2003

ILLUSTRATED
PARTS LIST

Club C
a r

DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 102318701
EDITION CODE 1202F1004C
 USING THE ILLUSTRATED PARTS LIST

∆ 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 2003 Club Car® DS Tranquility®, DS V-Glide 36-Volt, DS PowerDrive® System 48™,
and IQ System™ vehicles.
The manual is divided into 16 sections. Sections 1 through 5 pertain to both gasoline and electric vehicles,
sections 6 through 11 pertain to gasoline vehicles only, sections 12 through 15 pertain to electric vehicles
only, and section 16 pertains to tools that are used on all Club Car products. 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 either the letter G or E, signifying that the page pertains to either the
gasoline or electric vehicle only, or to both the gasoline and electric vehicles.
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. Some item
numbers have more than one part number because several configurations of a component are represented
together on one spread.
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 2 part 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 Club Car contact by visiting our web
site at www.clubcar.com and clicking on the “Distributor Search” link or by calling our toll-free Service Parts
and Technical Assistance hotline at (800) 872-2246 or (706) 863-3000, extension 3281 or 3854.

P. O. Box 204658
Augusta, Georgia 30917-4658 USA
Telephone 706-863-3000
Service Parts Fax 706-855-7413
www.clubcar.com
 NOTE: This illustrated parts list 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 improve-
ments may affect the parts used to service the vehicle. Any modification and/or significant change
in specifications will be forwarded to all Club Car and Carryall distributors/dealers and will, when
applicable, appear in future editions of this illustrated parts list.
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.

Copyright © 2003 Club Car, Inc.

Club Car, ArmorFlex, PowerDrive
and Tranquility are registered trademarks of Club Car, inc.
This manual effective July 22, 2002.

2003 DS Golf Cars Illustrated Parts List

 CONTENTS
SECTION 1 – BODY AND TRIM

Body Trim ......................................................................................................................................... 1-3

Front Body ........................................................................................................................................ 1-5
Rear Body and Fender – Gasoline Vehicle ...................................................................................... 1-7
Rear Body and Fender – Electric Vehicle ......................................................................................... 1-9
Seat Bottom and Armrest ................................................................................................................. 1-11
Seat Back and Bag Hoop ................................................................................................................. 1-13
Canopy ............................................................................................................................................. 1-15

SECTION 2 – WHEELS AND TIRES

Wheels and Tires .............................................................................................................................. 2-3

SECTION 3 – DECALS

Decals – Gasoline Vehicle ................................................................................................................ 3-3

Decals – Electric Vehicle .................................................................................................................. 3-5

SECTION 4 – BRAKES, PEDAL, AND CABLE ASSEMBLIES

Brake Assembly ................................................................................................................................ 4-3

Brake Pedal and Cable Assembly .................................................................................................... 4-5
Accelerator Pedal Assembly ............................................................................................................. 4-7

SECTION 5 – STEERING, FRONT AND REAR SUSPENSION

Steering Column ............................................................................................................................... 5-3

Steering Gear Assembly ................................................................................................................... 5-5
Front Suspension, Upper .................................................................................................................. 5-7
Front Suspension, Lower .................................................................................................................. 5-9
Rear Suspension .............................................................................................................................. 5-11

SECTION 6 – ELECTRICAL SYSTEM – GASOLINE VEHICLE

Wiring – Gasoline Vehicle ................................................................................................................. 6-3

Forward/Reverse Shifter Assembly – Gasoline Vehicle ................................................................... 6-5
Electrical Component Box – Gasoline Vehicle ................................................................................. 6-7
Electrical Components, Front Body – Gasoline Vehicle ................................................................... 6-9
Starter/Generator Assembly ............................................................................................................. 6-11
Starter/Generator Mounting .............................................................................................................. 6-13
Battery – Gasoline Vehicle ............................................................................................................... 6-15

2003 DS Golf Cars Illustrated Parts List

 CONTENTS
SECTION 7 – FE290 ENGINE

FE290 Engine – Shrouds and Brackets ........................................................................................... 7-3

FE290 Engine – Ignition Components and Flywheel ....................................................................... 7-5
FE290 Engine – Oil Circulation ........................................................................................................ 7-7
FE290 Engine – Cylinder Head ........................................................................................................ 7-9
FE290 Engine – Crankcase, Camshaft and Oil Sensor ................................................................... 7-11
FE290 Engine – Crankcase and Crankshaft .................................................................................... 7-13
Engine Mounting .............................................................................................................................. 7-15

SECTION 8 – FUEL, INTAKE, AND GOVERNOR SYSTEMS

Fuel System ..................................................................................................................................... 8-3

Carburetor Assembly ....................................................................................................................... 8-5
Carburetor Installation ...................................................................................................................... 8-7
Governor and Accelerator Cables .................................................................................................... 8-9
Intake Duct, Choke, and Air Box Assembly ..................................................................................... 8-11

SECTION 9 – EXHAUST SYSTEM

Exhaust System ............................................................................................................................... 9-3

SECTION 10 – TORQUE CONVERTER

Drive Clutch ...................................................................................................................................... 10-3

