Club Car DS Villager 4 Manual

MANUAL NUMBER 102397603 
EDITION CODE 1203B0312A
2004
MAINTENANCE
SERVICE
MANUAL
VILLAGER 4, VILLAGER 6,
VILLAGER 8, TRANSPORTER 4,
TRANSPORTER 6
GASOLINE/ELECTRIC
TRANSPORTATION VEHICLES

2004 Transportation Vehicle Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of Villager and TransPorter vehicles
and should be used in conjunction with the appropriate maintenance and service supplement.
If you do not have the appropriate maintenance and service supplement, you may order one from your Club
Car representative. Maintenance and service supplements available include the following:
This manual and corresponding maintenance and service supplement should be thoroughly reviewed prior to
servicing the vehicle.The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.
This manual was written for the trained technician who already has knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to
the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be
performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained tech-
nician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This manual, used in conjunction with the appropriate maintenance and service supplement, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc.; P.O.
Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech-
nical Service Representative at [phone], extension 3580.
2004 PowerDrive System 48 Vehicle Maintenance and Service Supplement Publication Part No. 102397605
2004 FE290 Gasoline Vehicle Maintenance and Service Supplement Publication Part No. 102397607
2004 FE350 Gasoline Vehicle Maintenance and Service Supplement Publication Part No. 102397608
2004 IQ System Vehicle Maintenance and Service Supplement Publication Part No. 102397606
Copyright © 2003, 2012 Club Car, Inc.
Club Car, ArmorFlex, and PowerDrive
are registered trademarks of Club Car Inc.
This manual effective July 28, 2003.

Page ii 2004 Transportation Vehicle Maintenance and Service Manual
∆
WARNING
• Read Section 1 – Safety before attempting any service on the vehicle.
•Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is
continually working to further improve its vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car distributors and dealers and will, when applicable, appear in
future editions of this manual.
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.
There are no warranties expressed or implied in this manual. See the limited warranty found in the
vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.

2004 Transportation Vehicle Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ............................................................................................................................... 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
General Information .......................................................................................................................... 3-1
Serial Number Identification .............................................................................................................. 3-1
Storage – Gasoline Vehicle .............................................................................................................. 3-2
Preparing the Gasoline Vehicle for Extended Storage ................................................................. 3-2
Returning the Stored Gasoline Vehicle to Service ........................................................................ 3-4
Storage – Electric Vehicle ................................................................................................................ 3-4
Preparing the Electric Vehicle for Extended Storage .................................................................... 3-5
Returning the Stored Electric Vehicle to Service .......................................................................... 3-5
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 4-1
Front Body ........................................................................................................................................ 4-2
Center Body – Villager 6 and 8 ......................................................................................................... 4-3
Rear Body – Villager 4, 6, and 8 ....................................................................................................... 4-7
Front and Rear Body Repair ............................................................................................................. 4-12
Stress Lines or Streaks ................................................................................................................. 4-12
Minor Impact Damage/Deformations ............................................................................................ 4-13
Minor Scratches and Surface Blemishes ...................................................................................... 4-13
Small Scratches That Cannot Be Buffed Out ............................................................................... 4-13
Touch-up Paint Color Chart .......................................................................................................... 4-14
Gouges, Punctures, Tears, Large Scratches, and Abrasions ....................................................... 4-14
Center Body Repair – Villager 6 and 8 ............................................................................................. 4-14
Flat Bed – TransPorter 4 .................................................................................................................. 4-15
Rear Fender – TransPorter 4 and 6 ................................................................................................. 4-16
Tailskirt – TransPorter 4 and 6 ......................................................................................................... 4-16
Floor Mat ........................................................................................................................................... 4-17
Bumper ............................................................................................................................................. 4-19
Bumper Removal .......................................................................................................................... 4-19
Bumper Installation ....................................................................................................................... 4-19

