Club Car Villager Homologated LSV Manual
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Club Car Villager Homologated LSV Manual

Electric low-speed vehicles
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2011
Villager Homologated LSV
Electric Low-Speed Vehicles
Manual Number 103814624
Edition Code 0711D0112C

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Summary of Contents for Club Car Villager Homologated LSV

  • Page 1 2011 Villager Homologated LSV Electric Low-Speed Vehicles Manual Number 103814624 Edition Code 0711D0112C...
  • Page 3 Replacement parts and accessories can be obtained from our network of authorized dealers and distributors. You can obtain the name and phone number of your closest authorized Club Car dealer or distributor by visiting our web site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts and Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3887.
  • Page 4 NOTE: This illustrated parts list represents the most current information at the time of publication. Club Car, LLC. is continually working to further improve its vehicles and other products. These improvements may affect the parts used to service the vehicle. Any modification and/or significant change in specifications will be for- warded to all Club Car and Carryall distributors/dealers and will, when applicable, appear in future editions of this illustrated parts list.

  • Page 5: Table Of Contents

    Brake Cables and Equalizer ................................. 4-13 Accelerator Pedal Assembly (Style B) ............................4-15 SECTION 5 – STEERING, FRONT AND REAR SUSPENSION Steering Column ..................................... Steering Gear Assembly ................................Rear Suspension Components ..............................Front Suspension, Lower ................................2011 Villager Homologated LSV Page 1...
  • Page 6 Maintenance and Service Tools ..............................10-3 Maintenance and Service Tools, Continued ......................... 10-5 Maintenance and Service Tools, Continued ......................... 10-7 Maintenance and Service Tools, Continued ......................... 10-9 Maintenance and Service Tools, Continued ......................... 10-11 SECTION i – INDEX Page 2 2011 Villager Homologated LSV...

  • Page 7: Section 1 - Body And Trim

    BODY AND TRIM...
  • Page 8 000364-003 Page 1-2 2011 Villager Homologated LSV...

  • Page 9: Front Seat Bottom And Armrests

    Hip Restraint, Pass Side ..........................Washer, 1/4 Type A Narrow Flat ......................Note: Sub-components contained in items 10, 15, and 20 are the same as those shown for item 5, except for the vinyl seat covers. 2011 Villager Homologated LSV Page 1-3...
  • Page 10 000387-002 Page 1-4 2011 Villager Homologated LSV...

  • Page 11: Rear-Facing Seat Bottom - Villager 2+2

    Lockwasher, 1/4 Type A Int.tth ......................8963 Screw, 5/16-18 X 1.75 Hex-Head Cap ....................Note: Sub-components contained in items 17, 21, and 25 are the same as those shown for item 13, except for the vinyl seat covers. 2011 Villager Homologated LSV Page 1-5...
  • Page 12 000922-002 Page 1-6 2011 Villager Homologated LSV...

  • Page 13: Mirrors, Windshield, Wiper - To Be Determined

    MIRRORS, WINDSHIELD, WIPER – TO BE DETERMINED ITEM PART NO. DESCRIPTION 1 2 3 4 Kit, Wndshld/wiper/mirror, Hom ......................2011 Villager Homologated LSV Page 1-7...
  • Page 14 000920-003 Page 1-8 2011 Villager Homologated LSV...

  • Page 15: Front Body

    Dash Component, Passenger-Side, Black ..................1013344 Dash Component, Driver-Side ......................1013494 Cover, Screw Head ..........................1015528 Screw, #10 x 1-1/4 Phillips Head ..................... 102278001 Boot, Steering Column Round ......................7973 Rivet, 3/16 X .400 Blind ........................2011 Villager Homologated LSV Page 1-9...
  • Page 16 23-28 17-22 000921-003 Page 1-10 2011 Villager Homologated LSV...

  • Page 17: Rear Body And Fenders

    Trim, Body, Center, Homol Vill ....................... Instl, Floormat, Hndbrk, Badgd (includes item 32) ................ 101503204 Floormat - Badged Parkbrake ......................8248 Screw, 1/4-20 X 0.75 Truss-Head Machine ..................8251 Screw, 1/4-20 X 1.0 Truss-Head Machine ................... 2011 Villager Homologated LSV Page 1-11...
  • Page 18 000823-002 Page 1-12 2011 Villager Homologated LSV...

