Club Car Cafe Express Configuration guide

2004 OWNER’S MANUAL SUPPLEMENT
FOR CAFE EXPRESS VEHICLE
The following pages are supplemental to the 2004 Turf Utility Vehicle Owner’s Manual. If you do not have a Turf
Utility Vehicle Owner’s Manual for your vehicle, you may obtain one from your Club Car dealer or distributor.
This supplement contains the following information:
• Operating, maintenance, and cleaning procedures specific to the Cafe Express vehicle
• Installation instructions for the upper cabinet, canopy, and windshield
Supplement Part No. SVP202101
Edition Code 0803C1103B

Page 2 2004 Cafe Express Owner’s Manual Supplement
NOTICE
It is intended that this supplement be used in conjunction with the Turf Utility Vehicle Owner’s Manual shipped
with this vehicle. Please feel free to make copies of this supplement; or you may order additional copies from
your Club Car distributor or dealer.
The information contained in this document is subject to change without notice.
The Club Car Limited Warranty for Turf Utility vehicles appears at the end of the owner’s manual. No other
warranties, expressed or implied, are contained herein.
Club Car vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS
500 for low-speed vehicles, and are not designed or equipped for use on public streets, roads, or highways.
A vehicle safety video is provided with the vehicle, as is the Turf Utility Vehicle Owner’s Manual and this
Owner’s Manual Supplement. Have all operators view the safety video, and understand the safety warnings it
illustrates, before operating the vehicle. If a safety video was not provided with your Cafe Express vehicle, you
may obtain one through your service parts representative.
Copyright © 2003 Club Car, Inc.

2004 Cafe Express Owner’s Manual Supplement Page 3
TABLE OF CONTENTS
Safety Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Decals and Feature Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Vehicle Feature Identification – Cafe Express . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pre-Operation and Daily Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Vehicle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Refreshment Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Periodic Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cafe Express Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cafe Express Installation – General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts in this Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Upper Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Windshield Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Canopy Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Canopy Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safety Details
Page 4 2004 Cafe Express Owner’s Manual Supplement
SAFETY DETAILS
∆
WARNING
•This supplement and the 2004 Turf Utility Vehicle Owner’s Manual should be read completely
before attempting to operate the vehicle. The safety video provided with the Cafe Express
vehicle should also be viewed by all operators of the vehicle. Failure to heed the warnings or
follow the instructions in this supplement, the owner’s manual, and the safety video could
result in severe personal injury or death.
See the Turf Utility Vehicle Owner’s Manual for additional safety details.
SAFETY DECALS AND FEATURE IDENTIFICATION
The safety decals and feature identification contained on page 5 are specific to the Cafe Express unit. See the
Turf Utility Vehicle Owner’s Manual for the additional listing of safety decals and vehicle feature identification.
All additional information in the Turf Utility Owner’s Manual pertaining to the Turf 2 vehicle applies to the Cafe
Express vehicle.