Page iv 2004 Transportation Vehicle Maintenance and Service Manual
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Brake Pedal and Park Brake ............................................................................................................ 5-1
Brake Pedal Removal .................................................................................................................. 5-1
Brake Pedal Installation ............................................................................................................... 5-4
Park Brake Removal .................................................................................................................... 5-5
Park Brake Installation ................................................................................................................. 5-5
Accelerator Pedal – Gasoline Vehicles ............................................................................................ 5-6
Accelerator Pedal Removal – Gasoline Vehicles ......................................................................... 5-6
Accelerator Pedal Installation – Gasoline Vehicles ...................................................................... 5-8
Accelerator Pedal – Electric Vehicles .............................................................................................. 5-9
Accelerator Pedal Removal – Electric Vehicles ........................................................................... 5-9
Accelerator Pedal Installation – Electric Vehicle .......................................................................... 5-11
Pedal Group Adjustment – Gasoline Vehicles ................................................................................. 5-11
Pedal Group Adjustment – Electric Vehicles .................................................................................... 5-16
SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information ......................................................................................................................... 6-1
Brake Shoe Removal ....................................................................................................................... 6-1
Brake Assembly Cleaning (Self-Adjusting Brakes) .......................................................................... 6-3
Brake Shoe Installation (Self-Adjusting Brakes) .............................................................................. 6-5
Brake Adjustment (Self-Adjusting Brakes) ....................................................................................... 6-8
Brake Assembly Cleaning (Manually-Adjusted Brakes) ................................................................... 6-9
Brake Shoe Installation (Manually-Adjusted Brakes) ....................................................................... 6-10
Brake Adjustment (Manually-Adjusted Brakes) ................................................................................ 6-12
Brake Cluster Adjustment ............................................................................................................ 6-13
Brake Cable Equalization ............................................................................................................. 6-16
Final Brake Cluster Adjustment .................................................................................................... 6-17
Test Drive Vehicle ........................................................................................................................ 6-17
Brake Cluster Removal and Installation ........................................................................................... 6-17
Rear Brake Cluster Removal ....................................................................................................... 6-17
Rear Brake Cluster Installation .................................................................................................... 6-18
Front Brake Cluster Removal ....................................................................................................... 6-18
Front Brake Cluster Installation .................................................................................................... 6-19
Front Brake Cables .......................................................................................................................... 6-20
Front Brake Cable Removal ......................................................................................................... 6-20
Front Brake Cable Installation ...................................................................................................... 6-21
Rear Brake Cables ........................................................................................................................... 6-22
Rear Brake Cable Removal ......................................................................................................... 6-22
Rear Brake Cable Installation ...................................................................................................... 6-23

2004 Transportation Vehicle Maintenance and Service Manual Page v
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information .......................................................................................................................... 7-1
Steering Wheel ................................................................................................................................. 7-1
Steering Wheel Removal .............................................................................................................. 7-1
Steering Wheel Installation ........................................................................................................... 7-2
Steering Column ............................................................................................................................... 7-2
Steering Column Removal ............................................................................................................ 7-2
Steering Column Disassembly ...................................................................................................... 7-5
Steering Column Assembly .......................................................................................................... 7-5
Steering Column Installation ......................................................................................................... 7-5
Steering Adjustment ......................................................................................................................... 7-7
Rack and Pinion ............................................................................................................................... 7-8
Rack and Pinion Removal ............................................................................................................ 7-8
Rack and Pinion Disassembly ...................................................................................................... 7-8
Rack and Pinion Assembly ........................................................................................................... 7-10
Rack and Pinion Installation ......................................................................................................... 7-12
Tie Rod and Drag Link ...................................................................................................................... 7-13
Tie Rod and Drag Link Removal ................................................................................................... 7-13
Tie Rod and Drag Link Installation ................................................................................................ 7-13
Front Suspension ............................................................................................................................. 7-14
Lubrication .................................................................................................................................... 7-14
Wheel Alignment ........................................................................................................................... 7-14
Front Suspension Components ........................................................................................................ 7-16
Leaf Spring Removal .................................................................................................................... 7-16
Leaf Spring Installation ................................................................................................................. 7-16
Kingpin and Steering Spindle Removal ........................................................................................ 7-17
Kingpin and Steering Spindle Installation ..................................................................................... 7-22
Delta A-Plate Removal ................................................................................................................. 7-22
Delta A-Plate Installation .............................................................................................................. 7-22
Shock Absorber Removal ............................................................................................................. 7-22
Shock Absorber Installation .......................................................................................................... 7-23
Front Wheel Bearings and Hubs (All Except Villager 4) ................................................................... 7-23
Front Wheel Free Play Inspection ................................................................................................ 7-23
Front Wheel Bearings and Hub Removal ..................................................................................... 7-24
Front Wheel Bearings and Hub Installation .................................................................................. 7-24
Front Hubs (Villager 4 Vehicles) ....................................................................................................... 7-25
Front Wheel Free Play Inspection ................................................................................................ 7-25
Front Hub Removal ....................................................................................................................... 7-25
Front Hub Installation .................................................................................................................... 7-25

