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2004-2005 DS IPL Gas/Electric

1. 2 2 4 7473 Nut Nylon Lock 5 16 18 i u 2 2 5 1016967 Rivet Push Type 2 2 6 1014198 Nameplate A 1 1 7 101692501 Body Front Belgg u a a m 1 1 7 101692502 Body Front 1 1 7 101692504 Body Fron Gray u a u nu Q u Maa E AC he 1 1 7 101692506 Body Front Red 1 1 7 101692509 Body Front Pacific Blue Royal Blue 1 1 7 101692510 Body Front Dark Green r 1 1 7 101692511 Body Front Black ne aan a 1 1 7 101692512 Body Front Classic Blue Navy pp 1 1 7 101692513 Body Front 1 1 8 101693901 Body Front with Headlight Opening Beige 1 1 8 101693902 Body Front with Headlight Opening 1 1 8 101693904 Body Front with Headlight Opening Gray 1 1 8 101693906 Body Front with Headlight Opening 1 1 8 101693908 Body Front with Headlight Opening Pacific Blue Royal Blue 1 1 8 101693909 Body Front with Headlight Opening
2. 2004 2005 DS Golf Cars Illustrated Parts List Page 16 6 MAINTENANCE AND SERVICE TOOLS CONTINUED ITEM PARTNO DESCRIPTION ton EE 1234 49 1012151 Dry Moly 2 1 1 1 50 102674501 Flywheel Clutch Holder for Honda GX620 Gasoline Engines 1 51 102668601 Flywheel Puller for Kubota D722 Diesel Engines 1 52 1016627 Flywheel Puller Kit for Kawasaki Engines 1 53 102669801 Fuel Injection Pump Pressure Tester for Kubota D722 Diesel 1 54 102669901 Gauge Carburetor Float Level for Honda GX620 Gasoline Engines 1 55 102674701 Gauge Oil Pressure for Honda GX620 Gasoline Engines 1 56 102670001 Gauge Oil Pressure Attachment for Honda GX620 Engines 1 57 1016418 Yoke i eens 1 1 1 58 101933101 Governor Shaft Installation Tool for Kawasaki Engine Vehicles 1 59 102674901 Holder Valve Seat Cutter for use with items 44 through 48 for Honda GX620 Gasoline Engines 1 60 102169401 Hydraulic Brake Adjuster for gasoline vehicles equipped with hydraulic brakes except XRT 1500 Carryall 294 and 2200 2 2 2012 4120 ea denne 1 61 1011478 1 1 1
3. 2 4 101936801 Kit 2 Pin Plug and Wedge Lock uu 1 5 101920101 Kit 3 Pin Plug and Wedge 1 2004 2005 DS Golf Cars Illustrated Parts List Page 12 21 N eo _ T REVERSE SZ BUZZER FORWARD BATTERY REVERSE WARNING lt SWITCH LIGHT 10 8 Ye On Wer MOTOR Lp CONTROLLER 277 OUTPUT u REGULATOR 8 V Z TS O SWITCHES 3SNVHO LIHM FUSE AND RECEPTACLE 31IHM NOTI3A MOTI3A ama TYPICAL BATTERY 5 PLACES MOTI3A THREE PIN CONNECTOR ONBOARD 28 COMPUTER Page 12 22 2004 2005 DS Golf Cars Illustrated Parts List WIRING POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO DESCRIPTION QTY 1 2 3 4 102162101 Wire Harness includes items 1 18 1 1 N A Wire Assembly 18 BrOWM 1 2 Wire Assembly 18 Blue a 1 3 N A Wire Assembly 18 Purple 1 4 Wire Assembly 18 Yellow RN 1 5 N A Wire Assembly 18 Green White pp 1 6 101883002 Wire Assembly 18 Black includes resistor and 18 white wire 1 7 N A Wire Assembly 18 Green 1 8 N A Wire Assembly 18 Whit
4. 1 6 1012353 Stud Short Ball 4 28 a 1 7 1014003 Crank Bell 1 8 8449 Nut Dimpled Lock 1 4228 iecit add 1 9 1012903 Bearing Bronze 3 8 x 1 2 2 10 1014189 Screw Bronze Hex Head Cap 1 4 20 x2 1 11 1013886 Cover Wiper Switch Case 2 2 0 0 0 0000 00 1 12 1013061 Nut Nylon Lock 1 19 1014017 Carrier Wiper Switch Arm 1 14 1013998 Spring Wiper Switch Brush a 1 15 1014000 Stud Wiper Switch Adjusting 1 16 1014019 Screw Self Tapping 4 40 3 8 1 17 8058 Washer Lock Ada ui uqu admin 3 18 1013887 Arm Speed Switch uuu 1 19 1013860 Assembly Switch Brush a 1 20 8056 Screw Round Head Machine 4 40 x 3 4 2 21 1014807 Switch Eitmib na 1 22 1014010 Grommet Splits anne Se ee a 1 23 8057 Hex 24 40 aaa edu RI nu 2 24 451 Washer LOCK 114 iu sciet a ci e Ra u Oa Dada 1 25 N A Wire Assembly 18 1 26 N A Wire Assembly 18 Green r 1 27 1017692 Protector i iA nine idee SAN eae 1 28 1014109 Bolt Carri
5. 1 27 101926901 Bolt Flanged M8 x 1 25 x 40 mm sees 15 28 1012896 Pin DOWEL nm 2 29 1013759 Plug Drain includes item 30 2 30 1016432 Gasket nn 1 31 1012711 Breather ee poeta ee 1 32 101928701 Gasket Liquid 8 8 oz 250 A R 2004 2005 DS Golf Cars Illustrated Parts List Page 11 9 REFERENCE NE SEALED BEARING DRIVER SIDE Page 11 10 REFERENCE PASSENGER SIDE CA Parts identification for transaxles after serial number MC008C3H1264 EN Y B IS e 2004 2005 DS Golf Cars Illustrated Parts List MC008C ES00 AFTER SERIAL NUMBER MC008C3H1264 TRANSMISSION AND GEAR REDUCTION ITEM PART NO DESCRIPTION QTY 1234 33 101892001 ai NH 1 94 10189000 1 35 1012748 PMG lios DRUG imi 1 36 1012747 Ball A ma as eet ER ttt 1 37 101889401 qc 1 38 AM10080 Bearing Ball Sealed a 2 39 1016338 Washer Spring suan a aa ed ded 2 40 101892401 Gear u u Zb 1 41 101892201 Plate ee inl eed 3 42 101980901 Gear Assembly Input 28 Tooth 16 1 43 101927601 B
6. 1 1 11 7973 Rivet Aluminum Pop 3 16 3 3 12 101708301 Kit Drink Holder includes items 13 and 14 2 2 13 7847 Screw Hex Head 1 4 20 x 3 4 2 2 14 1016952 VEN 174 202 erkenne nei NINE 2 2 15 101768202 Kit Bagwell Protector includes item 16 1 1 16 1010434 Fastener Plastic BArrel ree Di ties ta Md etia na 9 9 17 1017079 Kit Rear Bumper includes items 18 22 1 1 18 1016379 Bumper Rear iiia teet idee tiunt 1 1 19 1016875 Plate Mounting Long pp 1 1 20 7473 Nut Nylon Lock 5 16 18 4 4 21 1011697 Washer Special 5 16 6 6 22 1016876 Bolt Phillips Truss Head Shoulder 3 8 18 x 2 4 4 23 101706702 Kit Scuff Guard includes item 24 1 1 24 1010434 Fastener Plastic Barrel 12 12 25 102221201 Wear e feti nae 2 2 2004 2005 DS Golf Cars Illustrated Parts List Page 1 3 2004 2005 DS Golf Cars Illustrated Parts List Page 1 4 FRONT BODY ITEM PARTNO DESCRIPTION ae 1234 1 1017080 Kit Front Bumper includes items 2 5 000 1 1 2 1016868 Bumper Front 1 1 3 7251 Screw Phillips Truss Head 5 16 18 x
7. 1 8 101897201 Breather 2 la 1 9 7330 Bearing Differential r 2 10 101895601 Assembly Axle Tube Passenger Side 20 1 11 1013794 Seal Oil Axle Shaft uuu an nalen 2 12 7335 Bearing Input Gear ne 3 13 101923701 Shaft Input um a edes ev emm e ats 1 14 7336 Bearing Intermediate Gear 1 15 101906901 Assembly Intermediate Gear 1 16 101895401 Gear Case Drver Side eri tiere d ee 1 17 101972201 Plug Fill 12 5 it eh ai dove od 1 18 101972101 Plugs Ez Ye o tii ee 1 19 101923201 Gasket Pl g 2 22 amata 2 20 101897001 Bolt 8 1 25 0 MM 5e ee tei ed eR CE 11 21 101897601 Pin nn 2 22 101923901 Gear Differential Mena 2 23 101903601 Plate Thrust idler gear cnn 2 24 101923001 Gear Differential ii neltine 2 25 101903701 me LU exei st ete 2 26 101922101 Pin Differential 55s e toe t eis ici 1 27 101923601 Housing Differential eto uen in 1 28 101906201 ECO Cie HA 1 29 101897401 Bolt X 153X25 mm et A 6 30 101895701 Assembly Axle Tube Driver Side 1 If you are replacing the Output Gear P N 101906201 or Differential Housing
8. 1 4 1015914 Assembly Heatsink with Diodes includes mounting hardware 1 5 1015905 Ammeter includes mounting hardware 1 6 1015911 Relay 36 V DG n ua ha ea de a akaqa 1 7 1015910 1 8 101643301 Cordset DC 108 Inch Long 12 AWG standard 1 8 101643302 Cordset DC 146 Inch Long 10 1 8 101643303 Cordset DC 242 Inch Long 10 1 9 1012101 Assembly Fuse includes mounting hardware 1 10 1012098 Bushing Strain Relief 12 AWG DC Cord pp 1 10 1012042 Bushing Strain Relief 10 AWG DC 1 11 1015917 Bushing Strain Relief AC Cord 1 12 1014696 Cordset AC 108 Inch Long standard a 1 13 1015906 Assembly Timer Kit includes mounting hardware 1 14 1015913 Assembly Control 1 2004 2005 DS Golf Cars Illustrated Parts List Page 15 5 2004 2005 DS Golf Cars Illustrated Parts List Page 15 6 ACCU POWER BATTERY CHARGER EXPORT 100 VOLT V GLIDE 36
9. 1 17 1015737 Wire Assembly 10 Red part of the electrical component box 1 18 1015332 Wire Assembly 10 Braided Ground pp 1 19 101837301 Wire Assembly 6 Green 1 2004 2005 DS Golf Cars Illustrated Parts List Page 6 3 gt Cees 3 6 4 2004 2005 DS Golf Cars Illustrated Parts List FORWARDIREVERSE SHIFTER ASSEMBLY GASOLINE VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1016947 Assembly Forward Reverse Shifter includes items 1 17 1 1 1012594 Screw Machine 4 40 1 12 77 2 2 8057 Nut 440 pieta eee 4 3 1012431 Washer Flat suyu taa hu tecti NR 4 4 101979101 Switch a Arne entire 1 5 1014807 Switch 1 6 8058 Washer Lock RA cr er ert 2 7 1013591 Pin Boll 4 82 ea Rear epe Pu u Ga 1 8 1014145 B shing Bronze tad 2 9 1014727 Washer Nylon Flat 4 2 10 1016342 Base Forward Reverse Shifter 1 11 1014089 Kit Neutral Lockout Cam includes item 12 1 12 1014065 Washer Flat tai a anni 1 13 1013590 Spring Forward Reverse Cam 1 14 1013589 FRING REMAIN RIDE PRIMUM 1 15 8717 Nut Nylon lock 1 4228 222 det 1 16 1013587
10. 1 22 1017948 Rigging n a uui aaa eine ena 1 23 1017949 Screw Brush Holder 6 32 1 2 2 24 102235201 B mper Moto ele alice 1 25 1014201 Screw Hex Head Cap 1 4 20 2 1 4 3 26 451 Washer Lock TA dic detecta aet ied 3 27 1010934 Screw Hex Head Cap 5 16 18 1 1 28 7174 5 16 uo Nut 1 29 101920101 Kit 3 Pin Plug and Wedge 1 30 102243403 Lubricant Moly Teflon Single Use Tube pp 1 2004 2005 DS Golf Cars Illustrated Parts List Page 13 7 000185 001 Page 13 8 2004 2005 DS Golf Cars Illustrated Parts List MOTOR MODEL EJ4 4001 IQ SYSTEM VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 1010934 Screw 5 16 18 X 1 00 1 2 1014201 Screw 1 4 20 X 225 Hex Gap u 3 3 101920101 Kit 3 pin Plug amp Wedge Lock iS 1 4 102235201 Bumper Drive Unit u ce dt 1 5 102243403 Lubricant Moly Teflon Single Use 1 6 102705001 IQ Electric Motor 48 VDC 3 3 hp includes items 7 through 34 1 7 102186001 Spring Kit Motor Brush includes item 8 pp 1 8 N A S
11. 2 11 7479 Screw Hex Head Cap 1 4 20 x 1 1 4 2 12 1017815 Spacer 1 2 50 ti a dete esca e e 2 13 1017748 Clip Body Keeper ne 2 14 1012047 Screw Self Tapping 18 22 2 15 101693301 Body Beige vp RP RENE 1 15 101693302 1 15 101693304 Body 1 15 101693306 Body Red 2 2224 eile a nella 1 15 101693309 Body Pacific Blue Royal Blue 1 15 101693310 Body Dark Green DOR 1 15 101693311 Body Black suya nen s Liane 1 15 101693312 Body Classic Blue Navy 1 15 101693313 Body Burgundy 1 16 101696201 Body with Taillight Opening 1 16 101696202 Body with Taillight Opening White pp 1 16 101696204 Body with Taillight Opening Gray 1 16 101696206 Body with Taillight Opening 1 16 101696217 Body with Taillight Opening Pacific Blue Royal Blue 1 16 101696218 Body with Taillight Opening Dark Green 1 16 101696222 Body with Taillight Opening 1 16 101696223 Body with Taillight Opening Classic Blue Navy 1 16 101696224 Bod
12. 1 6 101831101 a ner nn e ne nennen 1 7 101828901 Cordset DC 113 Inch Long with Male 3 Pin Plug 12 AWG 1 7 101828902 Cordset DC 154 Inch Long with Male 3 Pin Plug 12 AWG 1 7 101828903 Cordset DC 250 Inch Long with Male 3 Pin Plug 12 AWG 1 8 1012101 Assembly Fuse includes mounting hardware 1 9 1012098 Bushing Strain Relief DC Cord 12 AWG sss 1 10 101914401 Assembly Voltage 1 11 CCX8506 Breaker Circuit 15 Amp 120 1 12 101828601 Relay Power 48 V 1 13 101828801 Cordset AC 80 Inch Long 1 13 101828802 116 Inch E ong u dee ac a oen od 1 14 1015917 Bushing Strain Relief AC Cord 1 2004 2005 DS Golf Cars Illustrated Parts List Page 15 9 POWERDRIVE 2 BATTERY CHARGER DOMESTIC ITEM PART NO DESCRIPTION QTY 1234 PowerDrive 2 chargers can be used with PowerDrive System 48 and IQ System vehicles 101802204 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 g
13. 1 1 17 7473 Nut Nylon Lock 5 16 18 earlier style hardware 1 1 101187702 Kit Park Brake Latch includes items 18 22 and item 26 on page 1 1 18 N A Red and aWl aie ea Rn 1 1 19 1017029 Pin Cotter 7 64 n a te 1 1 20 1010877 Nutz PUSH 5 16 7 1 1 21 1010805 sleeves Park Brake ROG uu d eet cad er n Peur re Prog 1 1 22 1010932 Joint Ball 1 4 28 teu basis 1 1 23 1010933 Spring Park Brake Torsion a 1 1 24 1010927 Spacer Park Brake un u m ute itam a ns 1 1 25 1011402 Package Brake Mounting Block contains upper and lower for driver and passenger sides 1 1 26 1011418 Kit Park Brake Pedal includes items 27 30 1 1 27 1032 Bushing Nylon au s l seite uu d 2 2 28 8626 Screw Slotted Hex Washer Head 10 16 x 5 8 2 2 29 1013876 Nut 3 6 ee ee e Co edt uen 1 1 30 1013870 Pad Park Brake ar sn ee t a ut eet 1 1 31 1242 Nut Hex 5 16 18 u anne Baar 1 1 2004 2005 DS Golf Cars Illustrated Parts List Page 4 5 Page 4 6 2004 2005 DS Golf Cars Illustrated Parts List ACCELERATOR PEDAL ASSEMBLY ITEM PARTNO DESCRIPTION 1 2 3 4 1 1
14. sse eene eene nennen nnne ens 15 17 SECTION 16 MAINTENANCE AND SERVICE TOOLS Maintenance and Service na 16 3 Maintenance and Service Tools Continued pp 16 5 Maintenance and Service Tools Continued pp 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 9 PLACES 2 PLACES TYPICAL 5 2 PLACES TYPICA Front Body 2 PLACES TYPICAL 2004 2005 DS Golf Cars Illustrated Parts List Page 1 2 BODY TRIM ITEM PARTNO DESCRIPTION tere 1234 1 1013344 Component Driver Side Dash Black 1 1 2 101660404 Panel Center Dash Black u u u iran 1 1 3 101802601 Plug Hole V Glide 36 Volt vehicle only 1 4 1013343 Component Passenger Side Dash Black 1 1 5 1015032 Ma t Floor eM nn Een 1 1 6 1014645 Kit Snap Washer Black includes items 7 10 2 2 7 1011019 kus mauka 1 1 8 1011382 Washer 4107 a eet un ee een 1 1 9 1620 Screw 10 Sheet 1 1 10 1013494 Cover Screw Head
15. N WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH Before using vehicle read operating instructions Remain seated and hold on to seat handle while moving Do not start vehicle until all occupants are seated Two 2 persons per seat maximum Operate from driver side only and not on public roads Keep entire body inside vehicle while moving Drive slowly in turns and straight up and down slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs OPERATING INSTRUCTIONS ReadOwner s Manualand 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 vehicleis stopped select direction by placing shiftlever or switch in desired position Use brakes to reduce speed when coasting downhill F Forward N Neutral R Reverse Buzzer will sound Never stand in front of or behind vehicle OI 101900001 e Vehicle will start moving when accelerator pedal is depressed e Slowly depress accelerator pedal to increase speed Park brake will release when accelerator pedalis depressed To stop release accelerator pedal and depress brake pedal After stopping the vehicle Firmly depress park brake untilitlocks Place Forward Reverse switch in NEUTRAL position Turn key OFF and remove key when notin
16. 2 16 1017704 Assembly Axle Tube Passenger Side 1 17 1013794 Seal Axle Shaft Qil 2 18 7335 Beating Gear tt wlan 3 19 1013764 Shaft tbt 1 20 7336 Bearing Intermediate Gear 1 21 1013766 Gear Intermediate Small 1 22 1013780 Key X 1 23 1013765 Gear Intermediate Large 1 24 1013757 Gear Case Driver Side u ne an 1 25 1013759 2 26 1013763 Bolt M6 x 1 50 mm 10 27 1012710 Bin DOW6 u y n 2 28 1013779 M8 1 25 x 37 mim uuu o ut 8 29 1013782 Plate E 4 30 1013767 Gear OUTDO cT 1 31 1013772 Pin Differential au yma tiu 1 32 101910501 Kit Differential Gear Case includes items 33 36 1 33 1013768 Gear Case Differential driver side 1 34 1013773 Plate Thrust differential gear 2 35 1013774 Plate Thrust idler 2 36 1013769 Gear Case Differential passenger 1 37 1013771 Gear Differential 3 ite 2 38 1013770 Gear Differential Idler
17. 1 2 1015188 Gap Fuel Tank Nonvented 1 3 1015143 Assembly Fuel Tank 1 4 1015139 Grommet Insulation Za n itte ard ie eredi ee 1 5 1015137 Line Bulk Vent available by the foot 00 6 101896901 Valve Fuel Pickup Tube with Shut Off 1 7 1013746 Glamp Hose cnt ns TE 2 8 101824401 Barb Vent yuaya cites ae Sena eee 1 9 101824401 B rb cete pc 1 10 1014928 Assembly Rear Fuel Strap pp 1 11 1013746 Gl mp Hose eit u suu Ra ee a i ee 2 12 1014523 P utnp FEuel reete 1 19 1014524 Rebuild Kit Fuel Impulse PUMP r 1 14 1017203 Bolt Carriage ma t et ERR eds 2 15 101987701 Clamp Alas E NDA DERE 1 16 8233 Nut Nylon Lock 174220 ti nuy eet ee ie ede EE ee kusha tg 2 17 1014116 Nut U Type Speed 1 4 20 00 0 000000000000 2 18 1011988 Screw Phillips Truss Head 1 4 20 X 2 a 1 19 1013692 Line Bulk Fuel available by the foot A R 20 102003201 Filter EU6l 2 2 1012649 Clamp Hose arde d 9 22 8248 Screw Phillips Truss Head 1 4 20 x 3 4 1 23 1013687 Clamp Hose 3 8 ur un MER 1
18. 1 8 1014198 Nameplate Gold on front body 1 2004 2005 DS Golf Cars Illustrated Parts List Page 3 3 N WARNING ROLLOVER OR FALLING OFF MAY CAUSE DEATH Before using vehicle read operating instructions OPERATING INSTRUCTIONS Remain seated and hold on to seat handle while moving Da not siart Read Owner s Manual and safety warnings located on dash panel prior to driving Two 5 persone per sssi maximum e Study and understand controls 2 oparata anvar ony a roaga Make sure wheels are turned in desired direction Keep entire body inside vehicle while moving Drive slowly in turns straight up and down slopes Turn key to ON position and be sure nothing is in your path Do not leave children unattended on vehicle While vehicle is stopped select direction by placing Never operate under the influence of alcohol or drugs shift lever or switch in desired position Use brakes to reduce speed when coasting downhill 1 F Forward N Neutral R Reverse Buzzer will sound Never stand in front of or behind vehicle Vehicle will start moving when accelerator pedal is depressed e Slowly depress accelerator pedalto 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 untilitlocks Place Forward Revers
19. 2 39 1013781 Sin sq a Qhi 1 40 1017703 Assembly Axle Tube Driver Side a 1 41 1014193 DoWel 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 BATTERY CHARGER 15 a or rovs co 4 Page 15 2 2004 2005 DS Golf Cars Illustrated Parts List ACCU POWER BATTERY CHARGER DOMESTIC V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 101646401 Charger Accu Power Domestic 120 V AC 36 60 Hz model number 13800 11 includes items 1 14 108 inch DC cord 72 inch AC cord 1 1 1015907 Assembly Case includes fasteners pp 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 10 3 1015912 Assembly Transformer eem tite ERE MIROR as 1 4 1015914 Assembly Heatsink with Diodes includes mounting hardware 1 5 1015905 Ammeter includes mounting hardware sse 1 6 1015911 Relay 36 V DG gece 1 7 1015910 PEDES 1 8 101643301 Cordset DC 108 Inch Long standard 12 AWG 1 8 101643302 Cordse
