Club Car Villager Homologated LSV User manual

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

P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone [phone]
Service Parts Fax [phone]
www.clubcar.com
USING THE ILLUSTRATED PARTS LIST
ý WARNING
• This manual is to be used only for identification and ordering of service parts. Be sure to read and use
the maintenance and service manual before attempting any vehicle repairs.
This manual covers all Villager Homologated LSV vehicles built during the 2011 model year.
The manual is divided into sections. Note that there are two or three flags on the outside edge of each page. The
first flag contains the section number of which that page is a part. The other flag (or flags) contains the letter G or E,
signifying that the page pertains to the electric or gasoline vehicles only.
Use the Table of Contents to find the sections and pages that contain the parts and assemblies you seek. The Table
of Contents lists section numbers, and under them, the individual page titles and numbers to be found in that
section. The index can be used to find specific parts and assemblies. The index is divided into numerical and
alphabetical listings with the page numbers in italic text.
There is a two-page spread for each individual page title in the Table of Contents. On the left-hand page is an
illustration showing the parts in their relative positions; the parts are each tagged with an item number in a balloon.
The right-hand page is the parts list page, and gives the page title at the top, then the item numbers (corresponding
to the numbers on the illustration), part descriptions, and quantity of parts used.
Note that a part description may be indented. This indention corresponds to a parts assembly level indicated by the
numbers 1, 2, 3, and 4 at the top left corner of the parts description area of the parts list page. A part that is indented
to level 2 is a component of the level 1 part (assembly) that it is listed under. A level 3 part is a component of the level
2part that it is listed under, and a level 4 part is a component of the level 3 part preceding it. In each case, the part
quantity given for a level 2, 3, or 4 part is the quantity used per next higher level assembly of which it is a component. A
part that is not indented is a level 1 part. This means that the quantity given is the quantity used per the portion of
the vehicle illustrated on that particular spread.
HOW TO ORDER PARTS
Replacement parts and 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 [phone] or [phone], extension 3887.

2011 Villager Homologated LSV
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.
Club Car, LLC. reserves the right to change specifications and designs at any time without notice and without
the obligation of making changes to units previously sold.
Copyright © 2011 Club Car, LLC.
Club Car and ArmorFlex
are registered trademarks of Club Car, LLC.
This manual effective December 1, 2010.

2011 Villager Homologated LSV Page 1
CONTENTS
SECTION 1 – BODY AND TRIM
Front Seat Bottom and Armrests .............................................................................................................................................. 1-3
Rear-Facing Seat Bottom – Villager 2+2 ................................................................................................................................ 1-5
Mirrors, Windshield, Wiper – To Be Determined ................................................................................................................. 1-7
Front Body ........................................................................................................................................................................................ 1-9
Rear Body and Fenders ................................................................................................................................................................ 1-11
Dash Canopy Brace and Cowl Trim .......................................................................................................................................... 1-13
TOPS – Villager 2 with Bed Box ................................................................................................................................................. 1-15
TOPS – Villager 2 ............................................................................................................................................................................. 1-17
Rear Footrest and Handrails – Villager 2+2 ........................................................................................................................... 1-19
TOPS – Villager 2 + 2 ..................................................................................................................................................................... 1-21
Seat Backs ......................................................................................................................................................................................... 1-23
Seat Belts ........................................................................................................................................................................................... 1-25
Bed Box .............................................................................................................................................................................................. 1-27
Canopy ............................................................................................................................................................................................... 1-29
SECTION 2 – WHEELS AND TIRES
Wheels and Tires ............................................................................................................................................................................. 2-3
SECTION 3 – DECALS
Safety Decals .................................................................................................................................................................................... 3-3
Safety Decals – Continued .......................................................................................................................................................... 3-5
Logo Decals ...................................................................................................................................................................................... 3-7
SECTION 4 – BRAKES, PEDAL, AND CABLES
Rear Brake Assembly, Manually-Adjusted – Vehicles with 4-Wheel Brakes .............................................................. 4-3
Front Brake Assembly – Vehicles with Four-Wheel Brakes ............................................................................................. 4-5
Accelerator Pedal Assembly – Electric Vehicles with MCOR ........................................................................................... 4-7
Hand Brake ....................................................................................................................................................................................... 4-9
Brake Pedal ....................................................................................................................................................................................... 4-11
Brake Cables and Equalizer ......................................................................................................................................................... 4-13
Accelerator Pedal Assembly (Style B) ...................................................................................................................................... 4-15
SECTION 5 – STEERING, FRONT AND REAR SUSPENSION
Steering Column ............................................................................................................................................................................. 5-3
Steering Gear Assembly ............................................................................................................................................................... 5-5
Rear Suspension Components .................................................................................................................................................. 5-7
Front Suspension, Lower ............................................................................................................................................................. 5-9

