1995 - 1996 ILLUSTRATED

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1995 - 1996ILLUSTRATEDPARTS LISTTOURALL, RESORT VILLAGER,TRANS-PORTER/TRANS-SENDERMANUAL NUMBER 1018862-03PRINT CODE 0196B1008A

USING THE ILLUSTRATED PARTS LISTWARNING THIS MANUAL IS TO BE USED ONLY FOR IDENTIFICATION AND ORDERING OF SERVICE PARTS. BESURE TO READ AND USE THE MAINTENANCE AND SERVICE MANUAL BEFORE ATTEMPTING ANY VEHICLEREPAIRS.This manual covers all 1995 and 1996 Club Car Transportation vehicles. This includes Tourall,Resort Villager, Trans-porter and Trans-sender models. There were numerous product changesaffecting many 1995 and 1996 Transportation vehicles, and these changes are also covered in thismanual.The manual is divided into 17 sections. Sections 1 through 4 pertain to both gasoline and electric vehicles, sections 5 through 11 pertain to gasoline vehicles only, sections 12 through 15 pertain toelectric vehicles only, and sections 16 and 17 pertain to both gasoline and electric vehicles. Note thatthere are two or three flags on the outside edge of each page. The first flag will contain the sectionnumber of which that page is a part. The other flag (or flags) will contain either the letter G or E, signifying that the page pertains to either the gasoline or electric vehicle only, or to both the gasoline andelectric vehicles.Use the Table of Contents to find the sections and pages that contain the parts and assemblies youseek. The Table of Contents lists section titles and numbers, and under them, the individual page titlesand numbers to be found in that section.You will also find vehicle models and serial numbers specified within the listings for individual pagetitles. These model and serial number specifications identify the vehicles on which parts usage asdescribed on a particular page either began or ended. Have the serial number(s) of your vehicle(s) athand and read the listings carefully when using the table of contents.Typically, there is a two-page spread for each individual page title in the Table of Contents (however,some titles required several spreads). On the left-hand page is an illustration showing the parts in theirrelative positions; the parts are each tagged with an item number in a balloon. The right-hand pageis the parts list page, and gives the page title at the top, then the item numbers (corresponding to thenumbers on the illustration), part descriptions, and quantity of parts used. Some item numbershave more than one part number because several models and/or configurations of a component arerepresented 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 listpage. A part that is indented to level 2 is a component of the level 1 part (assembly) that it is listedunder. 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 partis the quantity used per next higher level assembly of which it is a component. A part that is not indented is a level one part. This means that the quantity given is the quantity used per the portion of thevehicle illustrated on that particular spread.P. O. Box 204658Augusta, Georgia 30917-4658 USATelephone 706-863-3000Service Parts Fax 706-855-7413 1996, CLUB CAR INC.All rights reserved.This manual effective August 1, 1995Manual print code: 0196A00000