Vehicle Feature Identification
2004 Cafe Express Owner’s Manual Supplement Page 5
CAFE EXPRESS
Remove canopy pins
before lifting bed.
NOTICE
CCI 102160601
Riding in cargo bed
can cause severe injury
or death.
Do not ride in cargo bed.
WARNING
CCI 1015539-01
CCI 000000000
CONSUMABLE ICE COMPARTMENT
FOOD POISONING CAN CAUSE
SERIOUS ILLNESS OR DEATH.
•This bin is not intended to store ice for human
consumption.
•Do not put unprotected food in this bin.
W
W
A
A
R
R
NIN
NIN
G
G
GO
STOP
TRASH
COMPARTMENT
DRAIN HOSES (3)
(VALVES INSIDE TRASH
COMPARTMENT)
COLD STORAGE
COMPARTMENT
CONSUMABLE ICE
COMPARTMENTS
PIN REMOVAL
NOTICE DECAL
(ON FRAME NEXT TO PINS)
DRY SNACKCOMPARTMENT
DRY SNACK
COMPARTMENT
BEVERAGE CONTAINER
COMPARTMENT
CUP DISPENSER
BED LOAD DECAL
FOOD WARNING DECAL
(EACH SIDE OF BASE UNIT )
CONSUMABLE ICE WARNING DECAL
(EACH SIDE OF BASE UNIT )
SVP203101
This vehicle is designed only for the conveyance of certain nonhazardous prepackaged
foods and non-dairy products. In California, those foods not permitted are defined in
Health & Safety Code section 113845. If you have any question concerning whether
any particular prepackaged food complies with those standards, please consult the
manufacturer or supplier of those foods before conveying them with this vehicle.
IMPORTANT NOTICE
FOOD NOTICE DECAL
(EACH SIDE OF BASE UNIT )
VEHICLE
LOADING
Read owner's manual,
supplement, and
warnings on vehicle.
• Vehicle rated capacity - 850 lbs. (385.6 kg) on level
surface only. Weight to include driver, passenger,
and total cargo load.
• Maximum cargo load - 450 lbs. (204.1 kg). Weight
to include total cargo load in ALL storage locations.
• Avoid top heavy loads.
• Cargo should be evenly distributed in the beverage
unit, as far forward as possible, and secured.
• For vehicle stability, when fully loaded, drive slowly
and avoid stopping on or backing down steep hills.
• When driving on uneven terrain or down steep hills,
reduce speed and load. CCI 102278901
VEHICLE LOAD WARNING DECAL
(UNDER THE DASH)
VEHICLE ROLLOVER COULD RESULT IN SERIOUS INJURY OR DEATH.
CCI 102056401
Operate vehicle only:
• On cart paths or improved surfaces.
• With 6-ply rated, 18x8.50-8 tires.
• With 30-34 psi (2.07-2.34 Bars) tire pressure
checked daily.
• With all compartment loads equally
distributed.
WARNING
!
VEHICLE LOAD WARNING DECAL
(UNDER THE DASH)
VEHICLE ROLLOVER COULD RESULT IN
SERIOUS INJURY OR DEATH.
Operate vehicle only:
•On cart paths or improved surfaces.
•With 6-ply, 18x8.50x8 tires.
•With 30-34 psi tire pressure checked daily.
•With all compartment loads equally distributed.
W
W
A
A
R
R
NIN
NIN
G
G
CCI 101940101
VEHICLE LOAD WARNING DECAL
(EACH SIDE OF BASE UNIT )

Pre-Operation and Daily Safety Checklist
Page 6 2004 Cafe Express Owner’s Manual Supplement
PRE-OPERATION AND DAILY SAFETY CHECKLIST
Do not operate the vehicle until the upper cabinet, canopy, and windshield have been installed. See Cafe
Express Installation – General Information on page 11.
Have all operators view the safety video and understand the safety warnings it illustrates before operating the
vehicle.
• General: Ensure that the windshield is installed before driving the vehicle.
•Safety and information decals: Check to be sure all safety and information decals are in place. See
page 5 of this supplement and the Vehicle Feature Identification pages in the Turf Utility Vehicle
Owner’s Manual.
• Tires: Check for proper tire pressure upon delivery and on a daily basis when the vehicle is in service.
See Tire Specifications on page 7.
• Loading: Before driving the vehicle, ensure that the load weight is evenly distributed in the Cafe
Express refreshment center. Also, make sure the drain valves are open if the refreshment center is
loaded with ice.
See the Turf Utility Owner’s Manual for remaining Pre-Operation and Daily Safety Checklist items
before driving the vehicle.
PERFORMANCE INSPECTION
•Governor: With the neutral lockout in the SERVICE position, check the engine RPM with a tachometer.
The correct setting for safe operation is 3050 ± 30.
• Brakes: Be sure the brakes function properly. When the brake pedal is fully pressed under moderate
pressure, it should not go more than halfway to the floor, and the vehicle should come to a smooth,
straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to
stop, have the brake system checked and adjusted as required. Brake adjustment must be maintained
so the brake pedal cannot be pressed to the floor under any circumstance.
See the Turf Utility Owner’s Manual for remaining Performance Inspection items.
CONTROLS AND INDICATORS
Controls for the Cafe Express vehicle are the same as described in the Turf Utility Vehicle Owner’s Manual for
the Turf 2 vehicle.
VEHICLE OPERATION
STABILITY
To maintain proper stability, the Cafe Express vehicle must not be driven over curbs, or on steep slopes, fair-
ways, or extremely uneven terrain.
∆
WARNING
•Driving the vehicle over curbs, or on steep slopes, fairways, or extremely uneven terrain could
cause vehicle rollover, resulting in serious injury or death.