  • Page 19: Dash Canopy Brace And Cowl Trim

    Strip, Trim, Dash, Black ........................103395101 Plate, Retention, Closeout ......................... 1241 Washer, 5/16 Type A Flat ........................1606 Rivet, 3/16 X .500 Alum Pop ......................Washer, 1/4 Type A Narrow Flat ...................... 8233 Locknut, 1/4-20 Nylon Insert ......................2011 Villager Homologated LSV Page 1-13...
  • Page 20 000930-003 Page 1-14 2011 Villager Homologated LSV...

  • Page 21: Tops - Villager 2 With Bed Box

    Tube, Gusset, V2, Rh (with Bed Box) ....................103801202 Tube, Gusset, V2, Lh (with Bed Box) ....................103801401 Weldment, Tube, Gusset, V2 ........................7561 Bolt, 3/8-16 X 3.00 Hex Head ......................... 8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 1-15...
  • Page 22 000930-004 Page 1-16 2011 Villager Homologated LSV...

  • Page 23: Tops - Villager 2

    Plate, Washer, Tops ..........................Washer, 3/8 Type B Flat ........................8754 Locknut, 3/8-16 Hex ..........................103762001 Cap, Dome, Black, 3/8 Hex ........................7561 Bolt, 3/8-16 X 3.00 Hex Head ......................... 8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 1-17...
  • Page 24 000924-002 Page 1-18 2011 Villager Homologated LSV...

  • Page 25: Rear Footrest And Handrails - Villager 2+2

    Washer, #10 Type A Flat ........................Washer, 1/4 Type A Narrow Flat ...................... 7410 Screw, 5/16-18 X 1.25 Truss Hd ......................7473 Locknut, 5/16-18 Nylon Insert ......................8419 Screw, 1/4-20 X .625 Truss Hd ......................2011 Villager Homologated LSV Page 1-19...
  • Page 26 000930-002 Page 1-20 2011 Villager Homologated LSV...

  • Page 27: Tops - Villager 2 + 2

    Washer, 3/8 Type B Flat ........................8754 Locknut, 3/8-16 Hex ..........................103762001 Cap, Dome, Black, 3/8 Hex ........................1624 Screw, 3/8-16 X 1.50 Hex-Head Cap ....................7561 Bolt, 3/8-16 X 3.00 Hex Head ......................... 8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 1-21...
  • Page 28 000929-002 Page 1-22 2011 Villager Homologated LSV...

  • Page 29: Seat Backs

    Seatback Asm, Front, Black ........................103739006 Seatback Asm, Front, Gray ........................103754601 Weldment, Support, Seatback ......................103755001 Plate, Spacer ..............................Washer, 3/8 Type A Flat ..........................8754 Locknut, 3/8-16 Hex ..........................8861 Bolt, 3/8-16 X 1.75 Hex ..........................2011 Villager Homologated LSV Page 1-23...
  • Page 30 000926-002 Page 1-24 2011 Villager Homologated LSV...

  • Page 31: Seat Belts

    Screw, 7/16-20 X 1.75 ..........................103803601 Bracket, Retractor, Lsv, Homol ....................... 103815901 Plate, Orient, Retractor ..........................103816001 Retractor, 3pt, Homol ..........................103816101 Seat Belt, 2pt, Homol ..........................103819001 Spacer, 12.7 Id X 5.0 L ..........................2011 Villager Homologated LSV Page 1-25...
  • Page 32 000939-001 Page 1-26 2011 Villager Homologated LSV...

  • Page 33: Bed Box

    Spacer .31 X .38 X .98 .......................... 103801001 Asm, Bedbox, V2 ........................... 103817401 Tube-support, Bedbox, V2 ........................ 7473 Locknut, 5/16-18 Nylon Insert ......................8963 Screw, 5/16-18 X 1.75 Hex-Head Cap .................... AM11262 Rubber Latch W/knob ......................... 2011 Villager Homologated LSV Page 1-27...
  • Page 34 000931-003 Page 1-28 2011 Villager Homologated LSV...

  • Page 35: Canopy

    Screw, 1/4-20 X 1.75 Hex Sems ......................103774601 Spacer, Al, .63 Hex-.28id-.81l ......................103814301 Trim, Canopy, Homol, Top ......................... 103818001 Trim, Edge, Canopy, Btm ........................Washer, 1/4 Type A Narrow Flat ...................... 8233 Locknut, 1/4-20 Nylon Insert ......................2011 Villager Homologated LSV Page 1-29...

