Club Car DS Villager 4 2006 User manual

Owner’s Manual
An business
2006
Transportation
Vehicles
Electric and Gasoline
DS Villager 4
Villager 6
Villager 8
TransPorter 4
TransPorter 6

P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone [phone]
Service Parts Fax [phone]
www.clubcar.com
2006 Transportation Vehicle Owner’s Manual Page 1
NOTICE
The Club Car Limited Warranties appear on the last pages of this manual. No other warranties, express or
implied, are contained herein. Your authorized representative checked the vehicle before it was delivered to
you and will provide you a copy of the completed vehicle warranty registration form.
Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the
use of the material in this manual.
This manual contains proprietary information that is protected by copyright. All rights are reserved. No part of
this manual may be photocopied, reproduced, or translated to another language without the written consent
of Club Car, Inc.
The information contained in this document is subject to change without notice.
Club Car reserves the right to make design changes to vehicles without obligation to make these changes on
units previously sold.
These vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500
for low-speed vehicles, and are not equipped for operation on public streets, roads, or highways.
Copyright © 2005 Club Car, Inc.
Club Car, PowerDrive, and ArmorFlex
are registered trademarks of Club Car, Inc.
This manual effective July 25, 2005.

Page 2 2006 Transportation Vehicle Owner’s Manual
FOREWORD
Thank you for choosing Club Car, the name most widely recognized as the industry leader in vehicle efficiency
and long-lasting value. You have chosen the finest utility vehicle on the market. Please protect your invest-
ment and ensure that your Club Car vehicle(s) provides years of reliable, superior performance by reading
and following the maintenance instructions in this manual.
Your comfort and safety are important to us, so we urge you to read and follow the step-by-step operating
instructions and safety procedures in this manual. These instructions must be followed in order to avoid the
risk of severe personal injury. If you rent or loan your vehicle to others, we recommend that you ask them to
read this manual before they operate the vehicle.
Club Car products are backed by a customer support system designed to offer you fast, courteous service. In
the event that your Club Car vehicle needs repairs or service, we recommend that your local authorized Club
Car representative perform them. For the name and address of the Club Car representative nearest you,
logon to our web site at www.clubcar.com or call 1-800-ClubCar (258-2227). If you would prefer to write to us,
direct your letter to: Club Car, Attention: Marketing Services, P.O. Box 204658, Augusta, Georgia 30917-4658
USA. Your local authorized Club Car representative can also provide technical advice, parts, and service
manuals.
We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehi-
cle, please include the manual so that the next owner will have the important operating, safety, and mainte-
nance information it contains.

2006 Transportation Vehicle Owner’s Manual Page 3
TABLE OF CONTENTS
Vehicle Feature Identification .................................................................................................................... 4
Safety Details ............................................................................................................................................ 19
General Warnings ...................................................................................................................................... 19
General Information ................................................................................................................................... 22
Model Identification .................................................................................................................................... 23
Controls and Indicators .............................................................................................................................. 23
Pre-Operation and Daily Safety Checklist ................................................................................................. 32
Performance Inspection ............................................................................................................................. 32
Driving Instructions .................................................................................................................................... 34
Loading and Unloading .............................................................................................................................. 37
Transporting on a Trailer ........................................................................................................................... 38
Storage – Electric Vehicles ........................................................................................................................ 38
Storage – Gasoline Vehicles ..................................................................................................................... 40
Maintenance .............................................................................................................................................. 43
Periodic Service Schedules ....................................................................................................................... 43
Periodic Lubrication Schedules ............................................................................................................ 46
Vehicle Controller – Electric Vehicles ........................................................................................................ 48
Batteries – Electric Vehicles ...................................................................................................................... 48
Battery Charger – Electric Vehicles ........................................................................................................... 50
Battery – Gasoline Vehicles ...................................................................................................................... 54
Engine Oil – Gasoline Vehicles ................................................................................................................. 55
Fueling Instructions – Gasoline Vehicles ................................................................................................... 56
Cleaning the Vehicle .................................................................................................................................. 57
Accessories ............................................................................................................................................... 58
Subsequent Owner Registration ................................................................................................................ 58
Vehicle Specifications – Electric Vehicles ................................................................................................. 59
Vehicle Specifications – Gasoline Vehicles .............................................................................................. 61

