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Download 2004-2005 DS IPL Gas/Electric
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2004-2005 ILLUSTRATED PARTS LIST Club C ar DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 102397501 EDITION CODE 1004C1205B USING THE ILLUSTRATED PARTS LIST ý WARNING • This manual is to be used only for identification and ordering of service parts. Be sure to read and use the maintenance and service manual before attempting any vehicle repairs. This manual covers all 2004 and 2005 Club Car® DS Tranquility®, DS V-Glide 36-Volt, DS PowerDrive® System 48™, 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, E, or D signifying that the page pertains to either the gasoline, electric, or diesel vehicle only, or to all gasoline, electric and diesel 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 or (706) 863-3000, extension 3281 or 3854. P. O. Box 204658 Augusta, Georgia 30917-4658 USA Telephone 706-863-3000 Service Parts Fax 706-855-7413 www.clubcar.com NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list. Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. Copyright © 2004 Club Car, Inc. Club Car, ArmorFlex, PowerDrive and Tranquility are registered trademarks of Club Car, inc. This manual effective July 22, 2003. 2004-2005 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 ................................................................................................................. 1-13 Canopy ............................................................................................................................................. 1-15 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 2004-2005 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 MC008C-ES00 Prior To Serial Number MC008C3H1264 – Gear Cases and Brackets .................. 11-3 MC008C-ES00 Prior To Serial Number MC008C3H1264 – Transmission and Gear Reduction ..... 11-5 MC008C-ES00 Prior To Serial Number MC008C3H1264 – Differential and Axles ......................... 11-7 MC008C-ES00 After Serial Number MC008C3H1264 – Gear Cases and Brackets ....................... 11-9 MC008C-ES00 After Serial Number MC008C3H1264 – Transmission and Gear Reduction .......... 11-11 MC008C-ES00 After Serial Number MC008C3H1264 – Differential and Axles ............................... 11-13 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 2004-2005 DS Golf Cars Illustrated Parts List CONTENTS 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 Motor Controller Output Regulator (MCOR) ..................................................................................... 12-21 Wiring – PowerDrive System 48 Vehicle .......................................................................................... 12-23 Wiring – IQ System Vehicle with Motor Controller Output Regulator (MCOR) ................................. 12-25 Forward/Reverse Switch, Tow/Run Switch – IQ System Vehicle ..................................................... 12-27 Batteries, Charger Receptacle – IQ System Vehicle ........................................................................ 12-29 Computer, Controller, and Solenoid – IQ System Vehicle ................................................................ 12-31 SECTION 13 – ELECTRIC MOTOR Motor – V-Glide 36-Volt Vehicle ....................................................................................................... 13-3 Motor – PowerDrive System 48 Vehicle ........................................................................................... 13-5 Motor (MODEL 5BC59JBS6365) – IQ System Vehicle .................................................................... 13-7 Motor (Model EJ4-4001) – IQ System Vehicle ................................................................................. 13-9 SECTION 14 – TRANSAXLE – ELECTRIC VEHICLE Transaxle, Type G – Electric Vehicle ................................................................................................ 14-3 Transaxle, Type K – Electric Vehicle ................................................................................................ 14-5 SECTION 15 – BATTERY CHARGER Accu-Power Battery Charger, Domestic – V-Glide 36-Volt Vehicle .................................................. 15-3 Accu-Power Battery Charger, Export, 230-Volt – V-Glide 36-Volt Vehicle ....................................... 15-5 Accu-Power Battery Charger, Export, 100-Volt – V-Glide 36-Volt Vehicle ....................................... 15-7 PowerDrive Battery Charger, Domestic ............................................................................................ 15-9 PowerDrive 2 Battery Charger, Domestic ......................................................................................... 15-11 GE PowerDrive Battery Charger, Domestic ...................................................................................... 15-13 PowerDrive Battery Charger, Export ................................................................................................ 15-15 PowerDrive Battery Charger, European ........................................................................................... 15-17 SECTION 16 – MAINTENANCE AND SERVICE TOOLS Maintenance and Service Tools ....................................................................................................... 16-3 Maintenance and Service Tools, Continued ..................................................................................... 16-5 Maintenance and Service Tools, Continued ..................................................................................... 16-7 Maintenance and Service Tools, Continued ..................................................................................... 16-9 Maintenance and Service Tools, Continued ..................................................................................... 16-11 2004-2005 DS Golf Cars Illustrated Parts List BODY AND TRIM 1 G E 1 G E 11 Frame 2 3 4 Front Body Of Car Center Dash Frame Dash Dash TYPICAL 3 PLACES 1 9 8 7 10 TYPICAL 2 PLACES 6 13 5 TYPICAL 2 PLACES 14 12 24 23 25 15 16 22 21 TYPICAL 2 PLACES 22 21 20 19 18 TYPICAL 2 PLACES 21 20 Page 1-2 2004-2005 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 1011019 1011382 1620 1013494 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 .................................................................................................. 2004-2005 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 2004-2005 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 – Pacific Blue (Royal 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 – Pacific Blue (Royal 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 ........................................................................................ Bolt, Carriage, 5/16-18 x 1 ......................................................................... Washer, Flat, 5/16 ...................................................................................... Screw, Flange Lock .................................................................................... T-Nut, Slab Base (package of 4) ................................................................ Bumper, Side Guard Trim .......................................................................... Screw, Hex Washer-Head, #8-18 x 3/8 ...................................................... Mat, Floor ................................................................................................... Nut, Nylon Lock, 5/16-18 ........................................................................... Emblem, IR, Golf Car ................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List Page 1-5 1 G E 1 G E 7 4 FRONT SEAT SUPPORT VERTICAL STRUT TYPICAL 2 PLACES 1 5 TYPICAL 2 PLACES 18 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 2004-2005 DS Golf Cars Illustrated Parts List 3 12 6 TYPICAL 2 PLACES REAR BODY AND FENDER – GASOLINE VEHICLE ITEM PART NO. 1 1 2 3 4 5 6 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 18 8251 101904101 1014306 1012412 332 8233 1013032 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 8248 QTY GAS DESCRIPTION 2 3 QTY ELEC 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 ................................................................................. Nut, Blind, 1/4-20 ....................................................................................... Body – Beige .............................................................................................. Body – White .............................................................................................. Body – Gray ............................................................................................... Body – Red ................................................................................................ Body – Pacific Blue (Royal 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 – Pacific Blue (Royal 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 .................................................................................................. Screw, Phillips Truss-Head, 1/4-20 x 3/4 .................................................... 2004-2005 DS Golf Cars Illustrated Parts List 8 1 2 2 10 12 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 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 2004-2005 DS Golf Cars Illustrated Parts List TYPICAL EACH SIDE OF VEHICLE 6 21 REAR BODY AND FENDER – ELECTRIC VEHICLE ITEM PART NO. 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 18 19 20 21 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 1015525 1015032 102221201 8248 QTY GAS DESCRIPTION 2 3 QTY ELEC 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 – Pacific Blue (Royal 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 – Pacific Blue (Royal 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 ................................................................................. Nut, Blind, 1/4-20 ....................................................................................... Mat, Floor ................................................................................................... Pad, Wear .................................................................................................. Screw, Phillips Truss-Head, 1/4-20 x 3/4 .................................................... 2004-2005 DS Golf Cars Illustrated Parts List 8 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 2 1 2 2 Page 1-9 1 G E 1 G E 5 4 7 TYPICAL 8 PLACES TYPICAL 2 PLACES 1 10 2 3 TYPICAL 4 PLACES 10 TYPICAL 2 PLACES REFERENCE REAR BODY AND FENDER Page 1-10 8 9 TYPICAL 4 PLACES 2004-2005 DS Golf Cars Illustrated Parts List 6 TYPICAL 8 PLACES SEAT BOTTOM AND ARMREST ITEM PART NO. DESCRIPTION 1 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 10 102174201 101998201 1010543 102174202 101998202 1010543 102174204 101998204 1010543 102174205 101998205 1010543 101987601 101985501 1016916 332 1011652 101954301 101998501 2 3 QTY GAS QTY ELEC 1 1 12 1 1 12 1 1 12 1 1 12 1 1 8 8 2 4 2 1 1 12 1 1 12 1 1 12 1 1 12 1 1 8 8 2 4 2 4 Assembly, Seat Bottom – Buff (includes items 2 and 3) ............................ Cover, Vinyl Seat Bottom – Buff ............................................................. Insert, Wood ........................................................................................... Assembly, Seat Bottom – White (includes items 2 and 3) .......................... Cover, Vinyl Seat Bottom – White .......................................................... Insert, Wood ........................................................................................... Assembly, Seat Bottom – Black (includes items 2 and 3) .......................... Cover, Vinyl Seat Bottom – Black .......................................................... Insert, Wood ........................................................................................... Assembly, Seat Bottom – Gray (includes items 2 and 3) ........................... 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 .............................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List Page 1-11 1 G E 1 G 7 E 8 TYPICAL 2 PLACES 9 10 2 13 3 1 11 4 12 TYPICAL 2 PLACES 15 5 TYPICAL 4 PLACES 21 16 8 17 6 8 20 22 19 9 20 TYPICAL 2 PLACES 14 18 TYPICAL 2 PLACES ON EACH SIDE OF VEHICLE Page 1-12 TYPICAL 2 PLACES 2004-2005 DS Golf Cars Illustrated Parts List 8 SEAT BACK AND BAG HOOP ITEM PART NO. DESCRIPTION 1 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 102238301 102060501 102237001 102238302 102060502 102237001 102238304 102060504 102237001 102238305 102060505 102237001 102236601 102236703 101910401 1010921 1015075 7473 1013935 1010434 1010413 1013754 1017774 102076701 8418 1014482 1028 7479 1241 7818 102242401 2 3 QTY GAS QTY ELEC 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 2 8 4 1 2 1 2 4 4 1 1 2 2 6 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 2 8 4 1 2 1 2 4 4 1 1 2 2 6 2 1 4 Assembly, Seat Back – Buff (includes items 2 and 3) ................................ Cover, Vinyl, Seat Back – Buff ............................................................... Cap, Seat Back – Black ......................................................................... Assembly, Seat Back – White (includes items 2 and 3) ............................. Cover, Vinyl, Seat Back – White ............................................................ Cap, Seat Back – Black ......................................................................... Assembly, Seat Back – Black (includes items 2 and 3) ............................. Cover, Vinyl, Seat Back – Black ............................................................. Cap, Seat Back – Black ......................................................................... Assembly, Seat Back – Gray (includes items 2 and 3) .............................. 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, Hex-Head Cap, 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 ................................................ Spacer, Nylon ............................................................................................. Nut, Hex, 1/4-20 ......................................................................................... Screw, Hex-Head Cap, 1/4-20 x 1-1/4 ....................................................... Washer, Flat, 5/16 ...................................................................................... Bolt, Carriage, 5/16-18 x 1-1/2 ................................................................... Nut, Nylon Insert with Cap, 1/4-20 ............................................................. 2004-2005 DS Golf Cars Illustrated Parts List Page 1-13 1 G E 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 4 PLACES 2 Page 1-14 2004-2005 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 4 8 4 1 1 2 2 1 1 1 1 8 8 4 8 4 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) ............................................................. 2004-2005 DS Golf Cars Illustrated Parts List Page 1-15 1 G E 1 G E WHEELS AND TIRES 2 G E 2 G E Club C ar 7 19 1 6 18 4 3 10 9 2 13 12 16 15 22 21 25 24 17 23 26 20 5 11 14 8 STANDARD TREAD Carlisle® PERFORMANCE GRADE TREAD Duro® PREMIUM TREAD Kenda® EXTRA TRACTION Duro Note: The performance grade tire has the wheel and tire matched and balanced at the Duro tire factory. Page 2-2 2004-2005 DS Golf Cars Illustrated Parts List WHEELS AND TIRES ITEM PART NO. DESCRIPTION 1 2 3 QTY GAS QTY ELEC 4 1 2 3 4 1010984 7310 101570501 1015707 Nut, Lug ..................................................................................................... Stem, Valve * .............................................................................................. Assembly, Wheel and Standard Tire (includes items 4-5) .......................... Wheel Rim – Beige ................................................................................ 16 1 4 1 16 1 4 1 5 6 7 727102 101570507 1015707 Tire, Unmounted, Standard Tread (18 x 8.50 - 8) (Carlisle®) ................. Assembly, Wheel and Extra Traction Tire (includes items 7 - 8) ................ Wheel Rim – Beige ................................................................................ 1 2 1 1 2 1 8 9 10 11 12 13 101769302 101570512 1015707 **** 101570513 1015707 Tire, Unmounted, Extra Traction, 6-Ply Rated (18 x 8.50 - 8) (Duro®) ... Assembly, Wheel and Performance Grade Tire (includes items 10 - 11) ... Wheel Rim – Beige ................................................................................ Tire, Unmounted, Performance Grade Tread (18 x 8.50 - 8) (Duro) ...... Assembly, Wheel and Premium Grade Tire (includes items 13 - 14) ......... Wheel Rim – Beige ................................................................................ 1 4 1 1 4 1 1 4 1 1 4 1 14 15 16 17 18 19 20 21 22 23 24 25 26 **** 101651401 1014771 727102 101651407 1014771 101769302 101651412 1014771 **** 101651413 1014771 **** Tire, Unmounted, Premium Tread (18 x 8.50 - 8) (Kenda®) .................. Assembly, Wheel and Standard Tire (includes items 16 - 17) .................... Wheel Rim – White ................................................................................ Tire, Unmounted, Standard Tread (18 x 8.50 - 8) (Carlisle) .................... Assembly, Wheel and Extra Traction Tire, (includes items 19 - 20) ........... Wheel Rim – White ................................................................................ Tire, Unmounted, Extra Traction, 6-Ply Rated (18 x 8.50 - 8) (Duro) ..... Assembly, Wheel and Performance Grade Tire (includes items 22 - 23) ... Wheel Rim – White ................................................................................ Tire, Unmounted, Performance Grade Tread (18 x 8.50 - 8) (Duro) ...... Assembly, Wheel and Premium Grade Tire (includes items 25 - 26) ........ Wheel Rim – White ................................................................................ Tire, Unmounted, Premium Tread (18 x 8.50 - 8) (Kenda) ..................... 1 4 1 1 2 1 1 4 1 1 4 1 1 1 4 1 1 2 1 1 4 1 1 4 1 1 * Note: Item 2 is a part of all wheel assemblies. **** Special order item available upon request. 2004-2005 DS Golf Cars Illustrated Parts List Page 2-3 2 G E 2 G E DECALS 3 G E 3 WARNING G 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. CCI 1019606-01 E OFF ON OPERATING INSTRUCTIONS 2 3 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 the vehicle: - Firmly depress park brake until it locks. - Place Forward/Reverse switch in "NEUTRAL" position. - Turn key “OFF” and remove key when not in use. CCI 101621601 WARNING CAN CAUSE SEVERE INJURY Rotating parts HOT manifold & muffler KEEP CLEAR CCI 1019605-01 (ON STARTER/GENERATOR AND ENGINE) 5 (ON VEHICLE FRAME NEAR FUEL TANK) 4 8 7 Club Car 6 (ON VEHICLE FRAME NEAR BATTERY) Page 3-2 2004-2005 DS Golf Cars Illustrated Parts List DECALS – GASOLINE VEHICLE ITEM PART NO. 1 1 2 3 4 5 6 7 8 101960601 101825101 101621601 101547601 101960501 101915201 102259001 1014198 QTY GAS DESCRIPTION 2 3 QTY ELEC G 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 ........................................... Emblem, IR, Gold (on front body) ............................................................... Nameplate, Gold (on front body)................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 3 1 1 1 1 2 1 1 1 E Page 3-3 3 E OFF WARNING ON ROLLOVER OR FALLING OFF MAY CAUSE DEATH. 2 • Before using vehicle, read operating instructions. • Remain seated and hold on to seat handle while moving. • Do not start vehicle until all occupants are seated. • Two (2) persons per seat maximum. • Operate from driver side only and not on public roads. • Keep entire body inside vehicle while moving. • Drive slowly in turns and straight up and down slopes. • Do not leave children unattended on vehicle. • Never operate under the influence of alcohol or drugs. • Use brakes to reduce speed when coasting downhill. • Never stand in front of or behind vehicle. CCI 101960601 OPERATING INSTRUCTIONS 3 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 the vehicle: - Firmly depress park brake until it locks. - Place Forward/Reverse switch in "NEUTRAL" position. - Turn key “OFF” and remove key when not in use. CCI 101621601 (ON SPEED CONTROLLER COVER) NOTICE 4 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. 101959902 • When towing vehicle, tow switch must be in the "TOW" position. 8 NOTICE • DO NOT OPERATE VEHICLE WITHOUT COVER IN PLACE. • DO NOT DIRECT WATER STREAM AT THIS SWITCH. CCI 1016109-01 (ON WIPER SWITCH COVER INSIDE BATTERY COMPARTMENT) 6 WARNING HOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS. (ON FRAME UNDER SEAT) 5 10 9 Club Car (ON TOW/RUN SWITCH BRACKET UNDER SEAT) TOW Place Tow/Run switch in TOW position before: • Disconnecting or connecting batteries • Towing • Extended storage • Servicing Page 3-4 RUN FAILURE TO HEED THIS WARNING COULD RESULT IN A BATTERY EXPLOSION OR SEVERE PERSONAL CCI 101908601 INJURY. 7 2004-2005 DS Golf Cars Illustrated Parts List F N G DECALS – ELECTRIC VEHICLE ITEM PART NO. 1 1 2 3 4 5 6 7 8 9 10 101960601 101825101 101621601 101959902 1013496 101610901 101908601 101931501 102259001 1014198 QTY GAS DESCRIPTION 2 3 QTY ELEC 4 Decal, Driver/Passenger Warning .............................................................. Decal, Key Switch ...................................................................................... Decal, Operating Instructions ..................................................................... Decal, Motor Braking (IQ System vehicle) ................................................. Decal, Resistor Warning (V-Glide 36-Volt vehicles) ................................... Decal, Potentiometer Caution (V-Glide 36-Volt vehicles) ........................... Decal, Tow/Run Switch (IQ System vehicles) ............................................ Decal, Electrical Component Cover (IQ System vehicle) ........................... Emblem, IR, Gold ....................................................................................... Nameplate, Gold ........................................................................................ 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 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 19 5 17 ELECTRIC VEHICLE 16 GASOLINE VEHICLE SEE REAR SUSPENSION– SECTION 6 FOR MOUNTING Page 4-2 2004-2005 DS Golf Cars Illustrated Parts List BRAKE ASSEMBLY ITEM PART NO. 1 1 1 2 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18 19 101823301 101823302 101824001 101824002 101816501 101816502 101823901 101823801 1010850 101823201 1011466 101816301 101815501 101815502 1013924 1014153 102022101 1010829 1035 1011779 101900801 1013207 101791101 102292801 QTY GAS DESCRIPTION 2 3 QTY ELEC 4 Cluster, Brake, Passenger-Side (includes items 1 - 9) ............................... 1 Cluster, Brake, Driver-Side (includes items 1 - 9) ...................................... 1 Assembly, Backing Plate, Passenger-Side (includes items 2 - 4) .......... 1 Assembly, Backing Plate, Driver-Side (includes items 2 - 4) ................. 1 Mechanism, Adjusting, Passenger-Side ............................................ 1 Mechanism, Adjusting, Driver-Side ................................................... 1 Washer .............................................................................................. 1 Washer, Plate .................................................................................... 1 Cover, Dust ............................................................................................ 1 Package, Brake Shoe (four pieces) ....................................................... 1 Kit, Shoe Retainer (four pieces) ............................................................. 1 Package, Brake Spring (four pieces) ..................................................... 1 Assembly, Lever, Passenger-Side ......................................................... 1 Assembly, Lever, Driver-Side ................................................................. 1 Nut, Hex Lock, Grade 8, 5/16-24 ............................................................... 8 Bolt, Brake Cluster Mounting, Grade 8, 5/16-24 x 7/8 ............................... 8 Kit, Brake Cable (includes items 13 -15) .................................................... 2 Pin, Clevis, 5/16 ..................................................................................... 2 Pin, Cotter .............................................................................................. 2 E-Clip, 1/2 .............................................................................................. 2 Hanger, Brake Cable (gasoline vehicle only) ............................................. 2 Hanger, Brake Cable (electric vehicle only) ............................................... Drum, Brake ............................................................................................... 2 Pin, Bow Tie Locking.............................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 2 2 2 2 2 22 Page 4-3 4 G E 4 G E OFF ON TYPICAL 2 PLACES 28 26 27 30 29 10 8 P O ST TYPICAL 4 PLACES 13 FLOORBOARD REMOVED FOR CLARITY 16 5 17 24 23 19 15 20 18 22 27 14 11 21 9 TYPICAL 3 PLACES SERVICE PART BRAKE PEDAL HAS SECOND WELDMENT 18 25 12 TYPICAL 2 PLACES TYPICAL 2 PLACES 2 TYPICAL 4 PLACES 3 4 31 1 6 Page 4-4 7 5 2 2004-2005 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 101990801 1241 1013531 1010921 7473 102022101 1011779 101878201 7716 1013869 1010878 1028 101953101 102323201 102323101 101953001 7473 101187702 18 19 20 21 22 23 24 25 N/A 1017029 1010877 1010805 1010932 1010933 1010927 1011402 26 27 28 29 30 31 1011418 1032 8626 1013876 1013870 1242 2 3 QTY GAS QTY ELEC 1 5 1 4 5 2 2 1 3 1 1 1 1 1 1 1 1 1 5 1 4 5 2 2 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 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 ........................................................................................... Pin, Clevis, 5/16 (later style hardware) ...................................................... Pin, Bow Tie Locking (later style hardware) ............................................... Bolt, Hex-Head Shoulder, 3/8 x 1 (earlier style hardware) ......................... Nut, Nylon Lock, 5/16-18 (earlier style hardware) ...................................... Kit, Park Brake Latch (includes items 18 - 22 and item 26 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 27 - 30) .......................................... Bushing, Nylon ....................................................................................... Screw, Slotted Hex Washer-Head, #10-16 x 5/8 .................................... Nut, Push, 3/8 ........................................................................................ Pad, Park Brake ..................................................................................... Nut, Hex, 5/16-18 ....................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List Page 4-5 4 G E 4 G E 2 GO 1 9 5 21 11 12 13 TYPICAL 4 PLACES 14 3 5 10 4 8 20 19 6 15 18 18 19 20 TYPICAL 4 PLACES 22 23 24 7 TYPICAL 4 PLACES 25 21 24 OFF ON 26 Page 4-6 2004-2005 DS Golf Cars Illustrated Parts List 16 17 ACCELERATOR PEDAL ASSEMBLY ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1017696 1013871 7716 1624 334 102026001 1011700 101818801 101862001 1017424 101966901 101817401 101796201 1017378 1017380 1241 7473 101871901 18 101912401 19 20 21 22 23 24 25 26 1011084 1011734 8754 8233 1014007 1011694 101861901 101187702 N/A 2 3 QTY GAS QTY ELEC 1 1 4 1 2 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-Head 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 (V-Glide 36-Volt vehicle only) (includes items 19 and 20) ......................................................................... Assembly, Accelerator Rod (gasoline vehicle only) (includes items 19 and 20) ......................................................................... 