  • Page 37: Section 2 - Wheels And Tires

    WHEELS AND TIRES...
  • Page 38 00269-014 Page 2-2 2011 Villager Homologated LSV...
  • Page 39 Asm-kenda Dot, E-marked ........................102540701 Lug Nut, 1/2" Closed End ........................103694501 Hub Cap, 7 Prong ............................103755602 Asm, Whl/tire, 10" Al, Emark ........................103755701 Cap, Wheel, Chrome Center ........................7310 Valve Stem ..............................2011 Villager Homologated LSV Page 2-3...

  • Page 41: Section 3 - Decals

    DECALS...
  • Page 42 2371 Page 3-2 2011 Villager Homologated LSV...

  • Page 43: Safety Decals

    Decal, Forward/Reverse, Electric ......................103809401 Decal, Op Instr, Roof Mount ........................103809501 Decal, Occ Warn, Roof Mount ........................ 103827201 Decal, Ignition, Homologated ....................... Note: Items without part numbers in the list above are for reference only. 2011 Villager Homologated LSV Page 3-3...
  • Page 44 2372 Page 3-4 2011 Villager Homologated LSV...

  • Page 45: Safety Decals - Continued

    DESCRIPTION 1 2 3 4 101705702 Decal, Warning, Lsv ........................... 101908601 Decal, Tow/Run Switch Warning ......................101931501 Decal, Component Cover ........................Note: Items without part numbers in the list above are for reference only. 2011 Villager Homologated LSV Page 3-5...
  • Page 46 000944-003 Page 3-6 2011 Villager Homologated LSV...

  • Page 47: Logo Decals

    Decal, Front Grill, 91 Mm Lx ........................103749002 Decal, Front Grill, 169 Mm Lx ......................... 103749101 Decal, Villager 2+2 Lsv ..........................103749201 Decal, Villager Lsv, Lx Pkg ........................103819901 Decal, Villager 2 Lsv ........................... 2011 Villager Homologated LSV Page 3-7...

  • Page 49: Section 4 - Brakes, Pedal, And Cables

    BRAKES, PEDAL, AND CABLES...
  • Page 50 000293-002 Page 4-2 2011 Villager Homologated LSV...

  • Page 51: Rear Brake Assembly, Manually-Adjusted - Vehicles With 4-Wheel Brakes

    Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) ....... Arm, Brake Lever ........................... 101791101 Drum without Center Hole, Brake ......................Note: Passenger-side brake cluster not shown. Components have a similar appearance to driver-side brake cluster components. 2011 Villager Homologated LSV Page 4-3...
  • Page 52 000298-001 Page 4-4 2011 Villager Homologated LSV...

  • Page 53: Front Brake Assembly - Vehicles With Four-Wheel Brakes

    Lockwasher, 1/4 Split ........................101880701 Shoe Brake Manual Adj (Available in Kit, Non-Asbestos Brake Shoe) ....... Arm, Brake Lever ........................... Note: Passenger-side brake cluster not shown. Components have a similar appearance to driver-side brake cluster components. 2011 Villager Homologated LSV Page 4-5...
  • Page 54 000188-004 Page 4-6 2011 Villager Homologated LSV...

  • Page 55: Accelerator Pedal Assembly - Electric Vehicles With Mcor

    Screw, 3/8-16 X 1.50 Hex-Head Cap ....................Washer, 3/8 Type A Flat ..........................7473 Locknut, 5/16-18 Nylon Insert ....................... 8233 Locknut, 1/4-20 Nylon Insert ......................... 8717 Locknut, 1/4-28 Nylon Insert ......................... 8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 4-7...
  • Page 56 **** 000956-002 Page 4-8 2011 Villager Homologated LSV...

  • Page 57: Hand Brake

    7473 Locknut, 5/16-18 Nylon Insert ....................... 8963 Screw, 5/16-18 X 1.75 Hex-Head Cap ....................Note: ****Key is special order item available upon request. Have the vehicle serial number available when ordering a replacement key. 2011 Villager Homologated LSV Page 4-9...
  • Page 58 000945-001 Page 4-10 2011 Villager Homologated LSV...