CONTENTSBODY AND TRIMSECTIONFRONT BODY .REAR BODY AND FENDER - TOURALL .FIRST SEAT AND SUPPORT STRUCTURE - TOURALL .SECOND SEAT AND COMPONENTS - TOURALL .REAR FOOTREST AND HANDRAILS - TOURALL .CENTER BODY AND TRIM - RESORT VILLAGER .REAR BODY AND FENDER - RESORT VILLAGER .SEATS AND SUPPORT STRUCTURES - RESORT VILLAGER .FIRST SEAT AND SUPPORT STRUCTURE - TRANS-PORTER/TRANS-SENDER .SECOND SEAT AND SUPPORT STRUCTURE - TRANS-PORTER/TRANS-SENDER .THIRD SEAT AND COMPONENTS - TRANS-SENDER .REAR FOOTREST AND HANDRAILS - TRANS-SENDER .REAR COVER - TRANS-PORTER/TRANS-SENDER .REAR CARGO BED - TRANS-PORTER .WHEELS AND TIRES .TRANSAXLEBRAKES, PEDAL, AND CABLE RING COLUMN .STEERING GEAR ASSEMBLY .FRONT SUSPENSION, UPPER - VEHICLES WITH 2-WHEEL BRAKINGFor All Tourall Vehicles; For Resort Villagers, Trans-porter/Trans-senders Prior to SerialNumber 9535-456328 .FRONT SUSPENSION, LOWER - VEHICLES WITH 2-WHEEL BRAKINGFor All Tourall Vehicles; For Resort Villagers, Trans-porter/Trans-senders Prior to SerialNumber 9535-456328 .FRONT SUSPENSION, UPPER - VEHICLES WITH 4-WHEEL BRAKINGFor Resort Villagers, Trans-porter/Trans-senders Serial Number 9535-456328 and Later .FRONT SUSPENSION, LOWER - VEHICLES WITH 4-WHEEL BRAKINGFor Resort Villagers, Trans-porter/Trans-senders Serial Number 9535-456328 and Later .22-3SECTIONREAR BRAKE ASSEMBLY, SELF-ADJUSTING - TOURALL .REAR BRAKES, MANUALLY ADJUSTED - RESORT VILLAGER, TRANS-PORTER/TRANS-SENDERFor 2 and 4-Wheel Brake Systems .BRAKE PEDAL AND CABLE ASSEMBLY - VEHICLES WITH 2-WHEEL BRAKINGFor Touralls, All Serial Numbers; For Resort Villagers, Trans-porter/Trans-sendersPrior to Serial Number 9535-456328 .BRAKE PEDAL AND CABLE ASSEMBLY - VEHICLES WITH 4-WHEEL BRAKINGFor Resort Villagers, Trans-porter/Trans-senders Serial Number 9535-456328 and Later .FRONT BRAKE ASSEMBLY - VEHICLES WITH 4-WHEEL BRAKINGFor Resort Villagers, Trans-porter/Trans-senders Serial Number 9535-456328 and Later .ACCELERATOR PEDAL ASSEMBLY, ELECTRIC VEHICLE - TOURALLFor Vehicles Prior to Serial Number 9529-445519 .ACCELERATOR PEDAL ASSEMBLY - GASOLINE VEHICLES AND ELECTRICRESORT VILLAGER, TRANS-PORTER/TRANS-SENDERFor Vehicles Prior to Serial Number 9529-445519 .ACCELERATOR PEDAL ASSEMBLYFor Vehicles Serial Number 9529-445519 and Later .STEERING AND 1-251-271-291-31SECTIONTRANSAXLE .14-34-54-74-94-114-134

CONTENTSELECTRICAL SYSTEM - GASOLINE VEHICLESSECTIONFORWARD AND REVERSE SHIFTER ASSEMBLY - GASOLINE VEHICLES .WIRING, GASOLINE VEHICLE - TOURALL .ELECTRICAL COMPONENT BOX, GASOLINE VEHICLE - TOURALL .ELECTRICAL COMPONENTS, GASOLINE VEHICLE - TOURALL .WIRING, GASOLINE VEHICLES - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER .ELECTRICAL COMPONENT BOX, GASOLINE VEHICLES - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER .ELECTRICAL COMPONENTS, FRONT BODY, GASOLINE - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER .CONTROLS AND GAUGES, GASOLINE VEHICLES - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER .ELECTRICAL COMPONENTS, REAR BODY, GASOLINE VEHICLE - RESORT VILLAGER .ELECTRICAL COMPONENTS, REAR BODY, GASOLINE - TRANS-PORTER/TRANS-SENDER .STARTER/GENERATOR ASSEMBLYFor Vehicles Prior to Serial Number 9533-452031 .STARTER/GENERATOR ASSEMBLYFor Vehicles Serial Number 9533-452031 and Later .STARTER/GENERATOR MOUNTING .BATTERY MOUNTING - GASOLINE VEHICLES 255-275-29SECTION6FE 290 ENGINE - TOURALL . 6-3 - 6-13FE 350 ENGINE - RESORT VILLAGER, TRANS-PORTER/TRANS-SENDER . 6-15 - 6-25FUEL, INTAKE, AND GOVERNOR SYSTEMSSECTIONFUEL SYSTEM .CARBURETOR ASSEMBLY, FE 290 - TOURALL .CARBURETOR ASSEMBLY, FE 350 - RESORT VILLAGER, TRANS-PORTER/TRANS-SENDER .CARBURETOR INSTALLATION .GOVERNOR AND ACCELERATOR CABLES .EXPANSION CHAMBER, CHOKE, AND FILTER, FE 290 - TOURALL .EXPANSION CHAMBER, CHOKE, AND FILTER, FE 350 - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER .EXHAUST SYSTEMTORQUE CONVERTER7-1588-38-5SECTIONDRIVE CLUTCH .DRIVEN CLUTCH .TRANSMISSION7-37-57-77-97-117-13SECTIONEXHAUST SYSTEM, FE 290 ENGINE - TOURALL .EXHAUST SYSTEM, FE 350 ENGINE - RESORT VILLAGER, TRANS-PORTER/TRANS-SENDER .799-39-5SECTION10TRANSMISSION . 10-3 - 10-5REAR SUSPENSION - GASOLINE VEHICLESSECTIONREAR SUSPENSION - GASOLINE VEHICLES .STABILIZER BAR - GASOLINE VEHICLES WITH 350 ENGINES .INNER FRAME - GASOLINE VEHICLES .11-311-511-711