Driven Clutch .................................................................................................................................... 10-5

SECTION 11 – UNITIZED TRANSAXLE

Unitized Transaxle – Gear Cases and Brackets .............................................................................. 11-3

Unitized Transaxle – F&R Transmission and Gear Reduction ......................................................... 11-5
Unitized Transaxle – Differential and Axles ..................................................................................... 11-7

SECTION 12 – ELECTRICAL SYSTEM – ELECTRIC VEHICLE

Electrical Components, Front Body – Electric Vehicle ..................................................................... 12-3

Wiring – V-Glide 36-Volt Vehicle ..................................................................................................... 12-5
Forward/Reverse Switch – V-Glide 36-Volt Vehicle ......................................................................... 12-7
Wiper Switch – V-Glide 36-Volt Vehicle ........................................................................................... 12-9
Resistor and Board Assembly – V-Glide 36-Volt Vehicle ................................................................. 12-11
Batteries, Charger Receptacle, Solenoid – V-Glide 36-Volt Vehicle ................................................ 12-13
Forward/Reverse Switch – PowerDrive System 48 Vehicle ............................................................. 12-15
Batteries, Charger Receptacle – PowerDrive System 48 Vehicle .................................................... 12-17
Computer, Controller, and Solenoid – PowerDrive System 48 Vehicle ........................................... 12-19

2003 DS Golf Cars Illustrated Parts List

 CONTENTS
Motor Controller Output Regulator (MCOR) ..................................................................................... 12-21
Wiring – PowerDrive System 48 Vehicle .......................................................................................... 12-23
Wiring – IQ System Vehicle with Motor Controller Output Regulator (MCOR) ................................. 12-25
Forward/Reverse Switch, Tow/Run Switch – IQ System Vehicle ..................................................... 12-27
Batteries, Charger Receptacle – IQ System Vehicle ........................................................................ 12-29
Computer, Controller, and Solenoid – IQ System Vehicle ................................................................ 12-31

SECTION 13 – ELECTRIC MOTOR

Motor – V-Glide 36-Volt Vehicle ....................................................................................................... 13-3

Motor – PowerDrive System 48 Vehicle ........................................................................................... 13-5
Motor – IQ System Vehicle ............................................................................................................... 13-7

SECTION 14 – TRANSAXLE – ELECTRIC VEHICLE

Transaxle, Type G – Electric Vehicle ................................................................................................ 14-3

Transaxle, Type K – Electric Vehicle ................................................................................................ 14-5

SECTION 15 – BATTERY CHARGER

Accu-Power Battery Charger, Domestic – V-Glide 36-Volt Vehicle .................................................. 15-3

Accu-Power Battery Charger, Export, 230-Volt – V-Glide 36-Volt Vehicle ....................................... 15-5
Accu-Power Battery Charger, Export, 100-Volt – V-Glide 36-Volt Vehicle ....................................... 15-7
PowerDrive Battery Charger, Domestic ............................................................................................ 15-9
PowerDrive 2 Battery Charger, Domestic ......................................................................................... 15-11
PowerDrive Battery Charger, Export ................................................................................................ 15-13
PowerDrive Battery Charger, European ........................................................................................... 15-15

SECTION 16 – MAINTENANCE AND SERVICE TOOLS

Maintenance and Service Tools ....................................................................................................... 16-3

Maintenance and Service Tools, Continued ..................................................................................... 16-5
Maintenance and Service Tools, Continued ..................................................................................... 16-7

2003 DS Golf Cars Illustrated Parts List

BODY AND TRIM 1
G
E
1
G
Front Body
11 Frame Of Car
E 3 2 4
Center
Dash Frame Dash

Dash

TYPICAL
3 PLACES

1 7
8
9
10
6
TYPICAL
2 PLACES

13 TYPICAL
2 PLACES

5 14

12
23
24
25

15
16 TYPICAL
9 PLACES

22

21
TYPICAL
2 PLACES

22
21

20 19
18

TYPICAL
2 PLACES
21

20 17

Page 1-2 2003 DS Golf Cars Illustrated Parts List

 BODY TRIM
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 1013344 Component, Driver-Side Dash, Black ........................................................ 1 1