Vehicle Feature Identification
Page 4 2006 Transportation Vehicle Owner’s Manual
ELECTRIC DS VILLAGER 4
OFF ON
• Before using vehicle, read operating instructions.
• Remain seated and hold on to seat handle while moving.
• Do not start vehicle until all occupants are seated.
• Two (2) persons per seat maximum.
• Operate from driver side only and not on public roads.
• Keep entire body inside vehicle while moving.
• Drive slowly in turns and straight up and down slopes.
• Do not leave children unattended on vehicle.
• Never operate under the influence of alcohol or drugs.
• Use brakes to reduce speed when coasting downhill.
• Never stand in front of or behind vehicle. CCI 101960601
WARNING
ROLLOVER OR FALLING OFF MAY CAUSE DEATH.
!
CCI 102518001
DRIVER/PASSENGER
WARNING DECAL
PASSENGER
WARNING DECAL
(ON REAR HANDRAIL
FACING SEAT)
OPERATING INSTRUCTIONS
DECAL
ACCELERATOR
PEDAL
SERIAL
NUMBER
HAND RAIL
HAND HOLDS
BRAKE
PEDAL
PARK BRAKE
PEDAL
BATTERY WARNING
LIGHT KEY SWITCH

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 5
ELECTRIC DS VILLAGER 4
C
l
u
b
C
a
a
r
CCI 101908601
CHARGER RECEPTACLE
AND FUSE LINK
FORWARD/REVERSE
SWITCH
(IQ SYSTEM VEHICLES ONLY)
(ON TOW SWITCH BRACKET UNDER SEAT)
TOW/RUN WARNING DECAL
BATTERY DANGER
(MOLDED ON BATTERY CAPS OR
ON BODY UNDER SEAT)

Vehicle Feature Identification
Page 6 2006 Transportation Vehicle Owner’s Manual
GASOLINE DS VILLAGER 4
CCI 101960601
CCI 101621601
DRIVER/PASSENGER
WARNING DECAL
PASSENGER
WARNING DECAL
(ON REAR HANDRAIL
FACING SEAT)
OPERATING INSTRUCTIONS
DECAL
ACCELERATOR
PEDAL
SERIAL
NUMBER
HAND RAIL
HAND HOLDS
BRAKE
PEDAL
PARK BRAKE
PEDAL
LOW OIL
WARNING
LIGHT
FUEL GAUGE/HOUR METER
KEY SWITCH

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 7
GASOLINE DS VILLAGER 4
CCI 101915201
!
CCI 101547601
FRAME GROUND AND
GOVERNOR WARNING DECAL
(ON VEHICLE FRAME NEAR BATTERY)
CHOKE
NEUTRAL LOCKOUT
CAM
GASOLINE WARNING DECAL
(ON VEHICLE FRAME NEAR FUEL TANK)
ROTATING PARTS AND
HOT MANIFOLD DECAL
(ON STARTER/GENERATOR
AND ENGINE)
FORWARD/REVERSE
HANDLE
OIL FILL
FUEL SHUT-OFF
VALVE

Vehicle Feature Identification
Page 8 2006 Transportation Vehicle Owner’s Manual
ELECTRIC VILLAGER 6 AND 8
CCI 101960601
!
CCI 101621601
CCI 102518001
DRIVER/PASSENGER
WARNING DECAL
OPERATING INSTRUCTIONS
DECAL
(IQ PLUS VEHICLES)
OPERATING INSTRUCTIONS
DECAL
(POWERDRIVE SYSTEM 48 VEHICLES)
PASSENGER
WARNING DECAL
BRAKE PEDAL
PARK BRAKE PEDAL
SERIAL
NUMBER
BATTERY CONDITION
INDICATOR
BATTERY
WARNING LIGHT
KEY SWITCH
ACCELERATOR
PEDAL
LIGHT
SWITCH
OR