20. 1 11 1014729 Coil Resistor 1st Speed 128 Inch Wire Diameter 6 Coil 1 12 1012285 Screw Hex 1 4 20 8 4 13 1013971 Shield RESISTE A EE ERE Cede 1 2004 2005 DS Golf Cars Illustrated Parts List Page 12 11 EN VEHICLE TYPICAL BODY 2 PLACES TYPICAL IN TYPICAL TYPICAL 2 PLACES TYPICAL TYPICAL 6 PLACES 3 PLACES TYPICAL 12 PLACES 5 V J 5 PLACES 12 12 2004 2005 DS Golf Cars Illustrated Parts List BATTERIES CHARGER RECEPTACLE SOLENOID V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 1015072 Nut Nylon Lock Stainless Steel 5 6 18 6 2 1011578 Washer Flat B Wide 5 16 RN 6 3 101090801 Hold Down Battery 3 4 1013683 JABOlt ik eet uy ute 6 5 101661601 Battery 6 tpe 6 5 101661602 Battery 6 Volt Dry coccion e dee ee 6 6 1010958 Wire Assembly 6 Black a ata anna alus entren nennen nnne 5 7 101831401 6 VoltiBattery u eoe 6 8 1014904 Nut Hex Stainless Steel 5 6 18 1 ii iod e cct atis ed ci crab a 12 9 1012022 AMO 2 10 1606 RIV
21. 1 15 101875401 Screw Pole Piece set of 4 1 16 101875501 Goll Field een dine net E bet t 1 17 101875601 Irisulator F Terminal A 2 18 101877601 Package Terminal Hardware F1 and F2 2 19 101875701 Insulator DF Terminal 24 0 000 1 20 101877701 Package Terminal Hardware DF seem 1 21 101301102 Holder Brush includes item 22 Ne 1 22 101878101 Spring au rl ae nnd 4 23 101876001 Package Terminal Hardware 1 and A2 2 24 101876301 Cover Brush Inspection Port set of 4 includes item 25 1 25 1017653 Cover Brush Inspection Port with Drain 1 26 101876402 End Bell Commutator aa aaa nennen nnns 1 27 101879001 Bolt Clamp x 1 x 180 MM RN 2 28 101869302 Package Brush includes 4 brushes 4 screws 4 washers 1 29 101876202 Connector Brushy ze eo a 2 30 101875802 A Connector set of 2 treten nene nee 1 31 1014289 Pulley c aude dadas 1 2004 2005 DS Golf Cars Illustrated Parts List Page 6 11 AS VIEWED FROM DRIVER SIDE OF VEHICLE TERMINAL 1 d AS VIEWED FROM PASSENGER
22. 1 1 2 101816502 Mechanism Adjusting Driver Side 1 1 3 101823901 ECIAM PIE 1 1 4 101823801 Washer Plate iii cai 1 1 5 1010850 Cover Dust tei cn agitata tea laeti isa 1 1 6 101823201 Package Brake Shoe four pieces 1 1 7 1011466 Kit Shoe Retainer four pieces uu u u mH 1 1 8 101816301 Package Brake Spring four pieces 1 1 9 101815501 Assembly Lever Passenger Side 1 1 9 101815502 Assembly Lever Driver Side 1 1 10 1013924 Nut Hex Lock Grade 8 5 16 24 a 8 8 11 1014153 Bolt Brake Cluster Mounting Grade 8 5 16 24 x 7 8 8 8 12 102022101 Kit Brake Cable includes items 13 15 2 2 13 1010829 Pin Clevis 8 16 u anna assasi ani 2 2 14 1035 Pin a ae dete 2 2 15 1011779 E 3 5 asus mia 2 2 16 101900801 Hanger Brake Cable gasoline vehicle only 2 17 1013207 Hanger Brake Cable electric vehicle only 2 18 101791101 Drum 2 2 19 102292801 Pin Bow Tie Locking die 22 2004 2005 DS Golf Cars Illu
23. 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 2004 2005 DS Golf Cars Illustrated Parts List Page 8 4 CARBURETOR ASSEMBLY ITEM PART NO DESCRIPTION QTY 1 101905601 Assembly Carburetor includes items 2 11 1 2 1016501 Assembly 1 3 N A Assembly Pilot Air Screw 1 4 101973101 Jet Pilot 40 e Eh am 1 5 1016486 Assembly F gat petia ditte e RA ran nigra 1 6 101973201 epe p E ECL inet 1 Standard Jetting 7 101642582 Jet Main 0 3 000 1 7 101642580 Jet Main 3 000 5 000 feet ul e ist leet i ed qns AIR 7 101642578 Jet Main 5 000 8 000 feet 7 101642575 Jet Main 8 000 10 000 feet AIR 7 101642572 Jet Main 10 000 Feet and Above pp A R 8 1016437 Gasket Float Chamber Qua 1 9 1017461 Assembly Float Chamber includes item 10 1 10 1016499 Assembly Screw A 1 11 1016585 Assembly Bolt ace tete E bate kas 1 2004 2005 DS Golf Cars Illustrated Parts List Page 8 5 Page 8 6 2004 2005 DS Golf Cars Illustrated Parts List CARBURETOR INSTALLATION
24. 2 85 1013773 Plate Thrust differential gear u u m 1 86 1013769 Cover Gear Case itti oa a 1 87 1013772 Pin Differential ec ase 1 88 1013770 Gear Differential Idl r na 2 89 1013771 Gear Differential A aA 2 2004 2005 DS Golf Cars Illustrated Parts List Page 11 13 ELECTRICAL SYSTEM ELECTRIC VEHICLE 12 AS SEEN FROM FRONT DRIVER SIDE ort OF VEHICLE BODY REMOVED 2 SE 1 J gt EN ZU TZ TYPICAL 2 PLACES 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 QTY 1 2 3 4 1 1016859 Kit Reverse Buzzer includes items 2 and 3 a 1 2 1016849 Screw Pan Head Hi Lo 4 24 x 5 16 2 3 1016851 Buzzer Reversen cscs sas un ree s tc sa sbs ak 1 4 101830601 Assembly Screw and Washer 2 5 101826201 Switch Key E 1 6 101851101 Washer Key Switch A 1 7 101830701 Nut Key Switeh s 1 8 101834502 Cap Key E 1 9 1012505 Key io e l tee hu 1 9 AM10079 Key bag of 50 1 10 101802601 Plug Hole
25. EE 2 73 101891001 Assembly Axle Tube 74 101890901 Assembly Axle Tube Passenger Side 00 1 75 1013790 M10 x 1 5 x 30MM nti hess aa 14 76 1013791 Washer Lock M10 uu u 14 77 7330 Bearing Inner Axle Tube 2 78 101928301 ME X 1 25 x 37 RR 8 79 101892701 Gear uere 1 80 1014193 Pim 1 81 101910501 Kit Differential Gear Case includes items 82 85 1 82 1013768 Case Gear Cartier mine tete 1 83 1013774 Plate Thrust idler 2 84 1013773 Plate Thrust differential gear u u m 1 85 1013769 Cover Gear Case iii ehe etant 1 86 1013772 Pin Differential nd ett ec 1 87 1013770 Gear Differential Idl r na 2 88 1013771 Gear Differential A aA 2 2004 2005 DS Golf Cars Illustrated Parts List Page 11 7 2004 2005 DS Golf Cars Illustrated Parts List Page 11 8 MC008C ES00 AFTER SERIAL NUMBER MC008C3H1264 GEAR CASES AND BRACKETS ITEM PART NO DESCRIPTION QTY 1234 1 101922601 Bracket Transmission Cable Support 1 2 1012285 Screw Hex 1 4 20
26. u s tus uu yG 1 9 N A Plug Drive Clutch rr 3 10 1014453 Kit Drive Clutch Button includes item 11 14 1 11 1014287 Spring Drive B ttOn u a 3 12 1014062 Driver Drive Gl tch aa ea N 3 13 183 Washer Flat 10 Type A iind nde Hee RIND 3 14 8450 Screw Hex Head 10 24 X 5 a nennen enne 3 15 1014058 Washer ThEUSE tiic iare di Pep uu a tera riet 1 16 1014056 Ring Spiral 2 17 1014052 Assembly Movable Face includes items 18 and 19 1 18 N A B shing aot 1 19 1014055 Retalligr 2 i awama ES 1 20 1016203 Belt Drive mnia te 1 21 101916701 Belt Starter Generator pp 1 22 101916501 Screw Hex Head Cap 3 8 24 x 5 1 2 left hand threads 1 23 808 Washer Ela 3 8 Sq ee ne eed ae uu al asada 1 24 357 Washer nun Paid Hae fava tees 1 2004 2005 DS Golf Cars Illustrated Parts List Page 10 3 DRIVEN CLUTCH ITEM PART NO DESCRIPTION QTY 1234 1 101834001 Assembly Driven Clutch includes items 2 8 1 2 1014080 RING RETAINING uuu hodic ee ln au has tad 1 3 1014078 Kay acte Det ttim arm e 1 4 101768
27. 1 12 CCX8506 Breaker Circuit 15 Amp 120 V AC 1 13 101828801 Cordset AC 80 Inch Long 1 13 101828802 Gordset AC 116 Inch E Ong ei ied ac Pet leute 1 14 102274001 Handle PowerDrive 2 Charger with four 1 15 101828601 Relay Power 48 V nana Tn 1 2004 2005 DS Golf Cars Illustrated Parts List Page 15 11 12 PLACES F DS A CA 000184 001 Page 15 12 2004 2005 DS Golf Cars Illustrated Parts List GE POWERDRIVE BATTERY CHARGER DOMESTIC ITEM PART NO DESCRIPTION QTY 1 2 3 4 1 102496401 Charger 120VAC 48VDC 103 74in 7 1 2 102496402 Charger 120VAC 48VDC 144 108in 1 3 102496403 Charger 120VAC 48VDC 240 108in includes items 4 through 23 1 4 102814201 Handle PowerDrive 1 5 102814301 Transformer u u rer t neta an 1 6 102814401 GOVer Base bum 1 7 102814501 Cover TOD a ares 1 8 102814601 Plate a 1 9 102814701 Gordset 80 Inch LONG u u oet d IRE eodd 1 10 102814702 Cordset AC 108 Inch Long 1 11 102814801 Cordset DC 113 In
28. O yo 14 15 SOLENOID WIRING IQ SYSTEM VEHICLE WITH MOTOR CONTROLLER OUTPUT REGULATOR MCOR ITEM PART NO DESCRIPTION QTY 1 2 3 4 1 102196601 Wire a iin eda 1 2 N A Wire Assembly 18 Orange White part of battery warning light 1 3 N A Wire Assembly 10 Red part of fuse and receptacle assembly 1 4 N A Wire Assembly 6 Black ende aa tee eti RO erdt ER head 1 5 N A Wire Assembly 10 Black part of onboard computer assembly 1 6 N A Wire Assembly 18 Gray part of onboard computer assembly 1 7 N A Wire Assembly 10 Black part of onboard computer assembly 1 8 101795701 Wire Assembly 6 5 9 101978101 Wire Assembly 10 Orange essent nennen nhanh nnn sss 1 10 102199601 Wire Assembly 6 1 11 101978201 Wire Assembly 10 Blue 1 12 101968701 Wire Assembly 6 White Ne 2 13 101978001 Wire Assembly 6 Green RN 1 14 101920001 Wire Assembly 6 Yellow 1 15 102263601 Wire Assembly 10 1 2004 2005 DS Golf Cars Illustrated Parts List Page 12 25 REFERENCE x Kr J 19 DECALS d TYPICA
29. nas 4 4 11 102061301 Canopy White en nun esse 1 1 11 102061302 Canopy Beige 2 2 1 1 100 1 10 01 0 1 1 12 102198301 Pad Mounting windshield frame 2 2 2 2004 2005 DS Golf Cars Illustrated Parts List Page 1 15 WHEELS AND TIRES B 16 Ne uf 77754555 DIAS III STANDARD TREAD PERFORMANCE PREMIUM TREAD EXTRA TRACTION Carlisle GRADE TREAD Kenda 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 PARTNO DESCRIPTION oe Pe 1 2 3 4 1 1010984 N t LUJ titi ag dede ae 16 16 2 7310 Stem Valve saq 1 1 3 101570501 Assembly Wheel and Standard Tire includes items 4 5 4 4 4 1015707 Wheel Rim Beige 1 1 5 727102 Tire Unmounted Standard Tread 18 x 8 50 8 Carlisle 1 1 6 101570507 Assembly Wheel and Extra Traction Tire includes items 7 8 2 2 7 1015707 Wheel Rim Sq qaa kama 1 1 8 101769302 Tire Unmounted Extra Traction 6 Ply Rated 18 x 8 50 8 Duro X 1 9 101570512 Assembly Wheel and Performance Grade Tire includes items 10 11
30. 5 8 3 3 1013061 Nut Nylon Lock 10 32 ly nupus bs in 1 4 183 Washer Flat 3710 iia T Sa ys 1 5 1010954 Ball 1 4228 9 16 unu nan an al 1 6 1016341 Lever Transmission Shifter aa 1 7 1017082 Screw Hex Washer Head 10 32 x 3 4 1 8 8717 Nut Nylon Lock 1 4 28 1 9 1017231 Key Woodrulf ole te diui e ttes 1 10 101834801 Arm Governor Lever 1 11 101886101 Screw Square Head 1 4 20 X 1 1 12 1014007 Washer A 1 13 8233 Nut Nylon Lock 1 4 20 1 101833601 Unitized Transaxle includes items 14 89 1 14 101890201 Maite 1 15 101927301 1 16 101892901 Washers Flat a ds 1 17 101927201 RIED 1 18 101890101 Lever Shifter a ser a 1 19 1012752 Ri 1 20 10192860 Pin Gotten itemm dtt e d 1 21 1016513 a li 1 22 101927101 ae 1 23 101893801 ttn 1 24 101891301 Arm PIVOU 1 anni ele 1 25 101890601 Gear Case passenger Side pp 1 26 101890501 Gear Case driver side
31. pr 2004 2005 ILLUSTRATED PARTS LIST DS GOLF CARS GASOLINE ELECTRIC MANUAL NUMBER 102397501 EDITION CODE 1004C1205B USING THE ILLUSTRATED PARTS LIST WARNING This manual is to be used only for identification and ordering of service parts Be sure to read and use the maintenance and service manual before attempting any vehicle repairs This manual covers all 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 i
32. 2 2 29 1016214 Gripy Pencil 4 4 Ad 1 1 30 1016154 Clip Scorecard as ar 1 1 1014216 Kit Steering Column Rebuild not shown pp AIR A R 2004 2005 DS Golf Cars Illustrated Parts List Page 5 3 24 zn TYPICAL 3 PLACES Z Z 000 gt 42 CN 7 g AN al YE LD 97 5 4 2004 2005 DS Golf Cars Illustrated Parts List STEERING GEAR ASSEMBLY ITEM PARTNO DESCRIPTION 1 2 3 4 101878302 Assembly Steering Gear Box includes items 1 20 1 1 1 1013035 Seal Dust Passenger Side 11111 1 1 2 8990 WINGY ann lute 2 2 3 101880201 Assembly Inner Ball Joint 1 1 4 101880301 Washer a Ei 1 1 5 Box Steering Gear 1 1 6 N A Bearing Lower Pinion 1 1 7 N A a 1 1 8 101879401 Bearing Upper Pinion a u n ob 1 1 9 101879901 Ring C Type 1 1 10 1013051 Ring sn 1 1 11 1013052 Seal Dust Steering Pinion 1 1 12 101879701 Guide Steering 1 1 13 101879801 Spring YORK 1 1 14
33. 48 Volt 250 amp customized 1 2 102240501 Screw Hex Washer Head 8 x 1 1 4 2 3 3 1012285 Screw Hex TT 1 4 20 x 5 8 9 4 102266501 Kit Connector IQ Controller u n a e 1 5 102240601 Cover Controller includes items 6 and 7 1 6 102240801 Gasket Controller cada 1 7 101931501 Decal Electrical Component Cover 2 0002 0 60000000 1 8 101965202 Plate Component Mounting SSD 1 9 1014288 Screw Thread Forming 5 16 18 x 3 4 2 10 101910401 Screw Thread Forming 5 16 18 x 1 1 4 2 11 101909902 Computer Onboard includes item 12 1 12 101932601 Kit 6 Pin Receptacle ana ee els ieee ine vee 1 13 101932701 Kit 6 Pin Plug and Wedge 1 14 101827801 Kit Wire and Terminal 6 Black 1 15 102259801 Block Terminal controller 3 1 16 102263601 Wire Assembly 10 1 17 102263701 Screw Phillips Thread Forming 10 24 x 3 4 20020 1 18 7174 Wash rmoekz5 161 sum E ter ms a fam sas 1 19 1242 Nuts Hex 5 16 18 1 20 101908701 Solenoid 48 Volt
34. 6 N A Nut FHlex 5 16 18 iue t rd et de e ees 4 7 N A Bushings Insulator 2 8 1017961 Screw Clamp 5 ict sc Ine 4 9 1017953 Screw Bearing Retainer 2 10 1017951 Shield End iuo IA Innen 1 11 1017949 Screw Brush Holder SSK LE ern 2 12 1017948 Rigging Brush lasa ente 1 13 1017946 Package Brush 2 pieces includes 4 brushes 1 14 1011411 Package Brush Spring 4 pieces 4 1 15 1011290 Bearings Ballu ote ettet te dest re oet ire ted 1 16 1017950 Retainer Bearing eni irc eee ee LE RE ttal 1 17 N A Armature e 1 18 1014201 Screw Hex Head 1 4 20 2 74 3 19 451 Washer Lock a eas oe is in 3 20 1010934 Screw Hex Head Cap 5 16 18 x 1 1 21 7174 Washer iLook 5 16 s k us uma reise d eee 1 22 102235201 Bumper Motor M 1 23 102243403 Lubricant Moly Teflon Single Use 1 2004 2005 DS Golf Cars Illustrated Parts List Page 13 5 2004 2005 DS Golf Cars Illustrated Parts List Page 13 6 MOTOR MODEL 5BC59JBS6365 IQ SYSTEM VEHICLE ITEM PART NO DESCRIPTION QTY 1234 102240102 Assembly 48 IQ Motor 3 20 hp includes items 1 23 1 1 1017944
35. 62 102669701 Idle Gear Bushing Replacement Tool for Kubota D722 Diesel Engines 1 63 1013593 Internal Retaining Ring 1 1 1 64 102248803 IQ Display Module IQDM Kit for IQ System vehicles only 1 includes items 65 and 66 65 102251501 Adaptor Cable u 1 66 102241502 IQDM Series 2 Cable a 1 67 102241501 IQDM Series 1 Cable replacement 1 68 101928701 Liquid Gasket transaxle case 1 1 1 69 102243402 Moly Teflon Lubricant 4 oz 113 gram tube 1 Please refer to the maintenance and service manual for proper tool application 2004 2005 DS Golf Cars Illustrated Parts List 16 7 D D 00 OD Q aq y O PERFECT PERFECT CIRCLE Page 16 8 2004 2005 DS Golf Cars Illustrated Parts List MAINTENANCE AND SERVICE TOOLS CONTINUED PARTNO DESCRIPTION EE 1234 70 102669101 Oil Pressure Tester for Kubota D722 Diesel Engines 1 71 101997201 Paint Touch Up Beige 1 1 71 101997207 Paint T
36. 7 N A O Ring 5 16 red i Re 1 8 N A O Ring 3 8 green dei 1 9 N A Valve sacudida dida 1 10 101812301 Spring eed eee de HH 1 11 1015426 de E 1 12 101811901 Bottom Air BOX iii nel aaa 1 13 101921501 oto um etes ad an tig e etes t 1 14 183 Washer Flat 70 aan RERO leihen ranking 4 15 101971301 Clamp Hose air Intake enne ka nennen teniente nnn 2 16 101837101 OSE Intake Au entier 1 17 101850301 Screw Hex Washer Head Hi Lo 12 x 1 2 a 4 18 101917701 POSITIONG CHOKE up kus deter ete Ma creta unsi eh a Ama 1 19 101805701 Assembly Choke Button includes items 20 21 and 22 1 20 101811501 Guide Choke ever casi ci al 1 21 101856201 Spring Compression pp 1 22 101811401 Lever Choke S 1 23 332 Washer Flat kayu atau a 3 24 1015752 Screw Washer Head Hi Lo 12 16 x 5 8 3 25 101958101 Assembly 1 26 1606 Kivet Pop 3 10 5 sitos iie 2 101971001 Air Duct Repair Kit not shown A R 2004 2005 DS Golf Cars Illustrated Parts List Page 8 11 EXHAUST SYSTEM B EXHAUST SYSTEM ITEM PART NO DESCRIPTION QTY 1234 1 101859301 Sys
37. Dark Green 1 1 8 101693910 Body Front with Headlight Opening 1 1 8 101693911 Body Front with Headlight Opening Classic Blue Navy 1 1 8 101693912 Body Front with Headlight Opening Burgundy 1 1 9 1011014 Trim Front Body ie edt seen dt e 1 1 10 1010435 Bolt Carriage 5 16 18 X T ie ut 2 2 11 1241 Washer Flat 5 16 niue Eo UD EP Re REI 2 2 12 1011017 Screw Flange Lock ia E HERE ee 6 6 13 1011394 T Nut Slab Base package of 4 1 1 14 101347501 Bumper Side Guard TiM 2 22 Ran 2 2 15 102310701 Screw Hex Washer Head 88 18 x 3 8 8 8 16 1015032 Mat Elda a a 1 1 17 TAT3 Nut Nylon lock 5 16 n et P ed et olas 2 2 18 102259001 Emblem IR Golf uu n L t c ER te ehren 1 1 2004 2005 DS Golf Cars Illustrated Parts List Page 1 5 gt _ TYPICAL 2 PLACES gt SUPPORT VERTICAL STRUT TYPICAL 2 PLACES TYPICAL 2 PLACES Page 1 6 2004 2005 DS Golf Cars Illustrated Parts List REAR BODY AND FENDER GASOLINE VEHICLE ITEM PARTNO DESCRIPTION 1234 1 8251 Screw Phillips Head 1 4 20 1 8 2 10190410
38. drive clutch 10 3 drum brake 4 3 dry moly lubricant 16 7 dust boot 5 5 5 7 dustcap 12 27 dust cover 4 3 drive bar E 8 volt battery 12 17 12 29 80 amp fuse 12 13 eccentric 5 9 e clip air box top 8 11 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 equalizerrod 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 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 floormat 1 3 1 5 1 7 1 9 flywheel 7 5 flywheelfan 7 5 flywheel puller 16 7 fork shift 11 5 11 11 forward reverse bell crank 6 5 forward reverse handle 6 5 12 27 forward reverse shifter 6 5 forward reverse shifter base 6 5 12 7 12 15 12 27 12 27 12 7 12 15 forward
39. part of onboard computer assembly 1 29 Wire Assembly 18 Orange White part of battery warning light 1 2004 2005 DS Golf Cars Illustrated Parts List Page 12 23 Page 12 24 SIX PIN CONNECTOR FORWARD KEY REVERSE SWITCH SWITCH PIN 9 GRAY WIRE PIN 10 TAN WIRE PIN 12 BLUE WHITE WIRE PIN 13 BLACK WHITE WIRE PIN 14 LIGHT GREEN WIRE PIN 15 RED WIRE PIN 16 BLUE WIRE F x 2 3 BATTERY m a WARNING FOUR PIN 8 LIGHT MOTOR CONNECTOR CONTROLLER OUTPUT REGULATOR 2 0 m m 0 SONIC 2 289 33 WELD 53195 53 Fmim lt ud zmo m 32 5 5 2 z m z AS FUSE AND m 3 RECEPTACLE AJIN ES 54 Ren gir i m O N A TOW RUN SWITCH vr THREE PIN CONNECTOR PIN 1 WHITE WIRE PIN 3 PURPLE WHITE WIRE PIN 4 GREEN WHITE WIRE PIN 5 LIGHT BLUE WIRE PIN 6 GREEN WIRE PIN 7 ORANGE WHITE WIRE PIN 8 BROWN WIRE uu 2004 2005 DS Golf Cars Illustrated Parts List PIN 2 YELLOW TWO PIN 7 MI I Pa amp o on Se J oon a NI Ji
40. reverse buzzer 6 9 shock absorber cushion 5 11 shock absorber rear 5 17 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 L latch park brake 4 5 4 7 latch wire air box 8 17 L bracket motor 13 9 lead wire 7 5 lens fuse 12 13 lever choke 8 11 shifter 11 3 11 9 transmission shifter 11 3 11 9 lever brake 4 3 light battery warning 12 3 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 i 12 2004 2005 DS Golf Cars Illustrated Parts List magnet 13 7 motor speed sensor 13 9 magnetic plug 14 3 main jet 8 5 mat floor 1 3 1 5 1 7 1 9 MCOR motor controller output regulator 12 21 mechanism brake adjusting 4 3 meter voltohm 16 11 module calibration test 16 3 communication display 16 5 moly teflon lubricant 16 7 motor 36 volt 13 3 48 volt 13 5 48 volt IQ 13 7 13 9 brush kit 13 9 frame and field 13 9 magnet speed sensor 13 9 motor brush spring kit 13 9 motor bumper 13 5 13 7 motorendcap 13 9 motor L bracket 13 9 motor terminal hardware kit 13 9