Tire Specifications
2004 Cafe Express Owner’s Manual Supplement Page 7
ENGINE SPEED
A Club Car vehicle with a Cafe Express refreshment center installed must have a maximum engine RPM of
3050 ± 30. This is necessary to limit maximum level ground travel speed to 14 mph (23 km/h) or less.
TIRE SPECIFICATIONS
∆ WARNING
•All Cafe Express vehicles must be equipped with 18 x 8.50 x 8 6-ply rated tires on all four
wheels. Never install oversized tires on the vehicle. Oversized tires can increase the vehicle’s
maximum travel speed. Oversized tires can also raise the vehicle’s center of gravity, reducing
the vehicle stability.
•Never install tires that are rated below 6-ply on the vehicle. Less than 6-ply rated tires may not
have sufficient side wall strength to adequately support the vehicle.
•Correct tire pressure is essential. Low air pressure will reduce vehicle travel speed and result
in weakened tire sidewall strength. Tires with weakened sidewall strength will not adequately
support the vehicle when making sharp turns.
• Tire pressure must be checked daily and adjusted as required on a regular basis.
PROP ROD
See the Turf Utility Owner’s Manual for prop rod information.
WINDSHIELD
The Cafe Express vehicle is often driven in the opposite direction of play. This exposes the driver to the hazard
of flying golf balls.
∆
WARNING
•AClub Car vehicle with a Cafe Express refreshment center installed must be equipped with
the one-piece windshield supplied with this kit to reduce the hazard of flying golf balls.
SPECIFICATIONS
CAFE EXPRESS
VEHICLE
Tires 18 x 8.50 x 8 6-ply
Tire pressure 30-34 psi (2.07-2.34 Bars)

Refreshment Center
Page 8 2004 Cafe Express Owner’s Manual Supplement
REFRESHMENT CENTER
LOADING
When stocking the Cafe Express refreshment center, make sure the load weights are approximately equal in
all lower (cold storage) compartments containing ice and/or beverages.
∆
WARNING
• An unevenly distributed load can cause vehicle instability.
REFRESHMENT CENTER COMPARTMENTS
Cold Storage Compartments
The cold storage compartments are designed to carry canned beverages and cooling ice. See page 5. Pre-
packaged cold sandwiches and snacks can also be served from these compartments. We recommend they
be kept on the snack shelves, or in a plastic container if placed directly on the ice, so that food will remain dry.
Pre-cooling the canned beverages will minimize the amount of ice required to keep the product cool. Main-
taining ice in the cold storage compartments when they are not in service will help to maintain a colder tem-
perature when the unit is put back into service.
∆
WARNING
•Do not use the cold storage compartments to store unprotected food, or ice that is intended
for human consumption. Failure to heed this warning could result in food poisoning.
Consumable Ice Compartments
The consumable ice compartments, located in the rear driver and passenger sides of the Cafe Express
refreshment center should be used for consumable ice only. See page 5. In order to prevent contamination of
consumable ice, do not place food in these compartments. Consumable ice should not be stored in any other
compartment of the Cafe Express refreshment center.
Trash Compartment
The trash compartment is located in the rear of the base unit. The trash bin should be lined with a disposable
plastic bag to maintain cleanliness. This compartment should not be used for storing or transporting consum-
able ice, drinks, or food.
WATER DRAIN VALVES
The three drain valves, located in the trash compartment of the base unit, are used to drain the ice compart-
ments.
• The valve on the passenger side of the base unit drains the passenger side consumable ice compart-
ment.
• The valve on the driver side of the base unit, nearest the rear of the vehicle, drains the driver side con-
sumable ice compartment.
• The valve on the driver side of the base unit, toward the front of the vehicle, drains the cold storage
compartment.