  • Page 59: Brake Pedal

    Pin, Bow Tie Locking ..........................102323201 Pin, 3/8 X 1-5/16 Clevis ........................1241 Washer, 5/16 Type A Flat ........................1242 Nut, 5/16-18 Hex ........................... Washer, 3/8 Type A Flat ........................7473 Locknut, 5/16-18 Nylon Insert ......................2011 Villager Homologated LSV Page 4-11...
  • Page 60 000943-002 Page 4-12 2011 Villager Homologated LSV...

  • Page 61: Brake Cables And Equalizer

    1016319 Equalizer Weld Assembly ........................1035 Cotter Pin, 3/32 x 1 ..........................103808101 Cable, Brake, Ind Park, Rear ....................... 1242 Nut, 5/16-18 Hex ............................Nut, Hex 3/8-16 ............................7473 Locknut, 5/16-18 Nylon Insert ....................... 2011 Villager Homologated LSV Page 4-13...
  • Page 62 000188-005 Page 4-14 2011 Villager Homologated LSV...

  • Page 63: Accelerator Pedal Assembly (Style B)

    Screw, 3/8-16 X 1.50 Hex-Head Cap ....................Washer, 3/8 Type A Flat ..........................7473 Locknut, 5/16-18 Nylon Insert ....................... 8233 Locknut, 1/4-20 Nylon Insert ......................... 8717 Locknut, 1/4-28 Nylon Insert ......................... 8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 4-15...

  • Page 65: Section 5 - Steering, Front And Rear Suspension

    STEERING, FRONT AND REAR SUSPENSION...
  • Page 66 000935-001 Page 5-2 2011 Villager Homologated LSV...

  • Page 67: Steering Column

    Shaft, Intermediate Steering (includes items 31 and 32) ............1017226 Bolt, Hex-Head, 8mm X 1.25 - 30 ....................7174 Lockwasher, 5/16 Split ........................Washer, 3/8 Type A Flat ..........................8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 5-3...
  • Page 68 000960-001 Page 5-4 2011 Villager Homologated LSV...

  • Page 69: Steering Gear Assembly

    Tie Wrap, 8" Nylon ..........................103653401 Link, Drag, Male Thd ..........................1624 Screw, 3/8-16 X 1.50 Hex-Head Cap ....................Washer, 3/8 Type A Flat ..........................7555 Nut, 1/2-20 Hex, Left-Hand Thread ...................... 8754 Locknut, 3/8-16 Hex ..........................2011 Villager Homologated LSV Page 5-5...
  • Page 70 000937-002 Page 5-6 2011 Villager Homologated LSV...

  • Page 71: Rear Suspension Components

    Bracket, Shock Mount, Ind Park, Rh ..................... 103807302 Bracket, Shock Mount, Ind Park, Lh ..................... Note: Only the driver-side rear suspension is shown. Parts for the passenger- side rear suspension are identical except for the leaf spring/shock mounting plate. 2011 Villager Homologated LSV Page 5-7...
  • Page 72 000940-001 Page 5-8 2011 Villager Homologated LSV...

  • Page 73: Front Suspension, Lower

    Spring Asm, Front, 2 Leaf (includes items 19 through 21) ............1012303 Bushing, Steel ............................1015583 Bushing, Urethane ..........................103502701 Spring, Front, 2 Leaf ..........................Nut, Hex 3/8-16 ............................8754 Locknut, 3/8-16 Hex ..........................8755 Screw, 3/8-16 X 3.375 Hex Cap ......................2011 Villager Homologated LSV Page 5-9...
  • Page 74 000941-001 Page 5-10 2011 Villager Homologated LSV...

  • Page 75: Front Suspension, Upper

    Screw, 3/8-16 X 1.50 Hex-Head Cap ....................2402 Screw, 3/8-16 X 2.25 Hx Hd Cap ...................... Washer, 3/8 Type A Flat ........................8754 Locknut, 3/8-16 Hex ..........................8861 Bolt, 3/8-16 X 1.75 Hex ........................2011 Villager Homologated LSV Page 5-11...
  • Page 76 000938-001 Page 5-12 2011 Villager Homologated LSV...