41. 1013044 Nut Lock Rack Screw 1 1 15 N A Screw RACK GUIDE z u oq ais Mm ada 1 1 16 N A Rack Steering rinda 1 1 17 101879501 Washer Stop u 53x xe 1 1 18 101879601 Ring G Type SOD 1 19 101880001 Seal Dust Driver Side 1 1 20 101880101 Ring Retaining oct echte Hr e 1 1 21 1035 Pin Cotter 3 32 XT as inue Ob ua 1 1 22 7540 Ball Joint Left Hand Thread includes items 23 24 and 25 1 1 23 1015597 Fitting Thread Forming Grease 1 4 28 1 1 24 7602 Nut Hex Slotted 3 8 24 1 1 25 1011930 Boot u sum tle dal i Dei rected la deri ida 1 1 26 7555 Nut Hex Left Hand Thread 1 2 20 1 1 27 1012467 Link Rack and Pinion Drag 1 1 28 1013042 N t Flex MT 1 1 29 1624 Screw Hex Head Cap 3 8 16 x 1 1 2 3 3 30 334 Washer Flat 3 8 ctas ee 3 3 31 8754 Nut Nylon Lock 3 8 16 3 3 2004 2005 DS Golf Cars Illustrated Parts List Page 5 5 Page 5 6 2004 2005 DS Golf Cars Illustrated Parts List FRONT SUSPENSION UPPER ITEM PARTNO DESCRIPTION C ler ce 1234 1 1016
42. 1015913 Assembly Control Cable 1 2004 2005 DS Golf Cars Illustrated Parts List Page 15 7 Page 15 8 2004 2005 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER DOMESTIC ITEM PART NO DESCRIPTION QTY 1234 PowerDrive chargers can be used with PowerDrive System 48 and IQ System vehicles 101802201 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 cord with male grounded plug 1 101802202 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 cord with male grounded plug 1 101802203 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 cord with male grounded plug 1 1 101828301 Assembly Case includes fasteners 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 10 3 101819701 Assembly II 1 4 1015914 Assembly Heatsink with Diodes includes mounting hardware 1 5 101828501 Ammeter includes mounting hardware
43. 1017948 Rigging Brush lasa nente chads ech ended eT a dua d 1 13 1017946 Package Brush 2 pieces includes 4 brushes 1 14 1011411 Package Brush Spring 4 1 15 1011290 Bearings ote een t t dest etit hd 1 16 1017950 Retainer Bearing eee ee Henn 1 17 N A 2 ee u etate 1 18 1014201 Screw Hex Head Cap 1 4 20 2 1 4 3 19 451 Washer Lock 1 4 cua asia eas oe i En 3 20 1010934 Screw Hex Head Cap 5 16 18 x 1 nnns 1 21 7174 Washer Lock 5 16 1 22 102235201 Bumper Motor M 1 2004 2005 DS Golf Cars Illustrated Parts List Page 13 3 2004 2005 DS Golf Cars Illustrated Parts List Page 13 4 MOTOR POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO DESCRIPTION QTY 1234 102237701 Assembly 48 Volt Motor 3 10 hp includes items 1 17 1 1 1017944 Shield una l a uka aa il 1 2 1017958 Assembly Stator Shell and Winding a 1 3 1017947 Package Hardware includes items 4 7 1 4 N A Bushings Insulator 2 5 Washer 56 h OS nee eren Rep t ET 4
44. 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 17 36 volt motor 2 97 hp 13 3 36 solenoid 12 13 10 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 INDEX 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
45. 13 14 5 pivot support 4 7 plain counterbalance rod 7 13 thrust 5 9 upper pinion 5 5 bearing and oil seal remover 16 3 bearing driver set 16 3 bearing puller 16 3 bearing puller wedge 16 3 bearing retainer 13 3 13 5 13 7 bearing retainer starter generator 6 11 bearing retainer screw 13 3 13 5 bell crank 12 9 bell crank and shaft 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 4 5 fuse 6 7 terminal controller 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 INDEX body front 1 5 bolt brake cluster mounting 4 3 bolt j 12 13 12 17 12 29 boot dust 5 5 5 7 steering column 5 3 tow run switch 12 27 box electrical component 6 7 bracket adjusting starter generator 6 13 engine shroud 7 3 fe290 mounting 6 13 fuse and receptacle mounting muffler mounting 9 3 oil filter 7 7 oil level switch 7 11 12 13 power relay mounting 15 15 rpm limiter 7 5 snubber 7 15 steering column mounting 5 3 throttle 8 7 tow run switch 12 27 transmission cable support 11 9 brake adjusting mechanism 4 3 brake adjustment tool 16 3 brake cable 4 3 4 5 brake cable equalizer 4 5 brake cable hanger 4 3 5 11 brake cable release tool 16 3 6 5 11 3 brake cluster 4 3 brake
46. 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 airbox 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 2004 2005 DS Golf Cars Illustrated Parts List tune up kit 16 9 U u bolt 5 11 unitized transaxle 11 3 11 9 upper pinion bearing 5 5 urethane bushing 5 7 5 9 5 11 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 16 11 valve guide 7 9 valve guide driver tool 16 9 valve guide reamer 16 9 valve guide replacement tool 16 9 valveseal 7 9 valveseat 7 7 valve seat cutter 16 5 16 11 valve seat cutter guide 16 11 valve seat t wrench 16 17 valve spring compressor 16 11 valve spring retainer 7 9 valve spring engine 7 9 valve stem 2 3 ventbarb 8 3 vent line fuel 8 3 8 7 vent fue
47. 2 1 2 101825101 Decal Key 5 iio 1 3 101621601 Decal Operating Instructions 1 4 101959902 Decal Motor Braking IQ System vehicle 1 5 1013496 Decal Resistor Warning V Glide 36 Volt vehicles 1 6 101610901 Decal Potentiometer Caution V Glide 36 Volt vehicles 1 7 101908601 Decal Tow Run Switch IQ System vehicles 1 8 101931501 Decal Electrical Component Cover IQ System vehicle 1 9 102259001 Emblem IR Gold 5 2 Dui Ong MED 1 10 1014198 Nameplate Gold 2 20000000000 0 nnn nnn nnn nen nene ns 1 2004 2005 DS Golf Cars Illustrated Parts List Page 3 5 BRAKES PEDAL AND CABLE ASSEMBLIES Page 4 2 2004 2005 DS Golf Cars Illustrated Parts List BRAKE ASSEMBLY ITEM PARTNO DESCRIPTION SE 1234 101823301 Cluster Brake Passenger Side includes items 1 9 1 1 101823302 Cluster Brake Driver Side includes items 1 9 1 1 1 101824001 Assembly Backing Plate Passenger Side includes items 2 4 1 1 1 101824002 Assembly Backing Plate Driver Side includes items 2 4 1 1 2 101816501 Mechanism Adjusting Passenger Side
48. 29 axle 11 7 11 13 14 3 14 5 axle shaft seal 14 3 axle tube 11 7 11 13 14 3 14 5 axle tube seal 14 5 B backing plate brake 4 3 bag hoop 1 13 bag strap 1 13 bag strap buckle 1 13 bagwell protector 1 3 ball bearing output shaft 6 11 ball joint 6 5 ball joint tie rod 5 7 ball joint inner 5 5 ball joint left hand thread 5 5 5 7 ballstud 6 5 6 7 ball stud shifter lever 11 3 11 9 ball stud accelerator pedal 4 7 ball steel shift fork retainer 11 5 11 11 ball steel pressure relief 7 7 band rpm limiter mount 7 5 bar bus 12 15 bar drive 12 21 barb vent 8 3 barrel fastener 1 13 barrel plastic 1 3 base forward reverse shifter 6 5 base mounting 12 13 basket sweater 1 13 battery 6 volt 8 volt battery cap battery charger PowerDrive 15 17 battery charger PowerDrive 2 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 12 13 12 17 12 29 12 13 12 17 12 29 15 9 15 15 15 11 15 13 bearing ball crankshaft 7 11 ball motor 13 3 13 5 13 7 13 9 ball input shaft 11 5 11 11 ball output shaft 6 11 bronze 12 9 differential 14 3 idler drive clutch 10 3 inner axle tube 11 7 11 13 14 5 14 3 14 5 14 3 14 5 input gear intermediate gear lower pinion 5 5 needle 11 5 11 11 outer axle tube 11 7 11
49. 3 16 1016454 Bolt Flanged M5 x 8 x 8 mm 2 17 1016472 Plate OiliFilter SGfeen eet m Tua wa a E reet red 1 18 1016521 Screen FMS ore oe ku Q he 1 19 101915401 Camshaft Complete 22 2 eret 1 20 1016453 NEEDLE 2 2004 2005 DS Golf Cars Illustrated Parts List Page 7 11 FE290 ENGINE CRANKCASE AND CRANKSHAFT ITEM PART NO DESCRIPTION QTY 1234 1 1016568 Seal Qil ET 1 2 101915501 Crankcase OHV uuu sa anida a kn laica 1 3 1016558 Rings Snap E Rest tas EE 2 4 1016460 Pin iPiston ee rd 1 5 101645901 Piston TANTA zur su amu ous a Sima 1 5 101645902 Piston 25 mim Oversized ira uu Q 1 5 101645903 Piston 5011 OVefslzed ua ae 1 6 101646101 Ring Set Piston Standard 1 6 101646102 Ring Set Piston 25 mm Oversized 2 1 6 101646103 Ring Set Piston 50 mm Oversized 1 7 101647501 Assembly Connecting Rod Standard includes 2 each of item 8 1 7 101647502 Assembly Connecting Rod 50 mm Undersized includes 2 each of item 8 1 8 1016509 Screw Hex Head Cap M7 x 1 x 36 MM 2 9 101922301 Crankshaft FE290 left hand thread includes items 10 11 and one each of item 12 1 10 1016533 Geam Flell
50. 3 1012303 Bushing tt a e tide shh cae 6 6 4 1015583 B shi g Urethare uru uu un Dea ed eee Rt dens 12 12 5 1010145 Nut UNF Hex 3 8 24 4 4 6 1013164 Kit Shock Absorber includes items 7 9 and 10 1 1 7 102706401 Shock Absorber Rear 2 2 8 1011415 Kit Shock Absorber Cushion includes 2 each of items 9 and 10 4 4 9 N A Retainer Shock Absorber Cushion 8 8 10 N A Cushion Shock Absorber 7 8 8 11 1012180 U BOlt a ya dede ve era aku 2 2 12 1012324 Spring Rear Leaf gasoline vehicle 2 12 1010974 Spring Rear Leaf electric vehicle 2 13 1014555 Nut Nylon Lock 7 16 24 4 4 14 8755 Screw Hex Head 3 8 16 x 3 3 8 6 6 15 1012182 Pad Spring Driver Side 1 1 15 1012181 Pad Spring Passenger Side 1 1 16 101900801 Hanger Brake Cable gasoline 2 17 1013207 Hanger Brake Cable electric 2 2004 2005 DS Golf Cars Illustrated Parts List Page 5 11 ELECTRICAL SYSTEM GASOLINE VEH
51. 3 5 12 19 12 31 7 5 7 5 7 5 7 5 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 8 11 101917701 101920001 101920101 13 9 101921501 101922101 101922201 101922301 101922501 101922601 101923001 101923201 101923501 101923601 101923701 101923901 101925701 101927101 101927201 101927501 101927601 101927901 101928001 101928101 101928301 101928701 101929801 101931501 101932401 101932501 101932601 101932701 101933101 101935501 101936801 101939901 101942301 101949201 101951501 101953001 101953101 101953901 101954301 101956201 101956202 101956502 101958101 101958201 101958301 101959902 101960501 101960601 101963401 101965201 101966901 101968701 101971001 8 11 12 25 12 19 12 21 12 27 13 7 8 11 14 3 14 3 7 13 12 27 6 5 11 3 11 9 14 3 14 3 14 3 14 3 14 3 14 3 8 11 11 3 11 9 11 3 11 9 11 5 11 11 11 5 11 11 11 5 11 11 11 5 11 11 11 5 11 11 11 7 11 13 11 3 11 9 14 3 14 5 16 7 10 3 3 5 12 27 12 27 12 31 12 31 16 7 12 3 12 21 6 11 12 19 12 27 13 7 13 9 12 9 6 5 4 5 4 5 7 3 1 11 15 17 15 17 12 31 8 11 15 17 15 17 3 5 3 3 3 3 3 5 7 15 12 19 12 31 4 7 12 25 8 11 101971301 101972001 101972002 101972003 101972004 101972005 101972006 101972007 101972009 101972011 101972012 101972101 101972201 101972801 101973101 10
52. 31 36 volt motor 13 3 48 volt motor 13 5 ac voltage suppressor 15 17 accelerator rod 4 7 airbox top 8 11 air duct 8 11 armature 6 11 axle 11 7 11 13 14 3 14 5 axle tube 14 3 14 5 bag hoop 1 13 bearing steering column 5 3 bell crank and shaft 6 7 bolt float chamber 8 5 brush rigging 13 7 carburetor 8 5 charger case 15 3 15 5 15 7 15 9 15 11 15 15 15 17 control cable 15 3 15 5 15 7 current limiter 15 17 cylinder head 7 9 delta a plate 5 7 diode 12 19 diode with heatsink film 15 11 drive hub 10 3 driven clutch 10 5 eccentric 5 9 end shield 13 7 float carburetor 8 5 float chamber 8 5 forward reverse shifter 6 5 forward reverse switch 12 7 12 15 12 27 fuel strap rear 8 3 heatsink 15 3 15 5 15 7 15 9 15 15 2004 2005 DS Golf Cars Illustrated Parts List 15 17 hub and ball bearing 5 9 idle screw 8 5 lever brake 4 3 moveable face driven clutch 10 5 pilot airscrew 8 5 resistor 12 19 12 23 12 31 rod counterbalance 7 13 screw float chamber 8 5 seatback 1 13 seat bottom 1 11 spindle 5 9 stator shell 13 3 13 5 13 7 steering column 5 3 steering gearbox 5 5 switch brush 12 9 timer 15 3 15 5 15 7 transformer 15 3 15 5 15 7 15 9 15 11 15 15 15 17 v glide wiper switch 12 9 voltage regulator 6 7 voltage suppressor 15 9 15 15 wheel and tire 2 3 wire 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
53. 4 4 10 1015707 Wheel Rim Belge ite tH pe D bn ER EEG E ada 1 1 11 Tire Unmounted Performance Grade Tread 18 x 8 50 8 Duro 1 1 12 101570513 Assembly Wheel and Premium Grade Tire includes items 13 14 4 4 13 1015707 Wheel Rim Beige 0 1 1 14 Tire Unmounted Premium Tread 18 x 8 50 8 Kenda 1 1 15 101651401 Assembly Wheel and Standard Tire includes items 16 17 4 4 16 1014771 A 1 1 17 727102 Tire Unmounted Standard Tread 18 x 8 50 8 Carlisle 1 1 18 101651407 Assembly Wheel and Extra Traction Tire includes items 19 20 2 2 19 1014771 Wheel Rim White U nn nennen 1 1 20 101769302 Tire Unmounted Extra Traction 6 Ply Rated 18 x 8 50 8 1 1 21 101651412 Assembly Wheel and Performance Grade Tire includes items 22 23 4 4 22 1014771 Wheel Rim da e Pa Mb alaq squa 1 1 23 Tire Unmounted Performance Grade Tread 18 x 8 50 8 Duro 1 1 24 101651413 Assembly Wheel and Premium Grade Tire includes items 25 26 4 4 25 1014771 A 1 1 26 MN Tire Unmounted Premium Tread 18 x 8 50 8 Kenda 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 DECALS B
54. 9 D damper rpm limiter 7 5 dash panel center 1 3 dash driver side 1 3 dash passenger side 1 3 decal driver passenger warning 3 3 3 5 electrical component cover 3 5 12 31 frame ground and governor warning 3 3 gasoline warning 3 3 2004 2005 DS Golf Cars Illustrated Parts List key switch 3 3 3 5 motor braking 3 5 operating instructions 3 3 3 5 potentiometer caution 3 5 resistor warning 3 5 rotating parts and hot manifold warning 3 3 tow run switch 3 5 wiper switch warning 12 9 delta a plate 5 7 delta shock and gear support 5 7 delta sleeve 5 7 diesel tachometer probe 16 9 differential bearing 14 3 differential gear 11 7 11 13 14 3 14 5 differential gear case 11 7 11 13 14 5 differential housing 14 3 differential idler gear 11 7 11 13 14 3 14 5 differential pin 11 7 11 13 14 3 diode 12 13 12 19 dipstick 7 3 door access 1 7 1 9 drag link rack and pinion 5 5 drain plug crankcase 7 7 drink holder 1 3 12 21 drive belt 10 3 10 5 drive clutch 10 3 drive clutch button 10 3 drive clutch fixed sheave tool 16 5 drive clutch holder tool 16 5 drive clutch hub puller 16 5 drive clutch puller 16 5 drive clutch spider removal tool 16 5 drive hub 10 3 driven clutch 10 5 driven clutch cam puller 16 5 driven clutch puller plug 16 5 driven clutch spring compression base tool 16 5 driven clutch spring compression collar tool 16 5 driven clutch spring compression nut tool 16 5 driver
55. 94 102048301 Base Mounting Lee te td nl 1 35 8639 Tier WI ien t ta ete tuts 1 2004 2005 DS Golf Cars Illustrated Parts List Page 12 13 TYPICAL 2 PLACES Q ANTI ARCING zn LIMIT SWITCH SEAT SUPPORT FRONT PANEL REVERSE BUZZER LIMIT SWITCH HALF SPEED LIMIT SWITCH x TYPICAL 3 PLACES PLACES TYPICAL 4 PLACES TYPICAL 3 A PLACES i 2 PLACES 12 14 2004 2005 DS Golf Cars Illustrated Parts List FORWARD REVERSE SWITCH POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 101753005 Assembly Forward Reverse Switch includes items 2 10 1 2 102250201 Switch Limit Sealed 1 3 101979101 Switch Limit Sealed coc eret iei abo shua gaa 1 4 1014808 Switch LM 1 5 8057 Nut nenn 2 6 8058 Washer A ed e ex EUN E NEP EE TE ers 2 7 1014871 Screw Hex Washer Head 4 40 x 2 2 8 1017799 Bal BUS at ee ua u Tama de e TREE 2 9 451 Washer LOCK 1 4 Jun y allas 4 10 1028 Nut Hex 1 4 20 ac 4 11 1012987 Handle Forward Reverse Switch a eene 1 12 1015064 Screw Phillips Oval Countersunk Machine SS 48 32 5 8 1 13 1016845 Screw
56. AND ACCELERATOR CABLES ITEM PART NO DESCRIPTION QTY 1234 1 1013700 Clamp Cable Retaining pp 2 2 1016546 Nut Flanged Hex M85125 u u 2 3 1012285 Screw Hex 1 4 20 x 5 8 l 4 4 101903501 Screw Hex Head Cap M8 x 1 25 x 24 MM 1 5 7174 Washer Lock lt 1 6 1011697 Washer Ela A e ee PA ls 1 7 102336101 Cable Accelerator Snap in 2 1 8 102336001 Cable Governor 2 1 9 101832302 Bracket Accelerator Support 1 10 101832202 Bracket Support 1 11 101584502 Bracket Governor Cable 1 2004 2005 DS Golf Cars Illustrated Parts List Page 8 9 2004 2005 DS Golf Cars Illustrated Parts List Page 8 10 INTAKE DUCT CHOKE AND AIR BOX ASSEMBLY ITEM PART NO DESCRIPTION QTY 1234 101821501 Assembly Air Box includes items 1 13 1 1 101804301 Screw Hex Head Hi Lo 8 1 2 2 2 101881701 Washer Stainless Steel 8 nennen nnne nennen 2 3 101925701 aa p dera edet n 2 4 101972801 Assembly Air Box Top includes items 5 10 1 5 101813001 Ee MES 1 6 101917601 Lever tette dt adds 1
57. Opening Classic Blue Navy 1 10 101696221 Body with Taillight Opening Burgundy pp 1 11 1017748 Clip Body Keeper 2 12 1012047 Screw Self Tapping 8 32 x 3 8 sss 2 13 7847 Screw Hex Head 1 4 20 3 4 a 4 14 1017936 Fender Inner e A ea 2 15 1017141 Support Front B dy aia 1 16 1015032 1 17 102221201 Pad Wal idas 2 18 8248 Screw Phillips Truss Head 1 4 20 x 3 4 2 2004 2005 DS Golf Cars Illustrated Parts List Page 1 7 2004 2005 DS Golf Cars Illustrated Parts List Page 1 8 REAR BODY AND FENDER ELECTRIC VEHICLE ITEM PARTNO DESCRIPTION SE 1234 1 8251 Screw Phillips Head 1 4 20 1 8 2 101904101 Plate Body Kick 24 etse itc ep ghe 1 3 1017141 Support Front 1 4 1012412 Plate Body Hinge Q a rei nn 2 5 332 Washer Flat lt 10 6 8233 Nut Nylon Lock 1 4 20 12 7 1017936 Fender Inner os ri bd e eta ena is ere 2 8 1014306 Washer Flat Type B 1 4 2 9 1017814 ee 2 10 1012159 Screw Hex Head Cap 1 4 20 x 2 3 4
58. SIDE OF VEHICLE Ad ox 25 e 2004 2005 DS Golf Cars Illustrated Parts List Page 6 12 STARTERIGENERATOR MOUNTING ITEM PART NO DESCRIPTION QTY 1234 1 101833701 Starter Generator clockwise rotation pp 1 2 101524001 Bracket Mounting FE290 uuu ee C Ho dae su oe CER ERR tdg 1 3 101916701 Belt Start r Generator nu u er trade Thaqu DAN DOR ORE RN cs 1 4 1016883 Bracket Adjusting 5 8754 Nut Nylon Lock 3 8 16 2 6 1241 Washer Flat Type 5 16 1 7 705 Screw Cap 3 8 16 1 1 4 2 2 8 1012830 Screw Hex Head Cap M8 x 1 25 x 22 MM a 2 9 7174 Washer Lock TO tica ete tuti 3 10 1016074 Screw Torx Head M8 x 1 25 x 18 mm 1 11 1015932 Bolt Carriage 5 16 18 1 1 12 1242 L K a er 1 13 101837301 Wire Assembly 6 Green 1 14 1015920 Wire Assembly 6 Braided Ground Nt 1 15 7473 Nut Nylon Lock 5 16 18 1 16 1241 Washer Flat 1 17 7173 Screw Hex Head Cap 5 16 18 x 3 4 a 1 2004 2005 DS Golf Cars Illustrated Parts List Page 6 13 NEW STYLE
59. Shield 2 102265501 Assembly Stator Shell and Winding 2 1 3 1017947 Package Hardware includes items 4 7 1 4 N A Bushings Insulator eg 2 5 N A Washer Flat 5 16 re ae T E ECL End 4 6 N A Nut Hex 5 16 18 en 4 7 N A Bushing 2 8 102266101 Screw Clamp 10 32 4 9 1017953 Screw Bearing Retainer 48 32 7 8 2 102265901 Assembly End Shield includes items 10 13 1 10 102266001 Shield EDA a anne 1 11 102265601 Sensor Motor Speed includes item 12 1 12 101942301 Housing Female 3 Wire Gray sss 1 13 102267001 Screw Steel Hex Thread Rolling 8 x 3 8 1 14 102265701 Kit Bearing and Magnet includes items 15 and 16 1 15 N A Bearing Ball ita ii t etai meme 1 16 N A MEDI 1 17 1017950 Retainer Bearing ne arena 1 18 N A uni cue Ls Ier 1 19 102327801 Assembly Brush Rigging includes items 20 22 1 20 1011411 Package Brush Spring 4 pieces a 1 21 102251901 Package Brush 2 pieces includes 4 brushes
60. VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 101646201 Charger Accu power Export 100 AC 36 DC 50 Hz model number 14900 includes items 1 14 108 inch DC cord 108 inch cord 1 1 N A Assembly Gase L on Sa amna ec 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 10 3 1016336 Assembly Transformer 2 di te 1 4 1015914 Assembly Heatsink with Diodes includes mounting hardware 1 5 1015905 Ammeter Includes Mounting Hardware a nenn 1 6 1015911 Relay 1 7 1015939 OT o E 1O 1 8 101643301 Cordset DC 108 Inch Long 12 AWG standard 1 8 101643302 Cordset DC 146 Inch Long 10 AWG a 1 8 101643303 Cordset 242 Inch Long 10 AWG 1 9 1012101 Assembly Fuse includes mounting hardware 1 10 1012098 Bushing Strain Relief 12 AWG DC Cord RN 1 10 1012042 Bushing Strain Relief 10 AWG DC Cord 1 11 1015917 Bushing Strain Relief AC Cord 1 12 1016282 Gordset 10 5 Long edet tuta bei 1 13 1015906 Assembly Timer Kit includes mounting hardware 1 14
61. a 4 12 101797701 Battery 8 Volt PowerDrive includes item 13 a 6 12 101797702 Battery 8 Volt PowerDrive Dry includes item 13 6 13 101797801 Cap Battery 4 Port Gang 1 14 101795701 Wire Assembly 6 Black 5 15 1014304 Nut Hex Stainless Steel 5 16 18 u na these e 12 16 101090801 Hold Down Battery 3 17 1015072 Nut Nylon Lock Stainless Steel 5 16 18 6 18 1011578 Washer Flat Type B Wide 5 16 6 19 TREMENDO 6 2004 2005 DS Golf Cars Illustrated Parts List Page 12 17 2 PLACES 4 PLACES 3 ONBOARD COMPUTER TYPICAL 2 PLACES 2004 2005 DS Golf Cars Illustrated Parts List Page 12 18 COMPUTER CONTROLLER AND SOLENOID POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 101965201 Plate Component Mounting pp 1 2 1014288 Screw Thread Forming 5 16 18 x 3 4 05 2 3 101908701 Solenoid 48 Volt with diode includes items 4 8 1 4 1011558 Nut Hex 6 32 iii aaa a ae 2 5 N A Washer Flat 2 6 MATS IRIS TEM Lock re ee 2 7 1012528 N t Hex 8 al ann a 2 8 7174 Washer Lock 5 16 2 9 1014947 Assembly R
62. mounting base 12 13 mounting block brake pedal 4 5 mounting bracket fuse and receptacle 12 13 mounting pad windshield frame 1 15 mounting plate engine 7 15 mounting plate rear bumper 1 3 movable face 10 3 moveable face driven clutch 10 5 muffler clamp 9 3 N nameplate 1 5 3 3 3 5 neutral lockout cam 6 5 nozzle 8 5 nut flange lock 5 9 nut key switch 6 9 12 3 nut lug 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 16 9 oil pump and rotor 7 7 oil seal crankshaft 7 13 oil sending wire clamp 7 11 onboard computer 12 19 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 pilotjet 8 5 pin differential 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 p
63. reverse switch forward reverse switch case forward reverse switch handle frame and field motor 13 9 front body 1 5 INDEX front spring retainer plate 5 9 f terminal insulator 6 11 fuel filter 8 3 fuel impulse pump 8 3 fuel injection pump pressure testertool 16 7 fuel line 8 3 fuel pickup tube valve 8 3 fuel strap rear 8 3 fueltank 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 liquid transaxle case 11 3 11 9 oilpump 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 gearcase 11 3 11 9 14 3 14 5 gear yoke 16 7 governor 11 5 11 11 governor guard 8 7 2004 2005 DS Golf Cars Illustrated Parts List governorleverarm 11 3 11 9 governor shaft installation tool 16 7 grease fitting 5 5 5 7 5 9 grip p
64. u IS SSS asta rennen 1 1 21 1016385 Assembly Delta Shock and Gear Support 1 1 22 1035 Pins Cotten 3 3250 s eb eI 3 3 2004 2005 DS Golf Cars Illustrated Parts List Page 5 7 2004 2005 DS Golf Cars Illustrated Parts List Page 5 8 FRONT SUSPENSION LOWER ITEM PARTNO DESCRIPTION 1234 1 102354201 Assembly Spindle Driver Side includes items 3 4 and 5 1 1 2 102354101 Assembly Spindle Passenger Side includes items 3 4 and 5 1 1 3 8067 Bushing Bronze Spindle 1 1 4 7048 Bushing Bronze iain tum ene ih ai 1 1 5 1015597 Fitting Grease 1 4 28 1 1 6 1012030 Spring Tapered Leaf 1 7 8745 Assembly Eccentric unu u unu 1 1 8 706 HB a asua Sama iod 1 1 102357701 Kit Front Hub Replacement includes items 9 12 2 2 9 102353201 GaDzHUD 12i au 1 1 10 102353301 Nut Flange Lock 14 2 1 1 11 102352801 Assembly Hub and Ball Bearing includes item 12 1 1 12 102353401 St d bug 4 4 19 8754 Nut Nylon Lock 3 8 16 4 4 14 1016387 Screw Hex Head Cap 3 8 16 x 2 3 4 2 2 15 1016384 Clevis Upper Delt
65. 01 102670001 102674001 102674101 102674201 102674401 102674501 102674601 102674701 102674801 102674901 102675001 102675101 102675201 102675301 102675401 102686101 102704701 102704801 102704901 102705001 102706401 102814201 102814301 102814401 102814501 102814601 102814701 102814702 102814801 102814802 102814803 102814901 102815001 102815101 102815201 102815301 102815401 102815501 102815601 102815701 102845701 727102 2 3 A ac voltage suppressor 16 7 16 7 16 7 16 7 16 5 16 5 16 5 16 9 16 7 16 9 16 7 16 11 16 7 16 5 16 5 16 5 16 5 16 5 16 3 13 9 13 9 13 9 13 9 5 11 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 15 13 13 9 accelerator pedal accelerator pedal adjustment tool accelerator pedal return spring 4 7 accelerator pivotrod 4 7 acceleratorrod 4 7 1 7 1 9 accu power charger a connector starter generator access door adapter Page i 8 15 3 15 5 15 7 INDEX cable IQDM 16 7 adhesive guide ring 16 3 adjuster hydraulic brake 16 7 adjusting stud 12 9 airbox 8 11 air duct 8 11 air duct repair kit 8 11 air filter 8 11 ammeter 15 3 15 5 15 7 15 9 15 117 15 13 15 15 15 17 a plate strap 5 7 arbor 16 3 arm governor lever 11 3 11 9 pivot 11 3 11 9 rocker 7 9 speed switch 12 9 armature 6 11 13 3 13 5 13 7 13 9 armrest 1 11 assembly 3 pin plug 13 7 6 pin plug 12
66. 017696 Sub Assembly Accelerator Pedal includes items 2 and 3 1 1 2 1013871 Accelerator Pedal u luu u u dee te 1 1 3 7716 Screw Slotted Hex Washer Head 10 16 x 1 2 4 4 4 1624 Screw Hex Head Cap 3 8 16 x 1 1 2 1 1 5 334 Washer 3 erat ed d rera ee a aO OT eoi 2 2 6 102026001 Kit Accelerator Pivot Rod includes item 7 1 1 7 1011700 iata b ere 1 8 101818801 Stud for all vehicles except those equipped with MCOR 1 1 9 101862001 Screw Cap 1 4 20 x 1 3 8 MCOR vehicles 1 10 1017424 Bearing Pivot Support pp 1 1 11 101966901 Nut Flange 1 4 28 e EU De 1 1 12 101817401 Retainer Spring eire cese 1 1 13 101796201 Spring e nee 1 1 14 1017378 Cup Spino ee veu 1 1 15 1017380 Bumper Return Spring pp 1 1 16 1241 Nasher Flat 5 16 ta u uu ede 1 1 17 7473 Nut Nylon Lock 5 16 18 1 1 18 101871901 Assembly Accelerator Rod V Glide 36 Volt vehicle only includes items 19 and 20 1 18 101912401 Assembly Accelerator Rod gasoline
67. 1 1016523 1016524 1016525 1016526 1016531 1016532 1016533 1016535 1016536 1016537 1016538 1016539 1016541 7 13 7 13 7 13 15 7 15 3 7 7 7 13 7 13 7 9 7 11 7 7 7 9 7 13 7 13 7 9 8 7 8 7 7 7 7 9 7 7 8 5 7 9 8 7 7 5 7 11 7 11 7 5 8 5 8 5 7 7 7 5 7 11 7 3 7 13 7 11 2 3 2 3 2 3 2 3 7 13 7 9 7 9 7 11 7 11 7 9 7 3 7 3 7 3 7 3 7 13 7 13 7 11 7 3 7 7 7 11 7 3 7 13 1 4 1016542 1016544 1016545 1016546 1016547 1016548 1016549 101655001 101655002 101655003 101655004 101655005 101655006 101655007 101655008 101655009 1016551 1016552 1016553 1016554 1016558 1016559 1016560 1016561 1016562 1016563 1016564 1016565 1016566 1016567 1016568 1016569 1016570 1016571 1016572 1016576 1016578 1016579 1016580 1016581 1016582 1016583 1016584 1016585 1016586 1016587 1016588 101660404 101661601 101661602 1016622 1016627 1016630 1016663 1016672 1016801 1016845 INDEX 7 9 7 5 7 9 7 11 7 9 12 19 8 9 7 3 7 13 8 7 7 5 7 9 7 13 7 13 7 13 7 13 7 13 7 13 7 13 7 13 7 13 16 11 16 11 16 11 16 11 7 13 7 13 7 9 7 5 7 5 7 13 7 9 7 11 7 11 7 9 7 11 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 7 5 1 3 12 13 12 13 5 3 16 7 6 9 5 3 11 7 11 13 14 5 10 3 12 7 12 15 2004 2005 DS Golf Cars Illustrated Parts
68. 1 101832202 101832302 101832701 101833001 101833201 101833401 101833601 101833701 101833902 101834001 101834502 101834601 101834801 101835601 101836201 101837101 101837301 101838201 101838301 101838401 101838501 101838601 101838701 101840201 101850301 101851101 101855002 101855801 101856001 101856102 101856201 101859301 101861901 101862001 101869302 101871001 101871901 101874901 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 12 17 12 29 7 15 8 9 8 9 7 15 7 15 7 15 10 5 11 3 11 9 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 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 1 5 101875001 101875101 101875201 101875301 101875401 101875501 101875601 101875701 101875802 101876001 101876202 101876301 101876402 101876501 101877601 101877701 101878101 101878201 101878302 101879001 101879401 101879501 101879601 101879701 101879801 101879901 101880001 101880101 101880201 101880301 101881701 101883002 101884801 101887101 101887601 101887901 101889302 101889401 101889901 101890001 101890101 101890201 101890601 101890901 101891001 101891301 101891401
69. 1 12 10079 50 rain 1 13 1016630 Eight Low Oll Warning a a 1 14 101900901 Retainer Harness 3 Must order in multiples of 50 2004 2005 DS Golf Cars Illustrated Parts List Page 6 9 2004 2005 DS Golf Cars Illustrated Parts List Page 6 10 STARTER GENERATOR ASSEMBLY ITEM PART NO DESCRIPTION QTY 1234 101833701 Starter Generator clockwise rotation includes items 1 30 1 1 101875201 HOUSING 1 2 101875101 Assembly Armature includes items 3 6 1 3 101875001 Retainer Beating ur untu 1 4 1013001 Ball Bearing Output Shaft a 1 5 1013005 Commutator Ball Bearing a 1 6 101939901 Spacer 5 16 au a ee 1 7 1013003 Key WOOQFUff MI 1 8 101876501 Kit Pulley Nut and Screw includes items 9 12 1 9 N A Washer Lock M14 1 10 N A N t Hex M14 X 2 itio a ee e Vi cede es 1 11 N A Screw Cross Recessed 5 8 x 18 mm 3 12 101896501 Screw Cross Recessed 5 x 8 x 16 mm with lock washer 2 13 101874901 End Bell Output Shaft uu ecce ru e 1 14 101875301 Set Pole SOFA
70. 1 40 102669501 Crankshaft Bearing Replacement Tool for Kubota D722 Diesel 1 41 102674001 Crankshaft Main Bearing Driver for use with items 42 and 43 for Honda GX620 Gasoline Engines 1 42 102674101 Crankshaft Main Bearing Driver Attachment for use with Honda GX620 Gasoline Engines 1 43 102674201 Crankshaft Main Bearing Pilot Attachment for Honda GX620 Gasoline Engines 1 44 102675201 Cutter Valve Seat Exhaust 32 Degree requires item 59 for Honda GX620 Gasoline Engines 1 45 102675301 Cutter Valve Seat Intake 32 Degree requires item 59 for Honda GX620 Gasoline Engines 1 46 102675401 Cutter Valve Seat 60 Degree requires item 59 for Honda GX620 Gasoline Engines 1 47 102675001 Cutter Valve Seat Exhaust 45 Degree requires item 59 for Honda GX620 Gasoline Engines 1 48 102675101 Cutter Valve Seat Intake 45 Degree requires item 59 for Honda GX620 Gasoline Engines 1 Please refer to the maintenance and service manual for proper tool application 2004 2005 DS Golf Cars Illustrated Parts List Page 16 5 Liquid Gasket
71. 1 53 1016337 Washer aen e 1 54 AM10081 Bearing Ball C 3 1 55 1012714 Seal Input IR 1 56 101892601 Gear 1 x5 a aaa 1 57 101893201 Node TE 1 58 101892501 Gear 61 Tooth ua eli 1 59 101928101 Bearing Ballen 1 60 101893901 Washer an sd 1 61 101892301 Governor Assembly asas ays 1 62 101891601 1 63 101891901 Gear Cl ster Idl6l tica do 1 64 7335 Bearing Ball REM 2 2004 2005 DS Golf Cars Illustrated Parts List Page 11 5 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 QTY 1234 65 101891501 Axle Assembly Driver Side Includes items 67 71 1 66 101891401 Axle Assembly Passenger Side includes items 67 71 1 67 1013787 4 68 1013792 Ring Retaining ic IR 1 69 1011291 Bearing Outer Axle Tube 1 70 1014207 Collar 25 mml 1 71 1016672 Ring Retaining u SS Heu 1 72 1013794
72. 1 2 3 9 1012987 Handle Forward Reverse Switch 2 1 10 1015064 Screw Phillips Oval Countersunk Machine SS 8 32 x 5 8 1 11 1016845 Screw Phillips Truss Head 1 4 20 x 2 1 8 3 12 8233 Nut Nylon Lock 1 4 20 3 13 8049 Washer Internal Tooth Lock 10 pp 2 14 8450 Screw Hex Head Machine 10 24 x 1 2 2 15 1014528 Washer Plastic 174 3 2004 2005 DS Golf Cars Illustrated Parts List Page 12 7 2004 2005 DS Golf Cars Illustrated Parts List Page 12 8 WIPER SWITCH V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1014735 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 1 1016140 Assembly V Glide Wiper Switch includes items 1 27 1 1 1014999 Assembly Wiper Switch Case 6 Speed includes items 2 and 3 1 2 1014414 Bumper Wiper Switch 8 1 3 101610901 Decal Wiper Switch Warning 1 4 1014253 Nut Brass Hex Jam 1 4 20 aa 3 5 7473 Nut Nylon Lock 5 16 18
73. 1 Plate 1 3 1014306 Washer Flat Type B 1 4 2 4 1012412 Plate Body HINGE pili 2 5 332 Washer Flats 10 6 8233 Nut Nylon Lock 1 4 20 12 7 1013032 Door Access Black Hana e 1 8 1015525 Nut Blind 1 4 20 aras 2 9 101692601 Body B6ige ciam b Ge Dd 1 9 101692602 Body White 1 9 101692604 Body nenne 1 9 101692606 1 9 101692609 Body Pacific Blue Royal Blue 1 9 101692610 Body Dark Greer u dies 1 9 101692611 Body Black suem 1 9 101692612 Body Classic Blue Navy u Sa Zaa emen 1 9 101692613 Body 1 10 101696208 Body with Taillight Opening 44 1 10 101696209 Body with Taillight Opening White pp 1 10 101696211 Body with Taillight Opening Gray pp 1 10 101696213 Body with Taillight Opening 1 10 101696215 Body with Taillight Opening Pacific Blue Royal Blue 1 10 101696216 Body with Taillight Opening Dark Green 1 10 101696219 Body with Taillight Opening Black pp 1 10 101696220 Body with Taillight
74. 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 INDEX 1017952 13 3 1017953 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 12 17 12 29 101801001 12 17 12 29 101802101 12 17 12 29 101802201 15 9 101802202 15 9 101802203 15 9 101802204 15 11 101802205 15 11 101802206 15 11 101802601 1 3 12 3 101804301 8 11 101805701 8 11 101808401 16 3 101809101 16 5 101811401 8 11 101811501 8 11 101811901 8 11 101812301 8 11 101813202 16 3 101815501 4 3 101815502 4 3 101816301 4 3 101816501 4 3 101816502 4 3 101817401 4 7 101818801 4 7 101819701 15 9 101820201 68 7 101821501 8 11 101823101 16 9 101823201 4 3 101823301 4 3 101823302 4 3 101823801 4 3 101823901 4 3 101824001 4 3 101824002 4 3 101824401 8 3 101825101 3 3 3 5 101826201 12 3 101826301 6 9 101827101 7 15 101827801 12 19 12 31 101828301 15 9 101828501 15 9 15 15 101828601 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 101832001 10183210
75. 101891501 101891601 101891901 101892001 101892201 101892301 101892401 101892501 101892601 101892701 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 6 11 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 16 3 7 3 8 7 12 31 6 3 11 5 11 5 11 5 11 3 11 3 11 3 11 7 11 7 11 3 11 7 11 7 11 5 11 5 11 5 11 5 11 5 11 5 11 5 11 5 11 7 11 11 11 11 11 9 11 9 11 9 11 13 11 13 11 9 11 13 11 13 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 13 101893201 101894901 101895401 101895501 101895601 101895701 101895801 101895901 101896001 101896501 101896901 101897001 101897201 101897401 101897601 101898001 101900801 101900901 101901201 101901301 101901401 101901501 101902801 101902901 101903001 101903101 101903501 101903601 101903701 101904101 101905601 101906201 101906901 101908101 101908401 101908601 101908701 101909201 101909301 101909401 101909501 101909701 101909901 101909902 101910401 101910501 101912401 101914401 101915201 101915401 101915501 101915601 101915701 101915801 101916501 101916701 101917601 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 14 3 14 3 6 15 4 3 5 11 6 9 42 23 12 23 12 23 12 23 12 23 12 23 12 23 5 9 8 9 14 3 14 3 1 7 1 9 8 5 8 7 14 3 14 3 12 27 12 27
76. 101915801 Fam Flywheel Gray ei tenete be 1 3 1017448 Screw Flanged Hex Head x 1 x 10 pp 3 4 1016548 Washer Flats iac liada 1 5 1016505 Nut Hex M16105 tetro 1 6 1017455 Plate Flywheel en 1 7 1016562 Keys awu 1 8 1016455 Bolt Flanged M5 x 8 x 25 MM RN 2 9 101909201 Coil Ignition with internal igniter 1 10 1016578 Grommet s s a ed 1 11 1016588 as ai 1 12 1016493 ss 1 13 AM10724 Plug Spark OHV 1 13 101881101 Plug Spark OHV Autolite 1 14 1016456 Bolt Flanged M6 x 1 12 n sassnsssssssssssissrrnnssnssresrtrnrtrnnnnnserertrnnnnnnnnnsereee renn 2 15 1012981 1 16 1016579 Band RPM Limiter Mount 1 17 1016586 Damper RPM Limiter daa oaa 1 18 101909401 Limiter RPM OFIVe trae aan 1 19 1016445 Bracket RPM Limiter Ia lunanii uluya 1 20 101909501 aite 1 21 1016497 Screw Cross Pan Head 5 x 8 x 8 mm 1 22 1016544 Screw Cross Pan Head Self Tapping 5 8 x 12 mm 1 23 1016561 Glamp x e
77. 11 9 spiral back up 10 3 i 13 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 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 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 16 9 scuff guard 1 3 seal axle tube oil 14 5 crankshaft 7 11 dust steering gear box 5 5 dust steering pinion 5 5 input shaft 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 INDEX seatback 1 13 seat back support 1 13 seat bottom 1 14 seat bottom cover 1 11 seat hinge plate 1 11 sensor motorspeed 13 7 13 9 sensor 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 roc
78. 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 1 5 7310 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 8049 8056 8057 8058 8067 8233 INDEX 6 5 6 7 12 13 1 3 12 7 12 15 12 9 6 5 6 7 12 7 12 9 12 15 6 5 6 7 12 7 12 9 12 15 5 9 1 7 1 9 1 15 4 7 6 5 8 3 12 7 12 15 12 27 8248 8251 8418 8449 8450 8626 8639 8717 8745 8754 8755 8795 8796 8797 8861 8990 8755 1 7 1 9 6 5 8 3 12 27 1 7 1 9 6 5 1 13 12 9 10 3 12 7 12 15 4 5 12 13 12 31 6 5 6 7 5 9 4 7 5 3 5 5 5 7 5 9 5 11 6 13 5 9 12 13 12 13 12 13 5 7 5 5 12 3 12 27 5 11 1010124 5 7 1010145 5 11 1010150 5 9 1010200 5 7 1010219 5 7 1010413 1 13 1010434 1 3 1 13 1010435 1 5 1010521 12 13 1010543 1 11 1010577 7 15 1010805 4 5 1010829 4 3 1010850 4 3 1010877 4 5 1010878 4 5 1010
