Clutch ..........................................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
1
1
1
1
1
1
1
1
1
1
1
Page 10-5
10
G
E
10
G
E
UNITIZED TRANSAXLE 11
G
E
11
5
3
G
7
4
E
11
8
6
REFERENCE FORWARD/
REVERSE SHIFTER—
GASOLINE SECTION
12
13
9
14
10
15
16
27
17
19
21
20
31
1
30
22
2
28
18
23
24
Clu
bCa
r
32
25
REFERENCE AXLE
TUBES ON PAGE 11-6
26
Page 11-2
2001/2002 DS Golf Cars Illustrated Parts List
29
UNITIZED TRANSAXLE – 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
101922601
1012285
1013061
183
1010954
1016341
1017082
8717
1017231
101834801
101886101
1014007
8233
101833601
101890201
101927301
101892901
101927201
101890101
1012752
101928601
1016513
101927101
101893801
101891301
101890601
101890501
101926901
1012896
1013759
1016432
1012711
101928701
2
3
QTY
4
Bracket, Transmission Cable Support ...................................................................
Screw, Thread-Rolling, 1/4-20 x 5/8 ......................................................................
Nut, Nylon Lock, #10-32 ........................................................................................
Washer, Flat, #10 ..................................................................................................
Stud, Ball, 1/4-28 x 9/16 ........................................................................................
Lever, Transmission Shifter ...................................................................................
Screw, Hex Washer Head, #10-32 x 3/4 ...............................................................
Nut, Nylon Lock, 1/4-28 .........................................................................................
Key, Woodruff ........................................................................................................
Arm, Governor Lever .............................................................................................
Screw, Square Head, 1/4-20 x 1 ...........................................................................
Washer, Type B, 1/4 ..............................................................................................
Nut, Nylon Lock, 1/4-20 .........................................................................................
Unitized Transaxle (includes items 14 - 88) ...........................................................
Shaft, Shifter .....................................................................................................
Ring, Snap ........................................................................................................
Washer, Flat ......................................................................................................
Seal, Oil ............................................................................................................
Lever, Shifter .....................................................................................................
Pin, Roll .............................................................................................................
Pin, Cotter .........................................................................................................
Washer, Flat ......................................................................................................
Seal, Oil ............................................................................................................
Washer ..............................................................................................................
Arm, Pivot .........................................................................................................
Gear Case (passenger side) .............................................................................
Gear Case (driver side) .....................................................................................
Bolt, Flanged, M8 x 1.25 x 40 mm ....................................................................
Pin, Dowel .........................................................................................................
Plug, Drain (includes item 30) ...........................................................................
Gasket ...........................................................................................................
Breather ............................................................................................................
Gasket, Liquid, 8.8 oz. (250 grams) ..................................................................
2001/2002 DS Golf Cars Illustrated Parts List
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15
2
2
1
1
A/R
Page 11-3
11
G
E
11
G
33
E
36
35
48
47
49
34
46
41
45
43
44
46
42
48
41
40
39
55
38
54
37
39
53
52
43
41
45
51
50
59
58
57
56
38
64
63
REFERENCE
DRIVER SIDE
CASE
64
62
61
60
Page 11-4
2001/2002 DS Golf Cars Illustrated Parts List
REFERENCE
PASSENGER SIDE
CASE
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