  • Page 77: Front Spindles And Hubs

    Asm, Spindle, Rh, 4wb, Sp (includes items 19 through 22) ............1015597 Fitting, 1/4-28 Thread-Forming Grease ..................Subasm, Spindle, Rh, 4wb ......................... 7048 Bushing, Flanged Bronze ........................8067 Bushing, Bronze Spindle ........................7840 Nut, 3/4-16 Hex Slotted ........................... 2011 Villager Homologated LSV Page 5-13...
  • Page 78 000470-003 Page 5-14 2011 Villager Homologated LSV...

  • Page 79: Steering Wheel

    Instl, Steer Wheel, Champ Lsv (includes items 2 through 6) ............1017273 Nut, 5/8-18 Nylon Insert Jam ......................101850301 Screw, #12-16 X 0.50 Washer-Head Hi-Lo ..................103724504 Steering Wheel, Soft Spl ........................103724602 Cover, Steering Wheel, Gener ......................103829401 Logo, Cci, Steer Wheel ........................2011 Villager Homologated LSV Page 5-15...

  • Page 81: Section 6 - Electrical System

    ELECTRICAL SYSTEM...
  • Page 82 000243-002 Page 6-2 2011 Villager Homologated LSV...

  • Page 83: Motor Controller Output Regulator (Mcor)

    PART NO. DESCRIPTION 1 2 3 4 1015752 Screw, #12-16 X 0.625 Hi-Lo ........................101920101 Kit, 3-Pin Wedge Lock ..........................101936801 Kit, 2-Pin Wedge Lock ..........................102101001 Bar, Drive, Cast ............................102101101 MCOR ................................2011 Villager Homologated LSV Page 6-3...
  • Page 84 4257_44 W51 18_RED_WHT W52 18_GRN_WHT 1 2 3 4 5 6 W70 16_BLK 101942801_2 102420301_1 TO SPEEDOMETER G(5) L(2) 102196801_1 W68 18_BLK X(1) W39 18_BRN FLASHER W49 18_RED HORN 4257_29 W71 16_BLK 4257_5 000954-003 Page 6-4 2011 Villager Homologated LSV...
  • Page 85 W46 16_RED SW_18 SW_5 BRK/TURN/POS LAMP W43 16_GRN_WHT W48 16_GRN SW_10 W04 16_YEL W01 16_YEL W03 16_YEL SW_11 HAZARD RELAY HAZARD RELAY W29 16_BRN W30 16_BRN SW_17 SW_19 W40 16_BRN BRAKE LIGHT RELAY 000954-003 2011 Villager Homologated LSV Page 6-5...
  • Page 86 See previous two pages for illustration. Page 6-6 2011 Villager Homologated LSV...

  • Page 87: Lighting Harness

    LIGHTING HARNESS ITEM PART NO. DESCRIPTION 1 2 3 4 103802901 Harness, Lighting, Vill, Homol ........................ 103816901 Harn, Converter, Ds Lsv Homol ......................103848601 Harness, Jumper, Brake Switch ......................2011 Villager Homologated LSV Page 6-7...
  • Page 88 000854-002 Page 6-8 2011 Villager Homologated LSV...

  • Page 89: Speedometer

    103740101 Cover, Koso Speedometer ......................... 103740201 Cap, Koso Speedometer Cover ......................103740301 Bracket, Koso Speedometer ......................103740401 Screw, Panhead 10-32 X 5/8 ......................103740501 Screw, Panhead 10-32 X 2-1/2 ......................103740801 Grommet, Speedometer ........................2011 Villager Homologated LSV Page 6-9...
  • Page 90 10 11 14 000952-005 Page 6-10 2011 Villager Homologated LSV...

  • Page 91: Electrical Components, Front Body

    Screw, 1/4-20 X 1.0 Hex-Head Cap ...................... Washer, 1/4 Type A Narrow Flat ......................7173 Screw, 5/16-18 X 0.75 Hex-Head Cap ....................7473 Locknut, 5/16-18 Nylon Insert ....................... 8233 Locknut, 1/4-20 Nylon Insert ......................... 2011 Villager Homologated LSV Page 6-11...
  • Page 92 101942801_3 SW_3 W16 18_BRN (FORWARD) W17 18_BLU_YEL (REVERSE) W40 18_LT_GRN 103754401_1 W33 18_WHT W37 18_ORG 101942601_2 W07 18_BLU W24 18_GRN 453 OHM W15 18_PUR_WHT W04 18_WHT 453 OHM W18 18_YEL 453 OHM 101942801_2 000954-002 Page 6-12 2011 Villager Homologated LSV...
  • Page 93 W13 18_YEL LEAD W46 18_PUR_WHT W09 18_BLK_WHT TO (B-) CONTROLLER TO (B-) BATTERY SW_6 W39 18_ORG_WHT W41 18_LT_GRN SW_5 B- TERM. BLOCK 8294_2 8287_1 NC19 12_BLK NC10 10_BLK NC12 18_GRAY 000954-002 ON BOARD CHARGER 2011 Villager Homologated LSV Page 6-13...
  • Page 94 See previous two pages for illustration. Page 6-14 2011 Villager Homologated LSV...