Page vi 2004 Transportation Vehicle Maintenance and Service Manual
SECTION 8 – WHEELS AND TIRES
General Information ......................................................................................................................... 8-1
Wheels ............................................................................................................................................. 8-1
Wheel Removal ............................................................................................................................ 8-1
Wheel Installation ......................................................................................................................... 8-1
Tires ................................................................................................................................................. 8-2
Tire Removal ................................................................................................................................ 8-2
Tire Repair ................................................................................................................................... 8-3
Tire Installation ............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information ......................................................................................................................... 9-1
Shock Absorbers .............................................................................................................................. 9-1
Shock Absorber Inspection and Removal .................................................................................... 9-1
Shock Absorber Installation ......................................................................................................... 9-2
Multi-Leaf Springs ............................................................................................................................ 9-2
Multi-Leaf Spring Removal ........................................................................................................... 9-2
Multi-Leaf Spring Installation ........................................................................................................ 9-3
Snubber ............................................................................................................................................ 9-6
Snubber Removal ........................................................................................................................ 9-6
Snubber Installation ..................................................................................................................... 9-6
Stabilizer Bar .................................................................................................................................... 9-7
Stabilizer Bar Removal ................................................................................................................. 9-7
Stabilizer Bar Installation .............................................................................................................. 9-8
Jounce Bumpers .............................................................................................................................. 9-8
Jounce Bumper Removal ............................................................................................................. 9-8
Jounce Bumper Installation .......................................................................................................... 9-8
SECTION i – INDEX

2004 Transportation Vehicle Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage
resulting from improper service or maintenance, the procedures in this manual must be followed.
It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or
CAUTION. These special statements relate to specific safety issues, and must be read, understood, and
heeded before proceeding with procedures. There are statements labeled NOTE, which provide other essen-
tial service or maintenance information.
∆
DANGER
•ADANGER indicates an immediate hazard that will result in severe personal injury or death.
∆
WARNING
•AWARNING indicates an immediate hazard that could result in severe personal injury or
death.
∆
CAUTION
•ACAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result
in minor personal injury or product or property damage.
CAUTION
•ACAUTION without the safety alert symbol indicates a potentially hazardous situation that
could result in property damage.
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements. Also, other specific
safety statements appear throughout this manual and on the vehicle.
∆
DANGER
•Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area.Ventilate when charging or operating vehicle in an enclosed area.Wear a full face
shield and rubber gloves when working on or near batteries.
•Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
-Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
-Eyes: Flush with water for 15 minutes. Call a physician immediately.
•Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the
vehicle and service area. Service only in a well-ventilated area.
•Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.

SAFETY General Warning
Page 1-2 2004 Transportation Vehicle Maintenance and Service Manual
1
∆
WARNING
•Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle.
•Only trained technicians should service or repair the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
The appropriate instructions must be used when performing maintenance, service, or
accessory installation.
•Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
Gasoline vehicles only:
•To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3).
- Disconnect the spark plug wire from the spark plug.
•Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch
the vehicle frame, engine, or any other metal component.
Electric vehicles only:
• IQ System vehicles:
Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries.
Failure to heed this warning could result in a battery explosion or severe personal injury.
• All electric vehicles:
To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-2,
Page 1-3 or Figure 1-3, Page 1-3).
• IQ System vehicles:
After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
•PowerDrive System 48 vehicles:
After disconnecting the batteries, discharge the controller capacitors as follows:
-Turn the key switch to ON and place the Forward/Reverse handle in the REVERSE position.
-Slowly press the accelerator pedal and keep it pressed until the reverse warning buzzer can no
longer be heard.When the buzzer stops sounding, the controller capacitors are discharged.
All vehicles:
•Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working on or near batteries.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle.
•Moving parts! Do not attempt to service the vehicle while it is running.
•Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning
could result in severe burns.
•Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
•Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
•Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
WARNING CONTINUED ON NEXT PAGE...