79. 12565 5 3 1013700 8 9 1014034 12 5 1012566 5 3 1013734 9 3 12 31 1014035 12 5 1012571 7 15 1013746 8 3 8 7 1014036 12 5 1012594 6 5 1013754 1 13 1014039 12 5 1012604 5 3 1013756 14 5 1014045 12 11 1012605 5 3 1013757 14 5 1014049 10 3 1012649 8 3 1013758 14 5 1014050 10 3 1012651 12 5 1013759 11 3 11 9 14 5 1014051 10 3 1012710 14 5 1013763 14 5 1014052 10 3 1012711 11 3 11 9 14 5 1013764 14 5 1014055 10 3 1012714 11 5 11 11 1013765 14 5 1014056 10 3 1012740 11 5 11 11 1013766 14 5 1014057 10 3 1012741 11 5 11 11 1013767 14 5 1014058 10 3 1012747 11 5 11 11 1013768 11 7 11 13 14 5 1014059 10 3 1012748 11 5 11 11 1013769 11 7 11 13 14 5 1014062 10 3 1012752 11 3 11 9 1013770 11 7 11 13 14 5 1014065 6 5 6 7 1012809 16 9 1013771 11 7 11 13 14 5 1014070 10 5 1012811 16 3 1013772 11 7 11 13 14 5 1014072 10 5 1012812 16 3 1013773 11 7 11 13 14 5 1014078 10 5 1012830 6 13 9 3 1013774 11 7 11 13 14 5 1014080 10 5 1012903 12 9 1013775 14 5 1014089 6 5 1012981 7 5 1013779 14 5 1014109 12 9 1012987 6 5 12 7 12 15 1013780 14 5 1014115 16 9 1013001 6 11 1013781 14 5 1014116 8 3 1013003 6 11 1013782 14 5 1014119 6 3 1013005 6 11 1013785 14 5 1014125 5 3 101301102 6 11 1013786 14 5 1014126 5 3 1013032 1 7 1 9 1013787 11 7 11 13 14 5 1014145 6 5 6 7 1013035 5 5 1013790 11 7 11 13 14 5 1014153 4 3 1013042 5 5 1013791 11 7 11 13 14 5 1014161 16 9 1013044 5 5 1013792 14 5 1014162 16 9 1013051 5 5 1013794 11 7 11 13 14 3 14
80. 14808 6 7 12 7 12 15 1014828 12 5 1014871 12 15 1014928 8 3 1014947 12 19 12 23 12 31 1014948 12 13 12 19 1014999 12 9 1015032 1 3 1 5 1 7 1 9 1015064 6 5 12 7 12 15 1015072 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 1015707 2 3 1015720 1015737 1015741 1015752 1015769 1015777 1015814 INDEX 6 9 6 3 6 7 6 7 6 7 8 11 12 21 6 3 6 7 9 3 101584502 8 9 1015878 1015905 1015906 1015907 1015910 1015911 1015912 1015913 1015914 15 17 101591601 101591602 1015917 1015920 1015932 1015936 1015939 1015969 1016003 1016068 1016069 1016070 1016074 101610901 101611003 1016140 1016154 1016156 1016175 1016181 1016183 1016201 1016203 1016214 101621601 1016219 1016263 1016269 1016282 1016289 1016336 1016337 1016338 1016341 1016342 1016346 1016349 1016350 1016353 6 7 15 3 15 5 15 7 15 3 15 5 15 7 15 3 15 3 15 5 15 3 15 5 15 7 15 3 15 3 15 5 15 7 15 3 15 5 15 7 15 9 15 15 15 3 15 3 15 3 15 5 15 7 15 9 15 15 6 3 6 13 6 13 15 5 15 7 7 3 8 3 12 5 12 5 12 5 6 13 3 5 12 9 16 9 12 9
81. 1973201 101973501 101975901 101976601 101978001 101978101 101978201 101979101 101980801 101980901 101981001 101984801 101985501 101987501 101987601 101987701 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 102099101 8 11 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 14 3 14 3 8 11 8 5 8 5 15 17 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 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 1 15 102101001 102101101 102155501 102162101 102169401 102174201 102174202 102174204 102174205 102186001 102186101 102186201 102186301 102186401 102186701 102186801 102186901 102187001 102187101 102187201 102196601 102198301 102199601 102221201 102235201 102236601 102236703 102237001 102237401 102237701 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 10
82. 2265901 INDEX 12 21 12 21 1 15 12 23 16 7 1 11 1 11 1 11 1 11 13 9 13 9 13 9 13 9 13 9 13 9 13 9 13 9 13 9 13 9 13 9 12 25 1 15 12 25 1 3 1 7 1 9 13 3 13 5 13 7 13 9 1 13 1 13 1 13 13 3 13 5 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 2004 2005 DS Golf Cars Illustrated Parts List 102266001 102266101 102266501 102266601 102266701 102267001 102273201 102273301 102273401 102273501 102273601 102273701 102273801 102273901 102274001 102278001 102292801 102304701 102310701 102323101 102323201 102327801 102330901 102336001 102336101 102352801 102353201 102353301 102353401 102354101 102354201 102355301 102357001 102357701 102453101 102496401 102496402 102496403 102540301 102555501 102562401 102601501 102603501 102605201 102606101 102607501 102668601 102668701 102668801 102668901 102669001 102669101 102669201 102669301 102669401 102669501 102669601 13 7 13 7 12 31 12 27 12 27 13 7 15 11 15 11 15 11 15 11 15 11 15 11 15 11 15 11 15 11 5 3 4 3 7 9 1 5 4 5 4 5 13 7 16 9 8 9 8 9 5 9 5 9 5 9 5 9 5 9 5 9 6 15 14 3 5 9 11 11 15 13 15 13 15 13 7 15 16 3 16 3 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 16 3 i 7 102669701 102669801 1026699
83. 3 drive clutch 16 5 drive clutch hub 16 5 driven clutch cam 16 5 flywheel 16 7 seal 16 9 puller special use tool 16 9 pulley starter generator 6 11 2004 2005 DS Golf Cars Illustrated Parts List pulley nut and screw starter generator 6 11 pump fuelimpulse 8 3 pushrod 7 9 R rack steering 5 5 ratchet park brake 4 7 reamer valve guide 16 9 rearbumper 1 3 rear leaf spring 5 11 rear spring shackle 5 11 receptacle 3 pin 12 19 6 pin 12 31 accord 15 17 charger 2 prong 12 13 receptacle fuse 12 13 12 17 12 29 receptacle backing plate 12 17 12 29 receptacle bezel 12 13 12 17 12 29 rectifier 15 13 regulator motor controller output MCOR 12 21 relay 36 vdc 15 3 15 5 15 7 relay 48 VDC 15 13 relay 48 vdc power 15 9 15 11 15 15 15 17 remover bearing and oilseal 16 3 resistor 12 19 12 23 12 31 resistor coil 12 11 resistor coil stand off 12 11 resistor mounting board 12 11 resistor shield 12 11 retainer bearing 13 3 13 5 13 7 bearing starter generator 6 11 cable 6 5 harness 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 reverse buzzer 6 9 12 3 rigging brush 13 3 13 5 13 7 rim tire 2 3 ring c type stop 5 5 piston set 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
84. 353 Assembly Delta A Plate includes items 2 and 4 2 2 2 1016346 Bushing Urethane ullu uuu uuu de 6 6 3 1016350 Sleeve Delta Outen s ibus x ti ct hare etd C a Y E Ud Oed 1 1 4 1016349 Sleeve Delta Inner dmt nae 2 2 5 8754 Nut Nylon Lock 3 8 6 10 10 6 1010200 Screw Hex Head 3 8 16 x 4 1 4 4 4 7 1308 Nut Hex 1722209 yom eet 1 1 8 8861 Screw Hex Head 3 8 16 x 1 3 4 2 2 9 1624 Nut Dimpled L ock 3 8216 p aede dit aed ud Hi ia in 2 2 10 2402 Screw Hex Head Cap 3 8 16 x 2 1 4 4 4 11 1010219 Rod MIT 1 1 12 7555 Nut Hex Left Hand Thread 1 2 20 a 1 1 13 7540 Ball Joint Left Hand Thread includes items 15 16 and 17 1 1 14 7539 Ball Joint includes items 15 16 and 17 1 1 15 1015597 Fitting Thread Forming Grease 1 4 28 1 1 16 1011930 Boot Dust tet i niei 1 1 17 7602 Nut Slotted Hex 3 8 24 2 2 a aaa etes i tiana 1 1 18 1017266 Strap A ad 2 2 19 1014235 Sho k ADSOrber Front et eee rade ena 2 2 20 1010124 Plate Spring Mounting uuu u
85. 4 28 1 9 1017231 Key Woodrulf ole te diui e ttes 1 10 101834801 Arm Governor Lever 1 11 101886101 Screw Square Head 1 4 20 x 1 1 12 1014007 Washer 1 4 tende nae asw 1 13 8233 Nut Nylon Lock 1 4 20 77 1 101833601 Unitized Transaxle includes items 14 88 1 14 101890201 Shaft 2 n UA EE 1 15 101927301 RING ua 1 16 101892901 Washers Flat ua uu a ds 1 17 101927201 Seal ann mie od 1 18 101890101 Lever Shifter a ser a 1 19 1012752 Ri 1 20 10192860 Pin Gotten itemm dtt e d 1 21 1016513 a li 1 22 101927101 ae 1 23 101893801 ttn 1 24 101891301 Arm PIVOU 1 anni ele 1 25 101890601 Gear Case passenger Side pp 1 26 101890501 Gear Case driver side 1 27 101926901 Bolt Flanged M8 x 1 25 x 40 mm sees 15 28 1012896 Pin DOWEL nm 2 29 1013759 Plug Drain includes item 30 2 30 1016432 Gasket nn 1 31 1012711 Breather ee poeta ee 1 32 101928701 Gasket Liquid 8 8 oz 250 A R 2004 2005 DS G
86. 5 1014189 12 9 1013052 5 5 1013860 12 9 1014193 11 7 11 13 14 5 1013061 12 9 12 17 12 29 1013861 5 3 1014198 1 5 3 3 3 5 1013092 12 5 12 13 1013869 4 5 1014201 13 3 13 5 13 7 13 9 1013164 5 11 1013870 4 5 1014207 11 7 11 13 14 5 1013207 4 3 5 11 1013871 4 7 1014213 5 3 1013266 12 13 1013876 4 5 1014214 5 3 1013343 1 3 1013886 12 9 1014216 5 3 1013344 1 3 1013887 12 9 1014217 5 3 101342501 12 13 1013924 4 3 7 15 1014235 5 7 101347501 1 5 1013935 1 13 1014253 12 9 1013494 1 3 1013971 12 11 1014259 16 9 1013496 3 5 1013998 12 9 1014264 16 9 1013531 4 5 1014000 12 9 1014276 5 9 1013582 16 3 1014003 12 9 1014287 10 3 1013587 6 5 1014007 4 7 1014288 5 3 6 15 12 19 12 31 1013589 6 5 6 7 1014010 12 9 1014289 6 11 1013590 6 5 1014012 12 11 1014304 12 13 12 17 12 29 1013591 6 5 1014013 12 11 1014305 16 3 1013593 16 7 1014014 12 11 1014306 1 7 1 9 1013609 6 7 1014017 12 9 1014374 6 15 1013628 12 13 1014019 12 9 1014375 6 15 1013649 12 13 1014029 12 5 1014414 12 9 1013683 12 13 12 17 12 29 1014030 12 5 1014453 10 3 1013687 8 3 1014032 12 5 1014454 10 5 1 2 2004 2005 DS Golf Cars Illustrated Parts List 1014476 12 11 1014482 1 13 1014496 16 5 1014497 16 5 1014498 16 5 1014507 16 5 1014508 16 5 1014510 16 5 1014516 12 13 1014523 8 3 1014524 8 3 1014528 12 7 12 15 1014555 5 11 1014645 1 3 1014696 15 5 1014727 6 5 1014728 12 11 1014729 12 11 1014735 12 9 1014771 2 3 1014807 6 5 6 7 12 9 10
87. 5 3 5 3 12 9 5 3 5 3 6 5 10 3 10 5 5 3 3 3 3 5 5 3 5 3 5 3 15 7 10 3 15 7 11 5 11 11 11 5 11 11 11 3 11 9 6 5 5 7 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 8 7 1016440 8 7 1016441 8 7 1016442 7 9 1016443 7 3 1016444 8 7 1016445 7 5 1016446 7 11 1016447 7 9 1016448 7 9 1016449 7 9 1016450 7 9 1016451 7 9 1016452 7 9 1016453 7 11 1016454 7 11 1016455 7 5 1016456 7 3 7 5 7 11 1016457 7 7 1016458 7 9 7 11 101645901 7 13 101645902 7 13 101645903 7 13 1016460 7 13 2004 2005 DS Golf Cars Illustrated Parts List Page i 3 101646101 101646102 101646103 101646201 101646401 1016467 1016469 1016470 1016471 1016472 1016473 1016474 101647501 101647502 1016479 1016480 101648102 101648203 1016483 1016484 1016486 1016489 101649002 1016493 1016494 1016496 1016497 1016499 1016501 1016502 1016505 1016506 1016507 1016509 1016510 101651401 101651407 101651409 101651413 1016516 1016517 1016519 1016520 101652
88. 6 ecoute atem td ec et ER 1 5 101836201 Spring CIC EE 1 6 1014454 Kit Driven Clutch Button includes screws and 3 buttons 1 7 1014072 Assembly Moveable Face with Bushing 1 8 1014070 Face Fixed sioe ec roc OR haat 1 9 1016203 Drive i e red ege top e m tab 1 AM10419 Kit Driven Clutch Hardware Repair includes items 10 12 1 10 101833401 Key Square Transmission 1 11 102242101 Screw Hex Head Thread Locking 5 16 18 x 3 4 1 12 1017327 Wa sher Driven Clutch nenni ce A de reden ein 1 2004 2005 DS Golf Cars Illustrated Parts List Page 10 5 UNITIZED TRANSAXLE 2004 2005 DS Golf Cars Illustrated Parts List Page 11 2 MC008C ES00 PRIOR TO SERIAL NUMBER MC008C3H1264 GEAR CASES AND BRACKETS ITEM PART NO DESCRIPTION QTY 1234 1 101922601 Bracket Transmission Cable 2 1 2 1012285 Screw Hex 1 4 20 x 5 8 3 3 1013061 Nut Nylon Lock 10 32 n uu bs in 1 4 183 Washer Flat 3710 iia T Sa ys 1 5 1010954 Ball 1 4228 9 16 unu nan an al 1 6 1016341 Lever Transmission Shifter aa 1 7 1017082 Screw Hex Washer Head 10 32 x 3 4 1 8 8717 Nut Nylon Lock 1
89. 7 1 9 11 7 11 13 component mounting plate compression gauge 16 5 compression tester 16 5 compressor piston ring 16 9 compressor valve spring 16 11 computer onboard 12 19 12 31 connecting rod 7 13 connecting rod alignment tool diesel 16 5 connector 4 pin 12 27 Page i 10 INDEX cord 7 11 IQ controller 12 31 continuity tester 16 5 control cable 15 3 15 5 15 7 controller 48 volt 225 amp 12 19 controller 48 volt 250 amp 12 31 cord connector 7 11 cordset 15 13 cordset ac 15 3 15 5 15 7 15 9 15 11 15 15 15 17 cordset DC 15 13 cordset de 15 3 15 5 15 7 15 9 15 11 15 15 15 17 counterbalance guide shaft 7 13 counterbalance weight 7 13 cover brush inspection port 6 11 12 31 crankcase 7 11 dust 4 3 electrical component box 6 7 gearcase 11 7 11 13 oil pump 7 7 seat back 1 13 seat bottom 1 11 steering column 5 3 wiper switch case 12 9 cover base battery charger controller 15 13 cover top battery charger 15 13 crank sleeve setter tool 16 5 crank bell 12 9 crankcase 7 13 crankcase cover 7 11 crankshaft 7 13 crankshaft bearing replacement tool 16 5 crankshaft main bearing driver attachment tool 16 5 crankshaft main bearing driver tool 16 5 crankshaft main bearing pilot attachment tool 16 5 crankshaft seal 7 11 crankshaft shim 7 13 cup accelerator pedal return spring 4 7 15 17 16 5 16 11 current limiter cutter valve seat cylinder head 7
90. 701 Cordset AC 80 Inch Long with Leads no 1 15 101831702 Cordset AC 116 Inch Long with Leads no plug 1 16 1015917 Bushing Strain Relief AC Cord 1 2004 2005 DS Golf Cars Illustrated Parts List Page 15 15 Page 15 16 2004 2005 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER EUROPEAN ITEM PART NO DESCRIPTION QTY 1 2 3 4 PowerDrive chargers can be used with PowerDrive System 48 and IQ System vehicles 101956201 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 plug 12 AWG 1 101956202 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 1 1 N A Assembly Case eel aaa 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 10 3 Assembly Transformer 1 4 1015914 Assembly Heatsink with Diodes includes mounting hardware 1 5 Assembly AC Voltag
91. 87601 Armrest DIVER coe Pee e eec orate 1 1 5 101985501 Armrest Passenger Side 1 1 6 1016916 Screw Hex Head 1 4 20 1 1 2 8 8 7 332 Washer Flat cite a tq e tite 8 8 8 1011652 Plate Seat Hinge Stainless Steel 2 2 9 101954301 Screw Hex Head Cap 1 4 20 x 3 4 with patch 4 4 10 101998501 Gasket Seats occ nn 2 2 2004 2005 DS Golf Cars Illustrated Parts List Page 1 11 Page 1 12 2004 2005 DS Golf Cars Illustrated Parts List SEAT BACK AND BAG HOOP ITEM PARTNO DESCRIPTION SE 1234 1 102238301 Assembly Seat Back Buff includes items 2 and 3 1 1 2 102060501 Cover Vinyl Seat Back Buff 1 1 3 102237001 Cap Seat Back Black 1 1 1 102238302 Assembly Seat Back White includes items 2 and 3 1 1 2 102060502 Cover Vinyl Seat Back White a 1 1 3 102237001 Cap Seat Back Black 1 1 1 102238304 Assembly Seat Back Black includes items 2 and 3 1 1 2 102060504 Cover
92. 90801 1010921 12 13 12 17 12 29 1 13 4 5 1010927 4 5 1010932 4 5 1010933 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 5 11 1010984 2 3 5 9 1011010 12 5 1011014 1 5 1011017 1 5 1011019 1 3 1011069 12 5 2004 2005 DS Golf Cars Illustrated Parts List 1011084 1011229 1011273 1011290 1011291 1011382 1011394 1011402 1011411 1011415 1011418 1011466 1011478 1011480 1011558 1011578 1011652 1011694 1011697 1011700 1011734 1011767 1011779 4 7 6 9 16 5 13 3 13 5 11 7 11 13 14 5 1 3 1 5 4 5 13 3 13 5 13 7 5 11 4 5 4 3 16 7 16 11 12 19 12 13 12 17 12 29 1 11 4 7 1 3 5 3 8 7 8 9 4 7 4 7 16 3 4 3 4 5 101187702 4 5 4 7 1011930 1011931 1011988 1011997 1012022 1012030 1012042 1012047 1012098 15 15 1012101 15 17 1012151 1012159 1012180 1012181 1012182 1012285 12 27 1012295 1012303 1012304 1012324 1012328 1012333 1012353 1012382 1012412 1012431 1012467 1012505 1012528 1012549 5 5 5 7 12 11 8 3 12 7 12 13 5 9 15 3 15 5 15 7 1 7 1 9 15 3 15 5 15 7 15 9 15 11 15 17 15 3 15 5 15 7 15 9 15 15 16 7 1 9 5 11 5 11 5 11 6 5 8 9 12 11 12 13 12 19 12 31 6 7 5 9 5 11 5 11 5 11 6 15 6 5 12 9 6 3 1 7 1 9 6 5 6 7 5 5 6 9 12 3 9 3 12 19 12 31 16 9 i 1 INDEX 1012560 16 9 1013692 8 3 1014033 12 5 10
93. C ES00 After Serial Number MC008C3H1264 Transmission and Gear Reduction 11 11 MC008C ES00 After Serial Number MC008C3H 1264 Differential and Axles 11 13 SECTION 12 ELECTRICAL SYSTEM ELECTRIC VEHICLE Electrical Components Front Body Electric Vehicle a 12 3 Wiring V Glide 36 Vehicle 12 5 Forward Reverse Switch V Glide 36 Volt Vehicle 12 7 Wiper Switch V Glide 36 Volt Vehicle 2 12 9 Resistor and Board Assembly V Glide 36 Volt Vehicle sss 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 RN 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 pp 12 21 Wiring PowerDrive System 48 Vehicle 12 23 Wiring IQ System Vehicle with Motor Controller Output Regulator MCOR 12 25 Forwa
94. Clutch Cam Puller for Kawasaki engines only 1 26 1014507 Driven Clutch Puller Plug for Kawasaki engines only 1 27 1015524 Drive Clutch Holder Tool Assembly for Kawasaki engines only 1 28 101809101 Press Weldment for Kawasaki engines only 1 29 102601501 Clutch Drive Fixed Sheave Tool for XRT 1500 Carryall 294 and Bobcat 2200 Vehicles 1 1 30 102607501 Clutch Drive Spider Removal Tool for XRT 1500 Carryall 294 and Bobcat 2200 Vehicles 1 1 31 102603501 Clutch Driven Spring Compression Base for use with items 32 and 33 for XRT 1500 Carryall 294 and Bobcat 2200 Vehicles 1 1 32 102605201 Clutch Driven Spring Compression Collar for use with items 31 and 33 for XRT 1500 Carryall 294 and Bobcat 2200 Vehicles 1 1 33 102606101 Clutch Driven Spring Compression Nut for use with items 31 and 32 for XRT 1500 Carryall 294 and Bobcat 2200 Vehicles 1 1 34 101831801 Communication Display Module 1 35 101641002 Compression Gauge and Adapter 1 36 102669001 Compression Tester for Kubota D722 Diesel Engines 1 37 102669201 Connecting Rod Alignment Tool for Kubota D722 Diesel Engines 1 38 1011273 Continuity Tester nessies rnt 1 1 39 102668901 Crank Sleeve Setter for Kubota D722 Diesel Engines
95. ICLE FORWARD REVERSE ASSEMBLY LIMIT SWITCHES ol KEY W 2 FRAME GROUND N STARTER GENERATOR M fi Page 6 2 2004 2005 DS Golf Cars Illustrated Parts List WIRING GASOLINE VEHICLE ITEM PART NO DESCRIPTION QTY 1234 101889302 Wire Harness includes items 1 11 1 1 N A Wire Assembly 18 Red White 2 1 2 N A Wire Assembly 18 Yellow r 1 3 N A Wire Assembly 18 Yellow and 16 Blue 1 4 N A Wire Assembly 18 White Black and 18 White 1 5 N A Wire Assembly 18 Green RN 1 6 N A Wire Assembly 18 Black 1 7 1015769 Wire Assembly 6 White 1 8 N A Wire Assembly 16 Red and 16 Orange 1 9 N A Wire Assembly 16 Yellow 1 10 1014119 Wire Assembly 6 Red 1 11 N A Wire Assembly 18 Yellow n a 1 12 1012382 Wire Assembly 6 Black 1 13 N A Wire Assembly 18 1 14 Wire Assembly 18 Black part of reverse buzzer 1 15 Wire Assembly 16 Orange part of the electrical component box 1 16 1015920 Wire Assembly 6 Braided
96. ION QTY 1234 1 1016442 Case ROCKER nina Lose a 1 2 1016436 Gasket Rocker Case isse lili im ad 1 3 1016583 Bolt Flanged M6 x 1 35 MM RN 2 4 1016569 OSRIDG dieat 2 5 1016545 NUS MS eed md eee 2 6 1016542 Screw Stud M5 X38 re PEU e EE PORTER 2 7 1016451 Atte Rocker rn an her tas t qaa a arusa 2 8 1016450 a sasa den pu 4 9 1016449 Retainer Valve Spi Ng 2 10 10165259 Spring Engine Valve u L A A uH a u uu an asi 2 11 1016431 Assembly Cylinder Head OHV includes items 12 and 13 1 12 1016560 Ring SNAP a m 2 13 1016519 Guide Valve es 22 DA 2 14 1016479 Seat Spring 5 pw memet 2 15 1016566 Seal ValVe 4s eie 2 16 1016448 EXNaust ria tte aed a to 1 17 1016447 nie EI e ch 1 18 1016544 Screw Cross Pan Head Self Tapping 5 x 8 x 12 mm 1 19 1016474 Plate m ttu am 1 20 1016483 E 1 2 1016563 Pin sh ua amaya Pa a h Ea 2 22 1016489 Bolt Stud M8 x 1 25 x 29 mm 0 04 2 2 0 0 000000000000 2 23 1016452 Shaft Rocker ren cad SD an ee 1 24 1016471 PUSO 35 eh r