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 9
ELECTRIC VILLAGER 6
FNR
BATTERY DANGER
PASSENGER
WARNING DECAL
CHARGER
RECEPTACLE
AND FUSE LINK
FORWARD/REVERSE
HANDLE
(MOLDED ON BATTERY CAPS OR ON BODY UNDER SEAT)
FORWARD/REVERSE SWITCH
(IQ PLUS VEHICLES) (POWERDRIVE SYSTEM 48
VEHICLES)
TOW/RUN WARNING DECAL
(IQ PLUS VEHICLES ONLY)
(ON TOW SWITCH BRACKET UNDER PASSENGER-SIDE SEAT)
OR
BATTERY WIRE WARNING DECAL
(UNDER FRONT SEAT ON ELECTRICAL COMPONENT BOX COVER
AND ON DRIVER SIDE I-BEAM UNDER SECOND SEAT)
(IQ PLUS VEHICLES ONLY)

Vehicle Feature Identification
Page 10 2006 Transportation Vehicle Owner’s Manual
ELECTRIC VILLAGER 8
CHARGER
RECEPTACLE
PASSENGER
WARNING DECAL
FORWARD / REVERSE
HANDLE
TOW/RUN WARNING DECAL
(IQ PLUS VEHICLES ONLY)
BATTERY DANGER
(MOLDED ON BATTERY CAPS OR ON BODY UNDER SEAT)
FORWARD/REVERSE
SWITCH
(IQ PLUS VEHICLES)
(POWERDRIVE SYSTEM 48
VEHICLES)
(ON TOW SWITCH BRACKET UNDER
PASSENGER-SIDE SEAT)
OR
BATTERY WIRE WARNING DECAL
(UNDER FRONT SEAT ON ELECTRICAL COMPONENT BOX COVER
AND ON DRIVER SIDE I-BEAM UNDER THIRD SEAT)
(IQ PLUS VEHICLES ONLY)

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 11
GASOLINE VILLAGER 6 AND 8
CCI 101693201
CCI 101960601
LOW OIL
WARNING
LIGHT
FUEL GAUGE
/HOUR METER
SERIAL
NUMBER
DRIVER / PASSENGER
WARNING DECAL
BRAKE PEDAL
PARK BRAKE PEDAL
ACCELERATOR
PEDAL
PASSENGER
WARNING DECAL
OPERATING INSTRUCTIONS
DECAL
KEY SWITCH
LIGHT SWITCH

Vehicle Feature Identification
Page 12 2006 Transportation Vehicle Owner’s Manual
GASOLINE VILLAGER 6
!
CCI 101547601
CCI 1019152-01
CHOKE
FRAME GROUND AND
GOVERNOR WARNING DECAL
(ON VEHICLE FRAME
NEAR BATTERY)
NEUTRAL
LOCKOUT CAM
FORWARD/REVERSE
HANDLE
OIL FILL
FUEL SHUT-OFF
VALVE
ROTATING PARTS AND
HOT MANIFOLD DECAL
(ON STARTER/GENERATOR
AND ENGINE)
GASOLINE WARNING DECAL
(ON VEHICLE FRAME NEAR FUEL TANK)

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 13
GASOLINE VILLAGER 8
!
CCI 101547601
CCI 1019152-01
CHOKE
GASOLINE
WARNING DECAL
(ON FRAME)
OIL FILL
FUEL SHUT-OFF
VALVE
(ON FUEL TANK) ROTATING PARTS AND
HOT MANIFOLD DECAL
(ON STARTER/GENERATOR
AND ENGINE)
PASSENGER
WARNING DECAL
FRAME GROUND
WARNING DECAL (ON FRAME)
NEUTRAL LOCKOUT CAM
(ON FORWARD/REVERSE SHIFTER INSIDE
SEAT SUPPORT)
FORWARD/REVERSE
HANDLE

Vehicle Feature Identification
Page 14 2006 Transportation Vehicle Owner’s Manual
ELECTRIC TRANSPORTER
!
TransPorte
TransPorter
BATTERY WARNING LIGHT
BATTERY CONDITION
INDICATOR
SERIAL
NUMBER
ACCELERATOR
PEDAL
BRAKE
PEDAL
PARK BRAKE
PEDAL
KEY SWITCH
OPERATING INSTRUCTIONS
DECAL
DRIVER/PASSENGER
WARNING DECAL
VEHICLE LOADING DECAL
LIGHT
SWITCH
OPERATING INSTRUCTIONS
DECAL
(IQ PLUS VEHICLES)
(POWERDRIVE SYSTEM 48 VEHICLES) OR