Maintenance
2004 Cafe Express Owner’s Manual Supplement Page 9
∆
WARNING
•All three drain valves must always be open while the Cafe Express refreshment center vehicle
is in service. Leaving them closed will allow water from melting ice to collect in storage and
beverage compartments. This water level will increase over time and the shifting weight of the
water, when making turns, can cause reduced vehicle stability.
MAINTENANCE
REFRESHMENT CENTER
The door latches and locks will require periodic tightening and adjusting. Periodically oiling the doors with a
silicone spray lubricant is also recommended. The door locks should be lubricated on a monthly basis with a
dry lubricant.
PERIODIC SERVICE SCHEDULE
See the Turf Utility Owner’s Manual for all other items to be included in the Periodic Service Sched-
ule.
CLEANING
WINDSHIELD
Use only mild liquid dishwashing soap with a sponge or soft cloth for cleaning the windshield.
CAUTION
•Do not use glass-cleaning products on the windshield. See the Turf Utility Owner’s Manual for
all other cleaning instructions for the vehicle.
PERIODIC SERVICE SCHEDULE
REGULAR INTERVAL SERVICE
Daily service by owner
or trained technician
Tires Check air pressure and adjust as
necessary to 30-34 psi (2.07-2.34 Bars).
Monthly service by owner or
trained technician
Door locks Lubricate with a dry lubricant.

Cafe Express Vehicle Specifications
Page 10 2004 Cafe Express Owner’s Manual Supplement
REFRESHMENT CENTER
Interior Aluminum Surfaces
The interior surfaces of the refreshment center should be cleaned and sanitized daily with an approved prod-
uct before being used. Check with local Health Department for rules and regulations in your area.
Exterior Aluminum Surfaces
The exterior surfaces should be cleaned on a daily basis using a soap and water solution. Periodic cleaning
with an aluminum or stainless steel cleaner is recommended.
CAUTION
•Using abrasive cleaners on aluminum and stainless steel will damage or scratch the surfaces.
Use a soft cloth with an industrial type stainless steel cleaner/polish to clean the aluminum
and stainless steel surfaces.
Drains
The drains should be flushed with a hose on a daily basis. Periodically, the drains should be cleaned and san-
itized.
Clear Plastic Doors
The clear plastic panels on the doors should be cleaned daily with a mild soap and water solution. Dry with a
clean, damp chamois. Do not use window cleaning sprays or paper towels.
Polypropylene
The polypropylene doors should be cleaned daily with a soap and water solution.
Canopy Cover
Periodically clean the canopy cover by spraying the fabric with water and allowing fabric to dry on the canopy
frame.
CAFE EXPRESS VEHICLE SPECIFICATIONS
Cafe Express vehicles are equipped with four-wheel, manually-adjusted drum brakes.
The unloaded (empty) weight of the Cafe Express vehicle is 1076 lb. (144.7 kg). The combined weight of pas-
sengers and refreshment center must not exceed the vehicle rated capacity.
See the Turf Utility Vehicle Owner’s Manual for a complete listing of Turf Utility vehicle specifications
and vehicle rated capacity.
NOTE: Club Car, Inc. reserves the right to change specifications and design of its vehicles at any time
without notice and without obligation to make these changes on units previously sold.