CONTENTSELECTRICAL SYSTEM - ELECTRIC VEHICLESSECTION12FORWARD AND REVERSE SWITCH - ELECTRIC VEHICLES . 12-3ON-BOARD COMPUTER - TOURALL, RESORT VILLAGER . 12-5ON-BOARD COMPUTER - TRANS-PORTER/TRANS-SENDER . 12-7MULTI-STEP POTENTIOMETERFor Vehicles Prior to Serial Number 9529-445799 . 12-9CONTINUOUSLY VARIABLE POTENTIOMETERFor Vehicles Serial Number 9529-445799 and Later . 12-11WIRING -TOURALL WITH MULTI-STEP POTENTIOMETERFor Vehicles Prior to Serial Number 9529-445799 . 12-13WIRING -TOURALL WITH CONTINUOUSLY VARIABLE POTENTIOMETERFor Vehicles Serial Number 9529-445799 and Later . 12-15ELECTRICAL COMPONENTS, FRONT BODY, ELECTRIC VEHICLE - TOURALL . 12-17ELECTRICAL COMPONENTS, REAR BODY, ELECTRIC VEHICLE - TOURALL . 12-19 - 12-21WIRING - RESORT VILLAGER WITH MULTI-STEP POTENTIOMETERFor Vehicles Prior to Serial Number 9529-445799 . 12-23WIRING - RESORT VILLAGER WITH CONTINUOUSLY VARIABLE POTENTIOMETERFor Vehicles Serial Number 9529-445799 and Later . 12-25ELECTRICAL COMPONENTS, CENTER BODY, (EARLY MODEL) ELECTRIC - RESORT VILLAGERFor Vehicles Made in Early 1995 . 12-27ELECTRICAL COMPONENTS, REAR BODY, (EARLY MODEL) ELECTRIC - RESORT VILLAGERFor Vehicles Made in Early 1995 . 12-29ELECTRICAL COMPONENTS, REAR BODY, (LATE MODEL) ELECTRIC - RESORT VILLAGERFor Vehicles Made in Late 1995 and All 1996 . 12-31 - 12-35WIRING - TRANS-PORTER/TRANS-SENDER WITH MULTI-STEP POTENTIOMETERFor Vehicles Prior to Serial Number 9529-445799 . 12-37WIRING - TRANS-PORTER/TRANS-SENDER WITH CONTINUOUSLY VARIABLE POTENTIOMETERFor Vehicles Serial Number 9529-445799 and Later . 12-39ELECTRICAL COMPONENTS, FRONT BODY, ELECTRIC - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER . 12-41CONTROLS AND GAUGES, ELECTRIC VEHICLES - RESORT VILLAGER,TRANS-PORTER/TRANS-SENDER . 12-43ELECTRICAL COMPONENTS, CENTER BODY - TRANS-PORTER/TRANS-SENDER . 12-45 - 12-47ELECTRICAL COMPONENTS, REAR BODY, ELECTRIC - TRANS-PORTER/TRANS-SENDER . 12-49BATTERY CHARGERSSECTIONPOWERDRIVE CHARGER, DOMESTIC - TOURALL, RESORT VILLAGER .POWERDRIVE CHARGER, EXPORT - TOURALL, RESORT VILLAGER .ON-BOARD POWERDRIVE CHARGER, DOMESTIC - TRANS-PORTER/TRANS-SENDER .ON-BOARD POWERDRIVE CHARGER, EXPORT - TRANS-PORTER/TRANS-SENDER .ELECTRIC MOTORREAR SUSPENSION - ELECTRIC VEHICLES13-313-513-713-9SECTIONMOTOR, POWERDRIVE 48 VOLT .131414-3SECTION15REAR SUSPENSION - ELECTRIC VEHICLES . 15-3SAFETY DECALSSECTIONSAFETY DECALS - TOURALL .16-3 - 16-5SAFETY DECALS - RESORT VILLAGER .16-7 - 16-9SAFETY DECALS - TRANS-PORTER/TRANS-SENDER . 16-11 -16 -1516