97. ITEM PART NO DESCRIPTION QTY 1234 1 1016440 Gasket Insulator aaa r 1 2 101648102 Insul tor Carburetot uuu 1 3 1016439 Gasket Carburetor Insulator to Throttle Bracket 1 4 1016444 Bracket Thtottle 2 5 tado tdi een 1 5 101820201 Guard COVE MO irritada Ra P ERR rand 1 6 1011697 Washer Flat 5 16 uu te ee Qasa ee 1 7 101887601 Nut Nylon Lock x 1 uuu 1 8 1016441 Gasket Throttle Bracket to Carburetor a a a 1 9 1016582 Springs Throttle ia ite i 1 10 101905601 Assembly Carburetor pp 1 11 1013746 Clamp Hose gray et educ A nde qusaqa 1 12 1017466 Clamp Hose bronze u z y T Q Tana a aus ayak Sas dann 2 13 1015137 Line Bulk Vent available by the foot 0 A R 14 1016572 T be Crankease u a A tie dc tas 1 15 1016438 Gasket Carburetor to Intake Manifold 1 16 1016480 Pipe ilntake he 1 17 101649002 Screw 2 Ended Stud M6 x 1 x 90 mm 2 18 1016547 Nut Flanged een 2 2004 2005 DS Golf Cars Illustrated Parts List Page 8 7 Page 8 8 2004 2005 DS Golf Cars Illustrated Parts List GOVERNOR
98. L SECTION 3 3 PLACES N o AA IT Fe R amp 2004 2005 DS Golf Cars Illustrated Parts List Page 12 26 FORWARDIREVERSE SWITCH TOW RUN SWITCH IQ SYSTEM VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 101856001 Switch Forward Reverse a lla lap a iya a 1 2 101855002 Case Forward Reverse Switch ccccccccccccssccccasasacssesstcaccuacsascaccaceessseccctacaascccaasnaces 1 3 1012285 Screw Hex Type 1 4 20 x 5 8 I 3 4 101942301 Kit 3 Pin Receptacle and Wedge LOCK 1 5 101932401 Kit 4 Pin Receptacle and Wedge 1 1 6 102266601 Wire Assembly Forward Reverse Switch includes items 7 10 1 7 101920101 Kit 3 Pin Plug and Wedge Lock ppp 1 8 N A Wire Assembly 18 Blue 1 9 N A Wire Assembly 18 Orange 1 10 N A Wire Assembly 18 Brown n 1 11 102266701 Wire Assembly IQDM Port includes items 12 18 1 12 101932501 Kit 4 Pin Plug and Wedge 1 13 N A Wire Assembly 18 Red Yellow 1 14 N A Wire Assembly 18 Black Yellow 1 15 N A Wire Assembly 18 Blue Yellow 1 16 N A Wire Assembly 18 Green Yellow 1 17 N A Gap Dust et rata rti e
99. List 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 101692509 1 5 101692510 1 5 101692511 1 5 101692512 1 5 101692513 1 5 101692601 1 7 101692602 1 7 101692604 1 7 101692606 1 7 101692609 1 7 101692610 1 7 101692611 1 7 101692612 1 7 101692613 1 7 101693301 1 9 101693302 1 9 101693304 1 9 101693306 1 9 101693309 1 9 101693310 1 9 101693311 1 9 101693312 1 9 101693313 1 9 101693901 1 5 101693902 1 5 101693904 1 5 101693906 1 5 101693908 1 5 101693909 1 5 101693910 1 5 101693911 1 5 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 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 1 3 1017080 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 5 7 1017273 5 3 1017327 10 5 1017378 4 7 1017380 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
100. NITIZED TRANSAXLE SECTION 11 Page 7 14 2004 2005 DS Golf Cars Illustrated Parts List ENGINE MOUNTING ITEM PART NO DESCRIPTION QTY 1234 1 102540301 SNubber MEE 1 2 1013924 Nut Hex Lock 5 16 24 UNF 2 6 3 101834601 Bracket Snubber a en d a pa 1 4 101827101 Plate Mounting kum ua A 1 5 101963401 Nut Flange S 16 18 S 4 6 101884801 Screw Hex Washer Head 5 16 24 7 8 6 7 705 Screw Hex Head Cap 3 8 16 x 1 25 4 8 101833201 Stud MBX 1 25 x 60 mm dond 2 9 101832101 O 2 10 102065901 Nut Flange 3 8 16 2 rr 4 11 1012571 Washer Heavy Flat 5 16 4 12 1010577 Screw Hex Head 5 16 18 x 1 50 a 4 13 101832701 Stiffener Flywheel Side 1 14 101833001 Nuts Flange M8 X 1 25 00 ts 2 15 334 Washer Flat 3 8 4 2004 2005 DS Golf Cars Illustrated Parts List 7 15 DB FUEL INTAKE AND GOVERNOR SYSTEMS 2004 2005 DS Golf Cars Illustrated Parts List Page 8 2 FUEL SYSTEM ITEM PART NO DESCRIPTION QTY 1234 1 1016003 Kit Fuel Tank includes items 2 8 U
101. ON QTY 1234 101992601 Box Electrical Component Complete includes items 1 25 1 1 1015372 Cover Electrical Component 1 2 1015752 Screw Hex Washer Head Hi Lo 12 16 x 5 8 5 3 1013589 Ring Ret ining ayu nana lil 1 4 1015373 Cam Electrical BOX S un 1 5 1014145 Bushing Bronze ee ebenen 2 6 1014065 Washer Ela s tiec i aeg 1 7 1010954 Stud Ball 1 428 nete nite aa ads 1 8 1015345 Assembly Bell Crank and 1 9 8717 Nut Nylon Lock 1 4 28 1 10 8057 Nut Hex 34 40 mal ae a Las End ete hin 4 11 8058 Washer Lock 2 12 1014807 Switch LIME Ae e e ee 1 13 1014808 Switch Linit 2 A eee 1 14 1012431 Washer Flat 2 15 N A Wire Assembly 16 Orange 2 1 16 1015878 Screw Hex Head Machine 4 40 x 1 5 8 2 17 101856102 Screw Washer Head Hi Lo 1 4 15 x 1 1 2 1 18 1015777 Assembly Voltage Regulator 2 1 19 7893 Nut 10 392 un A 2 20 1242 Nut Hex 5 16 18 Hi al 2 21 1013609 Solenoid A2Z VoOlt ira cre EY u TR es 1 22 1012295 Fuse 10 Amp ee esten RI 1 23 1015737 Wire Assembly 10 Red pp 1 24 1015741 Block AA as Sisapa um 1 25 1015371 Electric
102. 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 SN o gt Y e 5 amp Page 14 4 2004 2005 DS Golf Cars Illustrated Parts List TRANSAXLE TYPE K ELECTRIC VEHICLE ITEM PART NO DESCRIPTION QTY 1234 N A Transaxle includes items 1 41 1 1 1013785 Axle Assembly Passenger Side includes items 3 7 1 2 1013786 Axle Assembly Driver Side includes items 3 7 1 3 1013787 Stud 4 4 1014207 Bushing 25 naar geehrte 1 5 1011291 Bearing Outer Axle Tube 1 6 1013792 Circlip ee oa 1 7 1016672 Ring RAANG actina 1 8 1013790 x 1 5 X 90 10 9 1013791 Washer Lock asua A s a Sau 10 10 1013775 Seal Input Shaft uuu unas een en 1 11 1013756 Gear Case Passenger Side 1 12 1012711 Breather iii RL ee nee need 1 13 1013758 Gasket Case Ra h QU 1 14 7330 Bearing Inner Axle Tube pp 2 15 101928701 Gasket Liquid 8 8 oz 250 9
103. Phillips Truss Head 1 4 20 2 1 8 3 14 8233 Nut Nylon Eock 174 20 uu esaet eee S 3 15 8049 Washer Internal Tooth Lock 410 2 16 8450 Screw Hex Head Machine 10 24 x 1 2 2 17 1014528 W sher Pl astic un da 3 2004 2005 DS Golf Cars Illustrated Parts List Page 12 15 TYPICAL 2 PLACES TYPICAL 3 PLACES E 1 TYPICAL 5 PLACES TYPICAL 12 PLACES TYPICAL 3 PLACES e J TYPICAL 6 PLACES TYPICAL 6 PLACES 2004 2005 DS Golf Cars Illustrated Parts List Page 12 16 BATTERIES CHARGER RECEPTACLE POWERDRIVE SYSTEM 48 VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 101802101 Kit Fuse and Receptacle includes items 2 9 1 2 101796501 Bezel Receptacle nd ise 1 3 N A Wire Assembly Sense Lead Gray pp 1 4 N A Wire Assembly 40 Red iia ene u upam lieben 1 5 N A Wire Assembly 10 Black 1 6 101796801 Assembly Fuse 48 Volt includes item 7 1 7 1013061 Nut Nylon uit Neem 2 8 1017705 Screw Phillips Pan Head 8 Type ABR 3 9 101894901 Fuse 3 8 Ambp tle 1 10 101801001 Plate Receptacle Backing 2 2 a 1 11 101832001 Screw Phillips Pan Head 27 18 x 3 4
104. V Glide 36 Volt vehicle only 1 11 101935501 Light Battery Warning amber PowerDrive System 48 and IQ System 1 12 8990 Tie icd eh ee 2 Must order in multiples of 50 2004 2005 DS Golf Cars Illustrated Parts List Page 12 3 BUZZER FORWARD A REVERSE LIMIT v SWITCH SWITCH FUSE AND RECEPTACLE ge 9 s le CONNECTOR SWITCH ONN 33 ee TYPICAL 5 PLACES Page 12 4 2004 2005 DS Golf Cars Illustrated Parts List WIRING V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 1016070 Wire Assembly 6 Brown 1 2 1016069 Wire Assembly 6 Putple 1 etai o tr 1 3 1012651 Wire Assembly 6 1 4 1016068 Wire Assembly 6 Gy 1 5 1014036 Wire Assembly 6 Black 6th Speed 1 6 1014035 Wire Assembly 6 Blue Speed 1 7 1014034 Wire Assembly 6 Green 4th Speed 1 8 1014033 Wire Assembly 6 Yellow 3rd Speed 1 9 1014032 Wire Assembly 6 Orange 2nd Speed 1 10 1014029 Wire Assembly 6 White 1 11 1014030 Wire Assembly 6 White 1st Speed 1 12 1014828 Wire Assembly 6 Green RN 1 13 N A Wire Assembly 18 Black
105. Vinyl Seat Back Black 1 1 3 102237001 Cap Seat Back Black dtm 1 1 1 102238305 Assembly Seat Back Gray includes items 2 and 3 1 1 2 102060505 Cover Vinyl Seat Back Gray a 1 1 3 102237001 Cap Seat Back Black 0 0042 0 1 1 4 102236601 Weldment Support Seat Back Ne 2 2 5 102236703 Basket Sweater manm u n de ad 1 1 6 101910401 Screw Self Tapping 5 16 18 1 74 4 4 7 1010921 Screw Hex Head 5 16 18 x 2 1 2 2 2 8 1015075 Washer Flat 5 16 a 8 8 9 7473 Nut Nylon Lock 5 16 18 4 4 10 1013935 Assembly Bag Hoop includes items 11 13 1 1 11 1010434 Fastener Plastic Barrel 2 2 12 1010413 Strap Bag anna k tiat 1 1 13 1013754 Buckle Bag Strap 2 2 14 1017774 Spacer Body Eee S 4 4 15 102076701 Screw SEMS with patch 1 4 20 x 1 3 4 4 4 16 8418 Screw Phillips Truss Head 1 4 20 x 1 1 2 1 1 17 1014482 Spacer NYON cere beset 1 1 18 1028 Nut H V 4E20 riu Set be tm ree im Pr
106. WITH NEW HARDWARE AS SEEN FROM THE PASSENGER SIDE OF VEHICLE New style battery does not require spacer 4 AS SEEN FROM DRIVER SIDE OF VEHICLE Page 6 14 2004 2005 DS Golf Cars Illustrated Parts List BATTERY GASOLINE VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 1012328 Battery 12 Volt naar ea 1 2 102355301 Washer Lock Stainless Steel 3 8 2 3 1014375 Screw Hex Head Cap Stainless Steel 3 8 16 x 1 2 2 4 1014374 Spacer Battery Terminal Bolt 2 5 1010934 Screw Hex Head Cap 5 16 18 1 2 1 6 101898001 Clamp Battery ee ren 1 7 7173 Screw Hex 5 16 18 34 1 8 1241 Washer Flat 5 16 2 9 7473 Nut Nylon Lock D 16 18 1 eue 2 10 1014288 Screw Thread Forming 5 16 16 x 3 4 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 FE290 ENGINE 2004 2005 DS Golf Cars Illustrated Parts List Page 7 2 FE290 ENGINE SHROUDS AND BRACKETS ITEM PART NO DESCRIPTION QTY 1234 101953901 FE290 OHV Gasoline Engine clockwise rotation Without Automatic Compression Release w o ACR with Carbureto
107. Weldment Forward Reverse Bell Crank pp 1 17 1010954 1 18 101951501 Cable Transmission includes items 19 and 20 1 19 7893 Nut 10 32 usse nas bh aa ka 2 20 1012333 Joint u xot ede te 2 21 1015064 Screw Phillips Oval Countersunk Machine 8 32 x 5 8 S S 1 22 1012987 Handle Forward Reverse Switch 2 2 1 23 8248 Screw Phillips Truss Head 1 4 20 x 3 4 4 24 8233 Nut Nylon Lock 1 4 20 2 77 enne nnne nnne 8 25 1016201 Washer Wave3 8 essi 1 26 8251 Screw Phillips Head 14 20 1 4 27 101855801 Retainer Cable a Dee eo ipee bad 1 28 332 Washer Flat 1 4 ettet doe terre 4 29 101922601 Bracket Transmission Cable Support sss 1 30 1012285 Screw Hex Type TT 1 4 20 5 8 eene 3 2004 2005 DS Golf Cars Illustrated Parts List Page 6 5 REFERENCE ar ACCELERATOR CABLE i O ORANGE WIRE TYPICAL 2 ASSEMBLY YPICAL 2 PLACES LACES TYPICAL 2 PLACES TO FRAME GROUND TYPICAL 2 Tp PLACES OS REFERENCE 0 FRONT 1 7 N ACCELERATOR ROD I EM Q 272 2 6 6 2004 2005 DS Golf Cars Illustrated Parts List ELECTRICAL COMPONENT BOX GASOLINE VEHICLE ITEM PART NO DESCRIPTI
108. a ur uuu n u aQ 2 2 16 101903101 Nuts Nylon Lock 1122200 uuu Ran lidad 2 2 17 1010150 Bearing Thrust a nl 2 2 18 1016389 Washer Kingpin Wave r 2 2 19 1010984 INGE SLUG Di 8 8 20 8755 Screw Hex Head 3 8 16 x 3 3 8 2 2 21 1016386 2 2 22 1015583 Bushing Urethane 222 a 4 4 23 1012303 Bushing Steel 2 m dm 2 2 24 1014276 Plate Front Spring Retainer 1 1 25 1624 Screw Hex Head Cap 3 8 16 x 1 1 2 4 4 26 357 Washer LOCK sci chee asal be tener Siula u 4 4 27 706 Nut Hlex 3 8 106 iine edo nt e ann 4 4 2004 2005 DS Golf Cars Illustrated Parts List Page 5 9 5 47 OF VEHICLE BRAKE CABLE HANGER MOUNTING ELECTRIC VEHICLE ONLY TYPICAL 2 PLACES an NX 5 E if 2 2 dest NE CAD DO ama Wg Sy 2004 2005 DS Golf Cars Illustrated Parts List Page 5 10 REAR SUSPENSION ITEM PARTNO DESCRIPTION 1234 1 1012304 Shackle Rear Spring gasoline vehicle 4 1 7569 Shackle Rear Spring electric vehicle not shown 4 2 8754 Nut Nylon Lock 3 8 16 6 6
109. age 10 24 x 1 G sasa 2 29 1016175 Washer a S Su 2 30 1017 Nut Hex 10 24 ande ete NE eee 2 31 101949201 Shim Wiper Switch 000 C utu QG ae 1 32 1028 Nut Hex 1 4 20 m N 19 33 451 Washer 21 ai 9 2004 2005 DS Golf Cars Illustrated Parts List Page 12 9 TYPICAL 2 PLACES 6 PLACES TYPICAL 605 TYPICAL 6 PLACES TYPICAL 2 PLACES TYPICAL 6 PLACES ys 2004 2005 DS Golf Cars Illustrated Parts List Page 12 10 RESISTOR AND BOARD ASSEMBLY V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 1028 dd aes 12 2 451 Washers Lock 1 4 conti iia diia ita aida dias 12 3 1011931 Washer Flat Ml aio sk asas Es 6 4 1014045 Stand Off Resistor Coil 4 1 3 n A A ai 6 5 1014728 Board Resistor Mounting rr 1 6 332 Washer 6 7 1014476 Coil Resistor 5th Speed 182 Inch Wire Diameter 3 Coil 1 8 1014012 Coil Resistor 4th Speed 162 Inch Wire Diameter 3 Coil 1 9 1014013 Coil Resistor 3rd Speed 144 Inch Wire Diameter 3 1 10 1014014 Coil Resistor 2nd Speed 128 Inch Wire Diameter 4 Coil
110. al Component u u uu 1 26 1015405 Bolt Carriage 5 16 18 x 2 ennt 1 27 1241 Washer Flat 5 16 em d d e nein gu ede EU 2 28 TAT3 Nut Nylon Lock 5 16 18 2 29 7818 Bolt Carriage 5 16 18 1 12 1 2004 2005 DS Golf Cars Illustrated Parts List Page 6 7 AS SEEN FROM FRONT DRIVER SIDE OF VEHICLE BODY REMOVED a Page 6 8 2004 2005 DS Golf Cars Illustrated Parts List ELECTRICAL COMPONENTS FRONT BODY GASOLINE VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 1016859 Kit Reverse Buzzer includes items 2 and 4 1 2 1016849 Screw Pan Head Hi Lo 4 24 x 5 16 2 3 1016851 uama 1 4 N A Wire Assembly 18 Black 1 5 1011229 N t K Lock 6 32 a ob aede eade 1 6 1015720 Screw Hex Washer Head 6 32 1 2 eene 1 7 101830601 Assembly Screw and Washer 4 8 101826301 Ie P pP 1 9 101851101 MERERI T E 1 10 101830701 Nut Key Switch SEEE EE EEE EE EEEn e nena 1 11 101834502 Cap Key Switch black 22 111200 4 0000 0000000 eaa a a 1 12 1012505 KVAD S de eet p a gers ERE
111. arts List Page 11 11 Page 11 12 2004 2005 DS Golf Cars Illustrated Parts List MC008C ES00 AFTER SERIAL NUMBER MC008C3H1264 DIFFERENTIAL AND AXLES ITEM PART NO DESCRIPTION QTY 1 2 3 4 66 101891501 Axle Assembly Driver Side Includes items 68 72 1 67 101891401 Axle Assembly Passenger Side includes items 68 72 1 68 1013787 4 69 1013792 Retaining uuu eich eren tandi 1 70 1011291 Bearing Outer Axle Tube 1 71 1014207 Gollar 25 mmi ete Rail 1 72 1016672 Ring Retaining id dete ER Heu 1 73 1013794 SEA FON re ee u e et ide I RN 2 74 101891001 Assembly Axle Tube 1 75 101890901 Assembly Axle Tube Passenger Side 00 1 76 1013790 Bolt M10 x 1 5 x 30MM iniit aa 14 77 1013791 Washet Lock MO 14 78 7330 Bearing Inner Axle Tube 2 79 101928301 MI X 1 25 X37 MM ana Re Ee p RES can 8 80 101892701 Gear Output E EN 1 81 1014193 Pin DOWel T 1 82 101910501 Kit Differential Gear Case includes items 83 86 1 83 1013768 Case Gear Carrier 3 n ua Ai Belkin ln 1 84 1013774 Plate Thrust idler
112. asi 4 4 8 1016183 Screw Hex Head Cap 3 8 16 x 7 a nnne 2 2 9 8754 Nut Nylon Lock 3 0 10 2 n n e e a 2 2 10 1014288 Screw Hex Washer Head Thread Forming 5 16 18 x 3 4 1 1 11 1011697 Washer Flat 5 16 us susu edi hee eee teen eee 1 1 12 102278001 Boot Steering Column 1 1 13 1016181 Assembly Steering Column includes items 14 22 1 1 14 1012605 Ring Retaining u Ee 1 15 1012604 Washer Steel 5 8 1 1 16 1014217 Spring en ete 1 17 1014125 Wedge cites tette nds 2 2 18 1014213 Assembly Bearing 2 2 400 0 nnn dne 2 2 19 1014126 Seat Bearing ea nue 2 2 20 1015545 Shaft Steering Column pp 1 1 21 1016622 Column Aluminum Steering 1 1 22 1014214 Ring Retaining ne 1 1 23 1016263 Cover Steering Column 1 1 24 1016156 Wheel Steering 1 1 25 1017273 Nut Nylon Lock 5 8 18 1 1 26 1016219 Assembly Scorecard Plate includes items 27 30 1 1 27 1012565 Screw Round Head 12 14 x 1 a 2 2 28 1012566 Spring Tapered Compression
113. ch Long 1 12 102814802 Cordset 154 Inch 1 13 102814803 Cordset DC 250 Inch Long 1 14 102814901 Breaker Circuit 15 Amp 2 ana RI 1 15 102815001 Rectifier Le a 1 16 102815101 Relay 48 VDQG i sas sa 1 17 102815201 AMM kiku 1 18 102815301 Bushing Strain Relief 1 19 102815401 Bushing Strain Relief s de de al a Rea d 1 20 102815501 Fuse 25 Amp Type ppp 1 21 102815601 Wire Assembly Voltage 1 22 102815701 Holder ait titre d qe ede 1 23 7577 Screw 10 X 50 Phil Pan Head 12 2004 2005 DS Golf Cars Illustrated Parts List Page 15 13 Page 15 14 2004 2005 DS Golf Cars Illustrated Parts List POWERDRIVE BATTERY CHARGER EXPORT ITEM PART NO DESCRIPTION QTY 1234 PowerDrive chargers can be used with PowerDrive System 48 and IQ System vehicles 101831503 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 cord with no plug uu l I ISA y ayasa k du 1 101831504 Charger Battery PowerDrive Export with 4 Position Switch 100 200 220 240 V AC 48 V DC 50 60 Hz model numbe
114. cluster mounting bolt 4 3 brake drum 4 3 brake pedal 4 5 brake pedal adjustment tool 16 3 brake pedal mounting block 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 14 3 14 5 breather transaxle case bronze bushing 6 5 6 7 brush 6 11 13 3 13 5 13 7 brush box assembly 13 9 brush connector 6 17 brush holder 6 11 brush holder screw 13 3 13 5 brush inspection port cover 6 11 brush rigging 13 3 13 9 brush spring 6 11 12 9 13 3 13 5 13 7 13 9 brush switch 12 9 buckle bag strap 1 13 15 15 15 17 15 9 15 11 15 13 11 3 11 9 2004 2005 DS Golf Cars Illustrated Parts List bumper brake pedal stop 4 5 front 1 5 motor 13 3 13 5 13 7 rear 1 3 return spring 4 7 side guard trim 1 5 wiper switch 12 9 bus 12 15 bushing bronze 5 9 6 5 6 7 drive clutch 10 3 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 urethane 5 7 5 9 5 11 bushing axle 14 5 buzzer reverse 12 3 C 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 s
115. d Parts List MAINTENANCE AND SERVICE TOOLS ITEM PARTNO DESCRIPTION E sa 1234 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 101871001 Accelerator Pedal Adjustment Tool 1 1 2 101813202 Adhesive Guide Ring 3 Gram Tube 1 3 101641202 Arbor att Behand 1 4 101831901 Battery Discharge Machine 36 48 Volt 1 5 1014305 Battery Terminal Protector Spray 1 1 1 6 1011767 Battery Thermometer 01111 1 10060 rettet 1 1 1 7 1016417 Bearing and Oil Seal Remover Assembly 1 1 1 8 1016416 Bearing Driver Set ec dac In dee 1 1 1 9 1012811 Bearing E berti 1 1 1 10 1012812 Bearing Puller Wedge Attachment 1 1 1 11 1013582 Brake Adjustment Tool used only on vehicles with manually adjusted mechanical brakes 1 1 12 102555501 Brake Cable Release Tool 1 1 1 13 102249901 Brake Pedal Adjustment Tool Kit use
116. d for the Carryall Electric Industrial Truck only includes items 14 and 15 1 14 Brake Pedal Adjustment 1 15 SER Brake Pedal Tension Tool pp 1 16 102669601 Connecting Rod Small End Bushing Tool for Kubota D722 Diesel Engines 1 17 101887101 Calibration Test Module pp 1 18 101808401 Cam Installation Tool mem 1 19 102562401 Charger Bezel Tool 1 1 a ipe begins ide 1 20 102686101 Clutch Removal Tool for XRT 1500 Carryall 294 and Bobcat 2200 Vehicles 1 1 Please refer to the maintenance and service manual for proper tool application Special order item available upon request 2004 2005 DS Golf Cars Illustrated Parts List Page 16 3 9 O 2004 2005 DS Golf Cars Illustrated Parts List Page 16 4 MAINTENANCE AND SERVICE TOOLS CONTINUED ITEM PARTNO DESCRIPTION ton EE 1234 21 1014510 Clutch Tool Kit includes items 22 28 1 22 1014498 Clutch Alignment Tool for pre unitized transaxle vehicles built prior to 1997 model year 1 23 1014496 Drive Clutch Puller for Kawasaki engines only 1 24 1014497 Drive Clutch Hub Puller for Kawasaki engines only 1 25 1014508 Driven