SAFETY General Warning
2004 Transportation Vehicle Maintenance and Service Manual Page 1-3
1
∆
WARNING
•Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
•If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
•For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle.
If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is
raised. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all
crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed
this warning could result in severe personal injury or death.
•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Do not leave children unattended on vehicle.
Figure 1-1 Gasoline Vehicle
Figure 1-2 PowerDrive Vehicles Figure 1-3 Villager 4 IQ System Vehicle
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
FRONT
OF VEHICLE
Remove
negative
cable first.
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE
1
2
3
4
6
5
Remove negative
cable first.
Disconnect these
battery cables before
working on vehicle.
BATTERY CONFIGURATION FOR
VILLAGER 6, 8,
TRANSPORTER 4 AND 6
TOW RUN
WARNING
1
2
3
4
6
5
FRONT
OF VEHICLE
Place Tow/Run
Switch in TOW.
Remove negative
cable first.
PLACE TOW/RUN SWITCH
IN THE TOW POSITION BEFORE
DISCONNECTING OR
CONNECTING BATTERY CABLES

1

2004 Transportation Vehicle Maintenance and Service Manual Page 2-1
2
SECTION 2 – VEHICLE SPECIFICATIONS
SPECIFICATIONS
Villager 4 Villager 6
Villager 8 Transporter 4 Transporter 6
POWER SOURCE Pedal-Start
Gasoline
IQ System
48-Volt
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Engine: 4 cycle, OHV, 286 cc, 9
hp rated, single cylinder, air
cooled, with pressure lubrication
system
•
Engine: 4 cycle, OHV, 351 cc, 11
hp rated, single cylinder, air
cooled, with pressure lubrication
system
•••
Drive motor: Direct drive, 48 volts
DC, series-wound, 3.1 hp •••
Drive motor: Direct drive, 48 volts
DC, shunt-wound, 3.2 hp •
Fuel system: Side draft carbure-
tor with float bowl, fixed jets, fuel
filter, and impulse fuel pump ••••
Governor: Automatic ground
speed sensing, internally geared
in unitized transaxle ••••
Ignition: Transistor electronic igni-
tion with electronic RPM limiter ••••
Unitized transaxle: Fully syn-
chronized forward and reverse
with neutral (11.8:1 forward,
17.1:1 reverse)
••••
Transaxle: Double reduction heli-
cal gear with 12.28:1 direct drive
axle ••••
Electrical system: 12 volt, 500
cold cranking amps at 0 °F, 650 at
32 °F. 105 minute reserve capacity
and 35 amp charging capacity
••••
Electrical system: 48 volts DC,
reduced speed reverse ••••
Batteries: High capacity, deep
cycle, Trojan PowerDrive 8 volt,
117 min. capacity ••••
Charger: Automatic, 17 amp Pow-
erDrive; UL and CSA listed ••••
Torque converter: Automatic,
variable speed, dry type ••••
STEERING/SUSPENSION/BRAKES
Steering: Self-adjusting rack and
pinion ••••
Suspension: Front mono-leaf and
rear multi-leaf springs with dual
hydraulic shocks ••••
Brakes: Mechanical brake cable
system to self-adjusting drum brakes
on each rear wheel. Park brake is
automatically released. Self-adjust-
ing multi-latch ratchet and pawl
•
Brakes: Mechanical brake cable
system to manually adjusted drum
brakes on all four wheels. Park brake
is automatically released. Self-
adjusting multi-latch ratchet and pawl
•••
Specifications continued on next page...