CONTENTSMAINTENANCE AND SERVICE TOOLSSECTIONTHE LAST SECTION OF THIS MANUAL CONTAINS A LIST OF MAINTENANCE AND SERVICE TOOLSAVAILABLE FROM CLUB CAR.17

BODY AND TRIM1GE

1GE1-2

ITEMPART 25 -041016939 -011016939 -021016939 -041016939 -061016939 -081016939 79731016604 -04201016620 -02201016620 /A10110171015032101728910167181017083 CRIPTION112345677777778910111213141515FRONT BODY23QTYGAS4KIT, FRONT BUMPER (INCLUDES ITEMS 2 - 5) .BUMPER, FRONT .SCREW, PHILLIPS TRUSS HEAD, 5/16 - 18 x 1 .NUT, NYLON LOCK, 5/16 - 18 .RIVET, BLIND PUSH TYPE .NAMEPLATE, SILVER .BODY, FRONT - GRAY .BODY, FRONT WITH HEADLIGHT OPENING - BEIGE .BODY, FRONT WITH HEADLIGHT OPENING - WHITE .BODY, FRONT WITH HEADLIGHT OPENING - GRAY .BODY, FRONT WITH HEADLIGHT OPENING - RED .BODY, FRONT WITH HEADLIGHT OPENING - DARK BLUE .BODY, FRONT WITH HEADLIGHT OPENING - DARK GREEN .SCREW, PHILLIPS TRUSS HEAD, 5/16 - 18 x 1 .TRIM, FRONT BODY .BOLT, CARRIAGE, 5/16 - 18 x 1 .WASHER, FLAT, 5/16 .NUT, NYLON LOCK, 5/16 - 18 .SCREW, FLANGE LOCK, 8 - 32 x 3/8 .NUT, SLAB BASE “T” (PACKAGE OF 4 PIECES) .TRIM, SIDE BUMPER GUARD (TOURALL ONLY) .TRIM, SIDE BUMPER GUARD(RESORT VILLAGER, TRANS-PORTER/TRANS-SENDER) .SCREW, SELF-TAPPING, #8 - 32 x 3/8 .COMPONENT, LEFT DASH, BLACK .COMPONENT, RIGHT DASH, BLACK .R

This manual covers all 1995 and 1996 Club Car Transportation vehicles. This includes Tourall, Resort Villager, Trans-porter and Trans-sender models. There were numerous product changes affecting many 1995 and 1996 Transportation vehicles, and these changes are also covered in this manual. The manual is divided into 17 sections.

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