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-Head Cap, 1/4-20 x 1-1/8 ....................................................... Kit, Park Brake Latch (includes item 26, and items 18 - 22 on page 4-5) .. Ratchet, Park Brake ............................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 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 2004-2005 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 GAS QTY ELEC 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 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 A/R 2004-2005 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 2004-2005 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 GAS QTY ELEC 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 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 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 ............................................................................. 2004-2005 DS Golf Cars Illustrated Parts List Page 5-5 5 G E 5 TYPICAL 2 PLACES G 5 E 8 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 2004-2005 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 1624 2402 1010219 7555 7540 7539 1015597 1011930 7602 1017266 1014235 1010124 1016385 1035 2 3 QTY GAS QTY ELEC 2 6 1 2 10 4 1 2 2 4 1 1 1 1 1 1 1 2 2 1 1 3 2 6 1 2 10 4 1 2 2 4 1 1 1 1 1 1 1 2 2 1 1 3 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 ................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List Page 5-7 5 G E 5 G REFERENCE STEERING GEAR ASSEMBLY E 14 16 PASSENGER SIDE ONLY 2 13 15 17 3 25 TYPICAL 4 PLACES 5 21 1 DRIVER SIDE ONLY 20 22 19 13 4 23 18 7 12 8 22 11 TYPICAL 4 PLACES 6 26 22 24 27 23 22 Page 5-8 2004-2005 DS Golf Cars Illustrated Parts List 10 9 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 102354201 102354101 8067 7048 1015597 1012030 8745 706 102357701 102353201 102353301 102352801 102353401 8754 1016387 1016384 101903101 1010150 1016389 1010984 8755 1016386 1015583 1012303 1014276 1624 357 706 2 3 QTY GAS QTY ELEC 1 1 1 1 1 1 1 1 2 1 1 1 4 4 2 2 2 2 2 8 2 2 4 2 1 4 4 4 1 1 1 1 1 1 1 1 2 1 1 1 4 4 2 2 2 2 2 8 2 2 4 2 1 4 4 4 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 ......................................................................................... Kit, Front Hub Replacement (includes items 9 - 12) .................................. Cap, Hub ................................................................................................ Nut, Flange Lock M14 x 2 ...................................................................... Assembly, Hub and Ball Bearing (includes item 12) .............................. Stud, Lug ........................................................................................... 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 ..................................................................................................... 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 ......................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 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 2004-2005 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 102706401 1011415 N/A N/A 1012180 1012324 1010974 1014555 8755 1012182 1012181 101900801 1013207 QTY GAS DESCRIPTION 2 3 QTY ELEC G 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) ....................................................... 2004-2005 DS Golf Cars Illustrated Parts List 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 E 14 4 3 13 FORWARD / REVERSE ASSEMBLY CK BLA FRAME GROUND RED TE WHI L E/B WHIT / WH RED LIMIT SWITCHES E BLU ACK CK BLA 2 ITE NGE ORA KEY SWITCH 1 L YEL 2 M- M+ GRE ITE / WH RED 3 OW CK BLA LOW YEL 5 REVERSE LOW OIL BUZZER ITE WARNING / WH RED LIGHT 2 RED / WHITE WHITE BLUE 1 WH CK BLA E WHIT LIMIT SWITCHES CK BLA EEN GR NG ORA CK BLA ITE/ 6 15 E 7 WHIT K LAC E/B 4 TE WHI CK BLA R ED E BLU FRAME GROUND SOLENOID RED BRA RED E YELLOW BLACK NGE ORA RED WHITE / BLACK R ED BLU 16 RED ITE WH VOLTAGE REGULATOR ID RO ED G UND BR WIR 17 8 E DG AIDE N ROU DW IRE K LAC E/B WHIT TE WHI FUSE BLOCK 18 STARTER / GENERATOR F2 DF A1 9 F1 YELLOW GR ENGINE YELLOW OIL LEVEL SENSOR BLACK BLACK WHITE / BLACK 10 BATTERY BLACK 12 N EE YELLOW YELLOW A2 RPM LIMITER Page 6-2 1 EN FRAME GROUND 2004-2005 DS Golf Cars Illustrated Parts List YELLO YELLOW W 19 WHITE 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 ..................................................................................... 2004-2005 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 E 22 23 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 18 27 16 17 15 28 20 19 24 29 Clu bC ar 30 Club Car Page 6-4 Club Car 2004-2005 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 1015064 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, #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, S.S. .............................. 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, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ 2004-2005 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 14 17 TYPICAL 2 PLACES 20 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 2004-2005 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 1015345 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, Hex Washer-Head 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 ................................................................................ Bolt, Carriage, 5/16-18 x 2 .................................................................................... Washer, Flat, 5/16 ................................................................................................. Nut, Nylon Lock, 5/16-18 ...................................................................................... Bolt, Carriage, 5/16-18 x 1-1/2 .............................................................................. 2004-2005 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 2004-2005 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 12 13 14 1016859 1016849 1016851 N/A 1011229 1015720 101830601 101826301 101851101 101830701 101834502 1012505 AM10079 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) ............................................................................................................... Key (bag of 50) * ................................................................................................... Light, Low Oil Warning .......................................................................................... Retainer, Harness ................................................................................................. 1 2 1 1 1 1 4 1 1 1 1 1 1 1 3 * Must order in multiples of 50. 2004-2005 DS Golf Cars Illustrated Parts List Page 6-9 6 G E 6 G E TYPICAL 3 PLACES 26 29 24 TYPICAL 2 PLACES 21 15 TYPICAL 4 PLACES 28 TYPICAL 2 PLACES AT F1 AND F2 TERMINALS 27 TYPICAL 2 PLACES TYPICAL 4 PLACES 14 18 20 DF TERMINAL 17 19 TYPICAL 2 PLACES AT A1 AND A2 TERMINALS 16 23 22 30 25 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 12 8 TYPICAL 3 PLACES 11 1 9 7 5 2 10 3 4 6 13 Page 6-10 2004-2005 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 .................................................................................................................... 2004-2005 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 2004-2005 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 1241 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, Type A, 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 ................................................................. Bolt, Carriage, 5/16-18 x 1 .................................................................................... Nut, Hex, 5/16-18 .................................................................................................. Wire Assembly, #6 Green ..................................................................................... Wire Assembly, #6 Braided Ground ...................................................................... Nut, Nylon Lock, 5/16-18 ...................................................................................... Washer, Flat, 5/16 ................................................................................................. Screw, Hex-Head Cap, 5/16-18 x 3/4 ................................................................... 2004-2005 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 NEW-STYLE BATTERY WITH NEW HARDWARE E 2 4 1 AS SEEN FROM THE PASSENGER SIDE OF VEHICLE 3 New-style battery does not require spacer (4). 3 6 5 TO NEGATIVE BATTERY POST TERMINAL 10 8 9 8 9 Page 6-14 AS SEEN FROM DRIVER SIDE OF VEHICLE 2004-2005 DS Golf Cars Illustrated Parts List 7 BATTERY – GASOLINE VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 1012328 102355301 1014375 1014374 1010934 101898001 7173 1241 7473 1014288 2 3 QTY 4 Battery, 12-Volt ...................................................................................................... Washer, Lock, Stainless Steel, 3/8* ....................................................................... Screw, Hex-Head Cap, Stainless Steel, 3/8-16 x 1/2 ............................................ Spacer, Battery Terminal Bolt* ............................................................................... Screw, Hex-Head Cap, 5/16-18 x 1 ...................................................................... Clamp, Battery ...................................................................................................... Screw, Hex Cap, 5/16-18 x 3/4 ............................................................................. Washer, Flat, 5/16 ................................................................................................. Nut, Nylon Lock, 5/16-18 ...................................................................................... Screw, Thread-Forming, 5/16-16 x 3/4 ................................................................. 1 2 2 2 1 1 1 2 2 1 *NOTE: When ordering a new battery, you must order the new stainless steel lockwasher (2). Lockwasher cannot be used if battery terminal spacer (4) is required by battery design. 2004-2005 DS Golf Cars Illustrated Parts List 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 2004-2005 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 N/A 1016524 1016456 1016547 101909701 1016526 1017221 101915601 1016525 1016443 1016539 1016536 1016531 101887601 1015332 1015969 1015649 2 3 QTY G 4 FE290 OHV Gasoline Engine (clockwise rotation) Without Automatic Compression Release (w/o ACR) with Carburetor (does not include items 15 - 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 .......................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 7 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 2004-2005 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 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 AM10724 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 (NGK) ................................................................................... Plug, Spark, OHV (Autolite) .............................................................................. 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 ......................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 3 1 1 1 1 2 1 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 2004-2005 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 ................................................................................................................ 2004-2005 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 2004-2005 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 2004-2005 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 8 TYPICAL 6 PLACES TYPICAL 2 PLACES Page 7-10 2004-2005 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 ............................................................................................................... 2004-2005 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 2004-2005 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 1016568 101915501 1016558 1016460 101645901 101645902 101645903 101646101 101646102 101646103 101647501 101647502 8 9 1016509 101922301 10 11 12 13 14 15 15 15 15 15 15 15 15 15 16 17 18 19 20 21 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 ................................................................................... 2004-2005 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 TYPICAL 2 PLACES TYPICAL 4 PLACES 1 8 9 Clu bC ar 5 TYPICAL 2 PLACES 6 2 TYPICAL 2 PLACES 2 TYPICAL 4 PLACES 3 7 TYPICAL 4 PLACES 15 4 10 TYPICAL 4 PLACES 11 TYPICAL 4 PLACES 12 Clu bC ar TYPICAL 2 PLACES 13 14 6 TYPICAL 4 PLACES Page 7-14 2004-2005 DS Golf Cars Illustrated Parts List REFERENCE UNITIZED TRANSAXLE— SECTION 11 ENGINE MOUNTING ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 102540301 1013924 101834601 101827101 101963401 101884801 705 101833201 101832101 102065901 1012571 1010577 101832701 101833001 334 2 3 QTY 4 Snubber ................................................................................................................ Nut, Hex Lock, 5/16-24, UNF ................................................................................ Bracket, Snubber .................................................................................................. Plate, Mounting ..................................................................................................... Nut, Flange, 5/16-18 ............................................................................................. Screw, Hex Washer-Head, 5/16-24 x 7/8 .............................................................. Screw, Hex-Head Cap, 3/8-16 x 1.25 ................................................................... Stud, M8 x 1.25 x 60 mm ...................................................................................... Spacer ................................................................................................................... Nut, Flange, 3/8-16 ............................................................................................... Washer, Heavy Flat, 5/16 ...................................................................................... Screw, Hex-Head Cap, 5/16-18 x 1.50 ................................................................. Stiffener, Flywheel Side ......................................................................................... Nut, Flange, M8 x 1.25 .......................................................................................... Washer, Flat, 3/8 Type A ....................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 6 1 1 4 6 4 2 2 4 4 4 1 2 4 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 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 20 2004-2005 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 Bolt, Carriage, 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). 2004-2005 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 2004-2005 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 .................................................................................................. 2004-2005 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 2004-2005 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 ............................................................................................. 2004-2005 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 G E 3 2 9 1 TYPICAL 2 PLACES 8 TYPICAL 2 PLACES 7 10 4 5 TYPICAL 2 PLACES 3 6 11 Page 8-8 2004-2005 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 1013700 1016546 1012285 101903501 7174 1011697 102336101 102336001 101832302 101832202 101584502 2 3 QTY 4 Clamp, Cable Retaining ........................................................................................ Nut, Flanged Hex, M8 x 1.25 ................................................................................ Screw, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ Screw, Hex-Head Cap, M8 x 1.25 x 24 mm .......................................................... Washer, Lock, 5/16 ............................................................................................... Washer, Flat, 5/16 ................................................................................................. Cable, Accelerator, Snap-in .................................................................................. Cable, Governor, Snap-in ..................................................................................... Bracket, Accelerator Support ................................................................................ Bracket, Support ................................................................................................... Bracket, Governor Cable Engine ........................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 2 2 4 1 1 1 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 2004-2005 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, Hex-Head Hi-Lo, #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, Hex Washer-Head 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, Hex Washer-Head Hi-Lo, #12-16 x 5/8 ..................................................... Assembly, Air Duct ................................................................................................ Rivet, Pop, 3/16 .................................................................................................... Air Duct Repair Kit (not shown) ............................................................................. 2004-2005 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 2004-2005 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 Cap, 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 .................................................................................................... 2004-2005 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 1 2 E 3 TYPICAL 3 PLACES 10 13 14 12 11 4 5 8 6 16 7 16 15 18 9 19 21 20 23 22 24 Page 10-2 2004-2005 DS Golf Cars Illustrated Parts List 17 DRIVE CLUTCH ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 101833902 1016801 101929801 1014049 1014050 1014051 1016289 1014057 1014059 N/A 1014453 1014287 1014062 183 8450 1014058 1014056 1014052 N/A 1014055 1016203 101916701 101916501 808 357 2 3 QTY 4 Assembly, Drive Clutch (includes items 1 - 19) ..................................................... 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 item 11 - 14) ................................................ Spring, Drive Button ..................................................................................... Driver, Drive Clutch ...................................................................................... Washer, Flat, #10, Type A ............................................................................ Screw, Hex-Head, #10-24 x .5 ..................................................................... Washer, Thrust .................................................................................................. Ring, Spiral Back-Up ......................................................................................... Assembly, Movable Face (includes items 18 and 19) ....................................... Bushing ........................................................................................................ Retainer ........................................................................................................ Belt, Drive ............................................................................................................. Belt, Starter/Generator .......................................................................................... Screw, Hex-Head Cap, 3/8-24 x 5-1/2 (left-hand threads) .................................... Washer, Flat, 3/8 ................................................................................................... Washer, Lock, 3/8 ................................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 1 3 1 3 3 3 3 1 2 1 1 1 1 1 1 1 1 Page 10-3 10 G E 10 G 8 E 7 5 4 3 TYPICAL 3 PLACES 6 2 10 12 11 1 9 Page 10-4 2004-2005 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 1016203 AM10419 101833401 102242101 1017327 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 ....................................................................................................... Belt, Drive ............................................................................................................. Kit, Driven Clutch Hardware Repair (includes items 10 - 12) ................................ Key, Square Transmission ................................................................................ Screw, Hex-Head Cap, Thread-Locking, 5/16-18 x 3/4 .................................... Washer, Driven Clutch ...................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 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 G E 5 3 7 4 11 8 6 REFERENCE FORWARD/ REVERSE SHIFTER— GASOLINE SECTION 12 13 9 14 10 27 15 16 17 19 21 20 31 1 30 22 2 28 18 23 24 Clu bCa r 32 25 REFERENCE AXLE TUBES 26 Page 11-2 2004-2005 DS Golf Cars Illustrated Parts List 29 MC008C-ES00 PRIOR TO SERIAL NUMBER MC008C3H1264 – 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, Hex, Type TT, 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) .................................................................. 2004-2005 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 E 33 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 REFERENCE PASSENGER SIDE CASE Clu bC ar Parts identification for transaxles prior to serial number MC008C3H1264 Page 11-4 2004-2005 DS Golf Cars Illustrated Parts List MC008C-ES00 PRIOR TO SERIAL NUMBER MC008C3H1264 – TRANSMISSION AND GEAR REDUCITEM PART NO. DESCRIPTION 1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 101892001 101890001 1012748 1012747 101889401 AM10080 1016338 101892401 101892201 101980901 101927601 101927501 101981001 1012741 101928001 1012740 101927901 101927701 101889901 101980801 1016337 AM10081 1012714 101892601 101893201 101892501 101928101 101893901 101892301 101891601 101891901 7335 2 3 QTY 4 Rod, Shift .......................................................................................................... Fork, Shift .......................................................................................................... Spring ................................................................................................................ Ball, Steel .......................................................................................................... Guide ................................................................................................................ Bearing, Ball, Sealed ........................................................................................ Washer, Spring .................................................................................................. Gear, Spur ......................................................................................................... Plate, Thrust ...................................................................................................... Gear Assembly, Input, 28 Tooth (16°) ............................................................... Bearing, Needle ................................................................................................ Bearing, Needle ................................................................................................ Ring, Synchronizer (16°) ................................................................................... Spring, Synchronizer ......................................................................................... Hub, Synchronizer Clutch ................................................................................. Insert, Synchronizer .......................................................................................... Sleeve, Synchronizer ........................................................................................ Pin, Dowel ......................................................................................................... Shaft, Input ........................................................................................................ Gear Assembly, Input, 25 Tooth (16°) ............................................................... Washer, Thrust .................................................................................................. Bearing, Ball, C-3 Sealed .................................................................................. Seal, Oil, Input Shaft ......................................................................................... Gear, 17 Tooth .................................................................................................. Key .................................................................................................................... Gear, 61 Tooth .................................................................................................. Bearing, Ball ...................................................................................................... Washer .............................................................................................................. Governor Assembly .......................................................................................... Sleeve ............................................................................................................... Gear, Cluster Idler ............................................................................................. Bearing, Ball ...................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 2 2 1 3 1 3 1 2 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Page 11-5 11 G E 11 G 73 E 71 76 69 75 67 REFERENCE PASSENGER SIDE CASE 72 70 78 68 65 86 83 88 87 88 79 77 80 87 82 Clu bC ar 83 84 85 72 75 81 77 76 REFERENCE DRIVER SIDE CASE 74 66 69 68 70 71 67 Page 11-6 2004-2005 DS Golf Cars Illustrated Parts List MC008C-ES00 PRIOR TO SERIAL NUMBER MC008C3H1264 – DIFFERENTIAL AND AXLES ITEM PART NO. DESCRIPTION 1 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 101891501 101891401 1013787 1013792 1011291 1014207 1016672 1013794 101891001 101890901 1013790 1013791 7330 101928301 101892701 1014193 101910501 1013768 1013774 1013773 1013769 1013772 1013770 1013771 2 3 QTY 4 Axle Assembly, Driver-Side (Includes items 67 - 71) ........................................ Axle Assembly, Passenger-Side (includes items 67 - 71) ................................. Stud, Lug ...................................................................................................... Ring, Retaining ............................................................................................. Bearing, Outer Axle Tube ............................................................................. Collar, 25 mm I. D. ........................................................................................ Ring, Retaining ............................................................................................. Seal, Oil ............................................................................................................ Assembly, Axle Tube, Driver-Side ..................................................................... Assembly, Axle Tube, Passenger-Side ............................................................. Bolt, M10 x 1.5 x 30 mm ................................................................................... Washer, Lock, M10 ........................................................................................... Bearing, Inner Axle Tube .................................................................................. Bolt, M8 x 1.25 x 37 mm ................................................................................... Gear, Output ..................................................................................................... Pin, Dowel ......................................................................................................... Kit, Differential Gear Case (includes items 82 - 85) .......................................... Case, Gear Carrier ....................................................................................... Plate, Thrust (idler gear) ............................................................................... Plate, Thrust (differential gear) ..................................................................... Cover, Gear Case ......................................................................................... Pin, Differential .................................................................................................. Gear, Differential Idler ....................................................................................... Gear, Differential ............................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 4 1 1 1 1 2 1 1 14 14 2 8 1 1 1 1 2 1 1 1 2 2 Page 11-7 11 G E 11 G E 5 3 7 4 11 8 6 REFERENCE FORWARD/ REVERSE SHIFTER— GASOLINE SECTION 12 13 9 14 10 27 15 16 17 19 21 20 31 1 30 22 2 28 18 23 24 Clu bCa r 32 25 REFERENCE AXLE TUBES 26 Page 11-8 2004-2005 DS Golf Cars Illustrated Parts List 29 MC008C-ES00 AFTER SERIAL NUMBER MC008C3H1264 – 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, Hex, Type TT, 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 - 89) .......................................................... 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) .................................................................. 2004-2005 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 11-9 11 G E 11 G 36 35 E 34 33 48 47 49 46 45 42 43 41 46 44 55 65 54 48 39 41 40 53 39 52 38 37 43 SEALED C3 BEARING 41 45 51 50 SEALED BEARING 59 58 57 56 38 64 63 64 REFERENCE DRIVER SIDE CASE 62 61 REFERENCE PASSENGER SIDE CASE 60 Clu bC ar Parts identification for transaxles after serial number MC008C3H1264 Page 11-10 2004-2005 DS Golf Cars Illustrated Parts List MC008C-ES00 AFTER SERIAL NUMBER MC008C3H1264 – TRANSMISSION AND GEAR REDUCTION ITEM PART NO. DESCRIPTION 1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 101892001 101890001 1012748 1012747 101889401 AM10080 1016338 101892401 101892201 101980901 101927601 101927501 101981001 1012741 101928001 1012740 101927901 101927701 102453001 101980801 1016337 AM10081 1012714 101892601 101893201 101892501 101928101 101893901 101892301 101891601 101891901 7335 102453101 2 3 QTY 4 Rod, Shift .......................................................................................................... Fork, Shift .......................................................................................................... Spring ................................................................................................................ Ball, Steel .......................................................................................................... Guide ................................................................................................................ Bearing, Ball, Sealed ........................................................................................ Washer, Spring .................................................................................................. Gear, Spur ......................................................................................................... Plate, Thrust ...................................................................................................... Gear Assembly, Input, 28 Tooth (16°) ............................................................... Bearing, Needle ................................................................................................ Bearing, Needle ................................................................................................ Ring, Synchronizer (16°) ................................................................................... Spring, Synchronizer ......................................................................................... Hub, Synchronizer Clutch ................................................................................. Insert, Synchronizer .......................................................................................... Sleeve, Synchronizer ........................................................................................ Pin, Dowel ......................................................................................................... Shaft, Input, w/Circlip Groove ........................................................................... Gear Assembly, Input, 25 Tooth (16°) ............................................................... Washer, Thrust .................................................................................................. Bearing, Ball, C-3 Sealed .................................................................................. Seal, Oil, Input Shaft ......................................................................................... Gear, 17 Tooth .................................................................................................. Key .................................................................................................................... Gear, 61 Tooth .................................................................................................. Bearing, Ball ...................................................................................................... Washer .............................................................................................................. Governor Assembly .......................................................................................... Sleeve ............................................................................................................... Gear, Cluster Idler ............................................................................................. Bearing, Ball ...................................................................................................... Circlip, Input Shaft.............................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 2 2 1 3 1 3 1 2 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Page 11-11 11 G E 11 G 74 E 72 77 70 76 68 REFERENCE PASSENGER SIDE CASE 73 71 79 69 66 87 84 89 88 89 80 78 81 88 83 Clu bC ar 84 85 86 73 76 82 78 77 REFERENCE DRIVER SIDE CASE 75 67 70 69 71 72 68 Page 11-12 2004-2005 DS Golf Cars Illustrated Parts List MC008C-ES00 AFTER SERIAL NUMBER MC008C3H1264 – DIFFERENTIAL AND AXLES ITEM PART NO. DESCRIPTION 1 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 101891501 101891401 1013787 1013792 1011291 1014207 1016672 1013794 101891001 101890901 1013790 1013791 7330 101928301 101892701 1014193 101910501 1013768 1013774 1013773 1013769 1013772 1013770 1013771 2 3 QTY 4 Axle Assembly, Driver-Side (Includes items 68 - 72) ........................................ Axle Assembly, Passenger-Side (includes items 68 - 72) ................................. Stud, Lug ...................................................................................................... Ring, Retaining ............................................................................................. Bearing, Outer Axle Tube ............................................................................. Collar, 25 mm I. D. ........................................................................................ Ring, Retaining ............................................................................................. Seal, Oil ............................................................................................................ Assembly, Axle Tube, Driver-Side ..................................................................... Assembly, Axle Tube, Passenger-Side ............................................................. Bolt, M10 x 1.5 x 30 mm ................................................................................... Washer, Lock, M10 ........................................................................................... Bearing, Inner Axle Tube .................................................................................. Bolt, M8 x 1.25 x 37 mm ................................................................................... Gear, Output ..................................................................................................... Pin, Dowel ......................................................................................................... Kit, Differential Gear Case (includes items 83 - 86) .......................................... Case, Gear Carrier ....................................................................................... Plate, Thrust (idler gear) ............................................................................... Plate, Thrust (differential gear) ..................................................................... Cover, Gear Case ......................................................................................... Pin, Differential .................................................................................................. Gear, Differential Idler ....................................................................................... Gear, Differential ............................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 4 1 1 1 1 2 1 1 14 14 2 8 1 1 1 1 2 1 1 1 2 2 Page 11-13 11 G E 11 G E ELECTRICAL SYSTEM – ELECTRIC VEHICLE 12 G E 12 G E AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE, BODY REMOVED TYPICAL 2 PLACES OFF ON 4 8 9 7 3 5 6 2 1 OFF ON 11 12 TYPICAL 2 PLACES 10 POWERDRIVE SYSTEM 48 AND IQ SYSTEM VEHICLES V-GLIDE 36-VOLT VEHICLE Page 12-2 2004-2005 DS Golf Cars Illustrated Parts List ELECTRICAL COMPONENTS, FRONT BODY – ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 9 10 11 12 1016859 1016849 1016851 101830601 101826201 101851101 101830701 101834502 1012505 AM10079 101802601 101935501 8990 2 3 QTY 4 Kit, Reverse Buzzer (includes items 2 and 3) ....................................................... Screw, Pan-Head Hi-Lo, #4-24 x 5/16 .............................................................. Buzzer, Reverse ................................................................................................ Assembly, Screw and Washer .............................................................................. Switch, Key ........................................................................................................... Washer, Key Switch .............................................................................................. Nut, Key Switch ..................................................................................................... Cap, Key Switch .................................................................................................... Key (pair) ............................................................................................................... Key (bag of 50) * ................................................................................................... Plug, Hole (V-Glide 36-Volt vehicle only) .............................................................. Light, Battery Warning (amber) (PowerDrive System 48 and IQ System) ............. Tie, Wire ................................................................................................................ 1 2 1 2 1 1 1 1 1 1 1 1 2 * Must order in multiples of 50. 2004-2005 DS Golf Cars Illustrated Parts List Page 12-3 12 G E 12 G 22 E BL 20 UE 1 D RE 2 16 ITE WH E G AN OR KEY SWITCH REVERSE BUZZER FORWARD / REVERSE SWITCH 15 LIMIT SWITCH BR OW N PU RP GR LE EE N RE D 1 UE BL 24 D RE WH ITE K D RE LAC B SNUBBER YE LL OW WH ITE 21 IT WH 12 E DIODE N EE GR FUSE AND RECEPTACLE GR GE N RA EE 17 N 10 13 O BL 25 RE D 23 SOLENOID BL CK LA UE GR B AC K ITE WH EE D RE N - BULLET CONNECTOR CK LA B GR EE N 5 + WHITE 18 7 + E IT H - 8 GR AY 2 3 4 BL AC K 4 RESISTOR BOARD 26 AY R G K AC BL 5 + 2 - + - - BLUE EN GREEN W + 6 RE BATTERY BANK + WHITE - 1 G 11 - ORANGE + YELLOW 19 9 D RE RE D BLACK 14 6 WHITE SPEED SWITCH TYPICAL 5 PLACES LE A2 RP PU S2 S1 A1 N OW BR MOTOR 3 Page 12-4 2004-2005 DS Golf Cars Illustrated Parts List 1 WIRING – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1016070 1016069 1012651 1016068 1014036 1014035 1014034 1014033 1014032 1014029 1014030 1014828 N/A 1013092 N/A N/A N/A 102018001 1011010 N/A 1014039 N/A 1011069 N/A N/A 1010958 2 3 QTY 4 Wire Assembly, #6 Brown ..................................................................................... Wire Assembly, #6 Purple ..................................................................................... Wire Assembly, #6 Black ....................................................................................... Wire Assembly, #6 Gray ........................................................................................ Wire Assembly, #6 Black, 6th Speed ..................................................................... Wire Assembly, #6 Blue, 5th Speed ...................................................................... Wire Assembly, #6 Green, 4th Speed ................................................................... Wire Assembly, #6 Yellow, 3rd Speed ................................................................... Wire Assembly, #6 Orange, 2nd Speed ................................................................ Wire Assembly, #6 White ...................................................................................... Wire Assembly, #6 White, 1st Speed .................................................................... Wire Assembly, #6 Green ..................................................................................... Wire Assembly, #18 Black ..................................................................................... Wire Assembly, #10 Red ....................................................................................... Wire Assembly, #18 Orange ................................................................................. Wire Assembly, #18 White .................................................................................... Wire Assembly, #18 Green ................................................................................... Wire Assembly, #10 Red ....................................................................................... Wire Assembly, #10 White .................................................................................... Wire Assembly, #18 Red ....................................................................................... Wire Assembly, #6 White ...................................................................................... Wire Assembly, #18 Blue ...................................................................................... Wire Assembly, #6 Red ......................................................................................... Wire Assembly, #18 Yellow ................................................................................... Wire Assembly, #18 Black ..................................................................................... Wire Assembly, #6 Black ....................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 Page 12-5 12 G E 12 G 3 9 E TYPICAL 2 PLACES 2 10 TYPICAL 2 PLACES 4 5 TYPICAL 3 PLACES 1 11 15 13 TYPICAL 3 PLACES 14 TYPICAL 2 PLACES SEAT SUPPORT FRONT PANEL 12 8 TYPICAL 3 PLACES Page 12-6 7 6 2004-2005 DS Golf Cars Illustrated Parts List TYPICAL 3 PLACES FORWARD/REVERSE SWITCH – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1011997 1014808 8057 8058 1016896 1028 451 304 1012987 1015064 1016845 8233 8049 8450 1014528 2 3 QTY 4 Assembly, Forward/Reverse Switch (includes items 2 - 5) ................................... Switch, Limit ...................................................................................................... Nut, Hex, #4-40 ................................................................................................. Washer, Lock, #4 .............................................................................................. Screw, Hex-Head Machine, #4-40 x 1-1/8 ........................................................ Nut, Hex, 1/4-20 .................................................................................................... Washer, Lock, 1/4 ................................................................................................. Screw, Hex-Head Cap, 1/4-20 x 1 ........................................................................ Handle, Forward/Reverse Switch ......................................................................... Screw, Phillips Oval Countersunk, Machine, SS, #8-32 x 5/8 ............................... Screw, Phillips Truss-Head, 1/4-20 x 2-1/8 ........................................................... Nut, Nylon Lock, 1/4-20 ........................................................................................ Washer, Internal Tooth Lock, #10 .......................................................................... Screw, Hex-Head Machine, #10-24 x 1/2 ............................................................. Washer, Plastic, 1/4 .............................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 2 2 2 3 3 3 1 1 3 3 2 2 3 Page 12-7 12 G E 12 G TYPICAL 8 PLACES TYPICAL 5 PLACES 26 E 22 25 1 21 33 32 REF. SEE PAGE 4-6 23 17 TYPICAL 2 PLACES 32 5 3 7 20 19 9 NO TI C E 18 6 17 16 8 15 14 27 4 13 33 4 2 12 9 TYPICAL 2 PLACES 28 4 24 10 31 Club Car 29 30 MOUNTING DETAIL 11 Page 12-8 2004-2005 DS Golf Cars Illustrated Parts List TYPICAL 2 PLACES WIPER SWITCH – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1014735 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 1016140 1014999 1014414 101610901 1014253 7473 1012353 1014003 8449 1012903 1014189 1013886 1013061 1014017 1013998 1014000 1014019 8058 1013887 1013860 8056 1014807 1014010 8057 451 N/A N/A 1017692 1014109 1016175 1017 101949201 1028 451 2 3 QTY G 4 Assembly, V-Glide Wiper Switch and Resistor Group (includes Wiper Switch Assembly listed below, Resistor and Board Assembly – items 1 - 11 on page 12-11, and connecting wires – items 5 - 11 on page 12-5) ...................................................... Assembly, V-Glide Wiper Switch (includes items 1 - 27) ................................... Assembly, Wiper Switch Case, 6-Speed (includes items 2 and 3) ............... Bumper, Wiper Switch ............................................................................. Decal, Wiper Switch Warning .................................................................. Nut, Brass Hex Jam, 1/4-20 ......................................................................... Nut, Nylon Lock, 5/16-18 .............................................................................. Stud, Short Ball, 1/4-28 ................................................................................ Crank, Bell .................................................................................................... Nut, Dimpled Lock, 1/4-28 ............................................................................ Bearing, Bronze, 3/8 x 1/2 ............................................................................ Screw, Bronze Hex-Head Cap, 1/4-20 x 2 ................................................... Cover, Wiper Switch Case ............................................................................ Nut, Nylon Lock, #10-32 ............................................................................... Carrier, Wiper Switch Arm ............................................................................ Spring, Wiper Switch Brush .......................................................................... Stud, Wiper Switch Adjusting ....................................................................... Screw, Self-Tapping, #4-40 x 3/8 .................................................................. Washer, Lock, #4 .......................................................................................... Arm, Speed Switch ....................................................................................... Assembly, Switch Brush ............................................................................... Screw, Round-Head Machine, #4-40 x 3/4 ................................................... Switch, Limit ................................................................................................. Grommet, Split .............................................................................................. Nut, Hex, #4-40 ............................................................................................ Washer, Lock, 1/4 ......................................................................................... Wire Assembly, #18 Black ............................................................................ Wire Assembly, #18 Green ........................................................................... Cap, Protector .............................................................................................. Bolt, Carriage, #10-24 x 1 ..................................................................................... Washer, Lock, #10 ................................................................................................ Nut, Hex, #10-24 ................................................................................................... Shim, Wiper Switch ............................................................................................... Nut, Hex, 1/4-20 .................................................................................................... Washer, Lock, 1/4 ................................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 12 E 1 1 1 1 1 3 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 2 1 1 2 1 1 1 1 2 2 2 1 13 9 Page 12-9 12 G FRONT R OF CA E 12 13 7 8 9 10 11 1 TYPICAL 6 PLACES 2 TYPICAL 6 PLACES 4 3 5 6 2 TYPICAL 6 PLACES 1 TYPICAL 2 PLACES Page 12-10 12 2004-2005 DS Golf Cars Illustrated Parts List TYPICAL 2 PLACES RESISTOR AND BOARD ASSEMBLY – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1028 451 1011931 1014045 1014728 332 1014476 1014012 1014013 1014014 1014729 1012285 1013971 2 3 QTY 4 Nut, Hex, 1/4-20 .................................................................................................... Washer, Lock, 1/4 ................................................................................................. Washer, Flat, 1/4 ................................................................................................... Stand-Off, Resistor Coil ......................................................................................... Board, Resistor Mounting ..................................................................................... Washer, Flat, 1/4 ................................................................................................... Coil, Resistor, 5th Speed, .182 Inch Wire Diameter, 3-Coil ................................... Coil, Resistor, 4th Speed, .162 Inch Wire Diameter, 3-Coil ................................... Coil, Resistor, 3rd Speed, .144 Inch Wire Diameter, 3-Coil .................................. Coil, Resistor, 2nd Speed, .128 Inch Wire Diameter, 4-Coil .................................. Coil, Resistor, 1st Speed, .128 Inch Wire Diameter, 6-Coil ................................... Screw, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ Shield, Resistor ..................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 12 12 6 6 1 6 1 1 1 1 1 4 1 Page 12-11 12 G E 12 G VEHICLE BODY 26 E TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES 31 TYPICAL 2 PLACES 26 27 28 16 18 23 19 17 30 20 29 22 TYPICAL 3 PLACES TYPICAL 6 PLACES 3 25 21 TYPICAL 2 PLACES TYPICAL 2 PLACES 14 24 22 1 TYPICAL 2 PLACES 15 2 TYPICAL 12 PLACES 6 TYPICAL 2 PLACES TYPICAL 5 PLACES 8 4 11 13 32 35 TYPICAL 6 PLACES 33 34 12 TYPICAL 2 PLACES 7 5 TYPICAL 6 PLACES 10 9 Page 12-12 2004-2005 DS Golf Cars Illustrated Parts List BATTERIES, CHARGER RECEPTACLE, SOLENOID – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 1015072 1011578 101090801 1013683 101661601 101661602 1010958 101831401 1014304 1012022 1606 101975901 1012285 7893 1010521 7174 101342501 1014516 N/A N/A N/A 1016 8797 4107 1013092 1013628 8796 8795 1013649 8797 1016 1013266 1014948 102047201 102048301 8639 2 3 QTY 4 Nut, Nylon Lock, Stainless Steel, 5/6-18 ............................................................... Washer, Flat, Type B Wide, 5/16 ........................................................................... Hold-Down, Battery ............................................................................................... J-Bolt ..................................................................................................................... Battery, 6-Volt ........................................................................................................ Battery, 6-Volt, Dry ................................................................................................ Wire Assembly, #6 Black ....................................................................................... Cap, 6-Volt Battery ................................................................................................ Nut, Hex, Stainless Steel, 5/6-18 .......................................................................... Clamp, Cable ........................................................................................................ Rivet, Pop, 3/16 .................................................................................................... Solenoid, 36-Volt ................................................................................................... Screw, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ Nut, Hex, #10-32 ................................................................................................... Nut, Hex, 5/16-24 .................................................................................................. Washer, Lock, 5/16 ............................................................................................... Kit, Fuse and Receptacle (includes items 17 - 31) ................................................ Kit, Fuse (includes items 18 - 22) ..................................................................... Lens, Fuse .................................................................................................... Fuse, 80-Amp ............................................................................................... Holder, Fuse ................................................................................................. Washer, Lock, #10 ........................................................................................ Nut, Brass, #10-32 ....................................................................................... Receptacle, Charger, 2-Prong .......................................................................... Wire Assembly, #10 Red ................................................................................... Bracket, Fuse and Receptacle Mounting .......................................................... Screw, Phillips Pan-Head Self-Tapping, #7-19 x 3/4 ......................................... Screw, Phillips Pan-Head Self-Tapping, #7-19 x 1-3/4 ..................................... Bezel, Charger Receptacle ............................................................................... Nut, Brass, #10-32 ............................................................................................ Washer, Lock, #10 ............................................................................................ Screw, Phillips Pan-Head Self-Tapping, #8-18 x 1/2 ......................................... Diode ..................................................................................................................... Snubber ................................................................................................................ Base, Mounting ..................................................................................................... Tie, Wire ................................................................................................................ 2004-2005 DS Golf Cars Illustrated Parts List 6 6 3 6 6 6 5 6 12 2 2 1 2 2 2 2 1 1 1 1 1 2 4 1 1 1 6 2 1 2 2 2 1 1 1 1 Page 12-13 12 G E 12 G 5 E 11 TYPICAL 2 PLACES ANTI-ARCING LIMIT SWITCH SEAT SUPPORT FRONT PANEL REVERSE BUZZER LIMIT SWITCH 2 NC NO M CO 12 HALF-SPEED LIMIT SWITCH NC NO M CO 4 3 TYPICAL 3 PLACES 13 6 7 TYPICAL 2 PLACES 10 9 15 TYPICAL 4 PLACES 17 16 TYPICAL 3 PLACES 1 8 TYPICAL 2 PLACES TYPICAL 3 PLACES 14 NC NO COM NC NO COM Page 12-14 TYPICAL 2 PLACES 2004-2005 DS Golf Cars Illustrated Parts List FORWARD/REVERSE SWITCH – POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 101753005 102250201 101979101 1014808 8057 8058 1014871 1017799 451 1028 1012987 1015064 1016845 8233 8049 8450 1014528 2 3 QTY 4 Assembly, Forward/Reverse Switch (includes items 2 - 10) ................................. Switch, Limit, Sealed ......................................................................................... Switch, Limit, Sealed ......................................................................................... Switch, Limit ...................................................................................................... Nut, Hex, #4-40 ................................................................................................. Washer, Lock, #4 .............................................................................................. Screw, Hex Washer-Head, #4-40 x 2 ................................................................ Bar, Bus ............................................................................................................. Washer, Lock, 1/4 ............................................................................................. Nut, Hex, 1/4-20 ................................................................................................ Handle, Forward/Reverse Switch ......................................................................... Screw, Phillips Oval Countersunk, Machine, SS, #8-32 x 5/8 ............................... Screw, Phillips Truss-Head, 1/4-20 x 2-1/8 ........................................................... Nut, Nylon Lock, 1/4-20 ........................................................................................ Washer, Internal Tooth Lock, #10 .......................................................................... Screw, Hex-Head Machine, #10-24 x 1/2 ............................................................. Washer, Plastic, 1/4 .............................................................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 2 2 2 2 4 4 1 1 3 3 2 2 3 Page 12-15 12 G E 12 11 G TYPICAL 4 PLACES E 10 6 5 17 19 TYPICAL 3 PLACES TYPICAL 3 PLACES 16 2 TYPICAL 12 PLACES 3 15 9 14 TYPICAL 5 PLACES TYPICAL 6 PLACES 13 NC NO COM NC NO COM 12 TYPICAL 6 PLACES Page 12-16 TYPICAL 2 PLACES 8 TYPICAL 6 PLACES 18 7 2004-2005 DS Golf Cars Illustrated Parts List 1 4 BATTERIES, CHARGER RECEPTACLE – POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 101802101 101796501 N/A N/A N/A 101796801 1013061 1017705 101894901 101801001 101832001 101797701 101797702 101797801 101795701 1014304 101090801 1015072 1011578 1013683 2 3 QTY 4 Kit, Fuse and Receptacle (includes items 2 - 9) .................................................... Bezel, Receptacle ............................................................................................. Wire Assembly, Sense Lead, Gray ................................................................... Wire Assembly, #10 Red ................................................................................... Wire Assembly, #10 Black ................................................................................ Assembly, Fuse, 48-Volt (includes item 7) ........................................................ Nut, Nylon Lock, #10 .................................................................................... Screw, Phillips Pan-Head, #8 Type AB ............................................................. Fuse, 3/8-Amp .................................................................................................. Plate, Receptacle Backing .................................................................................... Screw, Phillips Pan-Head, #7-18 x 3/4 .................................................................. Battery, 8-Volt PowerDrive (includes item 13) ....................................................... Battery, 8-Volt PowerDrive, Dry (includes item 13) ............................................... Cap, Battery, 4-Port Gang ................................................................................. Wire Assembly, #6 Black ....................................................................................... Nut, Hex, Stainless Steel, 5/16-18 ........................................................................ Hold-Down, Battery ............................................................................................... Nut, Nylon Lock, Stainless Steel, 5/16-18 ............................................................. Washer, Flat, Type B Wide, 5/16 ........................................................................... J-Bolt ..................................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 2 3 1 1 4 6 6 1 5 12 3 6 6 6 Page 12-17 12 G E 12 G TYPICAL 2 PLACES E 7 9 8 2 SOLENOID TYPICAL 2 PLACES 3 6 12 TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES 1 5 21 12 TYPICAL 2 PLACES 22 4 13 14 CONTROLLER 16 ONBOARD COMPUTER 20 14 10 11 11 15 17 14 12 14 TYPICAL 2 PLACES 11 18 14 19 NC NO COM NC NO COM Page 12-18 10 14 2004-2005 DS Golf Cars Illustrated Parts List 15 COMPUTER, CONTROLLER, AND SOLENOID – POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 101965201 1014288 101908701 1011558 N/A N/A 1012528 7174 1014947 1242 7174 1012285 101840201 1241 7173 1218 101909901 101942301 101920101 101827801 1014948 101910401 2 3 QTY 4 Plate, Component Mounting ................................................................................. Screw, Thread-Forming, 5/16-18 x 3/4 ................................................................. Solenoid, 48-Volt (with diode) (includes items 4 - 8) ............................................. Nut, Hex, #6-32 ................................................................................................. Washer, Flat ...................................................................................................... Washer, Lock .................................................................................................... Nut, Hex, M8 ..................................................................................................... Washer, Lock, 5/16 ........................................................................................... Assembly, Resistor ................................................................................................ Nut, Hex, 5/16-18 .................................................................................................. Washer, Lock, 5/16 ............................................................................................... Screw, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ Controller, 48-Volt (225-amp) ................................................................................ Washer, Flat, 5/16 ................................................................................................. Screw, Hex-Head Cap, 5/16-18 x 3/4 ................................................................... Screw, Hex-Head Cap, 5/16-18 x 1-1/4 ................................................................ Computer, Onboard (includes item 18) ................................................................. Kit, 3-Pin Receptacle ........................................................................................ Kit, 3-Pin Plug and Wedge Lock ........................................................................... Kit, Wire and Terminal, #6 Black ........................................................................... Assembly, Diode (Service Part replacement for existing diode that comes standard with solenoid) .............................................................................. Screw, Thread-Forming, 5/16-18 x 1-1/4 .............................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 2 1 2 2 2 2 2 1 3 3 8 1 6 2 1 1 1 1 1 1 2 Page 12-19 12 G E 12 G 1 E 2 4 3 5 OFF ON Page 12-20 2004-2005 DS Golf Cars Illustrated Parts List MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 102101101 102101001 1015752 101936801 101920101 2 3 QTY 4 Regulator, Motor Controller Output (MCOR) ......................................................... Bar, Drive .............................................................................................................. Screw, Hex Washer-Head Hi-Lo, #12-16 x 5/8 ..................................................... Kit, 2-Pin Plug and Wedge Lock ........................................................................... Kit, 3-Pin Plug and Wedge Lock ........................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 2 1 1 Page 12-21 12 G E 12 2 N EE D RE E NG A OR G 1 GR N OW BR OR AN GE / REVERSE BUZZER 9 FORWARD / REVERSE SWITCH U E BATTERY WARNING LIGHT 1 29 BL E KEY SWITCH TE I WH 10 BL UE MOTOR CONTROLLER OUTPUT REGULATOR OR AN GE UE BL 2 BL UE WH ITE LIMIT SWITCHES 8 1 CK LA E /B ITE WHIT ITE H H / D /W W E RE ANG EN E N GR EE OR GR 7 5 6 OR RE N LL O P U BL W RP AC LE K D EE N 15 GR AY YE RE BLK FUSE D SOLENOID + + YELLOW D RE 3 + GREEN 1 BLUE YELLOW YELLOW RED BROWN BLACK 2 18 RED 23 GRAY + - TYPICAL 5 PLACES OW D RE 26 19 LL D + - - RED/WHITE PURPLE WHITE/ BLACK K AC BL BATTERY BANK EN 17 20 + RE 22 21 E PL RED 24 R 11 UE RED D RE 16 PU BL GRE FUSE AND RECEPTACLE K AC BL 4 YE GE 12 WHITE GR ITE WH ORANGE BLUE 14 3 GR EE N/ W HI TE 3 BR OW AN 2 2 1 CONTROLLER M- B- 3 - + 5 - 4 BLACK BLACK 6 LE E RP HIT PU D/W RE LOW L YE ITE WH UE BL B+ THREE PIN CONNECTOR GREEN OR A2 Page 12-22 GE S2 BL AC K 28 AN 13 ONBOARD COMPUTER 2004-2005 DS Golf Cars Illustrated Parts List 25 A1 S1 27 MOTOR WIRING – POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 102162101 N/A N/A N/A N/A N/A 101883002 N/A N/A 101901401 101901201 101901501 N/A 101901301 N/A N/A N/A N/A N/A 101795701 N/A 1014947 101902801 101903001 N/A N/A N/A 101902901 N/A N/A 2 3 QTY 4 Wire Harness (includes items 1 - 18) .................................................................... Wire Assembly, #18 Brown ............................................................................... Wire Assembly, #18 Blue .................................................................................. Wire Assembly, #18 Purple ............................................................................... Wire Assembly, #18 Yellow ............................................................................... Wire Assembly, #18 Green/White ..................................................................... Wire Assembly, #18 Black (includes resistor and #18 white wire) .................... Wire Assembly, #18 Green ............................................................................... Wire Assembly, #18 White/Black and #18 Red ................................................. Wire Assembly, #6 Blue .................................................................................... Wire Assembly, #6 Orange ............................................................................... Wire Assembly, #6 White .................................................................................. Wire Assembly, #18 Red/White ........................................................................ Wire Assembly, #6 Blue .................................................................................... Wire Assembly, #18 Green ............................................................................... Wire Assembly, #18 Red ................................................................................... Wire Assembly, #18 Orange ............................................................................. Wire Assembly, #18 Red ................................................................................... Wire Assembly, #18 Yellow ............................................................................... Wire Assembly, #6 Black ....................................................................................... Wire Assembly, #10 Black (part of onboard computer assembly) ......................... Assembly, Resistor ................................................................................................ Wire Assembly, #6 Red ......................................................................................... Wire Assembly, #6 Yellow ..................................................................................... Wire Assembly, #18 Gray (part of onboard computer assembly) .......................... Wire Assembly, #10 Black (part of onboard computer assembly) ......................... Wire Assembly, #10 Red (part of fuse and receptacle assembly) ......................... Wire Assembly, #6 Green ..................................................................................... Wire Assembly, #6 Black (part of onboard computer assembly) ........................... Wire Assembly, #18 Orange/White (part of battery warning light) ........................ 2004-2005 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 5 1 1 1 1 1 1 1 1 1 1 Page 12-23 12 G E 12 2 G GR TE GE /W 1 HI F BLUE ORANGE/WHITE O N RA R 1 3 2 THREE-PIN CONNECTOR REVERSE BUZZER BROWN BATTERY WARNING LIGHT BL HT N E LIG NG OW E U ORA BR BL + - 2 + - 5 E 4 B + SONIC WELD 3 4 RE CK LA D 10 FUSE AND RECEPTACLE RED BLK 6 PINK GRAY WHITE BROWN/WHITE ORANGE/WHITE SONIC WELD - + - 1 + BATTERY BANK PINK D RED RE EN NG D RE 8 BLACK/YELLOW RED/YELLOW BLUE/YELLOW GREEN/YELLOW BROWN BLUE TAN GREEN WHITE PURPLE/WHITE YELLOW A OR + - BLUE LIG RE LIG HT BL UE NK RE D UE 3 G HT PI W W LLO OW W LO E LL ELLO/YEL CK/Y E N/Y E/Y RED BLA EE LU GR B BLUE RED GREEN SONIC WELD TWO-PIN CONNECTOR N EE GR LUE HT HT B G I L LIG O BLU BR RAN E GE OW N FOUR-PIN CONNECTOR MOTOR CONTROLLER OUTPUT REGULATOR K AC K BL AC BL E 2 N EE D RE TOW/RUN SWITCH FORWARD / REVERSE SWITCH KEY SWITCH 15 + BL G AC RE RAY K D 5 TERMINAL B– K AC BL FUSE BR OW W W HI BL 6 N/ HI TE TE B CK LA LIGHT BLUE - K AC S1 M– S2 B+ K AC BLACK SIX-PIN CONNECTOR BL D REBLUE HT LT. RN/W G YEL ONBOARD COMPUTER GR UE /W HIT E SOLENOID 14 1 AY L BL IGH RE AC T G D K/ R W EE HI N TE 11 12 7 GR EE G R BL RE ED AC EN K N (PIN 9) GRAY WIRE 9 1 (PIN 1) WHITE WIRE (PIN 10) TAN WIRE 10 2 3 (PIN 2) YELLOW WIRE (PIN 12) BLUE/WHITE WIRE 11 12 13 (PIN 13) BLACK/WHITE WIRE (PIN 14) LIGHT GREEN WIRE (PIN 15) RED WIRE (PIN 16) BLUE WIRE 14 15 16 OW LL YE BL 4 5 6 7 (PIN 6) GREEN WIRE (PIN 7) ORANGE/WHITE WIRE 8 (PIN 8) BROWN WIRE (PIN 4) GREEN/WHITE WIRE (PIN 5) LIGHT BLUE WIRE UE AN GE 9 W BL OR (PIN 3) PURPLE/WHITE WIRE HI TE 13 A2 F2 A1 F1 MOTOR Page 12-24 2004-2005 DS Golf Cars Illustrated Parts List WIRING – IQ SYSTEM VEHICLE WITH MOTOR CONTROLLER OUTPUT REGULATOR (MCOR) ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 102196601 N/A N/A N/A N/A N/A N/A 101795701 101978101 102199601 101978201 101968701 101978001 101920001 102263601 2 3 QTY 4 Wire Harness ....................................................................................................... Wire Assembly, #18 Orange/White (part of battery warning light) ........................ Wire Assembly, #10 Red (part of fuse and receptacle assembly) ......................... Wire Assembly, #6 Black ....................................................................................... Wire Assembly, #10 Black (part of onboard computer assembly) ......................... Wire Assembly, #18 Gray (part of onboard computer assembly) .......................... Wire Assembly, #10 Black (part of onboard computer assembly) ......................... Wire Assembly, #6 Black ....................................................................................... Wire Assembly, #10 Orange ................................................................................. Wire Assembly, #6 Red ......................................................................................... Wire Assembly, #10 Blue ...................................................................................... Wire Assembly, #6 White ...................................................................................... Wire Assembly, #6 Green ..................................................................................... Wire Assembly, #6 Yellow ..................................................................................... Wire, Assembly, #10 Black .................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 5 1 1 1 2 1 1 1 Page 12-25 12 G E 12 G E 1 6 2 8 9 7 F 4 10 3 19 TYPICAL 3 PLACES 14 REFERENCE DECALS– SECTION 3 21 20 16 17 18 13 15 ING WARN 12 TOW RUN 5 11 22 23 F 25 Page 12-26 2004-2005 DS Golf Cars Illustrated Parts List 24 25 FORWARD/REVERSE SWITCH, TOW/RUN SWITCH – IQ SYSTEM 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 101856001 101855002 1012285 101942301 101932401 102266601 101920101 N/A N/A N/A 102266701 101932501 N/A N/A N/A N/A N/A N/A 8248 101922501 101908401 332 8233 101908101 8990 2 3 QTY 4 Switch, Forward/Reverse ...................................................................................... Case, Forward/Reverse Switch ............................................................................ Screw, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ Kit, 3-Pin Receptacle and Wedge Lock ................................................................. Kit, 4-Pin Receptacle and Wedge Lock ................................................................. Wire Assembly, Forward/Reverse Switch (includes items 7 - 10) ......................... Kit, 3-Pin Plug and Wedge Lock ....................................................................... Wire Assembly, #18 Blue .................................................................................. Wire Assembly, #18 Orange ............................................................................. Wire Assembly, #18 Brown ............................................................................... Wire Assembly, IQDM Port (includes items 12 - 18) ............................................. Kit, 4-Pin Plug and Wedge Lock ....................................................................... Wire Assembly, #18 Red/Yellow ....................................................................... Wire Assembly, #18 Black/Yellow ..................................................................... Wire Assembly, #18 Blue/Yellow ....................................................................... Wire Assembly, #18 Green/Yellow .................................................................... Cap, Dust .......................................................................................................... Connector, 4-Pin ............................................................................................... Screw, Phillips Truss-Head, 1/4-20 x 3/4 .............................................................. Bracket, Tow/Run Switch (without decal) .............................................................. Boot, Tow/Run Switch (with nut) ........................................................................... Washer, Flat, 1/4 ................................................................................................... Nut, Nylon Lock, 1/4-20 ........................................................................................ Switch, Tow/Run ................................................................................................... Tie, Wire ................................................................................................................ 2004-2005 DS Golf Cars Illustrated Parts List 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 A/R Page 12-27 12 G E 12 G 11 TYPICAL 4 PLACES E 10 6 TYPICAL 2 PLACES 5 7 TYPICAL 3 PLACES 8 TYPICAL 3 PLACES 16 TYPICAL 12 PLACES 17 TYPICAL 6 PLACES 15 TYPICAL 5 PLACES 14 2 3 18 4 1 19 TYPICAL 6 PLACES 13 12 F TYPICAL 6 PLACES Page 12-28 2004-2005 DS Golf Cars Illustrated Parts List 9 BATTERIES, CHARGER RECEPTACLE – IQ SYSTEM VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 101802101 101796501 N/A N/A N/A 101796801 1013061 1017705 101894901 101801001 101832001 101797701 101797702 101797801 101795701 1014304 101090801 1015072 1011578 1013683 2 3 QTY 4 Kit, Fuse and Receptacle (includes items 2 - 9) .................................................... Bezel, Receptacle ............................................................................................. Wire Assembly, Sense Lead, Gray ................................................................... Wire Assembly, #10 Red ................................................................................... Wire Assembly, #10 Black ................................................................................ Assembly, Fuse, 48-Volt (includes item 7) ........................................................ Nut, Nylon Lock, #10 .................................................................................... Screw, Phillips Pan-Head, #8 Type AB ............................................................. Fuse, 3/8-Amp .................................................................................................. Plate, Receptacle Backing .................................................................................... Screw, Phillips Pan-Head, #7-18 x 3/4 .................................................................. Battery, 8-Volt PowerDrive (includes item 13) ....................................................... Battery, 8-Volt PowerDrive, Dry (includes item 13) ............................................... Cap, Battery, 4-Port Gang ................................................................................. Wire Assembly, #6 Black ....................................................................................... Nut, Hex, Stainless Steel, 5/16-18 ........................................................................ Hold-Down, Battery ............................................................................................... Nut, Nylon Lock, Stainless Steel, 5/16-18 ............................................................. Washer, Flat, Type B Wide, 5/16 ........................................................................... J-Bolt ..................................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 2 3 1 1 4 6 6 1 5 12 3 6 6 6 Page 12-29 12 G E 12 G E 8 24 25 9 TYPICAL 2 PLACES 4 TYPICAL 3 PLACES 2 TYPICAL 2 PLACES 16 15 10 17 1 14 11 18 19 3 3 TYPICAL 2 PLACES TYPICAL 3 PLACES 12 6 5 13 7 3 F 21 TYPICAL 2 PLACES 22 20 TYPICAL 2 PLACES Page 12-30 2004-2005 DS Golf Cars Illustrated Parts List 3 TYPICAL 2 PLACES 23 COMPUTER, CONTROLLER, AND SOLENOID – IQ SYSTEM VEHICLE ITEM PART NO. DESCRIPTION 1 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 101956501 101956502 102240501 1012285 102266501 102240601 102240801 101931501 101965202 1014288 101910401 101909902 101932601 101932701 101827801 102259801 102263601 102263701 7174 1242 101908701 1012528 1013734 1014947 8639 **** **** 2 3 QTY 4 Controller, 48-Volt (250-amp) ................................................................................ Controller, 48-Volt (250-amp) (customized programming) ..................................... Screw, Hex Washer-Head, M8 x 1-1/4 x 12 mm ................................................... Screw, Hex, Type TT, 1/4-20 x 5/8 ........................................................................ Kit, Connector, IQ Controller ................................................................................. Cover, Controller (includes items 6 and 7) ............................................................ Gasket, Controller ............................................................................................. Decal, Electrical Component Cover .................................................................. Plate, Component Mounting ................................................................................. Screw, Thread-Forming, 5/16-18 x 3/4 ................................................................. Screw, Thread-Forming, 5/16-18 x 1-1/4 .............................................................. Computer, Onboard (includes item 12) ................................................................. Kit, 6-Pin Receptacle ........................................................................................ Kit, 6-Pin Plug and Wedge Lock ........................................................................... Kit, Wire and Terminal, #6 Black ........................................................................... Block, Terminal (controller) ................................................................................... Wire Assembly, #10 Black ..................................................................................... Screw, Phillips, Thread-Forming, #10-24 x 3/4 ..................................................... Washer, Lock, 5/16 ............................................................................................... Nut, Hex, 5/16-18 .................................................................................................. Solenoid, 48-Volt (with diode) (includes items 21 and 22) .................................... Nut, M8 x 1-1/4 ................................................................................................. Washer, Lock, 8 mm .......................................................................................... Assembly, Resistor ................................................................................................ Tie, Wire ................................................................................................................ Z-Bracket, Controller Cover .................................................................................. 1 1 3 9 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 Special order item available upon request. 2004-2005 DS Golf Cars Illustrated Parts List Page 12-31 12 G E 12 G E ELECTRIC MOTOR 13 G E 13 G TYPICAL 2 PLACES 11 12 E 9 13 TYPICAL 2 PLACES 14 10 7 17 8 TYPICAL 4 PLACES 15 16 20 21 22 1 6 5 4 3 19 18 2 TYPICAL 3 PLACES REFERENCE TRANSAXLE Page 13-2 2004-2005 DS Golf Cars Illustrated Parts List MOTOR – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 102237401 1017944 1017945 1017947 N/A N/A N/A N/A 1017952 1017953 1017951 1017949 1017948 1017946 1011411 1011290 1017950 N/A 1014201 451 1010934 7174 102235201 2 3 QTY 4 Assembly, 36-Volt Motor, 2.97-hp (includes items 1 - 17) ..................................... Shield, End ........................................................................................................ Assembly, Stator Shell and Winding ................................................................. Package, Hardware (includes items 4 - 7) ........................................................ Bushing, Insulator ......................................................................................... Washer, Flat, 5/16 ........................................................................................ Nut, Hex, 5/16-18 ......................................................................................... Bushing, Insulator ......................................................................................... Screw, Clamp .................................................................................................... Screw, Bearing Retainer ................................................................................... Shield, End ........................................................................................................ Screw, Brush Holder ......................................................................................... Rigging, Brush .................................................................................................. Package, Brush (2 pieces) (includes 4 brushes) .............................................. Package, Brush Spring (4 pieces) ..................................................................... Bearing, Ball ...................................................................................................... Retainer, Bearing .............................................................................................. Armature ........................................................................................................... Screw, Hex-Head Cap, 1/4-20 x 2-1/4 .................................................................. Washer, Lock, 1/4 ................................................................................................. Screw, Hex-Head Cap, 5/16-18 x 1 ...................................................................... Washer, Lock, 5/16 ............................................................................................... Bumper, Motor ...................................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 2 4 4 2 4 2 1 2 1 1 1 1 1 1 3 3 1 1 1 Page 13-3 13 G E 13 G TYPICAL 2 PLACES 11 12 E 9 13 TYPICAL 2 PLACES 14 10 7 17 23 8 TYPICAL 4 PLACES 15 16 21 22 20 1 6 5 4 3 19 18 2 TYPICAL 3 PLACES REFERENCE TRANSAXLE Page 13-4 2004-2005 DS Golf Cars Illustrated Parts List MOTOR – POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 102237701 1017944 1017958 1017947 N/A N/A N/A N/A 1017961 1017953 1017951 1017949 1017948 1017946 1011411 1011290 1017950 N/A 1014201 451 1010934 7174 102235201 102243403 2 3 QTY 4 Assembly, 48-Volt Motor, 3.10-hp (includes items 1 - 17) ..................................... Shield, End ........................................................................................................ Assembly, Stator Shell and Winding ................................................................. Package, Hardware (includes items 4 - 7) ........................................................ Bushing, Insulator ......................................................................................... Washer, Flat, 5/16 ........................................................................................ Nut, Hex, 5/16-18 ......................................................................................... Bushing, Insulator ......................................................................................... Screw, Clamp .................................................................................................... Screw, Bearing Retainer ................................................................................... Shield, End ........................................................................................................ Screw, Brush Holder ......................................................................................... Rigging, Brush .................................................................................................. Package, Brush (2 pieces) (includes 4 brushes) .............................................. Package, Brush Spring (4 pieces) ..................................................................... Bearing, Ball ...................................................................................................... Retainer, Bearing .............................................................................................. Armature ........................................................................................................... Screw, Hex-Head Cap, 1/4-20 x 2-1/4 .................................................................. Washer, Lock, 1/4 ................................................................................................. Screw, Hex-Head Cap, 5/16-18 x 1 ...................................................................... Washer, Lock, 5/16 ............................................................................................... Bumper, Motor ...................................................................................................... Lubricant, Moly-Teflon (Single-Use Tube) ............................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 2 4 4 2 4 2 1 2 1 1 1 1 1 1 3 3 1 1 1 1 Page 13-5 13 G E 13 TYPICAL 2 PLACES G 19 E 22 29 9 TYPICAL 2 PLACES 12 23 21 13 20 14 11 16 15 30 8 18 TYPICAL 4 PLACES 7 10 17 2 27 28 F11 A A2 24 F2 1 6 5 4 26 25 3 TYPICAL 3 PLACES REFERENCE TRANSAXLE Page 13-6 2004-2005 DS Golf Cars Illustrated Parts List MOTOR (MODEL 5BC59JBS6365) – IQ SYSTEM 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 102240102 1017944 102265501 1017947 N/A N/A N/A N/A 102266101 1017953 102265901 102266001 102265601 101942301 102267001 102265701 N/A N/A 1017950 N/A 102327801 1011411 102251901 1017948 1017949 102235201 1014201 451 1010934 7174 101920101 102243403 2 3 QTY 4 Assembly, 48-Volt IQ Motor, 3.20-hp (includes items 1 - 23) ................................ Shield, End ........................................................................................................ Assembly, Stator Shell and Winding ................................................................. Package, Hardware (includes items 4 - 7) ........................................................ Bushing, Insulator ......................................................................................... Washer, Flat, 5/16 ........................................................................................ Nut, Hex, 5/16-18 ......................................................................................... Bushing, Insulator ......................................................................................... Screw, Clamp, #10-32 x 8-1/4 ........................................................................... Screw, Bearing Retainer, #8-32 x 7/8 ............................................................... Assembly, End Shield (includes items 10 - 13) ................................................. Shield, End ................................................................................................... Sensor, Motor Speed (includes item 12) ...................................................... Housing, Female 3-Wire, Gray ................................................................ Screw, Steel Hex, Thread-Rolling, #8 x 3/8 .................................................. Kit, Bearing and Magnet (includes items 15 and 16) ........................................ Bearing, Ball ................................................................................................. Magnet ......................................................................................................... Retainer, Bearing .............................................................................................. Armature ........................................................................................................... Assembly, Brush Rigging (includes items 20 - 22) ............................................ Package, Brush Spring (4 pieces) ................................................................ Package, Brush (2 pieces) (includes 4 brushes) .......................................... Rigging, Brush .............................................................................................. Screw, Brush Holder, #6-32 x 1/2 ..................................................................... Bumper, Motor ...................................................................................................... Screw, Hex-Head Cap, 1/4-20 x 2-1/4 .................................................................. Washer, Lock, 1/4 ................................................................................................. Screw, Hex-Head Cap, 5/16-18 x 1 ...................................................................... Washer, Lock, 5/16 ............................................................................................... Kit, 3-Pin Plug and Wedge Lock ........................................................................... Lubricant, Moly-Teflon (Single-Use Tube) ............................................................. 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 2 4 4 2 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 3 1 1 1 1 Page 13-7 13 G E 13 TYPICAL 2 PLACES G 3 15 E TYPICAL 2 PLACES INCLUDES ALL 4 SPRINGS 22 18 7 14 21 TYPICAL 4 PLACES 20 8 19 29 TYPICAL 2 PLACES INCLUDES ALL 4 BRUSHES 10 31 30 TYPICAL 2 PLACES 28 33 11 32 12 13 16 25 TYPICAL 2 PLACES 24 27 23 9 34 36 1 26 17 5 TYPICAL 3 PLACES 4 35 2 000185-001 Page 13-8 2004-2005 DS Golf Cars Illustrated Parts List MOTOR (MODEL EJ4-4001) – IQ SYSTEM VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1010934 1014201 101920101 102235201 102243403 102705001 102186001 N/A 102186101 102186201 102845701 102186301 102186401 102186701 102186801 102186901 102187001 102187101 N/A N/A N/A N/A 102187201 N/A N/A 102704701 102704801 102704901 101942301 N/A N/A N/A N/A N/A 451 7174 2 3 QTY 4 Screw, 5/16-18 X 1.00 Hex Cap ............................................................................ Screw, 1/4-20 X 2.25 Hex Cap .............................................................................. Kit, 3-pin Plug & Wedge Lock ............................................................................... Bumper, Drive Unit ................................................................................................ Lubricant, Moly-Teflon (Single-Use Tube) ............................................................. IQ Electric Motor, 48-VDC 3.3 hp (includes items 7 through 34) .......................... Spring Kit, Motor Brush (includes item 8) .......................................................... Spring, Brush ................................................................................................ Brush Box Assembly ......................................................................................... Brush Kit, Motor (includes item 11) ................................................................... Assembly, Brush and Terminal ..................................................................... Ring, 2.24" Internal Retaining ........................................................................... Bearing, Ball ...................................................................................................... End Cap, Motor ................................................................................................. Screw, 1/4-20 X 2.25 Hx Washer ...................................................................... Screw, #8-32 X .5 Hx Hd Tptite ......................................................................... L-Bracket, Motor ............................................................................................... Hardware Kit, Motor Terminal (includes items 19 through 22) .......................... Bushing, Nylon ............................................................................................. Washer, Nylon Flat ....................................................................................... Washer, Flat, 5/16 Steel ............................................................................... Nut, Brass Hex, 5/16 - 18 ............................................................................. Plate Kit, Motor Cover (includes items 24 and 25) ............................................ Assembly, Cover Plate ................................................................................. Screw, #8-32 x 0.375, Taptite Thread ........................................................... Frame & Field Service Asm. ............................................................................. Armature Service Assembly .............................................................................. Speed Sensor Service Package (includes items 29 through 33) ...................... Kit, 3-pin Recept & Wedge Lock .................................................................. Sensor, Motor Speed, ADC .......................................................................... Screw, #8-32, Taptite Thread ....................................................................... Magnet, ADC Motor ...................................................................................... Screw, 1/4-20 x 0.5 ....................................................................................... Bolt, 1/4 - 20 x 0.73 Thread-Forming ................................................................ Lockwasher, 1/4 Helical Split ................................................................................ Lockwasher, 5/16 Split .......................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 3 1 1 1 1 1 4 1 1 2 1 1 1 2 2 1 2 2 2 2 2 1 1 1 1 1 1 1 1 2 1 1 2 3 1 Page 13-9 13 G E 13 G E TRANSAXLE – ELECTRIC VEHICLE 14 G E 14 G E REFERENCE MOTOR 8 7 6 4 3 1 16 12 20 5 10 13 12 15 11 12 14 19 17 18 21 28 22 5 9 29 30 11 26 27 9 26 24 25 4 23 32 23 Page 14-2 2004-2005 DS Golf Cars Illustrated Parts List 2 3 TRANSAXLE, TYPE G – ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 101896001 101895801 101895901 101922201 102357001 101928701 101923501 101895501 101897201 7330 101895601 1013794 7335 101923701 7336 101906901 101895401 101972201 101972101 101923201 101897001 101897601 101923901 101903601 101923001 101903701 101922101 101923601 101906201 101897401 101895701 2 3 QTY 4 Transaxle, Type G (includes items 1 - 30) ............................................................ Axle Assembly, Passenger-Side (includes item 3) ............................................ Axle Assembly, Driver-Side (includes item 3) ................................................... Stud, Lug ...................................................................................................... Screw, Flange-Head, M10 x 1.5 x 30 mm ......................................................... Gasket, Liquid, 8.8 oz. (250 g) .......................................................................... Seal, Oil, Input Shaft ......................................................................................... Gear Case, Passenger-Side ............................................................................. Breather ............................................................................................................ Bearing, Differential .......................................................................................... Assembly, Axle Tube, Passenger-Side ............................................................. Seal, Oil, Axle Shaft .......................................................................................... Bearing, Input Gear ........................................................................................... Shaft, Input ........................................................................................................ Bearing, Intermediate Gear ............................................................................... Assembly, Intermediate Gear ............................................................................ Gear Case, Driver-Side ..................................................................................... Plug, Fill ............................................................................................................ Plug, Magnetic .................................................................................................. Gasket, Plug ..................................................................................................... Bolt, M8 x 1.25 x 60 mm ................................................................................... Pin, Dowel ......................................................................................................... Gear, Differential ............................................................................................... Plate, Thrust (idler gear) ................................................................................... Gear, Differential Idler ....................................................................................... Plate, Thrust ...................................................................................................... Pin, Differential .................................................................................................. Housing, Differential * ........................................................................................ Gear, Output * .................................................................................................... Bolt, M10 x 1.5 x 25 mm ................................................................................... Assembly, Axle Tube, Driver-Side ..................................................................... 1 1 1 4 10 A/R 1 1 1 2 1 2 3 1 1 1 1 1 1 2 11 2 2 2 2 2 1 1 1 6 1 * If you are replacing the Output Gear, P/N 101906201, or Differential Housing, P/N 101923601, you must buy both. They are replacements for all gear and differential housing combinations in G type transaxles. (No pin required). 2004-2005 DS Golf Cars Illustrated Parts List Page 14-3 14 G E 14 G E REFERENCE MOTOR– SECTION 13 12 11 13 10 9 8 3 1 TYPICAL 10 PLACES 24 18 26 19 18 7 15 17 16 18 23 4 5 6 21 20 25 TYPICAL 2 PLACES 30 22 41 28 27 29 14 6 5 31 4 37 38 17 40 7 37 36 14 33 39 34 8 35 34 9 32 15 Page 14-4 2004-2005 DS Golf Cars Illustrated Parts List 3 2 TRANSAXLE, TYPE K – ELECTRIC VEHICLE ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 N/A 1013785 1013786 1013787 1014207 1011291 1013792 1016672 1013790 1013791 1013775 1013756 1012711 1013758 7330 101928701 1017704 1013794 7335 1013764 7336 1013766 1013780 1013765 1013757 1013759 1013763 1012710 1013779 1013782 1013767 1013772 101910501 1013768 1013773 1013774 1013769 1013771 1013770 1013781 1017703 1014193 2 3 QTY 4 Transaxle, Type K (includes items 1 - 41) ............................................................. Axle Assembly, Passenger-Side (includes items 3 - 7) ..................................... Axle Assembly, Driver-Side (includes items 3 - 7) ............................................ Stud, Lug ...................................................................................................... Bushing, 25 mm I. D. .................................................................................... Bearing, Outer Axle Tube ............................................................................. Circlip, Type C .............................................................................................. Ring, Retaining ............................................................................................. Bolt, M10 x 1.5 x 30 mm ................................................................................... Washer, Lock .................................................................................................... Seal, Input Shaft Oil .......................................................................................... Gear Case, Passenger-Side ............................................................................. Breather ............................................................................................................ Gasket, Case .................................................................................................... Bearing, Inner Axle Tube .................................................................................. Gasket, Liquid, 8.8 oz. (250 g) .......................................................................... Assembly, Axle Tube, Passenger-Side ............................................................. Seal, Axle Shaft Oil ........................................................................................... Bearing, Input Gear ........................................................................................... Shaft, Input ........................................................................................................ Bearing, Intermediate Gear ............................................................................... Gear, Intermediate, Small ................................................................................. Key, Sunk .......................................................................................................... Gear, Intermediate, Large ................................................................................. Gear Case, Driver-Side ..................................................................................... Plug, Fill, with Gasket ....................................................................................... Bolt, M6 x 1 x 50 mm ........................................................................................ Pin, Dowel ......................................................................................................... Bolt, M8 x 1.25 x 37 mm ................................................................................... Plate, Lock ........................................................................................................ Gear, Output ..................................................................................................... Pin, Differential .................................................................................................. Kit, Differential Gear Case (includes items 33 - 36) .......................................... Gear Case, Differential (driver side) ............................................................. Plate, Thrust (differential gear) ..................................................................... Plate, Thrust (idler gear) ............................................................................... Gear Case, Differential (passenger side) ..................................................... Gear, Differential ............................................................................................... Gear, Differential Idler ....................................................................................... Shim .................................................................................................................. Assembly, Axle Tube, Driver-Side ..................................................................... Pin, Dowel ......................................................................................................... 1 1 1 4 1 1 1 1 10 10 1 1 1 1 2 2 1 2 3 1 1 1 1 1 1 2 10 2 8 4 1 1 1 1 2 2 1 2 2 1 1 1 Note: Transaxle type is identified by orientation of gear case bolts (item 26). The Type K Transaxle has gear case bolt heads facing toward the driver side of the vehicle. 2004-2005 DS Golf Cars Illustrated Parts List Page 14-5 14 G E 14 G E BATTERY CHARGER 15 G E 15 G 1 E 2 4 3 5 6 8 9 7 1 10 14 11 12 Page 15-2 2004-2005 DS Golf Cars Illustrated Parts List 13 ACCU-POWER BATTERY CHARGER, DOMESTIC – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 101646401 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 12 13 14 1015907 7577 1015912 1015914 1015905 1015911 1015910 101643301 101643302 101643303 1012101 1012098 1012042 1015917 101591601 101591602 1015906 1015913 2 3 QTY G 4 Charger, Accu-Power, Domestic, 120-V AC, 36-V DC, 60-Hz (model number 13800-11) (includes items 1 - 14) 108-inch DC cord, 72-inch AC cord ...................................................................... Assembly, Case (includes fasteners) ................................................................ Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. Assembly, Transformer ..................................................................................... Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... Ammeter (includes mounting hardware) ........................................................... Relay, 36-V DC ................................................................................................. Capacitor ........................................................................................................... Cordset, DC, 108-Inch Long (standard) 12-AWG ............................................. Cordset, DC, 146-Inch Long, 10-AWG .............................................................. Cordset, DC, 242-Inch Long, 10-AWG .............................................................. Assembly, Fuse (Includes Hardware) ............................................................... Bushing, Strain Relief, 12-AWG DC Cord ......................................................... Bushing, Strain Relief, 10-AWG DC Cord ......................................................... Bushing, Strain Relief, AC Cord ........................................................................ Cordset, AC, 72-Inch Long (standard) .............................................................. Cordset, AC, 108-Inch Long ............................................................................. Assembly, Timer Kit (includes mounting hardware) .......................................... Assembly, Control Cable ................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 15 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 15-3 E 15 G 1 E 2 4 3 5 6 7 8 9 1 10 11 14 13 12 Page 15-4 2004-2005 DS Golf Cars Illustrated Parts List ACCU-POWER BATTERY CHARGER, EXPORT, 230-VOLT – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 101643401 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 13 14 N/A 7577 1015936 1015914 1015905 1015911 1015910 101643301 101643302 101643303 1012101 1012098 1012042 1015917 1014696 1015906 1015913 2 3 QTY G 4 Charger, Accu-Power, Export, 230-V AC, 36-V DC, 50-Hz (model number 14410-11) (includes items 1 - 14) 108-inch DC cord, 108-inch AC cord ..................................................................... Assembly, Case ................................................................................................ Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. Assembly, Transformer ..................................................................................... Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... Ammeter (includes mounting hardware) ........................................................... Relay, 36-V DC ................................................................................................. Capacitor ........................................................................................................... Cordset, DC, 108-Inch Long, 12-AWG (standard) ............................................ Cordset, DC, 146-Inch Long, 10-AWG .............................................................. Cordset, DC, 242-Inch Long, 10-AWG .............................................................. Assembly, Fuse (includes mounting hardware) ................................................ Bushing, Strain Relief, 12-AWG DC Cord ......................................................... Bushing, Strain Relief, 10-AWG DC Cord ......................................................... Bushing, Strain Relief, AC Cord ........................................................................ Cordset, AC, 108-Inch Long (standard) ............................................................ Assembly, Timer Kit (includes mounting hardware) .......................................... Assembly, Control Cable ................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 15 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 15-5 E 15 G 1 E 2 4 3 5 6 7 8 9 1 10 11 12 Page 15-6 2004-2005 DS Golf Cars Illustrated Parts List 14 13 ACCU-POWER BATTERY CHARGER, EXPORT, 100-VOLT – V-GLIDE 36-VOLT VEHICLE ITEM PART NO. DESCRIPTION 1 101646201 1 2 3 4 5 6 7 8 8 8 9 10 10 11 12 13 14 N/A 7577 1016336 1015914 1015905 1015911 1015939 101643301 101643302 101643303 1012101 1012098 1012042 1015917 1016282 1015906 1015913 2 3 QTY G 4 Charger, Accu-power, Export, 100-V AC, 36-V DC, 50-Hz (model number 14900) (includes items 1 - 14) 108-inch DC cord, 108-inch AC cord .................................................................... Assembly, Case ................................................................................................ Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. Assembly, Transformer ..................................................................................... Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... Ammeter (Includes Mounting Hardware) .......................................................... Relay, 36-V DC ................................................................................................. Capacitor ........................................................................................................... Cordset, DC, 108-Inch Long, 12-AWG (standard) ............................................ Cordset, DC, 146-Inch Long, 10-AWG .............................................................. Cordset, DC, 242-Inch Long, 10-AWG .............................................................. Assembly, Fuse (includes mounting hardware) ................................................ Bushing, Strain Relief, 12-AWG DC Cord ......................................................... Bushing, Strain Relief, 10-AWG DC Cord ......................................................... Bushing, Strain Relief, AC Cord ........................................................................ Cordset, AC, 108-Inch Long ............................................................................. Assembly, Timer Kit (includes mounting hardware) .......................................... Assembly, Control Cable ................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 15 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 15-7 E 15 G E 1 2 3 5 4 6 7 8 9 C lu b C ar R 11 10 13 14 1 12 Page 15-8 2004-2005 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER, DOMESTIC ITEM PART NO. DESCRIPTION 1 2 3 QTY G 4 PowerDrive chargers can be used with PowerDrive System 48 and IQ System vehicles. 101802201 101802202 101802203 1 2 3 4 5 6 7 7 7 8 9 10 11 12 13 13 14 101828301 7577 101819701 1015914 101828501 101831101 101828901 101828902 101828903 1012101 1012098 101914401 CCX8506 101828601 101828801 101828802 1015917 E Charger, Battery, PowerDrive, Domestic 120-V AC 48-V DC 60-Hz (model number 17930-11) (includes items 1 - 14) 103-inch DC cord with male 3-pin plug, 12-AWG 74-inch AC cord with male grounded plug ............................................................ Charger, Battery, PowerDrive 120-V AC 48-V DC 60-Hz (model number 17930-18) (includes items 1 - 14) 144-inch DC cord with male 3-pin plug, 12-AWG 108-inch AC cord with male grounded plug .......................................................... Charger, Battery, PowerDrive 120-V AC 48-V DC 60-Hz (model number 17930-19) (includes items 1 - 14) 240-inch DC cord with male 3-pin plug, 12-AWG 108-inch AC cord with male grounded plug ........................................................... Assembly, Case (includes fasteners) ................................................................ Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. Assembly, Transformer ..................................................................................... Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... Ammeter (includes mounting hardware) ........................................................... Kit, Wire Assembly ............................................................................................ Cordset, DC, 113-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Cordset, DC, 154-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Cordset, DC, 250-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Assembly, Fuse (includes mounting hardware) ................................................ Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ Assembly, Voltage Suppressor ......................................................................... Breaker, Circuit, 15-Amp, 120-V AC ................................................................. Relay, Power, 48-V DC ..................................................................................... Cordset, AC, 80-Inch Long ............................................................................... Cordset, AC, 116-Inch Long .............................................................................. Bushing, Strain Relief, AC Cord ........................................................................ 2004-2005 DS Golf Cars Illustrated Parts List 15 1 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 15-9 15 G 14 2 E 1 5 4 8 3 9 2 13 10 7 15 11 Page 15-10 12 1 2004-2005 DS Golf Cars Illustrated Parts List POWERDRIVE 2 BATTERY CHARGER, DOMESTIC ITEM PART NO. DESCRIPTION 1 2 3 QTY G 4 PowerDrive 2 chargers can be used with PowerDrive System 48 and IQ System vehicles. 101802204 101802205 101802206 1 2 3 4 5 6 7 7 7 8 9 10 11 12 13 13 14 15 102273201 7577 102273301 102273401 102273501 102273601 101828904 101828905 101828906 102273701 102273801 102273901 1012098 CCX8506 101828801 101828802 102274001 101828601 E Charger, Battery, PowerDrive 2, Domestic 120-V AC 48-V DC 60-Hz (model number 22110-11) (includes items 1 - 15) 103-inch DC cord with male 3-pin plug, 12-AWG 74-inch AC cord with male grounded plug ............................................................ Charger, Battery, PowerDrive 2 120-V AC 48-V DC 60-Hz (model number 22110-18) (includes items 1 - 15) 144-inch DC cord with male 3-pin plug, 12-AWG 108-inch AC cord with male grounded plug .......................................................... Charger, Battery, PowerDrive 2 120-V AC 48-V DC 60-Hz (model number 22110-19) (includes items 1 - 15) 240-inch DC cord with male 3-pin plug, 12-AWG 108-inch AC cord with male grounded plug ........................................................... Assembly, Case (includes item 2) ..................................................................... Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 ............................................. Assembly, Transformer (includes rivets) ........................................................... Plate, Heatsink ................................................................................................. Assembly, Diode with Heatsink Film (includes mounting hardware) ................. Kit, Wire Assembly (not shown) ........................................................................ Cordset, DC, 113-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Cordset, DC, 154-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Cordset, DC, 250-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Assembly, Fuse, 30-Amp (includes terminal hardware) .................................... Ammeter (includes mounting hardware) ........................................................... Bushing, Strain Relief, AC Cord ........................................................................ Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ Breaker, Circuit, 15-Amp, 120-V AC ................................................................. Cordset, AC, 80-Inch Long ............................................................................... Cordset, AC, 116-Inch Long .............................................................................. Handle, PowerDrive 2 Charger (with four screws) ............................................ Relay, Power, 48-V DC ..................................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 15 1 1 1 1 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page 15-11 15 G 4 E 23 TYPICAL 12 PLACES 21 7 9 10 8 5 15 17 22 11 12 13 20 18 6 16 19 14 000184-001 Page 15-12 2004-2005 DS Golf Cars Illustrated Parts List GE POWERDRIVE BATTERY CHARGER, DOMESTIC ITEM PART NO. DESCRIPTION 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 102496401 102496402 102496403 102814201 102814301 102814401 102814501 102814601 102814701 102814702 102814801 102814802 102814803 102814901 102815001 102815101 102815201 102815301 102815401 102815501 102815601 102815701 7577 2 3 QTY 4 Charger,120VAC/48VDC 103/74in ........................................................................ Charger,120VAC/48VDC 144/108in ...................................................................... Charger,120VAC/48VDC 240/108in (includes items 4 through 23) ...................... Handle, PowerDrive Charger ............................................................................ Transformer ....................................................................................................... Cover, Base ...................................................................................................... Cover, Top ......................................................................................................... Plate, Heatsink .................................................................................................. Cordset, AC, 80-Inch Long ............................................................................... Cordset, AC, 108-Inch Long ............................................................................. Cordset, DC, 113-Inch Long ............................................................................. Cordset, DC, 154-Inch Long ............................................................................. Cordset, DC, 250-Inch Long ............................................................................. Breaker, Circuit, 15-Amp ................................................................................... Rectifier ............................................................................................................. Relay, 48-VDC .................................................................................................. Ammeter ........................................................................................................... Bushing, Strain Relief ........................................................................................ Bushing, Strain Relief ........................................................................................ Fuse, 25-Amp, Type ABC ................................................................................. Wire Assembly, Voltage Suppressor ................................................................. Holder, Fuse ...................................................................................................... Screw, #10 X .50 Phil Pan Head ....................................................................... 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 Page 15-13 15 G E 15 G E 1 2 4 3 7 6 5 8 9 11 10 12 13 C lu b C ar R 14 1 15 Page 15-14 2004-2005 DS Golf Cars Illustrated Parts List 16 POWERDRIVE BATTERY CHARGER, EXPORT ITEM PART NO. DESCRIPTION 1 2 3 QTY G 4 PowerDrive chargers can be used with PowerDrive System 48 and IQ System vehicles. 101831503 101831504 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 15 16 N/A 7577 101838201 1015914 101914401 101838501 101828501 101838301 101838701 101838601 101828901 101828902 101828903 1012101 1012098 101838401 101831701 101831702 1015917 E Charger, Battery, PowerDrive, Export with 4-Position Switch 100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz (model number 18780-11) (includes items 1 - 16) 103-inch DC cord with male 3-pin plug, 12-AWG 74-inch AC cord with no plug ................................................................................ Charger, Battery, PowerDrive Export with 4-Position Switch 100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz (model number 18780-18) (includes items 1 - 16) 144-inch DC cord with male 3-pin plug, 12-AWG 108-inch AC cord with no plug .............................................................................. Assembly, Case ................................................................................................ Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. Assembly, Transformer ..................................................................................... Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... Assembly, Voltage Suppressor ......................................................................... Kit, Wire Assembly ............................................................................................ Ammeter (includes hardware) ........................................................................... Relay, Power, 48-V DC (includes mounting hardware) ..................................... Bracket, Power Relay Mounting ........................................................................ Switch, 4-Position Slide .................................................................................... Cordset, DC, 113-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Cordset, DC, 154-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Cordset, DC, 250-Inch Long with Male 3-Pin Plug, 12-AWG ............................ Assembly, Fuse (includes hardware) ................................................................ Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ Breaker, Circuit, 10-Amp ................................................................................... Cordset, AC, 80-Inch Long with Leads (no plug) .............................................. Cordset, AC, 116-Inch Long with Leads (no plug) ............................................ Bushing, Strain Relief, AC Cord ........................................................................ 2004-2005 DS Golf Cars Illustrated Parts List 15 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Page 15-15 15 G 15 E 2 5 6 1 4 3 7 8 18 9 1 10 11 12 C lu b C ar R 14 13 16 17 Page 15-16 2004-2005 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER, EUROPEAN ITEM PART NO. DESCRIPTION 1 2 3 QTY G 4 PowerDrive chargers can be used with PowerDrive System 48 and IQ System vehicles. 101956201 101956202 1 2 3 4 5 6 7 8 9 10 10 10 11 12 13 14 15 16 N/A 7577 **** 1015914 **** **** 101976601 101987501 101838601 101828901 101828902 101828903 1012101 1012098 101838401 101973501 **** 101958301 17 18 101958201 N/A **** E Charger, Battery, PowerDrive, European with 4-Position Switch 100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz (model number 20300) (includes items 1 - 15) 103-inch (261 cm) DC cord with male 3-pin plug, 12-AWG ................................... Charger, Battery, PowerDrive European with 4-Position Switch 100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz (model number 20310) (includes items 1 - 15) 144-inch (366 cm) DC cord with male 3-pin plug, 12-AWG .................................. Assembly, Case ................................................................................................ Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. Assembly, Transformer ..................................................................................... Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... Assembly, AC Voltage Suppressor .................................................................... Kit, Wire Assembly ............................................................................................ Ammeter (includes hardware) ........................................................................... Relay, Power, 48-V DC (includes mounting hardware) ..................................... Switch, 4-Position Slide .................................................................................... Cordset, DC, 103-Inch (261 cm) Long with Male 3-Pin Plug, 12-AWG ............. Cordset, DC, 144-Inch (366 cm) Long with Male 3-Pin Plug, 12-AWG ............. Cordset, DC, 250-Inch (635 cm) Long with Male 3-Pin Plug, 12-AWG ............. Assembly, Fuse (includes hardware) ................................................................ Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ Breaker, Circuit, 10-Amp ................................................................................... Receptacle, AC Cord ........................................................................................ Assembly, Current Limiter ................................................................................. Cordset, AC, Continental Europe, 96-Inch (244 cm) Long (with male 2-pin plug) ............................................................................................ Cordset, AC, U.K., 96-Inch (244 cm) Long (with male 3-pin plug) ........................ Wire, Jumper.......................................................................................................... 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 Special order item available on request 2004-2005 DS Golf Cars Illustrated Parts List 15 Page 15-17 15 G E MAINTENANCE AND SERVICE TOOLS 16 G E D 16 G E D Loctite® AC PE CE DA LE L RAT HE O IG R HT 1 2 4 3 8 5 9 6 7 11 10 BR EQ A K U E AL C IZ AB AT L IO E N BR CALIBRATION & TEST MODULE INSTRUCTIONS AK H EP EI E G DA H L T SPEED CONTROL SET POWER SWITCH TO "ON". TEST PEDAL CIRCUIT POT CALIBRATION: SET MODE SWIT CH TO "PO T". CHECK INTERNAL 4.30.03 VOL T SIGNAL BY PRESSING "TEST" BUTTON. CON NECT TEST SOCKET TO POT PLUG, CONNECT GREEN LEAD TO GREEN/ WHITE POT LIMIT SWIT CH LEAD, CONNECT BLUE LEAD TO BATTERY POSITIVE. ILLUMINATION OF THE L.E .D. INDICA TES A CLOSED PEDAL LIMIT SWIT CH, READ THE POTENTIOMETER SET VOLTAGE FROM THE L.C.D. DISPLAY. SEE SERVICE MANUAL FOR ADJUSTMENT PROCEDURE. SPEED SENSOR TEST:SET MODE SWITCH TO "SSAM", CONNECT TEST SOCKET TO MO TOR SPEED SENSOR PLUG,ROTATE MOTOR. L.E.D. SHOULD PULSE ON AND OFF INDICA TING SPEED SENSOR IS FUNCTIONAL. SEE OPERATING INSTRUCTIONS FOR MORE DETAIL POWER ON OFF Page 16-2 16 13 19 MODE SSAM POT 15 14 12 R Club Car 20 2004-2005 DS Golf Cars Illustrated Parts List 17 18 MAINTENANCE AND SERVICE TOOLS ITEM PART NO. QTY DESCRIPTION 1 2 3 DIESEL QTY GAS QTY ELEC G 4 The following tool list includes all tools available from Club Car for maintenance and service procedures for gasoline, electric, and/or diesel vehicles, both past and present models. Be sure to carefully examine the tool list for applicability to your vehicle before ordering. 1 2 3 4 5 6 7 8 9 10 11 12 13 101871001 101813202 101641202 101831901 1014305 1011767 1016417 1016416 1012811 1012812 1013582 102555501 102249901 14 15 16 **** **** 102669601 17 18 19 20 101887101 101808401 102562401 102686101 Accelerator Pedal Adjustment Tool ................................................. Adhesive, Guide Ring, 3-Gram Tube .............................................. Arbor ............................................................................................... Battery Discharge Machine, 36/48 Volt ........................................... Battery Terminal Protector Spray .................................................... Battery Thermometer ...................................................................... Bearing and Oil Seal Remover Assembly ....................................... Bearing Driver Set ........................................................................... Bearing Puller ................................................................................. Bearing Puller Wedge Attachment .................................................. Brake Adjustment Tool (used only on vehicles with manually adjusted mechanical brakes) ........................................... Brake Cable Release Tool .............................................................. Brake Pedal Adjustment Tool Kit (used for the Carryall Electric Industrial Truck only) (includes items 14 and 15)............................. Brake Pedal Adjustment Tool ...................................................... Brake Pedal Tension Tool ........................................................... Connecting Rod Small End Bushing Tool (for Kubota D722 Diesel Engines) ................................................... Calibration Test Module .................................................................. Cam Installation Tool ....................................................................... Charger Bezel Tool ......................................................................... Clutch Removal Tool (for XRT 1500, Carryall 294, and Bobcat 2200 Vehicles) ............... E D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. **** 16 Special order item available upon request 2004-2005 DS Golf Cars Illustrated Parts List Page 16-3 16 G R A W IN N G E D 22 25 24 23 28 27 26 21 30 29 31 33 32 I A B C E F G H COMMUNICATION DISPLAY MODULE DISPLAY FUNCTIONS: PRESS AND HOLD BUTTON TO SHOW FUNCTION NUMBER. RELEASE BUTTON TO SHOW FUNCTION VALUE. Func1 - Battery voltage. Func2 - Energy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Func4 - Last charge termination type (1 = Incomplete, 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER ON OFF R Club Car PART #17075 44 45 46 37 42 41 40 39 38 Page 16-4 36 35 34 47 2004-2005 DS Golf Cars Illustrated Parts List 48 43 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 21 22 23 24 25 26 27 28 29 1014510 1014498 1014496 1014497 1014508 1014507 1015524 101809101 102601501 30 102607501 31 102603501 32 102605201 33 102606101 34 35 36 37 38 39 40 101831801 101641002 102669001 102669201 1011273 102668901 102669501 41 102674001 42 102674101 43 102674201 44 102675201 45 102675301 46 102675401 47 102675001 48 102675101 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC G 4 Clutch Tool Kit (includes items 22 - 28) ........................................... Clutch Alignment Tool (for pre-unitized transaxle vehicles built prior to 1997 model year) ...................................... Drive Clutch Puller (for Kawasaki engines only) ......................... Drive Clutch Hub Puller (for Kawasaki engines only) ................. Driven Clutch Cam Puller (for Kawasaki engines only) .............. Driven Clutch Puller Plug (for Kawasaki engines only) ............... Drive Clutch Holder Tool Assembly (for Kawasaki engines only) Press Weldment (for Kawasaki engines only) ............................ Clutch, Drive, Fixed Sheave Tool (for XRT 1500, Carryall 294, and Bobcat 2200 Vehicles) ................ Clutch, Drive, Spider Removal Tool (for XRT 1500, Carryall 294, and Bobcat 2200 Vehicles) ................ Clutch, Driven, Spring Compression Base (for use with items 32 and 33) (for XRT 1500, Carryall 294, and Bobcat 2200 Vehicles) ... Clutch, Driven, Spring Compression Collar (for use with items 31 and 33) (for XRT 1500, Carryall 294, and Bobcat 2200 Vehicles) ... Clutch, Driven, Spring Compression Nut (for use with items 31 and 32) (for XRT 1500, Carryall 294, and Bobcat 2200 Vehicles) ... Communication Display Module ..................................................... Compression Gauge and Adapter .................................................. Compression Tester (for Kubota D722 Diesel Engines)................... Connecting Rod Alignment Tool (for Kubota D722 Diesel Engines) Continuity Tester ............................................................................. Crank Sleeve Setter (for Kubota D722 Diesel Engines) ................. Crankshaft Bearing Replacement Tool (for Kubota D722 Diesel Engines) .................................................. Crankshaft Main Bearing Driver (for use with items 42 and 43) (for Honda GX620 Gasoline Engines) ............................................. Crankshaft Main Bearing Driver Attachment (for use with Honda GX620 Gasoline Engines) Crankshaft Main Bearing Pilot Attachment (for Honda GX620 Gasoline Engines) ............................................ Cutter, Valve Seat Exhaust, 32 Degree (requires item 59) (for Honda GX620 Gasoline Engines) ........................................... Cutter, Valve Seat Intake, 32 Degree (requires item 59) (for Honda GX620 Gasoline Engines) ............................................ Cutter, Valve Seat, 60 Degree (requires item 59) (for Honda GX620 Gasoline Engines) ............................................ Cutter, Valve Seat, Exhaust, 45 Degree (requires item 59) (for Honda GX620 Gasoline Engines) ............................................ Cutter, Valve Seat, Intake, 45 Degree (requires item 59) (for Honda GX620 Gasoline Engines) ............................................ 1 E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. 2004-2005 DS Golf Cars Illustrated Parts List 16 Page 16-5 16 G E D 51 50 49 58 55 54 53 60 59 52 57 56 61 62 63 66 Liquid Gasket 2 3 65 64 Page 16-6 67 2004-2005 DS Golf Cars Illustrated Parts List 68 69 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. DESCRIPTION 1 49 50 51 52 53 1012151 102674501 102668601 1016627 102669801 54 102669901 55 56 57 58 59 102674701 102670001 1016418 101933101 102674901 60 102169401 61 62 1011478 102669701 63 64 1013593 102248803 65 66 67 68 69 102251501 102241502 102241501 101928701 102243402 2 3 QTY QTY GAS QTY ELEC 1 1 1 1 DIESEL 4 Dry Moly Lubricant .......................................................................... Flywheel Clutch Holder (for Honda GX620 Gasoline Engines) ....... Flywheel Puller (for Kubota D722 Diesel Engines) ......................... Flywheel Puller Kit (for Kawasaki Engines) .................................... Fuel Injection Pump Pressure Tester (for Kubota D722 Diesel Engines) ................................................... Gauge, Carburetor Float Level (for Honda GX620 Gasoline Engines) ............................................ Gauge, Oil Pressure (for Honda GX620 Gasoline Engines) ........... Gauge, Oil Pressure, Attachment (for Honda GX620 Engines) ...... Gear Yoke ....................................................................................... Governor Shaft Installation Tool (for Kawasaki Engine Vehicles) ... Holder, Valve Seat Cutter (for use with items 44 through 48) (for Honda GX620 Gasoline Engines) ............................................ Hydraulic Brake Adjuster (for gasoline vehicles equipped with hydraulic brakes, except XRT 1500, Carryall 294, and Bobcat 2200) ............................................................................ Hydrometer ..................................................................................... Idle Gear Bushing Replacement Tool (for Kubota D722 Diesel Engines) ................................................... Internal Retaining Ring Pliers .......................................................... IQ Display Module (IQDM) Kit (for IQ System vehicles only) .......... (includes items 65 and 66) Adaptor, Cable ............................................................................ IQDM Series 2 Cable .................................................................. IQDM Series 1 Cable (replacement) ............................................... Liquid Gasket (transaxle case) ....................................................... Moly-Teflon Lubricant (4-oz. (113-gram) tube) ................................ 