  • Page 95: Wiring

    WIRING ITEM PART NO. DESCRIPTION 1 2 3 4 103802801 Harness, Main, Vill, Homol ........................2011 Villager Homologated LSV Page 6-15...
  • Page 96 000073-004 Page 6-16 2011 Villager Homologated LSV...

  • Page 97: Headlights

    103801502 Bezel, Headlight, Homol, Left ........................ 103810601 Headlight, E-mark, Rght Dipped (includes item 6) ................ 102707701 Bulb, Headlamp, H4 ..........................103810602 Headlight, E-mark, Left Dipped (includes item 8) ................102707701 Bulb, Headlamp, H4 ..........................2011 Villager Homologated LSV Page 6-17...
  • Page 98 000849-003 Page 6-18 2011 Villager Homologated LSV...

  • Page 99: Turn Signals

    Wire Cover-steer Column 304 Mm ...................... 103531101 Isolator, Turn Signal ........................... 103803101 Asm, Turn Signal Switch, Homol ......................103810701 Turn Signal, Front, E-mark ........................103813701 Bracket, Signal, Turn, Homol, Ps ......................103813702 Bracket, Signal, Turn, Homol, Ds ......................2011 Villager Homologated LSV Page 6-19...
  • Page 100 000073-005 Page 6-20 2011 Villager Homologated LSV...

  • Page 101: Taillights And License Plate Light

    Wedge, Taillight, Vill 2 Homol ........................ 103849401 Asm, Lic Lamp, E-mark Reg 50 (Includes Mounting Hardware) (includes items 4 and 5) License Lamp, E-mark Reg 50 ......................Jumper, #10 Ring - 1/4 Male Qd ...................... 2011 Villager Homologated LSV Page 6-21...
  • Page 102 000952-004 Page 6-22 2011 Villager Homologated LSV...

  • Page 103: Electrical Components, Center Body

    Plate, Fuse / Relay ............................Washer, #10 Type A Flat ........................... Washer, 1/4 Type A Narrow Flat ......................8233 Locknut, 1/4-20 Nylon Insert ......................... 8248 Screw, 1/4-20 X 0.75 Truss-Head Machine ..................8990 Tie Wrap, 8" Nylon ............................. 2011 Villager Homologated LSV Page 6-23...
  • Page 104 000946-003 Page 6-24 2011 Villager Homologated LSV...

  • Page 105: Electrical Component Mounting Plate

    Harness, Main, Vill, Homol ......................... 103831802 Controller, 1515s, 350a, Sp ........................ 8990 Tie Wrap, 8" Nylon ..........................1242 Nut, 5/16-18 Hex ............................7174 Lockwasher, 5/16 Split ..........................**** Special order item available upon request. 2011 Villager Homologated LSV Page 6-25...
  • Page 106 000577-010 Page 6-26 2011 Villager Homologated LSV...

  • Page 107: Instrument Panel With Electrical Components

    Decal, Forward/Reverse, Electric ..................... 103805501 Switch, Master Lighting, Homol ...................... 103805601 Switch, High Beam, Homologated ....................103805701 Switch, Hazard, Homologated ......................103810301 Dash, Lsv, Punched ..........................103818901 Keyswitch, Random, Elec ........................103827201 Decal, Ignition, Homologated ......................2011 Villager Homologated LSV Page 6-27...
  • Page 108 000951-004 Page 6-28 2011 Villager Homologated LSV...

  • Page 109: Batteries

    Locknut, 5/16-18 Nylon Insert ......................102002801 Wire Assy, #4 Black ..........................102002901 Wire Assy, #4 Black ..........................103504301 Tee, Batt Ret Ctr Short ......................... 103696801 J Bolt, Batt Hold Down 12" ........................ 103719701 Battery, 8v, Cr165, Wet ........................2011 Villager Homologated LSV Page 6-29...