Cafe Express Installation – General Information
2004 Cafe Express Owner’s Manual Supplement Page 11
CAFE EXPRESS INSTALLATION – GENERAL INFORMATION
Review the following instructions and safety precautions before beginning installation procedures.
Installation of the upper cabinet, canopy frame and canopy will require the aid of an assistant.
Observe the following DANGER and WARNING statements and procedures. Failure to do so may result in
severe personal injury and (or) damage to the vehicle or property:
∆
DANGER
•Gasoline vapors – Flammable! Do not smoke! Keep sparks and flames away from vehicle and
service area. Tools, wires, and metal objects can cause sparks when “shorted” across a
battery. Use insulated tools. Extreme care should be taken when disconnecting batteries.
When wires are disconnected, be sure to keep them away from battery posts and other wires.
Service only in well-ventilated areas.
•Do not operate the gasoline vehicle in an enclosed area without proper ventilation. Gasoline
engines produce carbon monoxide gas, which is an odorless, deadly poison.
•Batteries release explosive gases! Keep all sources of ignition (cigarettes, sparks, flames)
away from charging and service areas. Charging and service areas should be well-ventilated
to prevent build-up of explosive gases.
∆
WARNING
•Only trained technicians should repair or service the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
Follow all procedures exactly and heed all warning statements in these instructions.
•Wear safety glasses or approved eye protection while servicing vehicle.
•Turn the key switch to the OFF position, place Forward/Reverse handle in the NEUTRAL
position, and remove the key prior to servicing.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc. when servicing
vehicle.
•To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 1).
- Disconnect the spark plug wire from the spark plug.
Figure 1 Battery Cable Removal
FRONT OF
VEHICLE
AS SEEN FROM
PASSENGER'S SIDE
OF VEHICLE
REMOVE
NEGATIVE
CABLE FIRST
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE
EARLIER CABLE
MOUNTING HARDWARE

Tools Required
Page 12 2004 Cafe Express Owner’s Manual Supplement
TOOLS REQUIRED
FLAT BLADE
SCREWDRIVER
PHILLIPS
SCREWDRIVER
9/16 IN.
WRENCH
1/2 IN.
WRENCH
7/16 IN.
WRENCH
1/2 IN.
SOCKET
7/16 IN.
SOCKET
3/8 DRIVE
x 2 IN. LONG
EXTENSION 3/8
DRIVE
RATCHET
TORQUE
WRENCH
10-100 IN-LB
NUT DRIVER
5/16 IN.
NUTDRIVER

Parts in this Kit
2004 Cafe Express Owner’s Manual Supplement Page 13
PARTS IN THIS KIT
BUSHING
1010237
CAPPED TEE NUT
1011878
RETAINING PINCONSUMABLE ICE
DOOR CLIP
1/4-20
HEX NUT
CANOPY COVER
(CHOICE OF ONE)
Pacific Blue - 102427901
Classic Blue - 102428001
Blue/White - 102428101
Green - 102428201
Green/White - 102428301
Custom - 102428401
5/16-18 x 1-1/2
HEX HEAD BOLT
1010577
1/4-20 x 3/4
PHILLIPS PAN
HEAD SCREW
W/ PATCH
#10 x 5/8
PHILLIPS PAN
HEAD SCREW
W/ PATCH
1/4-20 x 1-1/2
PHILLIPS PAN
HEAD SCREW
W/ PATCH
5/16-18 x 1-1/4
HEX HEAD
SCREW W/PATCH
1011937
CANOPY FRAME
102427801
WINDSHIELD
CHANNEL
1014441
WINDSHIELD
1011838
UPPER CABINET
102427701
(INCLUDES TWO
BEVERAGE CONTAINERS
SVP178501)
WINDSHIELD
FRAME ASSEMBLY
1011868
KNEE BRACE
(Passenger Side)
1011862
KNEE BRACE
(Driver Side)
1011865
WINDSHIELD FRAME
MOUNTING PAD
1011883
PROTECTIVE
BUMPER
1011897
1/4 WASHER
1011964
1/4 LOCK
WASHER
1011965
1/4-20 x 1-1/2
HEX HEAD BOLT
1703

Upper Cabinet Installation
Page 14 2004 Cafe Express Owner’s Manual Supplement
UPPER CABINET INSTALLATION
NOTE: The tallest end of the cabinet will be installed toward the rear of the vehicle as shown (Figure 2) .
1. With the aid of an assistant, slide the upper cabinet (1) forward using the angle brackets (with nut inserts)
on the base unit (2) as a guide. The upper cabinet must be on the outside of the angle brackets.
2. Align holes in upper cabinet with the nut inserts in angle brackets on base unit. Secure with three 1/4-
20 x 3/4 phillips pan-head screws (with patch) (3) on each side, four at rear and four at front. Tighten all
screws to 50 in-lb (5.6 N·m). See following CAUTION.
3. Locate the hole in the corner just above the consumable ice compartment door. See Detail in Figure 2.
Slide the clip (5) in between the upper cabinet and base unit as shown. Secure the clip to the upper cab-
inet with a #10 x 5/8 phillips pan-head screw (with patch) (6). Tighten screw to 18 in-lb (2.0 N·m). Install
remaining clip at opposite side of vehicle using same procedure. See following CAUTION.
CAUTION
• Do not overtighten screws.
WINDSHIELD FRAME INSTALLATION
1. Remove nuts (1), washers (2), and bolts (3) holding the trim (4) to the front body (5) (Figure 3). Retain
nuts and washers for later use. Discard bolts.
2. Remove the phillips-head screw (6) from each side of the front body (5).
Figure 2 Upper Cabinet Installation
GO
STOP
1
2
56
3