117. e 1 6 AE Kit Wire Assemb iy onte tet De 1 7 101976601 Ammeter includes hardware U a 1 8 101987501 Relay Power 48 V DC includes mounting hardware 1 9 101838601 Switch 4 Position Slide pe 1 10 101828901 Cordset DC 103 Inch 261 cm Long with Male 3 Pin Plug 12 AWG 1 10 101828902 Cordset DC 144 Inch 366 cm Long with Male 3 Pin Plug 12 AWG 1 10 101828903 Cordset DC 250 Inch 635 cm Long with Male 3 Pin Plug 12 AWG 1 11 1012101 Assembly Fuse includes hardware 1 12 1012098 Bushing Strain Relief DC Cord 12 AWG 1 13 101838401 Breaker Circuit dead 2 14 101973501 repete nde 1 15 Erud Assembly Current Limiter r 1 16 101958301 Cordset AC Continental Europe 96 Inch 244 cm Long with male 2 pin plug ans 1 17 101958201 Cordset AC U K 96 Inch 244 cm Long with male 3 pin plug 1 18 N A Wire JUMP a 1 Special order item available request 2004 2005 DS Golf Cars Illustrated Parts List Page 15 17 MAINTENANCE AND SERVICE TOOLS s E Page 16 2 2004 2005 DS Golf Cars Illustrate
118. e l 2 e editiert etae t A pk Suku mk 1 11 1016532 Gear SPU iiis ttd ad e etie tutae 1 12 1016516 Assembly Rod includes one each of item 13 2 13 1016580 Bearing Plain ee ee en 2 14 1016562 1 15 101655001 Shim Crankshaft 1 13 mm Thick pp A R 15 101655002 Shim Crankshaft 1 18 mm Thick A R 15 101655003 Shim Crankshaft 1 23 mm Thick A R 15 101655004 Shim Crankshaft 1 28 mm Thick A R 15 101655005 Shim Crankshaft 1 33 mm A R 15 101655006 Shim Crankshaft 1 38 mm Thick pp A R 15 101655007 Shim Crankshaft 1 43 mm Thick A R 15 101655008 Shim Crankshaft 1 48 mm Thick A R 15 101655009 Shim Crankshaft 1 53 mm Thick A R 16 1016559 e 1 17 1016541 Bolt Stud M6x 1 X22 mm ciet aedes ere q etsi dude sasa 4 18 1016547 Nut Flanged MOX 1 act a ade 4 19 1016470 Shaft Counterbalance Guide 1 20 1016571 1 21 1016469 Weight Counterbalance r 1 2004 2005 DS Golf Cars Illustrated Parts List Page 7 13 REFERENCE TYPICAL Pr 4 PLACES d 0 N S buc Den 7 TYPICAL 10 4 PLACES 1 2 Ni Pb dg or a o y ge 0 Ns O TYPICAL 4 PLACES REFERENCE U
119. e Black and 18 1 9 101901401 Wire Assembly 6 Blue 1 10 101901201 Wire Assembly 6 Orange 1 11 101901501 Wire Assembly 6 White 1 12 N A Wire Assembly 18 Red White 1 13 101901301 Wire Assembly 6 Blue 2 ete isch 1 14 N A Wire Assembly 18 Green 1 15 N A Wire Assembly 18 tese bei aei adus 1 16 N A Wire Assembly 18 Orange sse eene 1 17 N A Wire Assembly 18 Red 1 18 N A Wire Assembly 18 Yellow 1 19 101795701 Wire Assembly 6 7 5 20 N A Wire Assembly 10 Black part of onboard computer assembly 1 21 1014947 Assembly Resistor 2 1 22 101902801 Wire Assembly 6 Red 1 23 101903001 Wire Assembly 6 Yellow 1 24 Wire Assembly 18 Gray part of onboard computer assembly 1 25 Wire Assembly 10 Black part of onboard computer assembly 1 26 Wire Assembly 10 Red part of fuse and receptacle assembly 1 27 101902901 Wire Assembly 6 Green 1 28 Wire Assembly 6 Black
120. e NEN 2 25 1016549 Washer Flat M12 1 26 1016517 Circlip Type E G 1 27 1016458 Bolt Flanged M8 x 1 25 x 45 MM 6 28 1016430 Gasket Headset eee ew 1 102304701 Kit Gasket FE290 not shown contains one each of all internal gaskets for FE290 engine lid 1 2004 2005 DS Golf Cars Illustrated Parts List Page 7 9 Page 7 10 2004 2005 DS Golf Cars Illustrated Parts List FE290 ENGINE CRANKCASE CAMSHAFT AND OIL SENSOR ITEM PART NO DESCRIPTION QTY 1 2 3 4 1 1016535 Connector 1 2 1016538 ana 1 3 1016506 Clamp uh sk ene 1 4 1016544 Screw Cross Pan Head Self Tapping M5 x 8 x 12 mm 1 5 1016564 um EE 2 6 1016565 Bearing Ball L ete pere e egi d ee ara 1 7 1016567 Seal Crankshaft k aa m ad 1 8 1016584 Bolt 2 Ended M8 x 1 25 x 69 MM RN 2 9 1016458 Bolt Flanged M8 x 1 25 x 45 mm 1 sss 6 10 1016520 Cover 1 11 1016446 Gasket Crankcase Cover 1 12 1016456 Bolt Flanged 6 1 12 2 13 1016510 Bracket Qil Level SWiteh ia a E 1 14 1016494 Sensor Oil E vel uni en A ene bed aad a 1 15 1016496 Screw Cross Pan Head M4 x 7 x 8 MM pp
121. e UL 2 2 19 TAT9 Screw Hex Head 1 4 20 x 1 1 4 2 2 20 1241 Washer Flat 5 16 e ans aqa RA Sre 6 6 21 7818 Bolt Carriage 5 16 18 1 1 2 2 2 22 102242401 Nut Nylon Insert with Cap 1 4 20 1 1 2004 2005 DS Golf Cars Illustrated Parts List Page 1 13 REFERENCE SEAT BACK SUPPORT WELDMENT LO VA 19 Y A _ 12 10 PLACES Page 1 14 2004 2005 DS Golf Cars Illustrated Parts List CANOPY ITEM PARTNO DESCRIPTION 1234 1 102099101 Screw SEMS with patch 5 16 18 1 2 2 2 102155501 Kit Support includes items 10 u 1 1 3 102063901 Weldment Windshield 1 1 4 102065501 Support Rear Canopy driver side 1 1 5 102064601 Support Rear Canopy passenger side 1 1 6 102076701 Screw SEMS with patch 1 4 20 x 1 3 4 8 8 7 101835601 Nut Flange 1 4 20 eei 8 8 8 324 Screw Hex Head 1 4 20 x 2 1 2 4 4 9 332 Washer Flat TA Lie le ie o NP Ge ss 8 8 10 8233 Nut Lock 1 4 20
122. e switch in NEUTRAL position Turn key OFF and remove key when notin use 01101621601 ON SPEED CONTROLLER COVER Do not operate vehicle w it this cover properly installed Do not direct water stream in this area will cause damage to components See vehicle maintenance and service manual before servicing CCI 101931501 Maximum vehicle speed is limited by motor braking during downhill operation with accelerator pedal depressed motor brake enabled vehicle motor will brake when accelerator pedal is released Beeping alarm indicates reduction in motor braking Apply brakes to reduce speed System is activated only when tow switch is in the RUN position When towing vehicle tow switch must be in the TOW position 101959902 DO NOT OPERATE VEHICLE WITHOUT COVER IN PLACE NOTI GE DO NOT DIRECT WATER STREAM AT THIS SWITCH CCI 1016109 01 ON WIPER SWITCH COVER INSIDE BATTERY A WARNING ON FRAME UNDER SEAT ON TOW RUN SWITCH BRACKET UNDER SEAT Z WARNING Place Tow Run switch in TOW position before FAILURE TO HEED THIS Disconnecting or connecting batteries WARNING COULD RESULT IN A BATTERY EXPLOSION Senne eet OR SEVERE PERSONAL INJURY CC 101908601 Page 3 4 2004 2005 DS Golf Cars Illustrated Parts List DECALS ELECTRIC VEHICLE ITEM PARTNO DESCRIPTION C 1234 1 101960601 Decal Driver Passenger Warning
123. earing 1 pia 3 44 101927501 Bearing Needle ul a 1 45 101981001 Ring Synchronizer 169 2 46 1012741 Spring a u d Det ree RR D HORAE eee 2 47 101928001 Hub Synchronizer Clutch sess 1 48 1012740 Insert Synchronizer u u 3 49 101927901 Sleeve Synchronizer a 1 50 101927701 Pin DoWel ai tc eh etd 1 51 102453001 Shaft Input w Circlip Groove 2 1 52 101980801 Gear Assembly Input 25 Tooth 16 1 53 1016337 Washer ThEUSt 1 54 AM10081 Bearing Ball C 3 Sealed 1 55 1012714 Seal Input id 1 56 101892601 Gear 1 Tooth inn dmn 1 57 101893201 Anna 1 58 101892501 Gear 61 Tooth ec lun yasqa te e e dd 1 59 101928101 Bearing 1 60 101893901 Washer an mh tet eo e es 1 61 101892301 Governor Assembly arresi satandan 1 62 101891601 SEVEN A 1 63 101891901 tica do 1 64 7335 Bearing Ball 2 65 102453101 Circlip Input u u lolita 1 2004 2005 DS Golf Cars Illustrated P
124. encil 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 idle gear bushing replacement tool 16 7 idle screw 8 5 ignition coil 7 5 inner axle tube bearing 14 5 1 7 1 9 14 3 14 5 inner fender input gear bearing Page i 11 input shaft 14 3 14 5 input shaft oil seal 14 3 14 5 insert synchronizer 11 5 11 11 insert wood 1 11 insulator bushing 13 3 13 5 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 intermediate
125. erte 1 24 1016587 Clamp ceils eed tiat d edo et dv e ete 1 25 101909301 Wire Eead z eit divae Bol ioa blot tee taste te aaa Dai 1 2004 2005 DS Golf Cars Illustrated Parts List Page 7 5 DB FE290 ENGINE OIL CIRCULATION ITEM PART NO DESCRIPTION QTY 1 2 3 4 1 1016467 Oil Filters 2404s cate HH Ina LE 1 2 1016502 Bracket Oil Filter uuu uuu liada 1 3 1016457 Bolt Flanged Hex Head x 1 x 40 MM T 2 4 1017507 PIU ttti neto tune rer 2 5 1016570 O Ring Oil Filter Mount 2 2 1 11 0000 enne 1 6 1016576 Plug Drain FE290 5 ae a ele ee de 1 7 1016432 Gasket Drain Plug dae 1 8 1017456 Screw Flanged Hex Head x 1 x 12 mm 6 9 1016484 Cover Pump nne 1 10 1016495 Gasket Oil Pump 1 11 1016473 Plate Oil Pump i qaa er 1 12 101648203 Pump Oil and ROOM dee redet 1 13 1016429 Seat Valve oL a 1 14 1016537 Ball Steel Pressure Relief 1 15 1016581 epum 1 2004 2005 DS Golf Cars Illustrated Parts List Page 7 7 DB Page 7 8 2004 2005 DS Golf Cars Illustrated Parts List FE290 ENGINE CYLINDER HEAD ITEM PART NO DESCRIPT
126. es 1 18 N A 4 nay t ua u Si cds i dee ein ged a 1 19 8248 Screw Phillips Truss Head 1 4 20 x 3 4 2 20 101922501 Bracket Tow Run Switch without decal 1 21 101908401 Boot Tow Run Switch with nut pp 1 22 332 Washer Flat 1 4 x unu etam ce 2 23 8233 Nut Nylon Lock 14 20 2 7 9 2 24 101908101 bee 1 25 8990 A a A R 2004 2005 DS Golf Cars Illustrated Parts List Page 12 27 4 PLACES TYPICAL TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 3 PLACES Gea 69 men TYPICAL 12 PLACES TYPICAL 5 PLACES e gt ou TYPICAL 6 PLACES TYPICAL 6 PLACES Page 12 28 2004 2005 DS Golf Cars Illustrated Parts List BATTERIES CHARGER RECEPTACLE IQ SYSTEM VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 101802101 Kit Fuse and Receptacle includes items 2 9 1 2 101796501 Bezel Receptacle nd ise 1 3 N A Wire Assembly Sense Lead Gray pp 1 4 N A Wire Assembly 40 Red iia ene u upam lieben 1 5 N A Wire Assembly 10 Black 1 6 101796801 Assembly Fuse 48 Volt includes item 7 1 7 1013061 Nut Nylon uit Neem 2 8 1017705 Scre
127. esistor mu unn Mikes tia 1 10 1242 Nut Hex 5 16 18 3 11 7174 Washer Lock 5 104 sa erben 3 12 1012285 Screw Hex Type 1 4 20 5 8 8 13 101840201 Controller 48 Volt 225 1 14 1241 Washer Flat 5 10 etatem ten ed 6 15 7173 Screw Hex Head Cap 5 16 18 3 4 a 2 16 1218 Screw Hex Head 5 16 18 x 1 1 4 a 1 17 101909901 Computer Onboard includes item 18 u 1 18 101942301 Kit 3 Pin Receptacle Lina 1 19 101920101 Kit 3 Pin Plug and Wedge 1 20 101827801 Kit Wire and Terminal 6 Black 1 21 1014948 Assembly Diode Service Part replacement for existing diode that comes standard with solenoid eene 1 22 101910401 Screw Thread Forming 5 16 18 1 1 4 2 2004 2005 DS Golf Cars Illustrated Parts List Page 12 19 Z 4 2 AW Page 12 20 2004 2005 DS Golf Cars Illustrated Parts List MOTOR CONTROLLER OUTPUT REGULATOR MCOR ITEM PART NO DESCRIPTION QTY 1234 1 102101101 Regulator Motor Controller Output MCOR 2 2 1 2 102101001 B r DING uu 3 1015752 Screw Hex Washer Head Hi Lo 12 16 x 5 8
128. et POP 3 16 x cuti NA AA eee 2 11 101975901 Solenoid 36 Volt A Rede da 1 12 1012285 Screw Hex TT 1 4 20 x 5 8 2 13 7893 Nut Hex 10 32 d uu eee eee 2 14 1010521 Nut Hex 5716 24 2 15 7174 Washer Lock ista adi 2 16 101342501 Kit Fuse and Receptacle includes items 17 31 1 17 1014516 Kit Fuse includes items 18 22 u uu 1 18 N A S A a 1 19 F se SO 1 20 Holder au uii 1 21 1016 Washer LOCK 840 erkennen Pa E eed 2 22 8797 Nuit Brass 10232 au ee V us eures 4 23 4107 Receptacle Charger 2 Prong 1 24 1013092 Wire Assembly 10 Red nnne 1 25 1013628 Bracket Fuse and Receptacle Mounting 1 26 8796 Screw Phillips Pan Head Self Tapping 7 19 X 3 4 6 27 8795 Screw Phillips Pan Head Self Tapping 27 19 x 1 3 4 2 28 1013649 Bezel Charger Receptacle 1 29 8797 Nut Brass 3 10 32 u IR RT I a aa aes 2 30 1016 Washet lock en 2 31 1013266 Screw Phillips Pan Head Self Tapping 8 18 x 1 2 2 32 1014948 DIOGO Gai loa ad 1 33 102047201 Sn bber meine erahnen 1
129. gear 14 3 14 5 intermediate gear bearing 14 5 internal retaining ring pliers 16 7 IQ display module IQDM 16 7 IRemblem 1 5 3 3 3 5 J jbolt 12 13 12 17 12 29 jet 8 5 jet pilot 8 5 joint ball 4 5 6 5 ball rod 5 7 compound steering 5 3 inner ball 5 5 left hand thread ball 5 5 5 7 spring loaded ball 4 7 K key square 10 5 sunk 14 5 woodruff 6 11 11 3 11 9 key crankshaft 7 13 key driven clutch 10 5 key flywheel 7 5 key transmission shaft 11 5 11 11 key vehicle 6 9 12 3 key switch 6 9 12 3 key switch cap 6 9 key switch nut 6 9 12 3 kingpin 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 12 27 3 pin receptacle 12 19 3 pin receptacle and wedge lock 12 27 4 pin plug and wedge lock 12 27 4 pin receptacle and wedge lock 12 27 6 pin plug 12 31 6 pin receptacle 12 31 accelerator pivot rod 4 7 air ductrepair 8 11 INDEX 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
130. in 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 body kick 1 7 1 9 component mounting 12 19 12 31 INDEX flywheel fan 7 5 front spring retainer 5 9 heatsink 15 11 15 13 lock 14 5 mounting engine 7 15 mounting rear bumper 1 3 oil filter screen 7 11 oilpump 7 7 oil 7 9 receptacle backing 12 17 12 29 scorecard 5 3 seathinge 1 11 spring mounting 5 7 thrust 11 5 11 7 11 11 11 13 14 5 thrust gear 14 3 pliers internal retaining ring 16 7 piston ring 16 9 retaining ring 16 9 plug 2 pin 12 21 3 pin 12 19 12 21 13 7 6 pin 12 31 cap 7 5 drain crankcase 7 7 drain transaxle 11 3 11 9 drive clutch 10 3 driven clutch puller 16 5 fill 14 3 fill with gasket 14 5 filter bracket 7 7 12 3 hole dash board 1 3 magnetic 14 3 spark ohv 7 5 plug gasket 14 3 pole set starter generator 6 11 positioner choke 8 17 power relay 15 9 15 11 15 15 PowerDrive 2 battery charger 15 11 15 13 PowerDrive battery charger 15 9 15 15 15 17 press weldment 16 5 pressure relief ball 7 7 protectorcap 12 9 protector spray battery terminal 16 3 protector bagwell 1 3 puller bearing 16 3 clutch 16
131. ist Page 16 9 XL WAVETEK DN lt 2 e Page 16 10 2004 2005 DS Golf Cars Illustrated Parts List MAINTENANCE AND SERVICE TOOLS CONTINUED QTY QTY QTY ITEM PARTNO DESCRIPTION DIESEL GAS 1234 95 1016552 Valve Seat Cutter 1 96 102668701 Valve Seat Cutter Set for Kubota D722 Diesel Engines 1 97 1016551 Valve Seat Cutter T Wrench 1 98 1016553 Valve Seat Cutter 45 32 mm diameter for FE290 engines only 1 99 1016554 Valve Seat Cutter 45 30 35 mm diameter 1 100 101641101 Valve Spring Compressor 1 101 1011480 Volt Ohm Meter L u um 1 1 1 102 102674801 Wrench Valve Clearance Adjustment for Honda GX620 Gasoline Engines 1 2004 2005 DS Golf Cars Illustrated Parts List Page 16 11 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 27 334 4 7 5 3 5 5 7 15 357 5 9 10 3 451 9 3 12 7 12 9 12 11 12 15 13 3 13 5 13 7 13 9 705 6 13 7 15 706 5 9 808 10 3 1016 12 13 1017 12 9 1028 1 13 4 5 12 7
132. ker 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 shifterlever 11 3 11 9 shifter shaft 11 3 11 9 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 snapring 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 12 9 spindle 5 9 spray battery terminal protector 16 3 spring accelerator pedal retainer 4 7 brake shoe 4 3 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
133. l tank 8 3 v glide wiper switch 12 9 volt ohm meter 16 11 voltage regulator 6 7 voltage suppressor 15 9 15 15 warning light low 6 9 washer key switch 12 3 kingpin wave 5 9 mounting 10 3 10 5 snap washer kit dash mounting 1 3 spring 11 5 11 11 thrust transaxle 11 5 11 11 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 10 3 weldment press 16 5 wheel 2 3 wheel rim 2 3 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 wiretie 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 16 9 yoke spring 5 5 yoke gear 16 7 2 z bracket 12 31 1 16 2004 2005 DS Golf Cars Illustrated Parts List Your Comments Are Appreciated Please select your category Distributor Dealer Technician Individual Owne
134. nt Body Rear Body and Fender Gasoline Vehicle Rear Body and Fender Electric Seat Bottom and Armrest Seat Back and Bag Hoop Canopy SECTION 2 WHEELS Wheels and Tires SECTION 3 DECALS Decals Gasoline Vehicle Decals Electric Vehicle AND TIRES SECTION 4 BRAKES PEDAL AND CABLE ASSEMBLIES Brake Assembly Brake Pedal and Cable Assembly Accelerator Pedal Assemb SECTION 5 STEERIN Steering Column Steering Gear Assembly Front Suspension Upper Front Suspension Lower Rear Suspension lE G FRONT AND REAR SUSPENSION SECTION 6 ELECTRICAL SYSTEM GASOLINE VEHICLE Wiring Gasoline Vehicle Forward Reverse Shifter Assembly Gasoline Vehicle pp Electrical Component Box Gasoline Vehicle L la nennen Electrical Components Front Body Gasoline Vehicle Starter Generator Assembly l Gu nannte aset nn a n uaa na nena nan neni RR nune Starter Generator Mounting ku u dl ala ART Battery Gasoline Vehicle 3 3 3 5 2004 2005 DS Golf Cars Illustrated Parts List CONTENTS SECTION 7 FE290 ENGINE FE290 Engine Shrouds and Brackets 7 3 FE290 Engine Igniti
135. nto 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 acce
136. ock front suspension vehicles only 1 1 81 1014264 Steering Column Bearing Press 1 1 82 1014259 Steering Column Retaining Ring Tool 1 1 83 102061201 Steering Wheel Puller 1 1 1 84 AM10753 Tachometer includes gasoline engine pick up lead only 1 1 85 AM10771 Tachometer Diesel Probe for use with item 84 1 86 1014162 Transaxle Axle Seal Tool 1 87 1014161 Transaxle Pinion Seal 1 88 1014115 Transmission Tool u u 1 89 101611003 Tune Up Kit All OHV for Kawasaki Engines includes air filter spark plug oil filter fuel filters not shown 1 90 1016413 Valve Clearance Adjuster Screw Holder for FE290 engines only 1 91 102674601 Valve Guide Driver for Honda GX620 Gasoline Engines 1 92 101641201 Valve Guide Reamer FE290 FE350 and FE400 only 1 93 102674401 Valve Guide Reamer 6 6 mm for Honda GX620 Gasoline Engines 1 94 102669401 Valve Guide Replacement Tool for Kubota D722 Diesel Engines 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 L
137. olf Cars Illustrated Parts List Page 11 3 Page 11 4 2004 2005 DS Golf Cars Illustrated Parts List MC008C ES00 PRIOR TO SERIAL NUMBER MC008C3H1264 TRANSMISSION AND GEAR REDUC ITEM PART NO DESCRIPTION QTY 1234 33 101892001 Shift i Ltd tec n dee NH 1 34 101890001 uuu araa in ida eerie 1 35 1012748 PMG lios DRUG M e 1 36 1012747 Ball Steel A ma as eet a ER ttt 1 37 101889401 Gulden ara 1 38 AM10080 Bearing Ball Sealed a 2 39 1016338 Washer Spring suan a aa ed ded 2 40 101892401 Gear u u Zb 1 41 101892201 Plate ee inl eed 3 42 101980901 Gear Assembly Input 28 Tooth 16 1 43 101927601 Bearing Needle ii e ned edd 3 44 101927501 Bearing Needle 1 45 101981001 Ring Synchronizer 169 2 46 1012741 Spring PR D RUE 2 47 101928001 Hub Synchronizer Clutch 1 48 1012740 Insert Synchronizer el 3 49 101927901 Sleeve Synchronizer 1 1 50 101927701 Pin Eee a A en an 1 51 101889901 Shaft Input etta Heer 1 52 101980801 Gear Assembly Input 25 Tooth 16 sss