  • Page 111: Section 7 - Electric Motor

    ELECTRIC MOTOR...
  • Page 112 000955-002 Page 7-2 2011 Villager Homologated LSV...
  • Page 113 Magnet, ADC Motor ........................Screw, 1/4-20 x 0.5 ......................... 103792701 Headband, Motor, 5hp, Vented ....................... 103792801 Frame/field, Motor, 5hp, Vent ......................103792901 End Cap, Motor, 5hp, Vented ......................Lockwasher, 1/4 Split ..........................7174 Lockwasher, 5/16 Split ..........................2011 Villager Homologated LSV Page 7-3...

  • Page 115: Section 8 - Transaxle

    TRANSAXLE...
  • Page 116 000961-001 Page 8-2 2011 Villager Homologated LSV...
  • Page 117 Pin, 8mm X 14mm Dowel ........................101976001 Screw, M10-1.50 X 35mm Hex Cap ....................Gear, Intermediate - 10.3:1 ........................ Gear, Output - 10.3:1 ........................... 7330 Inner Axle Tube Bearing ........................7335 Bearing ..............................7336 Bearing ..............................2011 Villager Homologated LSV Page 8-3...

  • Page 119: Section 9 - Battery Charger

    BATTERY CHARGER...
  • Page 120 000353-001 Page 9-2 2011 Villager Homologated LSV...

  • Page 121: Powerdrive Battery Charger (Model 20310), European

    Cord, European AC, Battery Charger ....................**** Special order item available upon request. Note: Level 1 Battery Charger part numbers include one AC and one DC cord. They do not include all of the level 2 cords listed. 2011 Villager Homologated LSV Page 9-3...
  • Page 122 000355-001 Page 9-4 2011 Villager Homologated LSV...

  • Page 123: Onboard Powerdrive Battery Charger (Model 17790), Export

    Nut, 1/4-20 Hex ............................Lockwasher, 1/4 Split ..........................7479 Screw, 1/4-20 X 1.25 Hex-Head Cap ....................8796 Screw, #7-19 X 0.75 Pan-Head Type AB ....................**** Special order item available upon request. Note: Item 7 not shown. 2011 Villager Homologated LSV Page 9-5...
  • Page 124 000927-001 Page 9-6 2011 Villager Homologated LSV...

  • Page 125: Onboard Battery Charger And Reel Mounting

    Decal, No Ground Warning ....................... 101966801 Block, Terminal ............................101968801 Rivet, 3/16", Pop ............................ 1703 Screw, 1/4-20 X 1.50 Hx Hd Cap ...................... Washer, 1/4 Type A Narrow Flat ...................... 8233 Locknut, 1/4-20 Nylon Insert ......................2011 Villager Homologated LSV Page 9-7...