VEHICLE SPECIFICATIONS
Page 2-2 2004 Transportation Vehicle Maintenance and Service Manual
2
BODY/CHASSIS Pedal-Start
Gasoline
IQ System
48-Volt
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Frame/Chassis: Twin I-Beam
welded aluminum ••••
Side and rear body: All aluminum ••
Front body: ArmorFlex
®
••••
Front body finish: Matched paint
finish over molded-in color ••••
Center body: ABS/DR acrylic •
Tires: 18 x 8.50 - 8 tubeless, 4 ply
rated load range front and rear •
Tires: 18 x 8.50 - 8 tubeless, 6 ply
rated load range front and rear •••
DIMENSIONS/WEIGHT
Overall length: Standard flatbed
configuration 100 in. (254 cm) Vil. 6: 124 in. (315 cm) Vil. 8: 157 in. (398 cm) 134 in. (340 cm) 133 in. (338 cm)
Overall width
47.25 in.
(120 cm) 47.25 in. (120 cm) 49.25 in. (125 cm) 49.25 in. (125 cm)
Overall height: At steering wheel 48 in.
(122 cm) 48 in. (122 cm) 48 in. (122 cm) 48 in. (122 cm)
Wheelbase
65.5 in.
(166 cm) Vil. 6: 98.5 in. (250 cm) Vil. 8: 131.5 in. (334 cm) 98.5 in. (250 cm) 98.5 in. (250 cm)
Ground clearance
4.5 in.
(11 cm) 4.5 in. (11 cm) 4.5 in. (11 cm) 4.5 in. (11 cm)
Front wheel tread
34.5 in.
(88 cm) 34.5 in. (88 cm) 34.5 in. (88 cm) 34.5 in. (88 cm)
Rear wheel tread
38.5 in.
(98 cm) 38.5 in. (98 cm) 38.5 in. (98 cm) 38.5 in. (98 cm)
Weight: Standard gasoline-pow-
ered vehicle (without gasoline in
fuel tank) / Standard electric pow-
ered vehicle (without batteries)
638 lb.
(289 kg)
PowerDrive
System-48:
495 lb.
(225 kg)
IQ System:
525 lb.
(238 kg)
Vil. 6:
745 lb.
(338 kg)
Vil. 8:
886 lb.
(402 kg)
Vil. 6:
590 lb.
(268 kg)
Vil. 8:
704 lb.
(328 kg)
825 lb.
(374 kg) 700 lb. (317 kg) 842 lb. (381 kg) 717 lb. (325 kg)
Forward speed
12-15 mph
(19-24
km/h)
12-15 mph
(19-24
km/h)
14-16 mph
(23-26
km/h)
12-15 mph
(19-24
km/h)
14-16 mph
(23-26
km/h)
12-15 mph
(19-24
km/h)
14-16 mph
(23-26
km/h)
12-15 mph
(19-24
km/h)
Clearance circle: (diameter) 17 ft. 6 in.
(533 cm) Vil. 6: 24 ft. 8 in. (752 cm) Vil. 8: 32 ft. 7 in. (993 cm) 24 ft. 8 in. (752 cm) 24 ft. 8 in. (752 cm)
Turning radius per SAE J 695
68 in.
(173 cm) Vil. 6: 129 in. (328 cm) Vil. 8: 191 in. (485 cm) 129 in. (328 cm) 129 in. (328 cm)
Intersecting aisle clearance
72 in.
(183 cm) Vil. 6: 89.75 in. (228 cm) Vil. 8 : 108 in. (274 cm) 89.75 in. (228 cm) 89.75 in. (228 cm)
Floorboard height
11.75 in.
(30 cm) 11.75 in. (30 cm) 11.75 in. (30 cm) 11.75 in. (30 cm)
Load bed height
27 in.
(69 cm)
Seat height
29.5 in.
(75 cm) 30 in. (76 cm) 30 in. (76 cm) 30 in. (76 cm)
Load bed size: Flat bed
dimensions 35.75 in.x 44.25 in. (91x112 cm)
Vehicle rated capacity: Level
surface only 800 lb. (363 kg) 1500 lb. (680 kg) 1500 lb. (680 kg) 1500 lb. (680 kg)
Specifications continued on next page...
SPECIFICATIONS
Villager 4 Villager 6
Villager 8 Transporter 4 Transporter 6