Page 2 2011 Villager Homologated LSV
CONTENTS
Front Suspension, Upper ............................................................................................................................................................. 5-11
Front Spindles and Hubs .............................................................................................................................................................. 5-13
Steering Wheel ................................................................................................................................................................................ 5-15
SECTION 6 – ELECTRICAL SYSTEM
Motor Controller Output Regulator (MCOR) ......................................................................................................................... 6-3
Lighting Harness ............................................................................................................................................................................. 6-7
Speedometer .................................................................................................................................................................................... 6-9
Electrical Components, Front Body .......................................................................................................................................... 6-11
Wiring .................................................................................................................................................................................................. 6-15
Headlights ......................................................................................................................................................................................... 6-17
Turn Signals ....................................................................................................................................................................................... 6-19
Taillights and License Plate Light .............................................................................................................................................. 6-21
Electrical Components, Center Body ....................................................................................................................................... 6-23
Electrical Component Mounting Plate .................................................................................................................................... 6-25
Instrument Panel with Electrical Components .................................................................................................................... 6-27
Batteries .............................................................................................................................................................................................. 6-29
SECTION 7 – ELECTRIC MOTOR
Electric Motor (Model EJ9-4002) ................................................................................................................................................ 7-3
SECTION 8 – TRANSAXLE
Transaxle ............................................................................................................................................................................................ 8-3
SECTION 9 – BATTERY CHARGER
PowerDrive Battery Charger (Model 20310), European .................................................................................................... 9-3
Onboard PowerDrive Battery Charger (Model 17790), Export ....................................................................................... 9-5
Onboard Battery Charger and Reel Mounting ..................................................................................................................... 9-7
SECTION 10 – MAINTENANCE AND SERVICE TOOLS
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

G
E
1
D
BODY AND TRIM

Page 1-2 2011 Villager Homologated LSV
G
E
1
D
1
2
4
8
25
27
3
26
5
7
6
9
000364-003

E
G
1
2011 Villager Homologated LSV Page 1-3
ITEM PART NO. DESCRIPTION
1 2 3 4
QTY
D
FRONT SEAT BOTTOM AND ARMRESTS
1 1010543 Insert - Wood ............................................................................................................................................... 4
2 1011652 Hinge Plate ................................................................................................................................................... 2
3 1016916 Screw, 1/4-20 X 1.50 Hex-Head Cap .................................................................................................... 8
4 101954301 Screw, 1/4-20 X 0.75 Hex-Head Cap .................................................................................................... 4
5 102174201 Seat Bottom Assembly, Buff (includes items 6 through 9) .......................................................... 1
6 N/A Plywood Assy ......................................................................................................................................... 1
7 101998211 Vinyl Cover Seat Btm - Buffsvc ......................................................................................................... 1
8 N/A Foam, Seat ............................................................................................................................................... 1
9 101998501 Gasket, Seat ............................................................................................................................................ 2
10 102174202 Seat Bottom Assembly, White (includes items 11 through 14) ................................................. 1
11 N/A Plywood Assy ......................................................................................................................................... 1
12 101998212 Vinyl Cover, Seat Bottom, White ...................................................................................................... 1
13 N/A Foam, Seat ............................................................................................................................................... 1
14 101998501 Gasket, Seat ............................................................................................................................................ 2
15 102174204 Seat Bottom Assembly, Black (includes items 16 through 19) .................................................. 1
16 N/A Plywood Assy ......................................................................................................................................... 1
17 101998214 Vinyl Cover, Seat Bottom, Black ....................................................................................................... 1
18 N/A Foam, Seat ............................................................................................................................................... 1
19 101998501 Gasket, Seat ............................................................................................................................................ 2
20 102174205 Seat Bottom Assembly, Gray (includes items 21 through 24) ................................................... 1
21 N/A Plywood Assy ......................................................................................................................................... 1
22 101998215 Vinyl Cover, Seat Bottom, Gray ........................................................................................................ 1
23 N/A Foam, Seat ............................................................................................................................................... 1
24 101998501 Gasket, Seat ............................................................................................................................................ 2
25 103246701 Hip Restraint, Drvr Side ............................................................................................................................ 1
26 103246801 Hip Restraint, Pass Side ............................................................................................................................ 1
27 332 Washer, 1/4 Type A Narrow Flat ............................................................................................................ 8
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.

Page 1-4 2011 Villager Homologated LSV
G
E
1
D
33
16 14 15
32
3
11
32
10 6 10 97 85
4
33
12
32
34
30
31
13
2
1
000387-002