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 15
ELECTRIC TRANSPORTER
TransPorte
TransPorter
TransPorter
TransPorte
TransPorter
TransPorter
CCI 101931501
CCI 101707801
FOUR-PASSENGER
TRANSPORTER
VEHICLE
SIX-PASSENGER
TRANSPORTER
VEHICLE
ELECTRICAL COMPONENT
MOUNTING PLATE NOTICE
(ON PLATE)
CRUSH AREA
DECAL
ELECTRICAL COMPONENT COVER CAUTION
(ON COVER)
BATTERY DANGER
PASSENGER
WARNING
DECAL
CHARGER
AC CORD
REEL
PASSENGER
WARNING DECAL
BED BOLT
WARNING DECAL
BED LOAD
WARNING DECAL
(MOLDED ON BATTERY CAPS)
TOW/RUN WARNING DECAL
(IQ PLUS VEHICLES ONLY)
(ON TOW SWITCH BRACKET UNDER
PASSENGER-SIDE SEAT)
FORWARD/REVERSE
HANDLE
FORWARD/REVERSE SWITCH
(IQ PLUS VEHICLES)
(POWERDRIVE SYSTEM 48
VEHICLES)
OR
BATTERY WIRE WARNING DECAL
(UNDER SEAT ON CENTER OF PANEL & ON PASSENGER SIDE I-BEAM)
(IQ VEHICLES ONLY)

Vehicle Feature Identification
Page 16 2006 Transportation Vehicle Owner’s Manual
GASOLINE TRANSPORTER
TransPorte
TransPorter
FUEL GAUGE
/HOUR METER
LOW OIL
WARNING
LIGHT
DRIVER/PASSENGER
WARNING DECAL
KEY SWITCH
SERIAL
NUMBER
VEHICLE LOADING DECAL
ACCELERATOR
PEDAL
BRAKE
PEDAL
PARK BRAKE
PEDAL
OPERATING INSTRUCTIONS
DECAL
LIGHT SWITCH
CCI 101693201

Vehicle Feature Identification
2006 Transportation Vehicle Owner’s Manual Page 17
GASOLINE TRANSPORTER
CCI 101707801
!
CCI 101547601
FNR
TransPorte
Tr
a
nsPor
ter
TransPorte
Tr
ansPor
ter
WARNING
FAILURETOFOLLOWTHESEINSTRUCTIONS
CANCAUSESEVEREINJURYORDEATH.
Bedcantipupunexpectedly.Bedholddown
CCI101707801
CCI 1019152-01
CRUSH AREA
DECAL
CHOKE
NEUTRAL
LOCKOUT
CAM BED LOAD
WARNING DECAL
PASSENGER
WARNING DECAL
SIX-PASSENGER
TRANSPORTER
VEHICLE
FOUR-PASSENGER
TRANSPORTER
VEHICLE
GASOLINE
WARNING DECAL
(ON FRAME)
FUEL SHUT-OFF
VALVE
FRAME GROUND
WARNING DECAL
(ON FRAME)
BED BOLT
WARNING DECAL
ROTATING PARTS AND
HOT MANIFOLD DECAL
(ON STARTER/GENERATOR
AND ENGINE)
FORWARD/REVERSE
HANDLE PASSENGER WARNING
DECAL

Page 18 2006 Transportation Vehicle Owner’s Manual
PROPOSITION 65 - STATE OF CALIFORNIA
This product contains or emits chemicals or substances that have been determined
by the state of California to cause cancer and birth defects or other reproductive harm.
!WARNING
Rotating Parts
Practice Safety
Safety signs like you see above may at first seem shocking, but their impact is mild
compared with the reality of severe personal injury.
Your safety and satisfaction are of the utmost importance to Club Car. That is why
before operating the vehicle, we urge you to review the information in this manual.
Understand and become familiar with the DANGER, WARNING and CAUTION statements
and procedures it contains, along with the safety decals that are affixed to your
vehicle.
Take time to understand the language of safety. It is a language that can save your life.