VEHICLE SPECIFICATIONS
2004 Transportation Vehicle Maintenance and Service Manual Page 2-3
2
DIMENSIONS/WEIGHT
(continued) Pedal-Start
Gasoline
IQ System
48-Volt
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Key-Start
Gasoline
Power-
Drive
System 48
Electric
Standard seating capacity 4 persons Vil. 6: 6 persons
Vil. 8: 8 persons 4 persons 6 persons
LIQUID CAPACITIES
Engine crankcase without filter
32 oz.
(0.95 liters) 32 oz. (0.95 liters) 32 oz. (0.95 liters) 32 oz. (0.95 liters)
Engine crankcase with filter
38 oz.
(1.12 liters) 38 oz. (1.12 liters) 38 oz. (1.12 liters) 38 oz. (1.12 liters)
Unitized transaxle
27 oz.
(0.8 liters) 27 oz. (0.8 liters) 27 oz. (0.8 liters) 27 oz. (0.8 liters)
Fuel tank
7 gallons
(26.5 liters) 7 gallons (26.5 liters) 7 gallons (26.5 liters) 7 gallons (26.5 liters)
Transaxle
22 oz.
(0.67 liters) 22 oz. (0.67 liters) 22 oz. (0.67 liters)
TIRE PRESSURE
Front and rear
12-14 psi
(0.83-0.96
Bars)
18-20 psi
(1.24-1.38
Bars)
30-34 psi
(2.07-2.34
Bars)
30-34 psi
(2.07-2.34
Bars)
30-34 psi
(2.07-2.34
Bars)
30-34 psi
(2.07-2.34
Bars)
30-34 psi
(2.07-2.34
Bars)
30-34 psi
(2.07-2.34
Bars)
SPECIFICATIONS
Villager 4 Villager 6
Villager 8 Transporter 4 Transporter 6

2

2004 Transportation Vehicle Maintenance and Service Manual Page 3-1
3
SECTION 3 – GENERAL INFORMATION
∆
DANGER
• See General Warning, Section 1, Page 1-1.
∆ WARNING
• See General Warning, Section 1, Page 1-1.
GENERAL INFORMATION
Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. rec-
ommends the owner/operator read and understand this manual and pay special attention to features specific
to their vehicle(s).
Each vehicle is equipped with either a two-position key switch or a three-position key switch. Vehicles
equipped with a two-position key switch are referred to as “pedal-start” and vehicles equipped with a three-
position key switch are referred to as “key-start.”
Refer to the owner’s manual provided with the vehicle for information on the following topics:
• Pre-Operation and Daily Safety Checklist
• Controls and Indicators
• Driving Instructions
• Loading and Unloading
•Bed Latch
•Transporting on a Trailer
•Subsequent Owner Registration
•Warranties
SERIAL NUMBER IDENTIFICATION
The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accel-
erator pedal (Example: D0401-123456 for electric or DG0401-123456 for gasoline) (Figure 3-1, Page 3-2).
There is a second serial number decal mounted on the front body frame behind the center dash panel. The
center dash panel must be removed to view this number (Figure 3-2, Page 3-2). See following NOTE.
NOTE: Always have the vehicle serial number available when ordering parts or making inquiries.

GENERAL INFORMATION Storage – Gasoline Vehicle
Page 3-2 2004 Transportation Vehicle Maintenance and Service Manual
3
STORAGE – GASOLINE VEHICLE
See General Warning, Section 1, Page 1-1.
∆ DANGER
•Never attempt to drain gasoline when the engine is hot or while it is running.
• Be sure to clean up any spilled gasoline before operating the vehicle.
•Store gasoline in an approved gasoline container only. Store in a well-ventilated area away
from sparks, open flames, heaters, or heat sources.
•Keep gasoline out of the reach of children.
• Do not siphon gasoline from the vehicle.
∆ WARNING
•Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse
handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the
vehicle or a fire hazard.
•Turn fuel shut-off valve to closed (OFF) position (Figure 3-3, Page 3-3).
•Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery.
Frozen batteries can explode.
∆ CAUTION
• Batteries in a low state of charge will freeze at low temperatures.
PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE
1. Unload the vehicle so that tires are supporting only the weight of the vehicle.
2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of
baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat-
teries. Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry
and then coat them with Battery Terminal Protector Spray (CCI P/N 1014305).
Figure 3-1 Serial Number Decal Figure 3-2 Serial Number Decal Behind Dash
Club
GO
GO
SERIAL NUMBER
D0401-123456
P O BOX 204658
AUGUSTA GA 30917
Club Car R
SERIAL NUMBER
DECAL
SERIAL NUMBER
D0301-583947
P O BOX 204658
AUGUSTA GA 30917
Club Car
R
REAR OF CENTER
DASH VIEWED FROM
THE FRONT OF
THE VEHICLE
(FRONT BODY
REMOVED)
SERIAL NUMBER DECAL