1 D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Please refer to the maintenance and service manual for proper tool application. 2004-2005 DS Golf Cars Illustrated Parts List G E 1 1 1 1 1 1 16 Page 16-7 16 G E D 70 73 72 71 Safety First Never use a vehicle that is unsafe. Inspect each day. Inspect GOOD NEED(S) ATTENTION • Brakes • Park Brake • Steering • Accelerator • F & R Selector • Reverse Buzzer • Key Switch • Speeds • Tires • Bag Straps and Buckles PERFECT CIRCLE PERFECT CIRCLE PLASTIGAGE Other Mechanical Problems • Unusual Noise • Will Not Run • Stopped on Course • Other: • • • Damage • Right Side • Left Side • Front • Rear • Other: ______________ No Damage NEED(S) ATTENTION Cleanliness • Seats • Floor Mat • Dash Compartments • Bag Well • Beverage Holders • Overall Appearance: ___________________ TYPE PR-1 Date: _____________ Inspected By: _________________ Car No. ___________ (Over) CCI 1018231 76 75 74 77 78 AM10753 ON OFF STR SPK MAX MIN GAS DSL GAS/DIESEL TACHOMETER 79 86 Page 16-8 80 87 81 88 90 2004-2005 DS Golf Cars Illustrated Parts List 85 84 83 82 91 92 93 94 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 70 71 71 71 71 71 71 71 71 71 71 72 73 74 75 76 77 78 79 80 102669101 101997201 101997207 101997212 101997211 101997205 101997209 101997204 101997203 101997206 101997202 1016414 1016415 102669301 102668801 1012549 1012560 101823101 1012809 102330901 81 82 83 84 85 86 87 88 89 1014264 1014259 102061201 AM10753 AM10771 1014162 1014161 1014115 101611003 90 91 92 93 94 1016413 102674601 101641201 102674401 102669401 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC G 4 Oil Pressure Tester (for Kubota D722 Diesel Engines) ................... Paint, Touch-Up – Beige* ................................................................ Paint, Touch-Up – Black* ................................................................ Paint, Touch-Up – Burgundy* .......................................................... Paint, Touch-Up – Classic Blue (Navy)* .......................................... Paint, Touch-Up – Dark Gray* ......................................................... Paint, Touch-Up – Dark Green* ...................................................... Paint, Touch-Up – Gray* ................................................................. Paint, Touch-Up – Red* .................................................................. Paint, Touch-Up – Royal Blue (Pacific Blue)* ................................. Paint, Touch-Up – White* ................................................................ Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) . Piston Ring Pliers (for Kawasaki Engines) ...................................... Plastigage (for Kubota D722 Diesel Engines) ................................. Puller, Special Use (for Kubota D722 Diesel Engines) .................... Retaining Ring Pliers, 45° External ................................................. Retaining Ring Pliers, 90° Internal .................................................. Safety First Card (50 per pack) ....................................................... Seal Puller ....................................................................................... Spanner Wrench (for coil over shock front suspension vehicles only) ............................................................... Steering Column Bearing Press Tool .............................................. Steering Column Retaining Ring Tool ............................................. Steering Wheel Puller Tool .............................................................. Tachometer (includes gasoline engine pick up lead only) ............... Tachometer Diesel Probe (for use with item 84) ............................. Transaxle Axle Seal Tool ................................................................. Transaxle Pinion Seal Tool .............................................................. Transmission Tool Kit ...................................................................... Tune-Up Kit, All OHV (for Kawasaki Engines) (includes air filter, spark plug, oil filter, fuel filters) (not shown) .................................... Valve Clearance Adjuster Screw Holder (for FE290 engines only) . Valve Guide Driver (for Honda GX620 Gasoline Engines) ............................................ Valve Guide Reamer (FE290, FE350, and FE400 only) .................. Valve Guide Reamer, 6.6 mm (for Honda GX620 Gasoline Engines) ............................................ Valve Guide Replacement Tool (for Kubota D722 Diesel Engines) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 * Item 71 is not for use on vehicles with Surlyn® body material, which is used on Precedent vehicles. 2004-2005 DS Golf Cars Illustrated Parts List 16 Page 16-9 E D 16 G E D 97 96 95 - + WAVETEK V 5XL 1000 OFF V 500 200 200 20 200 2m 2 200 m 20 m 200 m 2000 k 200k 20k 45 98 Page 16-10 45 V ! MAX 1000 --750V 99 100 2004-2005 DS Golf Cars Illustrated Parts List 200 A 2k ! COM 200nA FUSED 101 102 MAINTENANCE AND SERVICE TOOLS, CONTINUED ITEM PART NO. 1 95 96 97 98 99 100 101 102 1016552 102668701 1016551 1016553 1016554 101641101 1011480 102674801 QTY DESCRIPTION 2 3 DIESEL QTY GAS QTY ELEC G 4 Valve Seat Cutter Guide .................................................................. Valve Seat Cutter Set (for Kubota D722 Diesel Engines) ............... Valve Seat Cutter T-Wrench ............................................................ Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) Valve Seat Cutter, 45°/30° (35 mm diameter) ................................. Valve Spring Compressor ................................................................ Volt Ohm Meter ............................................................................... Wrench, Valve Clearance Adjustment (for Honda GX620 Gasoline Engines) ............................................ 1 1 1 2004-2005 DS Golf Cars Illustrated Parts List 1 1 1 1 1 16 E D 1 1 Page 16-11 16 G E D INDEX Part Number and Page AM10079 6-9, 12-3 AM10080 11-5, 11-11 AM10081 11-5, 11-11 AM10419 10-5 AM10724 7-5 AM10753 16-9 CCX8506 15-9, 15-11 183 8-11, 10-3 304 12-7 324 1-15 332 1-7, 1-9, 1-11, 1-15, 6-5, 8-11, 9-3, 12-11, 12-27 4-7, 5-3, 5-5, 7-15 334 5-9, 10-3 357 451 9-3, 12-7, 12-9, 12-11, 12-15, 13-3, 13-5, 13-7, 13-9 705 706 808 1016 6-13, 7-15 5-9 10-3 12-13 1017 12-9 1028 1-13, 4-5, 12-7, 12-9, 12-11, 12-15 1032 4-5 1035 4-3, 5-5, 5-7 1218 12-19 1241 1-5, 1-13, 4-5, 4-7, 6-7, 6-13, 6-15, 12-19 1242 4-5, 6-7, 6-13, 12-19, 12-31 1308 5-7 1606 8-11, 12-13 1620 1-3 1624 4-7, 5-5, 5-7, 5-9 2402 5-7 4107 12-13 7048 5-9 7173 6-13, 6-15, 12-19 7174 5-3, 6-13, 8-9, 9-3, 12-13, 12-19, 12-31, 13-3, 13-5, 13-7, 13-9 7251 7310 1-5 2-3 7330 11-7, 11-13, 14-3, 14-5 7335 11-5, 11-11, 14-3, 14-5 7336 14-3, 14-5 7473 1-3, 1-5, 1-13, 4-5, 4-7, 6-7, 6-13, 6-15, 12-9 7479 1-9, 1-13 7539 5-7 7540 5-5, 5-7 7555 5-5, 5-7 7569 5-11 7577 15-3, 15-5, 15-7, 15-9, 15-11, 15-13, 15-15, 15-17 7602 5-5, 5-7 7716 4-5, 4-7 7818 1-13, 6-7 7847 1-3, 1-7, 9-3 7893 7973 6-5, 6-7, 12-13 1-3 1011084 4-7 1011229 6-9 8049 8056 8057 12-7, 12-15 12-9 6-5, 6-7, 12-7, 12-9, 12-15 1011273 16-5 8058 6-5, 6-7, 12-7, 12-9, 12-15 8067 5-9 8233 1-7, 1-9, 1-15, 4-7, 6-5, 8-3, 12-7, 12-15, 12-27 1011290 13-3, 13-5 1011291 11-7, 11-13, 14-5 1011382 1011394 1-3 1-5 1011402 4-5 1011411 13-3, 13-5, 13-7 8248 8251 8418 1-7, 1-9, 6-5, 8-3, 12-27 1-7, 1-9, 6-5 1-13 1011415 5-11 1011418 4-5 1011466 4-3 8449 8450 8626 8639 12-9 10-3, 12-7, 12-15 4-5 12-13, 12-31 1011478 16-7 1011480 16-11 1011558 12-19 8717 8745 8754 6-5, 6-7 5-9 4-7, 5-3, 5-5, 5-7, 5-9, 5-11, 6-13 1011578 12-13, 12-17, 12-29 1011652 1-11 1011694 4-7 8755 8795 8796 8797 5-9 12-13 12-13 12-13 1011697 1-3, 5-3, 8-7, 8-9 1011700 4-7 1011734 4-7 1011767 16-3 8861 5-7 1011779 4-3, 4-5 8990 8755 5-5, 12-3, 12-27 5-11 101187702 1011930 4-5, 4-7 5-5, 5-7 1011931 12-11 1011988 8-3 1011997 12-7 1012022 12-13 1012030 5-9 1012042 15-3, 15-5, 15-7 1012047 1-7, 1-9 1010124 1010145 1010150 5-7 5-11 5-9 1010200 1010219 1010413 1010434 5-7 5-7 1-13 1-3, 1-13 1010435 1010521 1010543 1-5 12-13 1-11 1010577 1010805 1010829 1010850 7-15 4-5 4-3 4-3 1010877 4-5 1010878 4-5 101090801 12-13, 12-17, 12-29 1010921 1010927 1010932 1010933 1-13, 4-5 4-5 4-5 4-5 1010934 1010954 1010958 6-15, 13-3, 13-5, 13-7, 13-9 6-5, 6-7, 11-3, 11-9 12-5, 12-13 1010974 1010984 1011010 1011014 5-11 2-3, 5-9 12-5 1-5 1011017 1011019 1011069 1-5 1-3 12-5 1012098 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 1012101 15-3, 15-5, 15-7, 15-9, 15-15, 15-17 1012151 16-7 1012159 1-9 1012180 5-11 1012181 5-11 1012182 5-11 1012285 6-5, 8-9, 12-11, 12-13, 12-19, 12-27, 12-31 1012295 6-7 1012303 1012304 5-9, 5-11 5-11 1012324 5-11 1012328 6-15 1012333 6-5 1012353 12-9 1012382 6-3 1012412 1-7, 1-9 1012431 6-5, 6-7 1012467 1012505 5-5 6-9, 12-3 1012528 9-3, 12-19, 12-31 1012549 16-9 2004-2005 DS Golf Cars Illustrated Parts List Page i-1 INDEX 1012560 1012565 1012566 1012571 1012594 1012604 1012605 1012649 1012651 1012710 1012711 1012714 1012740 1012741 1012747 1012748 1012752 1012809 1012811 1012812 1012830 16-9 5-3 5-3 7-15 6-5 5-3 5-3 8-3 12-5 14-5 11-3, 11-5, 11-5, 11-5, 11-5, 11-5, 11-3, 16-9 16-3 16-3 6-13, 1013692 1013700 1013734 11-9, 14-5 11-11 11-11 11-11 11-11 11-11 11-9 9-3 1012903 12-9 1012981 7-5 1012987 6-5, 12-7, 12-15 1013001 6-11 1013003 6-11 1013005 6-11 101301102 6-11 1013032 1-7, 1-9 1013035 5-5 1013042 5-5 1013044 5-5 1013051 5-5 1013052 5-5 1013061 12-9, 12-17, 12-29 1013092 12-5, 12-13 1013164 5-11 1013207 4-3, 5-11 1013266 12-13 1013343 1-3 1013344 1-3 101342501 12-13 101347501 1-5 1013494 1-3 1013496 3-5 1013531 4-5 1013582 1013587 16-3 6-5 1013589 1013590 1013591 1013593 1013609 1013628 1013649 1013683 6-5, 6-7 6-5 6-5 16-7 6-7 12-13 12-13 12-13, 12-17, 12-29 1013687 8-3 Page i-2 1013746 1013754 1013756 1013757 1013758 1013759 1013763 1013764 1013765 1013766 1013767 1013768 8-3 8-9 9-3, 12-31 8-3, 8-7 1-13 14-5 14-5 14-5 11-3, 11-9, 14-5 14-5 14-5 14-5 14-5 14-5 11-7, 11-13, 14-5 1013769 1013770 1013771 1013772 11-7, 11-7, 11-7, 11-7, 1013773 1013774 1013775 1013779 1013780 1013781 1013782 1013785 1013786 1013787 1013790 1013791 11-13, 14-5 11-13, 14-5 11-13, 14-5 11-13, 14-5 11-7, 11-13, 14-5 11-7, 11-13, 14-5 14-5 14-5 14-5 14-5 14-5 1013792 1013794 1013860 1013861 1013869 1013870 1013871 1013876 1013886 1013887 1013924 1013935 1013971 1013998 1014000 1014003 1014007 1014010 1014012 1014013 1014014 14-5 14-5 11-7, 11-13, 14-5 11-7, 11-13, 14-5 11-7, 11-13, 14-5 14-5 11-7, 11-13, 14-3, 14-5 12-9 5-3 4-5 4-5 4-7 4-5 12-9 12-9 4-3, 7-15 1-13 12-11 12-9 12-9 12-9 4-7 12-9 12-11 12-11 12-11 1014017 1014019 12-9 12-9 1014029 1014030 12-5 12-5 1014032 12-5 2004-2005 DS Golf Cars Illustrated Parts List 1014033 1014034 12-5 12-5 1014035 1014036 12-5 12-5 1014039 1014045 12-5 12-11 1014049 1014050 10-3 10-3 1014051 1014052 1014055 1014056 1014057 1014058 1014059 1014062 1014065 1014070 1014072 1014078 1014080 1014089 1014109 1014115 1014116 10-3 10-3 10-3 10-3 10-3 10-3 10-3 10-3 6-5, 6-7 10-5 10-5 10-5 10-5 6-5 12-9 16-9 8-3 1014119 1014125 1014126 1014145 1014153 1014161 1014162 1014189 1014193 1014198 1014201 1014207 1014213 1014214 6-3 5-3 5-3 6-5, 6-7 4-3 16-9 16-9 12-9 11-7, 11-13, 14-5 1-5, 3-3, 3-5 13-3, 13-5, 13-7, 13-9 11-7, 11-13, 14-5 5-3 5-3 1014216 1014217 5-3 5-3 1014235 1014253 1014259 1014264 1014276 1014287 1014288 1014289 1014304 1014305 1014306 1014374 1014375 1014414 1014453 1014454 5-7 12-9 16-9 16-9 5-9 10-3 5-3, 6-15, 12-19, 12-31 6-11 12-13, 12-17, 12-29 16-3 1-7, 1-9 6-15 6-15 12-9 10-3 10-5 INDEX 1014476 1014482 1014496 1014497 1014498 1014507 1014508 1014510 1014516 1014523 1014524 12-11 1-13 16-5 16-5 16-5 16-5 16-5 16-5 12-13 8-3 8-3 1014528 1014555 1014645 1014696 1014727 1014728 1014729 1014735 1014771 12-7, 12-15 5-11 1-3 15-5 6-5 12-11 12-11 12-9 2-3 1014807 1014808 1014828 1014871 1014928 1014947 6-5, 6-7, 12-9 6-7, 12-7, 12-15 12-5 12-15 8-3 12-19, 12-23, 12-31 12-13, 12-19 12-9 1-3, 1-5, 1-7, 1-9 6-5, 12-7, 12-15 12-13, 12-17, 12-29 1015075 1-13, 9-3 1015137 8-3, 8-7 1015139 8-3 1015143 8-3 1015188 8-3 101524001 6-13 1015330 9-3 1015332 6-3, 7-3 1015345 6-7 1015371 6-7 1015372 6-7 1015373 6-7 1015405 6-7 1015426 8-11 101547601 3-3 1015524 16-5 1015525 1-7, 1-9 1015545 5-3 1015583 5-9, 5-11 1015597 5-5, 5-7, 5-9 1015649 7-3 101570501 2-3 101570507 2-3 101570509 2-3 101570513 2-3 1014948 1014999 1015032 1015064 1015072 1015707 2-3 1015720 1015737 6-9 6-3, 6-7 1015741 1015752 1015769 6-7 6-7, 8-11, 12-21 6-3 1015777 6-7 1015814 9-3 101584502 8-9 1015878 6-7 1015905 1015906 1015907 15-3, 15-5, 15-7 15-3, 15-5, 15-7 15-3 1015910 1015911 15-3, 15-5 15-3, 15-5, 15-7 15-3 15-3, 15-5, 15-7 1015912 1015913 1015914 15-3, 15-5, 15-7, 15-9, 15-15, 15-17 101591601 15-3 101591602 15-3 1015917 15-3, 15-5, 15-7, 15-9, 15-15 1015920 6-3, 6-13 1015932 1015936 1015939 1015969 6-13 15-5 15-7 7-3 1016003 8-3 1016068 1016069 12-5 12-5 1016070 12-5 1016074 6-13 101610901 3-5, 12-9 101611003 16-9 1016140 1016154 1016156 12-9 5-3 5-3 1016175 1016181 1016183 1016201 12-9 5-3 5-3 6-5 1016203 10-3, 10-5 1016214 5-3 101621601 3-3, 3-5 1016219 1016263 5-3 5-3 1016269 1016282 5-3 15-7 1016289 1016336 1016337 10-3 15-7 11-5, 11-11 1016338 1016341 1016342 1016346 11-5, 11-11 11-3, 11-9 6-5 5-7 1016349 1016350 1016353 5-7 5-7 5-7 1016379 1-3 1016384 5-9 1016385 5-7 1016386 5-9 1016387 5-9 1016389 5-9 101641002 16-5 101641101 16-11 101641201 16-9 101641202 16-3 1016413 16-9 1016414 16-9 1016415 16-9 1016416 16-3 1016417 16-3 1016418 16-7 101642572 8-5 101642575 8-5 101642578 8-5 101642580 8-5 101642582 8-5 1016429 7-7 1016430 7-9 1016431 7-9 1016432 7-7, 11-3, 11-9 101643301 15-3, 15-5, 15-7 101643302 15-3, 15-5, 15-7 101643303 15-3, 15-5, 15-7 101643401 15-5 1016435 7-7 1016436 7-9 1016437 8-5 1016438 8-7 1016439 1016440 1016441 1016442 1016443 1016444 1016445 1016446 1016447 1016448 1016449 1016450 1016451 1016452 1016453 1016454 1016455 8-7 8-7 8-7 7-9 7-3 8-7 7-5 7-11 7-9 7-9 7-9 7-9 7-9 7-9 7-11 7-11 7-5 1016456 7-3, 7-5, 7-11 1016457 7-7 1016458 7-9, 7-11 101645901 7-13 101645902 7-13 101645903 7-13 1016460 7-13 2004-2005 DS Golf Cars Illustrated Parts List Page i-3 INDEX 1016849 6-9, 12-3 1016851 6-9, 12-3 1016859 6-9, 12-3 1016868 1-5 1016875 1-3 1016876 1-3 1016883 6-13 1016896 12-7 1016916 1-11 101692501 1-5 101692502 1-5 101692504 1-5 101692506 1-5 101647502 7-13 1016479 7-9 7-9 7-5, 7-9, 7-11 1016545 7-9, 12-19 1016546 8-9 1016547 7-3, 7-13, 8-7 1016548 7-5 1016549 7-9 101655001 7-13 101655002 7-13 101655003 7-13 101655004 7-13 101655005 7-13 101655006 7-13 101655007 7-13 101655008 7-13 101692509 101692510 1-5 1-5 1016480 8-7 101648102 8-7 101655009 7-13 1016551 16-11 101692511 101692512 1-5 1-5 101648203 7-7 1016483 7-9 1016484 7-7 1016486 8-5 1016489 7-9 101649002 8-7 1016493 7-5 1016494 7-11 1016496 7-11 1016497 7-5 1016499 8-5 1016501 8-5 1016502 7-7 1016505 7-5 1016506 7-11 1016507 7-3 1016552 1016553 1016554 1016558 16-11 16-11 16-11 7-13 101692513 101692601 1-5 1-7 1016559 1016560 1016561 1016562 1016563 1016564 1016565 1016566 1016567 7-13 7-9 7-5 7-5, 7-13 7-9 7-11 7-11 7-9 7-11 1016568 1016569 1016570 1016571 1016572 1016576 1016578 1016579 1016580 1016581 1016582 1016583 1016584 1016585 1016586 1016587 7-13 7-9 7-7 7-13 8-7 7-7 7-5 7-5 7-13 7-7 8-7 7-9 7-11 8-5 7-5 7-5 101692602 101692604 101692606 101692609 101692610 101692611 101692612 101692613 101693301 101693302 101693304 101693306 101693309 101693310 101693311 101693312 1-7 1-7 1-7 1-7 1-7 1-7 1-7 1-7 1-9 1-9 1-9 1-9 1-9 1-9 1-9 1-9 101693313 101693901 101693902 1-9 1-5 1-5 101693904 101693906 1-5 1-5 101693908 101693909 1-5 1-5 101693910 101693911 1-5 1-5 101646101 7-13 101646102 7-13 101646103 7-13 101646201 15-7 101646401 15-3 1016467 7-7 1016469 7-13 1016470 7-13 1016471 7-9 1016472 7-11 1016473 7-7 1016474 7-9 101647501 7-13 1016509 7-13 1016510 7-11 101651401 2-3 101651407 2-3 101651409 2-3 101651413 2-3 1016516 7-13 1016517 1016519 7-9 7-9 1016520 1016521 7-11 7-11 1016523 1016524 1016525 1016526 1016531 1016532 1016533 1016535 1016536 1016537 1016538 1016539 7-9 7-3 7-3 7-3 7-3 7-13 7-13 7-11 7-3 7-7 7-11 7-3 1016541 7-13 Page i-4 1016542 1016544 1016588 7-5 101660404 1-3 101661601 101661602 12-13 12-13 1016622 1016627 5-3 16-7 1016630 1016663 6-9 5-3 1016672 1016801 1016845 11-7, 11-13, 14-5 10-3 12-7, 12-15 2004-2005 DS Golf Cars Illustrated Parts List 101693912 1-5 1016947 6-5 1016952 1-3 101696201 1-9 101696202 1-9 101696204 1-9 101696206 1-9 101696208 1-7 101696209 1-7 101696211 1-7 101696213 1-7 101696215 1-7 101696216 1-7 INDEX 101696217 1-9 101696218 1-9 101696219 1-7 101696220 1-7 101696221 1-7 101696222 1-9 101696223 1-9 101696224 1-9 1016967 1-5 1017029 4-5 101706702 1-3 1017079 1017080 1-3 1-5 101708301 1-3 1017141 1-7, 1-9 1017203 8-3 1017221 7-3 1017226 5-3 1017231 11-3, 11-9 1017266 1017273 1017327 1017378 1017380 5-7 5-3 10-5 4-7 4-7 1017424 4-7 1017448 7-5 1017455 7-5 1017456 7-7 1017461 8-5 1017466 8-7 1017507 7-7 101753005 12-15 1017653 6-11 101768202 1-3 1017686 10-5 1017689 9-3 1017692 12-9 101769302 2-3 1017696 4-7 1017703 14-5 1017704 14-5 1017705 12-17, 12-29 1017748 1-7, 1-9 1017774 1-13 1017799 12-15 1017814 1-9 1017815 1-9 101791101 4-3 1017936 1-7, 1-9 1017944 13-3, 13-5, 13-7 1017945 13-3 1017946 13-3, 13-5 1017947 13-3, 13-5, 13-7 1017948 13-3, 13-5, 13-7 1017949 13-3, 13-5, 13-7 1017950 13-3, 13-5, 13-7 1017951 13-3, 13-5 1017952 1017953 13-3 13-3, 13-5, 13-7 101795701 12-17, 12-23, 12-25, 12-29 1017958 13-5 1017961 13-5 101796201 4-7 101796501 12-17, 12-29 101796801 12-17, 12-29 101797701 12-17, 12-29 101797702 12-17, 12-29 101797801 101801001 101802101 101802201 101802202 101802203 101802204 101802205 101802206 101802601 101804301 101805701 101808401 101809101 101811401 101811501 101811901 101812301 12-17, 12-29 12-17, 12-29 12-17, 12-29 15-9 15-9 15-9 15-11 15-11 15-11 1-3, 12-3 8-11 8-11 16-3 16-5 8-11 8-11 8-11 8-11 101813202 101815501 101815502 101816301 101816501 101816502 101817401 101818801 16-3 4-3 4-3 4-3 4-3 4-3 4-7 4-7 101819701 101820201 101821501 101823101 101823201 101823301 101823302 101823801 101823901 101824001 101824002 101824401 101825101 101826201 101826301 101827101 101827801 101828301 101828501 101828601 15-9 8-7 8-11 16-9 4-3 4-3 4-3 4-3 4-3 4-3 4-3 8-3 3-3, 3-5 12-3 6-9 7-15 12-19, 12-31 15-9 15-9, 15-15 15-9, 15-11 101828801 15-9, 15-11 101828802 101828901 101828902 101828903 101828904 101828905 101828906 101830601 101830701 101831101 101831401 101831503 101831504 101831701 101831702 101831801 101831901 15-9, 15-11 15-9, 15-15, 15-17 15-9, 15-15, 15-17 15-9, 15-15, 15-17 15-11 15-11 15-11 6-9 6-9, 12-3 15-9 12-13 15-15 15-15 15-15 15-15 16-5 16-3 101832001 101832101 101832202 101832302 101832701 101833001 101833201 101833401 101833601 12-17, 12-29 7-15 8-9 8-9 7-15 7-15 7-15 10-5 11-3, 11-9 101833701 101833902 101834001 101834502 101834601 101834801 101835601 101836201 101837101 101837301 6-11, 6-13 10-3 10-5 6-9, 12-3 7-15 11-3, 11-9 1-15 10-5 8-11 6-3, 6-13 101838201 101838301 101838401 101838501 101838601 101838701 101840201 101850301 101851101 101855002 101855801 101856001 101856102 101856201 101859301 101861901 101862001 101869302 101871001 101871901 101874901 15-15 15-15 15-15, 15-17 15-15 15-15, 15-17 15-15 12-19 8-11 6-9 12-27 6-5 12-27 6-7 8-11 9-3 4-7 4-7 6-11 16-3 4-7 6-11 2004-2005 DS Golf Cars Illustrated Parts List Page i-5 6-11 6-11 101893201 101894901 101895401 101895501 101895601 101895701 101895801 101895901 101896001 101896501 101896901 101897001 101897201 11-5, 11-11 12-17, 12-29 14-3 14-3 14-3 14-3 14-3 14-3 14-3 6-11 8-3 14-3 14-3 101876501 101877601 6-11 6-11 101897401 101897601 14-3 14-3 101877701 101878101 6-11 6-11 101878201 101878302 101879001 101879401 101879501 101879601 101879701 101879801 101879901 101880001 101880101 101880201 101880301 101881701 101883002 101884801 4-5 5-5 6-11 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 8-11 12-23 7-15 101898001 101900801 101900901 101901201 101901301 101901401 101901501 101902801 101902901 101903001 6-15 4-3, 5-11 6-9 12-23 12-23 12-23 12-23 12-23 12-23 12-23 101903101 101903501 101903601 101903701 101904101 101905601 5-9 8-9 14-3 14-3 1-7, 1-9 8-5, 8-7 101887101 101887601 101887901 101889302 101889401 101889901 101890001 101890101 101890201 101890601 101890901 101891001 101891301 101891401 101891501 101891601 101891901 101892001 101892201 101892301 101892401 101892501 101892601 16-3 7-3, 8-7 12-31 6-3 11-5, 11-11 11-5 11-5, 11-11 11-3, 11-9 11-3, 11-9 11-3, 11-9 11-7, 11-13 11-7, 11-13 11-3, 11-9 11-7, 11-13 11-7, 11-13 11-5, 11-11 11-5, 11-11 11-5, 11-11 11-5, 11-11 11-5, 11-11 11-5, 11-11 11-5, 11-11 11-5, 11-11 101906201 101906901 101908101 101908401 101908601 101908701 101909201 101909301 14-3 14-3 12-27 12-27 3-5 12-19, 12-31 7-5 7-5 101909401 101909501 7-5 7-5 101909701 101909901 101909902 101910401 101910501 101912401 101914401 101915201 101915401 101915501 101915601 101915701 101915801 101916501 101916701 7-3 12-19 12-31 1-13, 12-19, 12-31 11-7, 11-13, 14-5 4-7 15-9, 15-15 3-3 7-11 7-13 7-3 7-5 7-5 10-3 6-13, 10-3 101892701 11-7, 11-13 101917601 8-11 101875001 101875101 101875201 101875301 101875401 101875501 101875601 101875701 101875802 101876001 101876202 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 6-11 101876301 101876402 101917701 101920001 8-11 12-25 101920101 13-9 101921501 12-19, 12-21, 12-27, 13-7, 8-11 101922101 101922201 101922301 101922501 14-3 14-3 7-13 12-27 101922601 101923001 101923201 6-5, 11-3, 11-9 14-3 14-3 101923501 101923601 101923701 101923901 14-3 14-3 14-3 14-3 101925701 101927101 101927201 8-11 11-3, 11-9 11-3, 11-9 101927501 101927601 11-5, 11-11 11-5, 11-11 11-5, 11-11 101927901 101928701 11-5, 11-11 11-5, 11-11 11-7, 11-13 11-3, 11-9, 14-3, 14-5, 16-7 101929801 101931501 101932401 10-3 3-5 12-27 101932501 101932601 101932701 101933101 12-27 12-31 12-31 16-7 101935501 101936801 101939901 12-3 12-21 6-11 101928001 101928101 101928301 101942301 12-19, 12-27, 13-7, 13-9 101949201 101951501 101953001 12-9 6-5 4-5 101953101 101953901 101954301 4-5 7-3 1-11 101956201 101956202 101956502 15-17 15-17 12-31 101958101 8-11 101958201 101958301 101959902 15-17 15-17 3-5 101960501 3-3 101960601 101963401 101965201 3-3, 3-5 7-15 12-19, 12-31 101966901 101968701 101971001 4-7 12-25 8-11 INDEX 101971301 101972001 101972002 101972003 101972004 101972005 101972006 101972007 101972009 101972011 101972012 8-11 16-9 16-9 16-9 16-9 16-9 16-9 16-9 16-9 16-9 16-9 101972101 101972201 14-3 14-3 101972801 101973101 8-11 8-5 101973201 101973501 8-5 15-17 101975901 101976601 101978001 101978101 101978201 101979101 101980801 101980901 101981001 101984801 101985501 101987501 101987601 101987701 12-13 15-17 12-25 12-25 12-25 6-5, 12-15 11-5, 11-11 11-5, 11-11 11-5, 11-11 5-3 1-11 15-17 1-11 8-3 101990801 101992601 101998201 101998202 101998204 101998205 101998501 102003201 102018001 102022101 102026001 102047201 102048301 102060501 102060502 102060504 102060505 102061201 102061301 102061302 102063901 102064601 102065501 102065901 102076701 4-5 6-7 1-11 1-11 1-11 1-11 1-11 8-3 12-5 4-3, 4-5 4-7 12-13 12-13 1-13 1-13 1-13 1-13 16-9 1-15 1-15 1-15 1-15 1-15 7-15 1-13, 1-15 102099101 1-15 102101001 102101101 102155501 102162101 102169401 102174201 102174202 102174204 102174205 102186001 102186101 102186201 12-21 12-21 1-15 12-23 16-7 1-11 1-11 1-11 1-11 13-9 13-9 13-9 102186301 102186401 102186701 102186801 102186901 102187001 102187101 102187201 102196601 102198301 102199601 13-9 13-9 13-9 13-9 13-9 13-9 13-9 13-9 12-25 1-15 12-25 102221201 102235201 102236601 102236703 102237001 102237401 102237701 1-3, 1-7, 1-9 13-3, 13-5, 13-7, 13-9 1-13 1-13 1-13 13-3 13-5 102238301 102238302 102238304 102238305 102240102 102240501 102240601 102240801 102241501 102241502 102242101 102242401 102243402 102243403 102248801 102249901 102250201 102251501 102251901 102259001 102259801 102263601 102263701 102265501 102265601 102265701 102265901 1-13 1-13 1-13 1-13 13-7 12-31 12-31 12-31 16-7 16-7 10-5 1-13 16-7 13-5, 13-7, 13-9 16-7 16-3 12-15 16-7 13-7 1-5, 3-3, 3-5 12-31 12-25, 12-31 12-31 13-7 13-7 13-7 13-7 102266001 102266101 102266501 102266601 102266701 102267001 102273201 102273301 13-7 13-7 12-31 12-27 12-27 13-7 15-11 15-11 102273401 102273501 102273601 102273701 102273801 102273901 102274001 102278001 102292801 102304701 102310701 15-11 15-11 15-11 15-11 15-11 15-11 15-11 5-3 4-3 7-9 1-5 102323101 102323201 102327801 102330901 102336001 102336101 102352801 102353201 102353301 102353401 102354101 4-5 4-5 13-7 16-9 8-9 8-9 5-9 5-9 5-9 5-9 5-9 102354201 102355301 102357001 102357701 102453101 102496401 102496402 102496403 102540301 5-9 6-15 14-3 5-9 11-11 15-13 15-13 15-13 7-15 102555501 102562401 16-3 16-3 102601501 102603501 102605201 102606101 102607501 102668601 102668701 102668801 102668901 102669001 102669101 102669201 102669301 102669401 102669501 16-5 16-5 16-5 16-5 16-5 16-7 16-11 16-9 16-5 16-5 16-9 16-5 16-9 16-9 16-5 102669601 16-3 2004-2005 DS Golf Cars Illustrated Parts List Page i-7 INDEX cable (IQDM) 102669701 16-7 102669801 16-7 102669901 16-7 102670001 16-7 102674001 16-5 102674101 16-5 102674201 16-5 102674401 16-9 102674501 16-7 102674601 16-9 102674701 16-7 102674801 16-11 102674901 16-7 102675001 16-5 102675101 16-5 102675201 16-5 102675301 16-5 102675401 16-5 102686101 16-3 102704701 13-9 102704801 13-9 102704901 13-9 102705001 13-9 102706401 5-11 102814201 15-13 102814301 15-13 102814401 15-13 102814501 15-13 102814601 15-13 102814701 15-13 102814702 15-13 102814801 15-13 102814802 15-13 102814803 15-13 102814901 15-13 102815001 15-13 102815101 15-13 102815201 15-13 102815301 15-13 102815401 15-13 102815501 15-13 102815601 15-13 102815701 15-13 102845701 13-9 727102 2-3 16-7 adhesive, guide ring 15-17 16-3 adjuster idle screw hydraulic brake adjusting stud 16-7 pilot air screw resistor air duct repair kit air filter 8-11 8-11 7-13 screw (float chamber) 8-5 a-plate strap spindle 5-7 13-3, 13-5, 13-7 steering column 11-3, 11-9 governor lever pivot 5-9 stator shell arm 7-9 timer speed switch 5-3 steering gearbox 5-5 switch brush 12-9 11-3, 11-9 rocker 12-9 15-3, 15-5, 15-7 transformer 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 armature 6-11, 13-3, 13-5, 13-7, 13-9 armrest 1-11 v-glide wiper switch assembly voltage regulator 3-pin plug 13-7 voltage suppressor 6-pin plug 12-31 wheel and tire 36-volt motor 13-3 48-volt motor 13-5 accelerator rod axle 15-17 axle 11-7, 11-13, 14-3, 14-5 axle shaft seal 6-11 11-7, 11-13, 14-3, 14-5 axle tube 14-3, 14-5 bag hoop 1-13 bearing (steering column) bell crank and shaft 6-7 bolt (float chamber) 8-5 5-3 brush rigging 13-7 carburetor 8-5 axle tube 14-3 11-7, 11-13, 14-3, 14-5 axle tube oil seal 14-5 B backing plate (brake) bag hoop 1-13 bag strap 1-13 bag strap buckle 1-13 charger case 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 bagwell protector 1-3 control cable 15-3, 15-5, 15-7 current limiter 15-17 ball joint cylinder head ball joint, inner delta a-plate diode 7-9 diode with heatsink film eccentric end shield 15-11 ball bearing, output shaft ball joint (tie rod) 5-7 5-5 5-5, 5-7 ball stud (shifter lever) 11-3, 11-9 4-7 ball, steel (shift fork retainer) 10-5 ball, steel, pressure relief 5-9 band, rpm limiter mount bar, bus 12-15 13-7 float (carburetor) 8-5 float chamber 8-5 bar, drive 12-21 forward/reverse shifter 6-5 barb, vent 8-3 forward/reverse switch 12-27 fuel strap, rear 8-3 12-7, 12-15, barrel fastener heatsink 6-11 6-5 ball stud, accelerator pedal 10-3 driven clutch 4-3 ball joint, left-hand thread ball stud 6-5, 6-7 5-7 12-19 drive hub 15-9, 15-15 2-3 6-3, 6-7, 6-9, 6-13, 7-3, 12-5, 12-9, 12-13, 12-17, 12-23, 12-25, 12-29, 12-31, 15-11, 15-13, 15-15, 15-17 wire, sense lead 12-17, 12-29 4-7 air box top 8-11 air duct 8-11 armature 12-9 6-7 wire ac voltage suppressor ac voltage suppressor 15-17 accelerator pedal 4-7 accelerator pedal adjustment tool 16-3 accelerator pedal return spring cup 