  • Page 127: Section 10 - Maintenance And Service Tools

    MAINTENANCE AND SERVICE TOOLS...
  • Page 128 Page 10-2 2011 Villager Homologated LSV...
  • Page 129 ELEC DIESEL 1 2 3 4 The following tool list includes all tools available from Club Car for maintenance and service procedures for gasoline, electric, and/or diesel vehicles, both past and present models. Be sure to carefully examine the tool list for applicability to your vehicle before ordering.
  • Page 130 Energy units removed since last charge cycle. Func3 - Total accumulated energy units removed. Last charge termination type (1 = Incomplete, Func4 - 2 = DVDT, 4 = Normal, 8 = Max. timer). POWER Club Car PART #17075 Page 10-4 2011 Villager Homologated LSV...
  • Page 131 Cutter, Valve Seat, 60 Degree (requires item 51) (for Honda GX620 Gasoline Engines) ..............102774201 Pilot, 6.6 MM ........................102774301 Pilot, 6.62 MM......................... 102774401 Pilot, 6.65 MM......................... Please refer to the maintenance and service manual for proper tool application. 2011 Villager Homologated LSV Page 10-5...
  • Page 132 52 53 59 60 Page 10-6 2011 Villager Homologated LSV...
  • Page 133 Paint Pen, Touch-Up, Precedent Underbody – Black ........Please refer to the maintenance and service manual for proper tool application. ® * Item 59 is not for use on Surlyn body material, which is used on Precedent vehicles. 2011 Villager Homologated LSV Page 10-7...
  • Page 134 Cleanliness ATTENTION • Seats • Floor Mat • Dash Compartments • Bag Well • Beverage Holders • Overall Appearance: ___________________ Date: _____________ Inspected By: _________________ Car No. ___________ (Over) CCI 1018231 AM10753 GAS/DIESEL TACHOMETER Page 10-8 2011 Villager Homologated LSV...
  • Page 135 Valve Clearance Adjuster Screw Holder (for FE290 engines only) ..... 102674601 Valve Guide Driver (for Honda GX620 Gasoline Engines) ..............101641201 Valve Guide Reamer (FE290, FE350, and FE400 only) ........102674401 Valve Guide Reamer, 6.6 mm (for Honda GX620 Gasoline Engines) ..............2011 Villager Homologated LSV Page 10-9...
  • Page 136 WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V Page 10-10 2011 Villager Homologated LSV...
  • Page 137 Tool, Disassembly, Driven Clutch, XRT 950 ............103600501 Screw, Driven Clutch Disassembly, M6, XRT 950 ..........*Note: The XRT 950 Drive Clutch Puller requires the use of Screw, Driven Clutch Disassembly, CCI Part Number 103600501. 2011 Villager Homologated LSV Page 10-11...
  • Page 139 4-11 8248 1-11 6-23 1011415 1013582 10-3 8251 1-11 1011439 6-11 1013593 10-7 8304 101146302 1013683 6-29 8419 1-19 1011464 1013734 6-25 8717 4-15 1011465 1013794 8754 1-15 1-17 1-21 1-23 4-15 1011466 1013871 2011 Villager Homologated LSV Page i-1...
  • Page 140 1016811 101856001 6-27 101562715 1016835 1-19 101861901 4-15 101564804 1016849 6-27 101862001 4-15 101564805 1016851 6-27 101865301 4-13 101564807 1016868 101870501 101564808 1016916 101871001 10-3 101565202 1-23 1016952 101874601 4-13 101565204 1-23 1016967 101879401 Page i-2 2011 Villager Homologated LSV...
  • Page 141 4-13 102174205 102674601 10-9 101954301 1-13 1-23 102186001 102675001 10-5 101956201 102186101 102675101 10-5 101956202 102186201 102675201 10-5 101957101 6-11 102186301 102675301 10-5 101957501 102186401 102675401 10-5 101958201 102186901 102684501 101958301 102187001 102686101 10-3 2011 Villager Homologated LSV Page i-3...
  • Page 142 6-25 103801401 1-15 103829401 5-15 103708301 1-29 103801501 6-17 103830601 6-21 103708302 1-29 103801502 6-17 103831802 6-25 103717302 5-13 103802801 6-15 6-25 103834601 6-11 103717402 5-13 103802901 103842201 103719701 6-29 103803101 6-19 103848501 1-19 Page i-4 2011 Villager Homologated LSV...
  • Page 143 10-3 brake spring controller cover gasket 6-25 battery thermometer 10-3 breaker, circuit cord reel bearing breather cord, AC ball (motor) brush cord, DC ball (steering pinion) brush box assembly cover front wheel hub 5-13 2011 Villager Homologated LSV Page i-5...
  • Page 144 10-7 holder, cup drum, brake lubricant, moly-teflon 10-7 hole plug 6-27 dry moly lubricant 10-7 lug nut housing dust cover 5-13 lug stud 2-pin 3-pin differential E-clip 4-13 magnet, speed sensor Page i-6 2011 Villager Homologated LSV...
  • Page 145 10-9 steering pinion dust seal bearing plug steering rack 2-way steering shaft assembly driven clutch puller 10-5 steering shaft column steering pinion dust hole 6-27 steering shaft compression spring 2011 Villager Homologated LSV Page i-7...
  • Page 146 10-7 puller, special use 10-9 steering column bearing press 10-9 steering column retaining ring 10-9 steering wheel puller 10-9 transaxle axle seal 10-9 transaxle pinion seal 10-9 transmission 10-9 valve guide driver 10-9 Page i-8 2011 Villager Homologated LSV...
  • Page 148 Club Car, Inc. www.clubcar.com P.O. Box 204658 Phone 1.706.863.3000 Augusta, GA 30917-4658 1.800.ClubCar Int’l +1 706.863.3000 1.706.863.5808...

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