GENERAL INFORMATION Storage – Gasoline Vehicle
2004 Transportation Vehicle Maintenance and Service Manual Page 3-3
3
3. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be
weak, have it charged by a trained technician. Use an automotive-type 12-volt battery charger rated at
10 amps or less.
4. Drain carburetor and seal the fuel tank.
4.1. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the
SERVICE (MAINTENANCE) position. Turn the fuel shut-off valve to the closed (OFF) position
(Figure 3-3, Page 3-3) and run the engine until fuel remaining in the carburetor and fuel lines is
depleted and the engine stalls. Return the neutral lockout cam to the OPERATE position.
4.2. Loosen, but do not remove, the carburetor drain screw and drain fuel remaining in bowl into a small
container, then pour the fuel from the container into vehicle fuel tank. Tighten the carburetor drain
screw.
4.3. Fill fuel tank to about 1 inch (2.5 cm) from top of fuel tank and, following manufacturer’s directions,
add a commercially available fuel stabilizer (such as Sta-Bil®).
4.4. Disconnect fuel vent line from fuel tank vent nipple.
4.5. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap.
5. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning, Section 1, Page 1-1.
6. To protect the engine, remove spark plug and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil into engine
through the spark plug hole. Rotate engine crankshaft by hand several times and then install the spark
plug.
7. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
8. Perform semiannual periodic lubrication. See Periodic Lubrication Schedule, Section 10 – Periodic
Maintenance, in the appropriate maintenance and service supplement.
9. Thoroughly clean front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle.
10. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling.
Figure 3-3 Fuel Shut-off Valve – Closed Position
CLOSED (OFF) POSITION
(SELECTOR IS ALIGNED
WITH OFF MARKINGS ON THE SIDES OF VALVE)
OFFOFF
VIEWED FROM SELECTOR
SIDE OF VALVE

GENERAL INFORMATION Storage – Electric Vehicle
Page 3-4 2004 Transportation Vehicle Maintenance and Service Manual
3
RETURNING THE STORED GASOLINE VEHICLE TO SERVICE
1. Connect the battery cables, positive (+) cable first.
2. Restore fuel system to operation.
2.1. Remove plug from the fuel tank vent nipple and connect fuel vent line to nipple. Open the fuel shut-
off valve (Figure 3-4, Page 3-4). Make sure the valve is fully open. A partially closed fuel shut-off
valve (Figure 3-5, Page 3-4) combined with the use of the choke can result in a fouled spark plug
and engine failure.
2.2. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the
SERVICE (MAINTENANCE) position. Crank the engine until fuel is pumped into the carburetor and
fuel lines and the engine starts.Turn the engine off and return neutral lockout cam to the OPERATE
position. See following NOTE.
NOTE: Due to the oil added to the engine in preparation for storage, engine may smoke excessively for a
short while when running it for the first time after storage.
3. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
4. Perform the Pre-Operation and Daily Safety Checklist. See the vehicle owner’s manual.
STORAGE – ELECTRIC VEHICLE
See General Warning, Section 1, Page 1-1.
∆ WARNING
•Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse
handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the
vehicle or a fire hazard.
•Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery.
Frozen batteries can explode.
Figure 3-4 Fuel Shut-off Valve – Open Position Figure 3-5 Incorrect Fuel Shut-off Valve Setting
FULL OPEN (ON) POSITION
VIEWED FROM SELECTOR
SIDE OF VALVE
VIEWED FROM SELECTOR
SIDE OF VALVE
PARTIALLY CLOSED POSITION