138. on Components and Flywheel 7 5 FE290 Engine Oil Circulation 11 2 1 1 1 6 a hua yk ass uses 7 7 FE290 Engine Cylinder Head 7 9 FE290 Engine Crankcase Camshaft and 7 11 FE290 Engine Crankcase and Crankshaft 7 13 Engine Mounting un al Qiu 7 15 SECTION 8 FUEL INTAKE AND GOVERNOR SYSTEMS Fuel System once tede deb eim a 8 3 Garburetor Assembly e iit trien 8 5 Carburetor Installation 2 n 8 7 Governor and Accelerator 8 8 9 Intake Duct Choke and Air Box Assembly 8 11 SECTION 9 EXHAUST SYSTEM Exhaust System usnu an 9 3 SECTION 10 TORQUE CONVERTER SA 2 05 CTUM 10 3 Driven Clutch tete dee te 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 MC008C3H 1264 Differential and Axles 11 7 008 500 After Serial Number 008 3 1264 Gear Cases and Brackets 11 9 MC008
139. ouch Up Black 1 1 71 101997212 Paint Touch Up Burgungy 1 1 71 101997211 Paint Touch Up Classic Blue Navy 1 1 71 101997205 Paint Touch Up Dark Gray 1 1 1 71 101997209 Paint Touch Up Dark Green 2 1 1 1 71 101997204 Paint Touch Up Gray 2 1 1 71 101997203 Paint Touch Up 1 1 1 71 101997206 Paint Touch Up Royal Blue Pacific Blue 1 1 71 101997202 Paint Touch Up White 1 1 1 72 1016414 Piston Ring Compressor Kit FE290 FE350 and FE400 engines 1 73 1016415 Piston Ring Pliers for Kawasaki Engines 1 74 102669301 Plastigage for Kubota D722 Diesel Engines 1 75 102668801 Puller Special Use for Kubota D722 Diesel Engines 1 76 1012549 Retaining Ring Pliers 45 External 1 1 1 77 1012560 Retaining Ring Pliers 90 Internal 1 1 1 78 101823101 Safety First Card 50 per pack 1 1 1 79 1012809 Seal Puller A aka 1 1 1 80 102330901 Spanner Wrench for coil over sh
140. pp 1 14 1013092 Wire Assembly 10 1 15 Wire Assembly 18 Orange u a 1 16 N A Wire Assembly 18 White 1 17 N A Wire Assembly 18 Green 1 18 102018001 Wire Assembly 10 Red 1 19 1011010 Wire Assembly 10 White 1 20 N A Wire Assembly 18 Red a 1 21 1014039 Wire Assembly 6 White 1 22 N A Wire Assembly 18 pp 1 23 1011069 Wire Assembly 6 Red smettere nnne 1 24 N A Wire Assembly 18 Yellow emn 1 25 N A Wire Assembly 18 1 26 1010958 Wire Assembly 6 Black ie ete t DRE ge a ERE ge ea Read 5 2004 2005 DS Golf Cars Illustrated Parts List Page 12 5 Page 12 6 2004 2005 DS Golf Cars Illustrated Parts List FORWARDIREVERSE SWITCH V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1 2 3 4 1 1011997 Assembly Forward Reverse Switch includes items 2 5 1 2 1014808 Switch Mito casita tin 1 3 8057 Nut 4240 uei 2 4 8058 Washer LOCK 4 ai ade 2 5 1016896 Screw Hex Head Machine 4 40 x 1 1 8 2 6 1028 Nut Hex 1 4220 n a ia En en ee ae 3 7 451 Washet LOCK 1 4 era et a e 3 8 304 Screw Hex Head 1 4 20
141. pring pE L1 A akan EE 4 9 102186101 Brush BOX Assembly ee eem pese led 1 10 102186201 Brush Kit Motor includes item 11 1 11 102845701 Assembly Brush and Terminal 2 12 102186301 Ring 2 24 Internal Retaining 1 13 102186401 Bearing ia 1 14 102186701 End Cap Motor dees ca eed ee ee aes 1 15 102186801 Screw 1 4 20 X 2 25 Hx Washer I 2 16 102186901 Screw 8 32 X S Hx Hd 2 17 102187001 L Bracket Motor sg eter uma a tdo 1 18 102187101 Hardware Kit Motor Terminal includes items 19 through 22 2 19 N A B shing Nylon id 2 20 Washer Nylon Flat 2 21 N A Washer Flat 5 16 Steel viii a S a 2 22 N A Nut Brass 5 16 18 a 2 23 102187201 Plate Kit Motor Cover includes items 24 and 25 1 24 N A Assembly Cover Plate 1 25 N A Screw 8 32 x 0 375 Taptite Thread 1 26 102704701 Frame 8 Field Service 1 27 102704801 Armature Service Assembly u uu u nnns 1 28 102704901 Speed Sensor Ser
142. r does not include items 15 18 r 1 1 1016507 Bolt 2 Ended x 1 29 1 2 N A Washer Flat 6 mm a u a a Ts sena sess u sual 1 3 1016524 Shroud Engine FE2907 coord 1 4 1016456 Bolt Flanged M6 x 1 x 12 MM RN 15 5 1016547 Nut Flange M6 x 1 ecru Lud ae dosi a o 3 6 101909701 Bolt 2 Ended x 1 x 27 MM 2 7 1016526 Shroud Engine 290 1 8 1017221 Bolt 2 Ended x 1 x 46 mm eene 1 9 101915601 Housing tu NUES 1 10 1016525 Shroud Engine FE290 1 11 1016443 EE ad Rda 1 12 1016539 OFRING u aaa el od 1 13 1016536 Tube Ol Biller FE290 1 faa Qha ba 1 14 1016531 Dipstick tt o 1 15 101887601 Nut Nylon Lock MO 1 16 1015332 Wire Assembly 10 Braided Ground 1 17 1015969 Screw Pan Head x 1 x 14 4 18 1015649 Shroud Fama a den o oue E et ala eee E E uet edere 1 2004 2005 DS Golf Cars Illustrated Parts List Page 7 3 Page 7 4 2004 2005 DS Golf Cars Illustrated Parts List FE290 ENGINE IGNITION COMPONENTS AND FLYWHEEL ITEM PART NO DESCRIPTION QTY 1 2 3 4 1 101915701 Flywheel 1 2
143. r 18780 18 includes items 1 16 144 inch DC cord with male 3 pin plug 12 AWG 108 inch cord with no 1 1 Assembly Case uu sense an 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 10 3 101838201 Assembly Transformer 2 00 010000000000 00000000 1 4 1015914 Assembly Heatsink with Diodes includes mounting hardware 1 5 101914401 Assembly Voltage Suppressor 1 6 101838501 Kit Wire Assembly rhet tet eei utet 1 7 101828501 Ammeter includes 1 8 101838301 Relay Power 48 DC includes mounting hardware 1 9 101838701 Bracket Power Relay Mounting pp 1 10 101838601 Switch 4 Position Slide et een 1 11 101828901 Cordset DC 113 Inch Long with Male 3 Pin Plug 12 AWG 1 11 101828902 Cordset DC 154 Inch Long with Male 3 Pin Plug 12 AWG 1 11 101828903 Cordset DC 250 Inch Long with Male 3 Pin Plug 12 AWG 1 12 1012101 Assembly Fuse includes hardware pp 1 13 1012098 Bushing Strain Relief DC Cord 12 0 00 1 14 101838401 Breaker Circuit 10 Amp 242202444 0000 2 15 101831
144. r Golf Course Superintendent Other In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent Ease of Understanding Ease of Finding Information Clarity of Illustrations Index Usability Comments Suggestions Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publications Department 2004 2005 DS Golf Cars Illustrated Parts List am Ingersoll Rand Er Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Intl 1 706 863 3000 Fax 1 706 863 5808
145. rd Reverse Switch Tow Run Switch IQ System Vehicle RN 12 27 Batteries Charger Receptacle IQ System Vehicle sss 12 29 Computer Controller and Solenoid IQ System Vehicle 12 31 SECTION 13 ELECTRIC MOTOR Motor V Glide 36 Volt Vehicle 2 13 3 Motor PowerDrive System 48 Vehicle n 13 5 Motor MODEL 5BC59JBS6365 IQ System Vehicle 2 13 7 Motor Model EJ4 4001 IQ System Vehicle U emere 13 9 SECTION 14 TRANSAXLE ELECTRIC VEHICLE Transaxle Type G Electric Vehicle 14 3 Transaxle 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 15 9 PowerDrive 2 Battery Charger Domestic u u uu 15 11 GE PowerDrive Battery Charger 15 13 PowerDrive Battery Charger Export 19 15 PowerDrive Battery Charger European
146. rearleaf 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 7 15 strap a plate 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 stud engine mounting 7 15 stud ug 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 seatback 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
147. rounded plug pp 1 101802205 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 cord with male grounded plug 1 101802206 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 cord with male grounded 1 1 102273201 Assembly Case includes item 2 sse 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 12 3 102273301 Assembly Transformer includes rivets a 1 4 102273401 Plate Heatsihk nn 1 5 102273501 Assembly Diode with Heatsink Film includes mounting hardware 1 6 102273601 Kit Wire Assembly not shown 1 7 101828904 Cordset DC 113 Inch Long with Male 3 Pin Plug 12 AWG 1 7 101828905 Cordset DC 154 Inch Long with Male 3 Pin Plug 12 AWG 1 7 101828906 Cordset DC 250 Inch Long with Male 3 Pin Plug 12 AWG 1 8 102273701 Assembly Fuse 30 Amp includes terminal hardware 1 9 102273801 Ammeter includes mounting hardware 1 10 102273901 Bushing Strain Relief AC Cord Nt 1 11 1012098 Bushing Strain Relief DC Cord 12 AWG
148. ssories 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 706 863 3000 extension 3281 or 3854 Club Car J P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com 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 improve ments 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 Fro
149. strated Parts List Page 4 3 TYPICAL 2 PLACES TYPICAL 2 PLACES i E 8 7 e 4 PLACES 2004 2005 DS Golf Cars Illustrated Parts List Page 4 4 BRAKE PEDAL AND CABLE ASSEMBLY ITEM PARTNO DESCRIPTION SE 1234 1 101990801 Irae Bene alla 1 1 2 1241 Washer Flat 1 5 5 3 1013531 Spring Brake Return pp 1 1 4 1010921 Screw Hex Head 5 16 18 x 2 1 2 4 4 5 7473 Nut Nylon Lock 5 16 18 5 5 6 102022101 Kit Brake Cable includes item 7 and items 13 and 14 on page 4 3 2 2 7 1011779 E Elip 1 2 rer cere 2 2 8 101878201 Kit Brake Pedal includes items 9 and 10 1 1 9 7716 Screw Slotted Hex Washer Head 10 16 x 1 2 3 3 10 1013869 Pad Brake Pedal nas 1 1 11 1010878 Bumper RUDDe ce RAL lan 1 1 12 1028 Nut 1 4 20 1 1 13 101953101 Equalizer arena tid 1 1 14 102323201 Pin Clevis 5 16 later style hardware 1 1 15 102323101 Pin Bow Tie Locking later style 1 1 16 101953001 Bolt Hex Head Shoulder 3 8 x 1 earlier style hardware
150. t DC 146 Inch Long 10 AWG 1 8 101643303 Cordset DC 242 Inch Long 10 1 9 1012101 Assembly Fuse Includes Hardware 1 10 1012098 Bushing Strain Relief 12 AWG DC Cord 1 10 1012042 Bushing Strain Relief 10 AWG DC 1 11 1015917 Bushing Strain Relief AC Cord Nt 1 12 101591601 Cordset AC 72 Inch Long standard pp 1 12 101591602 Cordset AC 108 Inch Long 1 13 1015906 Assembly Timer Kit includes mounting hardware 1 14 1015913 Assembly Control Cable pp 1 2004 2005 DS Golf Cars Illustrated Parts List Page 15 3 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 QTY 1234 101643401 Charger Accu Power Export 230 V 36 DC 50 Hz model number 14410 11 includes items 1 14 108 inch DC cord 108 inch AC cord 1 1 N A Assembly Gase ett 1 2 7577 Screw Pan Head Self Tapping 10 16 x 1 2 10 3 1015936 Assembly Transformer 2 cdi
151. tem Exhallst rie dada LS 1 2 1015814 Bracket Muffler cio ite ted cheat td diee Badge teda 1 3 332 Washer Rat ala ea a v terti 2 4 451 Washer Lock 1 4 ia EH i e ae hae i D reb di ded 2 5 7847 Screw Hex Head 1 4 20 x 3 4 2 6 1017689 Clamp Mule a eee 1 7 1012830 Screw Hex Head Cap M8 x 1 25 x 22 MM 1 8 7174 Washer Lock 5 16 5 US n cri 1 9 1015075 Washer Flat 5 16 iaa sc c aaa qana led 1 10 1012528 Nut Hex M8 x 1 25 2 11 1013734 Washer LOCK 8 mpm iii ee ann ern 2 12 1015330 Gasket EXhaust ans na a 1 2004 2005 DS Golf Cars Illustrated Parts List Page 9 3 TORQUE CONVERTER DRIVE CLUTCH ITEM PART NO DESCRIPTION QTY 1 2 3 4 101833902 Assembly Drive Clutch includes items 1 19 1 1 1016801 Kit Drive Clutch Weight 222 2 gore eter 1 2 101929801 Assembly Fixed 1 3 1014049 Bearing Du ua 1 4 1014050 Retainer aan een 1 5 1014051 Spring Drive Clutch Black 2 1 6 1016289 Spacer Fixed Face Shaft 1 7 1014057 RING Reta MING e DDR 1 8 1014059 Assembly Drive
152. upport kit 1 15 cap 6 volt battery battery 4 port dust 12 27 fuel tank 8 3 key switch 6 9 12 3 protector 12 9 seatback 1 13 cap hub 5 9 15 3 15 5 15 7 carburetor 8 5 8 7 carburetor float level tool 16 7 12 13 12 17 12 29 capacitor 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 12 27 Page i 9 gear carrier 11 7 11 13 rocker arm 7 9 wiper switch 12 9 case gasket 14 5 charger bezel tool 16 3 chargercase 15 3 15 5 15 7 15 9 15 11 15 15 15 17 charger accu power battery 15 3 15 5 15 7 charger PowerDrive 2 battery 15 11 15 13 charger PowerDrive battery 15 9 15 15 15 17 choke button 8 11 choke valve 8 11 choke valve o ring 8 11 circuit breaker 15 amp 15 9 15 11 15 13 clamp battery 6 15 cable 12 13 cable retaining 8 9 hose air intake 8 11 hose bronze 8 7 hose fuel 8 3 hose gray 8 3 8 7 hose red 8 3 muffler 9 3 plastic fuel line 8 3 clamp oil sending wire 7 11 clamp wire 7 5 clamp screw 13 3 13 5 13 7 clevis upper delta 5 9 clip 5 3 clip body keeper cluster brake 4 3 clutch alignment tool 16 5 clutch removal tool 16 3 clutch tool kit 16 5 clutch drive 10 3 clutch driven 10 5 coil field 6 11 ignition 7 5 resistor 12 11 collar axle shaft collet 7 9 column steering 5 3 communication display module 16 5 12 19 12 31 1
153. use col 101621601 N WARNING CAN CAUSE SEVERE INJURY lt ka manifold amp muffler KEEP CLEAR cci 1019605 01 ON STARTER GENERATOR GASOLINE EXPLOSION FIRE AND ENGINE Can cause severe injury or death No smoking sparks or open flame Stop engine allow to cool before refueling e Turn fuel valve on during operation off during storage or transport 101547601 ON VEHICLE FRAME NEAR BATTERY A WARNING N WARNING Negative frame ground Can cause severe injury Excessive speed can cause severe Do not contact positive battery post or cable injury or death Do not tamper with to Disconnect negative battery cable first engine governor adjustment CC1101915201 Page 3 2 2004 2005 DS Golf Cars Illustrated Parts List DECALS GASOLINE VEHICLE ITEM PARTNO DESCRIPTION c lence 1234 1 101960601 Decal Driver Passenger Warning 2 1 2 101825101 Decal Key SWIt Ru iae Pee toa Er 1 3 101621601 Decal Operating Instructions 1 4 101547601 Decal Gasoline Warning 1 5 101960501 Decal Rotating Parts and Hot Manifold Warning 2 6 101915201 Decal Frame Ground and Governor Warning 1 7 102259001 Emblem IR Gold on front
154. vehicle only includes items 19 and 20 u u 1 19 1011084 Nut UNF Hex Jam 1 4 28 2 2 20 1011734 Joint Spring Loaded Ballu z u 2 2 21 8754 Nut Nylon Lock 3 8 16 2 2 22 8233 Nut Nylon Lock 1 4 20 4 4 23 1014007 Washer Flat Type B 1 4 4 4 24 1011694 Support Accelerator Pivot Rod 2 2 25 101861901 Screw Hex Head Cap 1 4 20 x 1 1 8 4 4 101187702 Kit Park Brake Latch includes item 26 and items 18 22 on page 4 5 1 1 26 N A Ratchet Park Brake una uu a ha tried 1 1 2004 2005 DS Golf Cars Illustrated Parts List Page 4 7 STEERING FRONT AND REAR SUSPENSION B 2004 2005 DS Golf Cars Illustrated Parts List Page 5 2 STEERING COLUMN ITEM PARTNO DESCRIPTION Sl 1234 1 1013861 Joint Compound Steering includes items 2 and 3 1 1 2 1017226 Screw Hex Head Cap M8 x 1 25 x 30 mm 3 3 3 7174 Washer Lock 5 16 3 3 4 101984801 Kit Steering Column Mounting Bracket 1 1 5 1016663 Screw Phillips Type A 12 11 x 5 8 2 2 6 1016269 Screw Hex Washer Head Thread Forming 5 16 18 2 2 2 7 334 Washer um uu at
155. vice Package includes items 29 through 33 1 29 101942301 Kit 3 pin Recept 8 Wedge 1 30 N A Sensor Motor Speed ADG iii eere nei 1 31 N A Screw 8 32 Taptite Thread 2 32 N A Magnet ADC 1 33 Serew 1 4 20 X 0 5 atten imp ea 1 34 N A Bolt 1 4 20 x 0 73 Thread Forming 2 35 451 Lockwasher 1 4 Helical Split 2 3 36 7174 Lockwasher 5 16 Split m u Sun Rain 1 2004 2006 DS Golf Cars Illustrated Parts List Page 13 9 TRANSAXLE ELECTRIC VEHICLE ed Parts Page 14 2 2004 2005 DS Golf Cars Illustrat TRANSAXLE TYPE G ELECTRIC VEHICLE ITEM PART NO DESCRIPTION QTY 1234 101896001 Transaxle includes items 1 30 1 1 101895801 Axle Assembly Passenger Side includes item 3 1 2 101895901 Axle Assembly Driver Side includes item 3 1 3 101922201 SUL xta tr 4 4 102357001 Screw Flange Head M10 x 1 5 x 30 mm 10 5 101928701 Gasket Liquid 8 8 oz 250 9 A R 6 101923501 Seal Oil RI oe wae 1 7 101895501 Gear Case 5
156. w Phillips Pan Head 8 Type ABR 3 9 101894901 Fuse 3 8 Ambp tle 1 10 101801001 Plate Receptacle Backing 2 2 a 1 11 101832001 Screw Phillips Pan Head 27 18 x 3 4 a 4 12 101797701 Battery 8 Volt PowerDrive includes item 13 a 6 12 101797702 Battery 8 Volt PowerDrive Dry includes item 13 6 13 101797801 Cap Battery 4 Port Gang 1 14 101795701 Wire Assembly 6 Black 5 15 1014304 Nut Hex Stainless Steel 5 16 18 u na these e 12 16 101090801 Hold Down Battery 3 17 1015072 Nut Nylon Lock Stainless Steel 5 16 18 6 18 1011578 Washer Flat Type B Wide 5 16 6 19 TREMENDO 6 2004 2005 DS Golf Cars Illustrated Parts List Page 12 29 ware 0927 E D oh TYPICAL 2 PLACES 22 TYPICAL 3 PLACES TYPICAL 2 PLACES ae 1 j TYPICAL 2 PLACES TYPICAL 2 PLACES OS 1 2 PLACES 2004 2005 DS Golf Cars Illustrated Parts List Page 12 30 COMPUTER CONTROLLER AND SOLENOID IQ SYSTEM VEHICLE ITEM PART NO DESCRIPTION QTY 1234 1 101956501 Controller 48 250 1 1 101956502 Controller
157. with diode includes items 21 and 22 1 21 1012528 N t M85c1 1 4 cete t 2 22 1013734 Washer LOCK BoM u Su Sus 2 23 1014947 Assembly Resistor uuu settee sik aym Her t eA ee 1 24 8639 Tie Wire a ees see eee 1 25 Z Bracket Controller Cover u u uq q as 1 Special order item available upon request 2004 2005 DS Golf Cars Illustrated Parts List Page 12 31 ELECTRIC MOTOR 13 2004 2005 DS Golf Cars Illustrated Parts List Page 13 2 MOTOR V GLIDE 36 VOLT VEHICLE ITEM PART NO DESCRIPTION QTY 1234 102237401 Assembly 36 Volt Motor 2 97 hp includes items 1 17 1 1 1017944 Shield u au 1 2 1017945 Assembly Stator Shell and Winding a 1 3 1017947 Package Hardware includes items 4 7 1 4 N A B shing Insulator 2 5 N A Washer 5 16 ko A pee eren heuer eine 4 6 N A Nut Flex 5 16 18 u t EE ERE b ml 4 7 N A Bushing un a uD 2 8 1017952 Screw Clamp 5 ect sc 4 9 1017953 Screw Bearing Retainer r 2 10 1017951 Shield End sic p sm a asad A ee eve 1 11 1017949 Screw Br sh Holdet 2 12
158. y with Taillight Opening Burgundy pp 1 17 1013032 Door Access Blacks ita 1 18 1015525 Nut Blind 1 4 20 2 19 1015032 Mat Floor mte p I ee ad 1 20 102221201 Pad Wear at a Q a Sus 2 21 8248 Screw Phillips Truss Head 1 4 20 x 3 4 2 2004 2005 DS Golf Cars Illustrated Parts List Page 1 9 2004 2005 DS Golf Cars Illustrated Parts List Page 1 10 SEAT BOTTOM AND ARMREST ITEM PARTNO DESCRIPTION SIE 1234 1 102174201 Assembly Seat Bottom Buff includes items 2 and 3 1 1 2 101998201 Cover Vinyl Seat Bottom Buff 1 1 3 1010543 Insert Wood 5 xs muiata u iion hs 12 12 1 102174202 Assembly Seat Bottom White includes items 2 and 3 1 1 2 101998202 Cover Vinyl Seat Bottom White 1 1 3 1010543 Insert cR A pa 12 12 1 102174204 Assembly Seat Bottom Black includes items 2 and 3 1 1 2 101998204 Cover Vinyl Seat Bottom Black pp 1 1 3 1010543 Insert WOO ee Mee vA 12 12 1 102174205 Assembly Seat Bottom Gray includes items 2 and 3 1 1 2 101998205 Cover Vinyl Seat Bottom Gray 1 1 3 1010543 Insert WOOG A 12 12 4 1019

2004-2005 DS IPL Gas/Electric

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