Windshield Frame Installation
2004 Cafe Express Owner’s Manual Supplement Page 15
3. Place a windshield frame mounting pad (3) between each lug (5) on the windshield frame (1) and front
body (2) (Figure 4). Secure windshield frame (1) and two mounting pads (3) to front body with two 5/16
x 1-1/4 hex-head screws with patch (4). Tighten screws to 45 in-lb (5 N·m).
4. Secure the left and right knee braces (6 and 7) with new 5/16-18 x 1-1/2 hex-head cap bolts (8), and pre-
viously removed flat washers (9) and nuts (10) (Figure 4).Tighten bolts to 45 in-lb (5 N·m).
Figure 3 Remove Hardware from Front Body
Figure 4 Mount Windshield Frame
Club Car
33
4
2
1
6
5
8
4
16
9
10
32
5
7

Canopy Frame Installation
Page 16 2004 Cafe Express Owner’s Manual Supplement
CANOPY FRAME INSTALLATION
NOTE: Install the canopy frame with the channels toward the front of the vehicle.
1. Locate the four holes near the top edge of the upper cabinet (two in front and two in rear).
2. With the aid of an assistant, position the canopy frame (1) so that the cross tubes with pre-drilled holes
align with the nut inserts in the front and rear of the upper cabinet (Figure 5).
3. Secure the canopy frame (1) to the upper cabinet (2) using four 1/4-20 x 1-1/2 phillips pan-head screws
with patch (3) and stainless steel flat washers (4) (Figure 5). Tighten screws to 50 in-lb (5.6 N·m). See
following CAUTION.
CAUTION
• Do not overtighten screws.
4. Adjust the windshield frame legs so that the holes in the windshield frame (6) align with the holes in the
channels. Insert one retaining pin (7) in each side and place the retaining wires (8) over the ends of the
pins (Figure 5).
5. Making sure the surface is dry, clean and free of grease, apply velcro strip (2) all around the outside
suface of the canopy frame (1) (Figure 6). Align the bottom edge of the velcro to the bottom edge of the
tubing as shown.
Figure 5 Canopy Frame Installation
GO
STOP
STOP
TYPICAL 2
PLACES
1
1
2
34
7
6
6
8

Canopy Cover Installation
2004 Cafe Express Owner’s Manual Supplement Page 17
CANOPY COVER INSTALLATION
1. Spread the canopy cover (1) out over the canopy frame with the velcro strip facing inward toward the can-
opy frame (Figure 7).
2. Starting at one corner, align the bottom edge of the velcro strip on the cover with the bottom edge of the
velcro strip on the frame. Continue working around vehicle until canopy cover is completerly secured to
canopy frame.
NOTE: Installation of the canopy cover will require some stretching of the cover material. Be careful not to
stretch the canopy cover so tightly that the fabric tears.
Figure 6 Velcro Installation
Figure 7 Canopy Cover Installation
1
2
GO
STOP
1

WINDSHIELD INSTALLATION
1. Install the two rubber bumpers (2) on the frame side of the windshield (Figure 8).
2. Install the three mounting channels (1) onto the windshield as shown. Push all three channels onto the
frame evenly until the channels are firmly attached to the frame.
QUESTIONS
Questions or comments regarding this kit instruction should be referred to your local Club Car dealer or dis-
tributor. Please know your vehicle model and have this kit instruction available when you call.
Figure 8 Install Windshield
2
1
1