4-7 accelerator pivot rod 4-7 accelerator rod 4-7 access door 1-7, 1-9 accu-power charger 15-3, 15-5, 15-7 a-connector (starter/generator) 6-11 adapter 12-19, 12-23, 12-31 rod (counterbalance) seat back 1-13 seat bottom 1-11 16-3 10-5 8-5 ammeter 15-3, 15-5, 15-7, 15-9, 15-11, 15-13, 15-15, 15-17 arbor 5-9 8-5 lever (brake) 4-3 moveable face (driven clutch) 12-9 air box 8-11 air duct 8-11 A Page i-8 hub and ball bearing 15-3, 15-5, 15-7, 15-9, 15-15, 2004-2005 DS Golf Cars Illustrated Parts List 7-5 1-13 barrel, plastic 1-3 base, forward/reverse shifter base, mounting 11-5, 11-11 7-7 12-13 6-5 INDEX basket, sweater battery 1-13 body, front 6-volt 12-13 8-volt 12-17, 12-29 battery cap 12-13, 12-17, 12-29 battery charger, PowerDrive 15-9, 15-15, 15-17 battery charger, PowerDrive 2 15-11, 15-13 battery clamp 6-15 battery discharge machine 16-3 battery hold-down 12-13, 12-17, 12-29 battery terminal protector spray 16-3 battery thermometer 16-3 battery warning light 12-3 battery, 12-volt 6-15 bearing 1-5 boot dust 5-3 tow/run switch 12-27 box, electrical component ball, output shaft 6-11 bronze 12-9 differential 14-3 6-7 bracket adjusting (starter/generator) engine shroud 6-13 7-3 fe290 mounting 6-13 fuse and receptacle mounting rpm limiter 15-15 snubber 7-15 steering column mounting 5-3 brake adjusting mechanism 4-3 brake adjustment tool 16-3 lower pinion 5-5 needle 11-5, 11-11 outer axle tube 11-7, 11-13, 14-5 brake cable equalizer 4-5 brake cable hanger 4-3, 5-11 pivot support 4-7 plain (counterbalance rod) thrust 5-9 upper pinion 5-5 bearing and oil seal remover bearing driver set 16-3 bearing puller 16-3 7-13 6-7 bell crank, forward/reverse 6-5 belt, drive 10-3, 10-5 belt, starter/generator 6-13, 10-3 bezel, receptacle 12-13, 12-17, 12-29 block brake pedal mounting fuse 6-7 terminal (controller) 4-5 12-31 board, resistor mounting 12-11 body (rear) 1-7, 1-9 body hinge plate 1-7, 1-9 body keeper clip 1-7, 1-9 body kick plate 1-7, 1-9 body spacer 1-13 body support 1-7, 1-9 16-3 4-3 brake drum 4-3 brake pedal 4-5 brake pedal adjustment tool brake pedal mounting block bearing puller wedge 16-3 bearing retainer 13-3, 13-5, 13-7 bearing retainer (starter/generator) 6-11 bearing retainer screw 13-3, 13-5 bell crank 12-9 bell crank and shaft 4-3, 4-5 brake cluster mounting bolt 16-3 6-5, 11-3, transmission cable support 11-9 brake cable release tool brake cluster 4-3 16-3 4-5 brake pedal pad 4-5 brake pedal stop bumper 4-5 brake pedal tension tool 16-3 brake shoe 4-3 brake spring 4-3 breaker, circuit, 10-amp breaker, circuit, 15-amp breather 15-15, 15-17 15-9, 15-11, 15-13 14-3, 14-5 breather, transaxle case 11-3, 11-9 bronze bushing 6-5, 6-7 brush 6-11, 13-3, 13-5, 13-7 brush box assembly 13-9 13-3, 13-5 brush inspection port cover brush rigging 13-3, 13-9 brush spring 13-9 6-11 6-11, 12-9, 13-3, 13-5, 13-7, brush, switch 12-9 buckle, bag strap 1-13 cable accelerator, snap-in 8-9 brake 4-3, 4-5 control 15-3, 15-5, 15-7 governor, snap-in 8-9 IQDM 16-7 transmission 6-5 cable retainer 6-5 calibration test module 16-3 cam (driven clutch) 10-5 cam installation tool 16-3 cam, electrical box 6-7 cam, neutral lockout 6-5 camshaft 7-11 canopy 1-15 canopy support kit 1-15 cap 6-volt battery battery (4-port) dust 12-27 fuel tank 8-3 12-13 12-17, 12-29 key switch 6-9, 12-3 protector 12-9 seat back 1-13 cap, hub 5-9 capacitor 15-3, 15-5, 15-7 carburetor 8-5, 8-7 carburetor float level tool brush connector 6-11 brush holder 6-11 brush holder screw urethane 5-7, 5-9, 5-11 bushing (axle) 14-5 buzzer, reverse 12-3 C 12-27 idler (drive clutch) 10-3 inner axle tube 11-7, 11-13, 14-5 input gear 14-3, 14-5 intermediate gear 14-3, 14-5 brake cable insulator 13-3, 13-5, 13-7 stain relief 15-3, 15-15 steel 5-9, 5-11 strain relief 15-5, 15-7, 15-9, 15-11, 15-13, 15-17 12-13 7-5 throttle 8-7 tow/run switch wiper switch 12-9 bus bar 12-15 bushing bronze 5-9, 6-5, 6-7 drive clutch 10-3 9-3 oil level switch 7-11 power relay mounting 4-5 front 1-5 motor 13-3, 13-5, 13-7 rear 1-3 return spring 4-7 side guard trim 1-5 5-5, 5-7 steering column muffler mounting oil filter 7-7 ball (crankshaft) 7-11 ball (motor) 13-3, 13-5, 13-7, 13-9 ball, input shaft 11-5, 11-11 bumper brake pedal stop bolt, brake cluster mounting 4-3 bolt, j- 12-13, 12-17, 12-29 16-7 carburetor insulator 8-7 card, safety first 16-9 carrier, wiper switch arm 12-9 case charger 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 forward/reverse switch 2004-2005 DS Golf Cars Illustrated Parts List 12-27 Page i-9 INDEX 11-7, 11-13 gear carrier rocker arm wiper switch case gasket cord 7-9 12-9 12-31 motor braking 16-5 operating instructions 3-3, 3-5 control cable 15-3, 15-5, 15-7 controller, 48-volt (225-amp) 12-19 potentiometer caution 3-5 controller, 48-volt (250-amp) rotating parts and hot manifold warning 3-3 continuity tester 14-5 charger bezel tool 16-3 charger case 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 3-3, 3-5 key switch 7-11 IQ controller cord connector 3-5 resistor warning 12-31 7-11 3-5 charger, accu-power, battery 15-7 15-3, 15-5, cordset, AC charger, PowerDrive 2 battery 15-11, 15-13 cordset, ac 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 delta a-plate cordset, DC delta shock and gear support 15-9, 15-15, charger, PowerDrive battery 15-17 choke button 8-11 choke valve 8-11 choke valve o-ring 8-11 15-9, 15-11, 15-13 circuit breaker (15-amp) tow/run switch 15-13 15-13 delta sleeve counterbalance guide shaft differential bearing counterbalance weight cover 7-13 8-9 hose (air intake) hose (bronze) hose (fuel) muffler 7-11 8-7 oil pump 9-3 1-11 cover, base, battery charger cover, top, battery charger clamp screw 13-3, 13-5, 13-7 crank sleeve setter tool 1-7, 1-9 clip, body keeper cluster, brake 16-5 15-13 15-13 1-3 drive bar 12-21 drive belt 10-3, 10-5 drive clutch 16-5 10-3 drive clutch button 10-3 12-9 drive clutch fixed sheave tool crankcase 7-13 drive clutch holder tool 16-5 drive clutch hub puller 16-5 crankshaft clutch alignment tool drink holder 5-5 7-7 crank, bell crankcase cover 4-3 1-7, 1-9 drain plug (crankcase) 7-5 5-3 7-3 drag link, rack and pinion steering column 5-3 wiper switch case 12-9 5-9 11-7, 11-13, 14-3, 12-13, 12-19 dipstick 1-13 clamp (wire) clip diode door, access plastic (fuel line) 8-3 clamp (oil sending wire) 7-11 clevis, upper delta 6-7 7-7 seat bottom 11-7, 11-13, 14-5 14-3 11-7, 11-13, 14-3 differential pin seat back 8-3 11-7, 11-13, 14-3, 14-5 differential housing 4-3 16-9 14-3 differential idler gear 14-5 electrical component box gear case 11-7, 11-13 8-3, 8-7 hose (red) 12-31 crankcase dust 8-11 8-3 hose (gray) controller diesel tachometer probe differential gear 6-11 7-11 7-13 drive clutch puller crankshaft bearing replacement tool 16-5 drive clutch spider removal tool crankshaft main bearing driver attachment tool 16-5 drive hub clutch, drive crankshaft main bearing driver tool driven clutch cam puller 16-5 driven clutch puller plug 16-5 clutch, driven crankshaft main bearing pilot attachment tool 16-5 10-5 coil field crankshaft seal 7-11 7-5 crankshaft shim 7-13 12-11 cup, accelerator pedal return spring 6-11 ignition resistor collet 7-9 column, steering current limiter 11-7, 11-13 collar (axle shaft) cylinder head 5-3 component mounting plate 16-5, 16-11 16-5 damper, rpm limiter dash panel, center 1-3 dash, driver side 1-3 4-pin 12-27 Page i-10 driven clutch spring compression collar tool 16-5 driven clutch spring compression nut tool 16-5 16-9 dash, passenger side 16-11 12-19, 12-31 7-5 dust cap 12-27 4-3 E decal 8-volt battery 12-17, 12-29 electrical component cover 3-5, 12-31 frame ground and governor warning 3-3 80-amp fuse 12-13 gasoline warning e-clip (air box top) driver/passenger warning 16-5 16-7 5-5, 5-7 dust cover 1-3 10-3 4-3 dust boot 16-5 connector driven clutch spring compression base tool 16-5 dry moly lubricant 16-5 connecting rod 7-13 connecting rod alignment tool (diesel) 10-5 D compression tester compressor, valve spring driven clutch drum, brake 12-19, 12-31 3-3 2004-2005 DS Golf Cars Illustrated Parts List 3-3, 3-5 16-5 10-3 driver, drive clutch 7-9 compression gauge compressor, piston ring 4-7 15-17 cutter, valve seat communication display module computer, onboard 16-5 16-5 16-5 clutch removal tool 16-3 clutch tool kit 16-5 10-3 5-7 5-7 differential gear case brush inspection port battery 6-15 cable 12-13 7-13 12-9 5-7 cordset, dc 15-3, 15-5, 15-7, 15-9, 15-11, 15-15, 15-17 clamp cable retaining 3-5 wiper switch warning eccentric 5-9 8-11 INDEX electrical box cam 6-7 electrical component box 6-7 emblem, IR 1-5, 3-3, 3-5 end bell, commutator 6-11 end bell, output shaft 6-11 end cap motor 13-9 end shield 13-3, 13-5, 13-7 engine shroud 7-3 engine valve spring 7-9 engine, fe290 ohv gasoline 7-3 equalizer rod 4-5 equalizer, brake cable 4-5 exhaust gasket 9-3 exhaust system 9-3 exhaust valve 7-9 F 4-pin plug and wedge lock 12-27 4-pin receptacle and wedge lock 12-27 48-volt IQ motor 13-9 48-volt motor, 3.10-hp 13-5 48-volt motor, 3.20-hp 13-7 48-volt solenoid 12-19, 12-31 fan housing 7-3 fan shroud 7-3 fan, flywheel 7-5 fastener, barrel 1-13 fe290 ohv gasoline engine 7-3 fender, inner 1-7, 1-9 field coil (starter/generator) 6-11 fill plug 14-3 fill plug with gasket 14-5 filter air 8-11 fuel 8-3 oil 7-7 fitting, grease 5-9 fitting, thread-forming grease 5-5, 5-7 fixed face (drive clutch) 10-3 fixed face (driven clutch) 10-5 float (carburetor) 8-5 float chamber 8-5 floor mat 1-3, 1-5, 1-7, 1-9 flywheel 7-5 flywheel fan 7-5 flywheel puller 16-7 fork, shift 11-5, 11-11 forward/reverse bell crank 6-5 forward/reverse handle 6-5 forward/reverse shifter 6-5 forward/reverse shifter base 6-5 forward/reverse switch 12-7, 12-15, 12-27 forward/reverse switch case 12-27 forward/reverse switch handle 12-7, 12-15 frame and field, motor front body 1-5 13-9 front spring retainer plate 5-9 f-terminal insulator 6-11 fuel filter 8-3 fuel impulse pump 8-3 fuel injection pump pressure tester tool 16-7 fuel line 8-3 fuel pickup tube (valve) 8-3 fuel strap, rear 8-3 fuel tank 8-3 fuse 10-amp 6-7 3/8-amp 12-17, 12-29 30-amp 15-11 80-amp 12-13 charger 15-3, 15-5, 15-7, 15-9, 15-15, 15-17 fuse block 6-7 fuse holder 12-13, 15-13 fuse lens 12-13 fuse, 25-amp, type ABC 15-13 G gasket carburetor insulator 8-7 case 14-5 controller 12-31 crankcase cover 7-11 drain plug 7-7, 11-3, 11-9 exhaust 9-3 fe290 7-9 float chamber 8-5 head 7-9 insulator 8-7 intake pipe 8-7 liquid 14-3, 14-5, 16-7 11-3, 11-9 oil pump 7-7 plug 14-3 rocker arm case 7-9 seat 1-11 throttle bracket 8-7 gauge, compression 16-5 gear cluster idler 11-5, 11-11 differential 11-7, 11-13, 14-3, 14-5 differential idler 11-7, 11-13, 14-3, 14-5 helical (crankshaft) 7-13 input 11-5, 11-11 intermediate 14-3, 14-5 intermediate, small 14-5 output 11-7, 11-13, 14-3, 14-5 spur (crankshaft) 7-13 spur (transaxle) 11-5, 11-11 gear case 11-3, 11-9, 14-3, 14-5 gear yoke 16-7 governor 11-5, 11-11 liquid (transaxle case) governor guard 8-7 11-3, 11-9 governor shaft installation tool 16-7 grease fitting 5-5, 5-7, 5-9 governor lever arm grip, pencil 5-3 grommet 7-5 grommet, insulation 8-3 grommet, split 12-9 guard, governor 8-7 guard, scuff 1-3 guide choke lever 8-11 oil (transaxle) 11-5, 11-11 steering rack 5-5 valve 7-9 valve seat cutter 16-11 guide ring adhesive 16-3 H handle forward/reverse 6-5 forward/reverse switch 12-7, 12-15 GE PowerDrive battery charger 15-13 PowerDrive 2 15-11 hanger, brake cable 4-3, 5-11 hardware, terminal (starter/generator) 6-11 harness retainer 6-9 harness, wire 6-3, 12-23, 12-25 head gasket 7-9 heatsink 15-3, 15-5, 15-7, 15-9, 15-11, 15-13, 15-15, 15-17 helical gear (crankshaft) 7-13 hold-down, battery 12-13, 12-17, 12-29 holder, drink 1-3 holder, fuse 12-13, 15-13 hole plug 12-3 hose clamp 8-3 hose clamp (bronze) 8-7 hose clamp (gray) 8-7 hose clamp (red) 8-3 hose, intake 8-11 housing differential 14-3 fan 7-3 female 3-wire 13-7 field coil (starter/generator) 6-11 hub, drive 10-3 hub, synchronizer clutch 11-5, 11-11 hydraulic brake adjuster 16-7 hydrometer 16-7 I idle gear bushing replacement tool idle screw 8-5 ignition coil 7-5 inner axle tube bearing 14-5 inner fender 1-7, 1-9 input gear bearing 14-3, 14-5 2004-2005 DS Golf Cars Illustrated Parts List 16-7 Page i-11 INDEX 14-3, 14-5 input shaft 11-5, 11-11 insert, synchronizer insert, wood bagwell protector 1-3 bearing and magnet 13-7 brake cable 4-3, 4-5 brake pedal 4-5 brake pedal adjustment tool 16-3 canopy support 1-15 differential gear case 11-7, 11-13 drink holder 1-3 drive clutch weight 10-3 driven clutch button 10-5 front hub replacement 5-9 fuel impulse pump rebuild 8-3 fuse and receptacle 12-13, 12-17, 12-29 gasket 7-9 IQ controller connector 12-31 IQ display module (IQDM) 16-7 motor terminal hardware 13-9 park brake pedal 4-5 pulley nut and screw 6-11 reverse buzzer 6-9 shock absorber cushion 5-11 shock absorber, rear 5-11 snap washer (dash mounting) 1-3 spring, motor brush 13-9 steering column mounting bracket 5-3 steering column rebuild 5-3 tune-up 16-9 kit, motor brush 13-9 kit, plate, motor cover 13-9 14-3, 14-5 input shaft oil seal 1-11 13-3, 13-5 insulator bushing insulator gasket 8-7 insulator, carburetor 8-7 insulator, f-terminal 6-11 intake hose 8-11 intake pipe 8-7 intake valve 7-9 14-3, 14-5 intermediate gear intermediate gear bearing 14-5 internal retaining ring pliers IQ display module (IQDM) 16-7 16-7 1-5, 3-3, 3-5 IR emblem J j-bolt 12-13, 12-17, 12-29 jet, main 8-5 jet, pilot 8-5 joint ball 4-5, 6-5 ball (tie rod) 5-7 compound steering inner ball 5-3 5-5 5-5, 5-7 left-hand thread ball spring-loaded ball 4-7 K L key square sunk 10-5 14-5 6-11, 11-3, 11-9 woodruff key (crankshaft) 7-13 key (driven clutch) key (flywheel) 10-5 7-5 key (transmission shaft) 6-9, 12-3 key (vehicle) key switch 6-9, 12-3 key switch cap 6-9 key switch nut 6-9, 12-3 kingpin 11-5, 11-11 transmission shifter 11-3, 11-9 lever (brake) 4-3 light, battery warning 12-3 5-9 kingpin wave washer 5-9 kit 2-pin plug 12-21 3-pin plug 12-19, 12-21, 13-7 3-pin plug and wedge lock 3-pin receptacle 12-27 12-19 3-pin receptacle and wedge lock 4-pin plug and wedge lock 12-31 6-pin receptacle 12-31 accelerator pivot rod air duct repair Page i-12 8-11 4-7 12-27 12-27 4-pin receptacle and wedge lock 6-pin plug latch, park brake 4-5, 4-7 latch, wire (air box) 8-11 L-bracket, motor 13-9 lead wire 7-5 lens, fuse 12-13 lever choke 8-11 shifter 11-3, 11-9 12-27 light, low oil warning 6-9 limit switch 6-5, 6-7, 12-7, 12-9, 12-15 limiter, rpm, ohv 7-5 line, fuel 8-3 line, vent (fuel) 8-3, 8-7 link, rack and pinion drag 5-5 liquid gasket 14-3, 14-5, 16-7 lock plate 14-5 low oil warning light 6-9 lower pinion bearing 5-5 lubricant, dry moly 16-7 lubricant, moly-teflon 16-7 lug nut 2-3 lug stud 11-7, 11-13, 14-3, 14-5 2004-2005 DS Golf Cars Illustrated Parts List M magnet 13-7 motor speed sensor magnetic plug main jet 13-9 14-3 8-5 1-3, 1-5, 1-7, 1-9 mat, floor MCOR (motor controller output regulator) 12-21 mechanism, brake adjusting meter, volt ohm 4-3 16-11 module calibration test 16-3 communication display moly-teflon lubricant 16-5 16-7 motor 36-volt 13-3 48-volt 13-5 13-7, 13-9 48-volt IQ brush kit 13-9 frame and field 13-9 magnet, speed sensor motor brush spring kit 13-9 13-9 motor bumper 13-5, 13-7 motor end cap 13-9 motor L-bracket 13-9 motor terminal hardware kit mounting base 13-9 12-13 mounting block, brake pedal 4-5 mounting bracket, fuse and receptacle 12-13 mounting pad (windshield frame) mounting plate (engine) mounting plate (rear bumper) movable face 1-15 7-15 1-3 10-3 moveable face (driven clutch) muffler clamp 10-5 9-3 N nameplate 1-5, 3-3, 3-5 neutral lockout cam nozzle, main 6-5 8-5 nut flange lock 5-9 nut, key switch nut, lug 6-9, 12-3 2-3 O oil filler tube 7-3 oil filter screen 7-11 oil level sensor 7-11 oil pressure gauge tool 16-7 oil pressure tester (diesel) tool oil pump and rotor oil seal (crankshaft) 7-7 7-13 oil sending wire clamp onboard computer 7-11 12-19 16-9 INDEX o-ring (counterbalance shaft) 7-13 o-ring (oil sending connector) 7-11 o-ring (rocker case hardware) 7-9 o-ring, choke valve 8-11 o-ring, oil filter mount 7-7 outer axle tube bearing 14-5 output gear 14-3, 14-5 P package, brush 6-11, 13-3, 13-5 pad accelerator pedal 4-7 brake pedal 4-5 mounting (windshield frame) 1-15 park brake 4-5 spring 5-11 wear 1-3, 1-7, 1-9 paint, touch-up 16-9 panel, center dash 1-3 park brake latch 4-5, 4-7 park brake pedal 4-5 park brake ratchet 4-7 park brake rod sleeve 4-5 park brake torsion spring 4-5 pawl 4-5 pedal accelerator 4-7 brake 4-5 park brake 4-5 pencil grip 5-3 pilot air screw 8-5 11-7, 11-13, 14-3, 14-5 head locating 7-9 piston 7-13 roll (shifter lever) 11-3, 11-9 pin (crankcase cover locating) 7-11 pin, bow tie locking 4-5 pin, clevis 4-5 pinion, steering 5-5 pipe, intake 8-7 piston 7-13 piston pin 7-13 piston pin retaining ring 7-13 piston ring compressor 16-9 piston ring pliers 16-9 piston ring set 7-13 pivot arm 11-3, 11-9 pivot support bearing 4-7 plastic barrel 1-3 Plastigauge tool 16-9 plate backing (brake) 4-3 body hinge 1-7, 1-9 12-19, 12-31 pulley nut and screw (starter/ generator) 6-11 5-9 pump, fuel impulse push rod 7-9 heatsink 15-11, 15-13 lock 14-5 mounting (engine) 7-15 mounting (rear bumper) oil filter screen 7-11 oil pump 7-7 oil valve 7-9 rack, steering 16-7 6-pin 12-13 12-13, 12-17, 12-29 relay, 36-vdc 15-3, 15-5, 15-7 relay, 48-VDC 15-13 relay, 48-vdc power 15-17 15-9, 15-11, 15-15, remover, bearing and oil seal 16-3 resistor 12-19, 12-23, 12-31 resistor coil 12-11 resistor coil stand-off 7-7 12-11 resistor mounting board resistor shield 12-11 1-3 12-11 retainer 14-3 bearing spark (ohv) 7-5 plug gasket 14-3 pole set (starter/generator) 6-11 PowerDrive battery charger 15-17 press weldment 16-5 13-3, 13-5, 13-7 bearing (starter/generator) cable 6-5 positioner, choke 8-11 power relay 15-9, 15-11, 15-15 PowerDrive 2 battery charger 15-11, 15-13 15-9, 15-15, harness 6-11 6-9 shock absorber cushion 5-11 spiral ring 10-3 spring 4-7, 10-3 valve spring 7-9 retaining ring (driven clutch) 10-5 retaining ring pliers 16-9 return spring bumper 4-7 pressure relief ball 7-7 protector cap 12-9 protector spray, battery terminal protector, bagwell 1-3 16-3 reverse buzzer 6-9, 12-3 rigging, brush 13-3, 13-5, 13-7 rim, tire ring puller bearing 16-3 clutch 16-3 drive clutch 16-5 drive clutch hub 16-5 driven clutch cam 16-5 flywheel 16-7 pulley (starter/generator) 12-19 6-pin 12-31 ac cord 15-17 rectifier 15-13 regulator, motor controller output (MCOR) 12-21 drive clutch 10-3 driven clutch puller 16-5 fill 14-3 fill with gasket 14-5 seal 16-9 puller, special use tool 3-pin 5-11 receptacle backing plate 12-17, 12-29 receptacle bezel 12-13, 12-17, 12-29 cap 7-5 drain (crankcase) 7-7 drain (transaxle) 11-3, 11-9 magnetic rear spring shackle receptacle charger, 2-prong 12-21 12-19, 12-21, 13-7 12-31 filter bracket rear bumper 1-3 rear leaf spring 5-11 receptacle (fuse) plug 2-pin 3-pin 5-5 ratchet, park brake 4-7 reamer, valve guide 16-9 spring mounting 5-7 thrust 11-5, 11-7, 11-11, 11-13, 14-5 thrust (idler gear) 14-3 pliers internal retaining ring piston ring 16-9 retaining ring 16-9 8-3 R 1-3 12-17, 12-29 receptacle backing scorecard 5-3 seat hinge 1-11 hole 12-3 hole (dash board) pilot jet 8-5 pin differential body kick 1-7, 1-9 component mounting flywheel fan 7-5 front spring retainer 16-9 6-11 2-3 c-type stop piston (set) 5-5 7-13 piston pin retaining 7-13 retaining (driven clutch) 10-5 retaining (steering column) 5-3 retaining (steering gear box) 5-5 snap 5-5, 11-3, 11-9 spiral back-up 10-3 2004-2005 DS Golf Cars Illustrated Parts List Page i-13 INDEX synchronizer 11-5, 11-11 rivet, blind 1-5 rocker arm 7-9 rocker arm case 7-9 rocker arm shaft 7-9 rod accelerator 4-7 accelerator pivot 4-7 connecting 7-13 equalizer 4-5 push 7-9 shift 11-5, 11-11 seat back 1-13 seat back support 1-13 seat bottom 1-11 seat bottom cover 1-11 seat hinge plate 1-11 sensor, motor speed 13-7, 13-9 sensor, oil level 7-11 set, pole 6-11 shackle, rear spring 5-11 shaft counterbalance guide 7-13 input 11-5, 11-11, 14-3, 14-5 rocker arm 7-9 shifter 11-3, 11-9 steering column 5-3 shield, end 13-3, 13-5, 13-7 shield, resistor 12-11 shift fork 11-5, 11-11 shift rod 11-5, 11-11 shifter lever 11-3, 11-9 shifter shaft 11-3, 11-9 tie 5-7 rod (counterbalance) 7-13 rod and pawl 4-5 rpm limiter bracket 7-5 rpm limiter damper 7-5 rpm limiter mount band 7-5 rpm, ohv limiter 7-5 S 6-pin plug 12-31 6-pin receptacle 12-31 6-volt battery 12-13 safety first card 16-9 scorecard 5-3 scorecard clip 5-3 scorecard plate 5-3 screen, oil filter 7-11 screw bearing retainer 13-3, 13-5, 13-7 brush holder 13-3, 13-5 clamp 13-3, 13-5, 13-7 idle 8-5 pilot air 8-5 pole piece (starter/generator) 6-11 screw, valve clearance adjuster scuff guard 1-3 seal 16-9 axle tube oil 14-5 crankshaft 7-11 dust (steering gear box) 5-5 dust, steering pinion 5-5 input shaft oil 14-5 intake (air box) 8-11 oil (axle shaft) 11-7, 11-13 oil (crankshaft) 7-13 oil (governor pivot) 11-3, 11-9 oil (shifter shaft) 11-3, 11-9 oil, axle shaft 14-3 oil, input shaft 11-5, 11-11, 14-3 valve 7-9 seal puller 16-9 seat bearing 5-3 spring 7-9 valve 7-7 Page i-14 shifter, forward/reverse 6-5 shim (axle) 14-5 shim, crankshaft 7-13 shim, wiper switch 12-9 shock absorber 5-7 shock absorber cushion 5-11 shock absorber cushion retainer 5-11 shock absorber, rear 5-11 shoe retainer 4-3 shoe, brake 4-3 shroud, engine 7-3 shroud, fan 7-3 side guard trim bumper 1-5 sleeve delta 5-7 park brake rod 4-5 synchronizer 11-5, 11-11 sleeve (transaxle) 11-5, 11-11 slide switch, 4-position 15-15, 15-17 small intermediate gear 14-5 snap ring 5-5 snubber 7-15, 12-13 snubber bracket 7-15 solenoid 12-volt 6-7 36-volt 12-13 48-volt 12-19, 12-31 spacer 1/2 (fender mounting) 1-9 1-7/8 (fender mounting) 1-9 battery terminal bolt 6-15 body 1-13 fixed face shaft 10-3 nylon (sweater basket) 1-13 park brake 4-5 spacer (accelerator pivol rod) 4-7 2004-2005 DS Golf Cars Illustrated Parts List spacer (crankshaft) 7-13 spacer (engine) 7-15 spanner wrench 16-9 spark plug (ohv) 7-5 speed switch arm spindle 5-9 12-9 spray, battery terminal protector spring accelerator pedal retainer brake shoe 4-3 16-3 4-7 brush 6-11, 13-3, 13-5, 13-7 compression 5-3 compression (choke button) 8-11 drive button 10-3 drive clutch 10-3 engine valve 7-9 forward/reverse cam 6-5 oil pressure relief 7-7 park brake torsion 4-5 rear leaf 5-11 return 4-7 return (air box) 8-11 shift fork retainer 11-5, 11-11 synchronizer 11-5, 11-11 tapered compression 5-3 tapered leaf 5-9 throttle return 8-7 wiper switch brush 12-9 yoke 5-5 spring mounting plate 5-7 spring seat 7-9 spring, brush 13-9 spur gear (crankshaft) 7-13 stain relief bushing 15-3 stand-off, resistor coil 12-11 starter/generator 6-11, 6-13 stator shell 13-3, 13-5, 13-7 steel bushing 5-9, 5-11 steering column 5-3 steering column bearing press tool 16-9 steering column mounting bracket 5-3 steering column retaining ring tool 16-9 steering column shaft 5-3 steering gearbox 5-5 steering wheel 5-3 steering wheel puller tool 16-9 stem, valve 2-3 stiffener, flywheel side strap a-plate 7-15 5-7 bag 1-13 rear fuel 8-3 stud ball 4-7, 6-5, 6-7, 11-3, 11-9 lug 11-7, 11-13, 14-3, 14-5 short ball 12-9 wiper switch adjusting 12-9 INDEX stud (engine mounting) 7-15 stud, lug 5-9 sunk key 14-5 support accelerator pivot rod 4-7 body 1-7, 1-9 canopy 1-15 delta shock and gear 5-7 seat back 1-13 sweater basket 1-13 switch 4-position slide 15-15, 15-17 brush 12-9 forward/reverse 12-7, 12-15, 12-27 key 6-9, 12-3 limit 6-5, 6-7, 12-7, 12-9, 12-15 limit sealed 12-15 tow/run 12-27 v-glide wiper 12-9 synchronizer clutch hub 11-5, 11-11 synchronizer ring 11-5, 11-11 system, exhaust 9-3 T 12-volt battery 6-15 2-pin plug 12-21 2-prong charger receptacle 12-13 3-pin plug 12-19, 12-21, 13-7 3-pin plug and wedge lock 12-27 3-pin receptacle 12-19 3-pin receptacle and wedge lock 12-27 3/8-amp fuse 12-17, 12-29 30-amp fuse 15-11 36-volt motor, 2.97-hp 13-3 36-volt solenoid 12-13 10-amp fuse 6-7 12-volt solenoid 6-7 tachometer 16-9 tachometer probe, diesel 16-9 tapered compression spring 5-3 tapered leaf spring 5-9 tappet 7-11 terminal block (controller) 12-31 terminal hardware (starter/generator) 6-11 tester, continuity 16-5 thermometer, battery 16-3 throttle bracket 8-7 throttle return spring 8-7 thrust bearing 5-9 thrust plate (differential) 14-5 tie rod 5-7 tie, wire 5-5, 12-3, 12-13, 12-27, 12-31 timer 15-5, 15-7 tire 2-3 t-nut, slab base 1-5 tool accelerator pedal adjustment 16-3 brake adjustment 16-3 brake cable release 16-3 brake pedal adjustment 16-3 brake pedal tension 16-3 cam installation 16-3 carburetor float level 16-7 charger bezel 16-3 clutch alignment 16-5 connecting rod alignment 16-5 crank sleeve setter 16-5 crankshaft bearing replacement 16-5 crankshaft main bearing driver 16-5 crankshaft main bearing driver attachment 16-5 crankshaft main bearing pilot attachment 16-5 drive clutch fixed sheave 16-5 drive clutch holder 16-5 drive clutch spider removal 16-5 driven clutch spring compression base 16-5 driven clutch spring compression collar 16-5 driven clutch spring compression nut 16-5 fuel injection pump pressure tester 16-7 governor shaft installation 16-7 idle gear replacement 16-7 oil pressure gauge 16-7 oil pressure tester 16-9 Plastigauge 16-9 puller, special use 16-9 steering column bearing press 16-9 steering column retaining ring 16-9 steering wheel puller 16-9 transaxle axle seal 16-9 transaxle pinion seal 16-9 transmission 16-9 valve clearance adjustment 16-11 valve guide driver 16-9 valve guide replacement 16-9 tool kit, clutch 16-5 top, air box 8-11 touch-up paint 16-9 tow/run switch 12-27 transaxle 14-3, 14-5 transaxle axle seal tool 16-9 transaxle pinion seal tool 16-9 transaxle, unitized 11-3, 11-9 transformer 15-3, 15-5, 15-7, 15-9, 15-11, 15-13, 15-15, 15-17 transmission cable 6-5 transmission tool 16-9 trim, front body 1-5 tube axle 11-7, 11-13 crankcase vent 8-7 oil filler 7-3 tune-up kit 16-9 U u-bolt 5-11 unitized transaxle 11-3, 11-9 upper pinion bearing 5-5 5-7, 5-9, 5-11 urethane bushing V valve choke 8-11 exhaust 7-9 fuel pickup tube 8-3 intake 7-9 oil 7-9 valve clearance adjuster screw 16-9 valve clearance adjustment wrench valve guide 7-9 valve guide driver tool valve guide reamer 16-9 16-9 valve guide replacement tool valve seal 7-9 valve seat 16-11 16-9 7-7 valve seat cutter 16-5, 16-11 valve seat cutter guide 16-11 valve seat t-wrench 16-11 valve spring compressor valve spring retainer valve spring, engine valve, stem 16-11 7-9 7-9 2-3 vent barb 8-3 vent line (fuel) 8-3, 8-7 vent, fuel tank 8-3 v-glide wiper switch 12-9 volt ohm meter 16-11 voltage regulator 6-7 voltage suppressor 15-9, 15-15 W warning light, low oil 6-9 washer key switch 12-3 kingpin wave 5-9 mounting 10-3, 10-5 snap washer kit (dash mounting) spring 11-5, 11-11 1-3 11-5, 11-11 thrust (transaxle) wave 6-5 wear pad 1-3, 1-7, 1-9 wedge (steering column) 5-3 wedge, bearing puller 16-3 weight, counterbalance 7-13 weight, drive clutch weldment, press 10-3 16-5 wheel 2-3 wheel rim 2-3 2004-2005 DS Golf Cars Illustrated Parts List Page i-15 INDEX wheel, steering 5-3 windshield frame 1-15 wiper switch arm carrier 12-9 wiper switch bumper 12-9 wiper switch case 12-9 wiper switch shim 12-9 wiper switch, v-glide 12-9 wire and terminal 12-31 wire assembly 6-3, 6-7, 6-9, 6-13, 7-3, 12-5, 12-9, 12-13, 12-17, 12-23, 12-25, 12-29, 12-31, 15-9, 15-11, 15-13, 15-15, 15-17 wire assembly, forward/reverse switch 12-27 wire assembly, IQDM port 12-27 wire assembly, sense lead 12-17, 12-29 wire clamp 7-5 wire harness 6-3, 12-23, 12-25 wire terminal 12-19 wire tie 5-5, 12-3, 12-13, 12-27, 12-31 wire, jumper 15-17 wire, lead 7-5 wood insert 1-11 woodruff key 6-11, 11-3, 11-9 wrench, spanner 16-9 Y yoke spring 5-5 yoke, gear 16-7 Z z-bracket 12-31 Page i-16 2004-2005 DS Golf Cars Illustrated Parts List 2004-2005 DS Golf Cars Illustrated Parts List Club Car, Inc. P . Box P.O A GA 30917-4658 USA Web www.clubcar.com Phone 1.706.863.3000 1.800.ClubCar Int’l +1 706.863.3000 Fax 1.706.863.5808