G
2 101660404 Panel, Center Dash, Black ......................................................................... 1 1
3 101802601 Plug, Hole (V-Glide 36-Volt vehicle only) .................................................... 1
E
4 1013343 Component, Passenger-Side Dash, Black ................................................. 1 1
5 1015032 Mat, Floor ................................................................................................... 1 1
6 1014645 Kit, Snap Washer, Black (includes items 7 - 10) ........................................ 2 2
7 1011019 Nut, Speed ............................................................................................. 1 1
8 1011382 Washer, #10 ........................................................................................... 1 1
9 1620 Screw, #10 Sheet Metal ......................................................................... 1 1
10 1013494 Cover, Screw Head ................................................................................ 1 1
11 7973 Rivet, Aluminum Pop, 3/16 ......................................................................... 3 3
12 101708301 Kit, Drink Holder (includes items 13 and 14) .............................................. 2 2
13 7847 Screw, Hex-Head Cap, 1/4-20 x 3/4 ....................................................... 2 2
14 1016952 U-Nut, 1/4-20 ......................................................................................... 2 2
15 101768202 Kit, Bagwell Protector (includes item 16) ................................................... 1 1
16 1010434 Fastener, Plastic Barrel .......................................................................... 9 9
17 1017079 Kit, Rear Bumper (includes items 18 - 22) ................................................. 1 1
18 1016379 Bumper, Rear ......................................................................................... 1 1
19 1016875 Plate, Mounting, Long ............................................................................ 1 1
20 7473 Nut, Nylon Lock, 5/16-18 ....................................................................... 4 4
21 1011697 Washer, Special, 5/16 ............................................................................ 6 6
22 1016876 Bolt, Phillips Truss-Head Shoulder, 3/8-18 x 2 ....................................... 4 4
23 101706702 Kit, Scuff Guard (includes item 24) ............................................................ 1 1
24 1010434 Fastener, Plastic Barrel .......................................................................... 12 12
25 102221201 Pad, Wear .................................................................................................. 2 2

2003 DS Golf Cars Illustrated Parts List Page 1-3

1
G
E
TYPICAL
2 PLACES 12
13
10

11 TYPICAL
6 PLACES

17
9

8
6

18 Club
Car

14
TYPICAL
2 PLACES

16
1

3 TYPICAL
8 PLACES
TYPICAL
2 PLACES
15
4

Page 1-4 2003 DS Golf Cars Illustrated Parts List

 FRONT BODY
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 1017080 Kit, Front Bumper (includes items 2 - 5) ..................................................... 1 1

G
2 1016868 Bumper, Front ........................................................................................ 1 1
3 7251 Screw, Phillips Truss-Head, 5/16-18 x 1 ................................................. 2 2
E
4 7473 Nut, Nylon Lock, 5/16-18 ....................................................................... 2 2
5 1016967 Rivet, Push Type Blind ........................................................................... 2 2
6 1014198 Nameplate – Gold ...................................................................................... 1 1
7 101692501 Body, Front – Beige .................................................................................... 1 1
7 101692502 Body, Front – White .................................................................................... 1 1
7 101692504 Body, Front – Gray ..................................................................................... 1 1
7 101692506 Body, Front – Red ...................................................................................... 1 1
7 101692509 Body, Front – Pacific Blue (Royal Blue) ...................................................... 1 1
7 101692510 Body, Front – Dark Green .......................................................................... 1 1
7 101692511 Body, Front – Black .................................................................................... 1 1
7 101692512 Body, Front – Classic Blue (Navy) .............................................................. 1 1
7 101692513 Body, Front – Burgundy .............................................................................. 1 1
8 101693901 Body, Front with Headlight Opening – Beige .............................................. 1 1
8 101693902 Body, Front with Headlight Opening – White .............................................. 1 1
8 101693904 Body, Front with Headlight Opening – Gray ............................................... 1 1
8 101693906 Body, Front with Headlight Opening – Red ................................................ 1 1
8 101693908 Body, Front with Headlight Opening – Pacific Blue (Royal Blue) ................ 1 1
8 101693909 Body, Front with Headlight Opening – Dark Green .................................... 1 1
8 101693910 Body, Front with Headlight Opening – Black .............................................. 1 1
8 101693911 Body, Front with Headlight Opening – Classic Blue (Navy) ....................... 1 1
8 101693912 Body, Front with Headlight Opening – Burgundy ....................................... 1 1
9 1011014 Trim, Front Body ......................................................................................... 1 1
10 1010435 Bolt, Carriage, 5/16-18 x 1 ......................................................................... 2 2
11 1241 Washer, Flat, 5/16 ...................................................................................... 2 2
12 1011017 Screw, Flange Lock .................................................................................... 6 6
13 1011394 T-Nut, Slab Base (package of 4) ................................................................ 1 1
14 101347501 Bumper, Side Guard Trim ........................................................................... 2 2
15 102310701 Screw, Hex Washer-Head, #8-18 x 3/8 ...................................................... 8 8
16 1015032 Mat, Floor ................................................................................................... 1 1
17 7473 Nut, Nylon Lock, 5/16-18 ............................................................................ 2 2
18 102259001 Emblem, IR, Golf Car ................................................................................. 1 1

2003 DS Golf Cars Illustrated Parts List Page 1-5

1
G
7
E TYPICAL

FRONT SEAT
4 2 PLACES

SUPPORT 1
VERTICAL
STRUT

5
TYPICAL 1
2 PLACES
8
1 5
6 17
2 TYPICAL
6
2 PLACES

9
15 10

16

14

TYPICAL
2 PLACES
11
5
1
13
TYPICAL 3
6 TYPICAL EACH SIDE
2 PLACES OF VEHICLE TYPICAL
12 2 PLACES
TYPICAL 6
EACH SIDE
OF VEHICLE

Page 1-6 2003 DS Golf Cars Illustrated Parts List

 REAR BODY AND FENDER – GASOLINE VEHICLE
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 8251 Screw, Phillips-Head, 1/4-20 x 1 ............................................................ 10

G
2 101904101 Plate, Body Kick ..................................................................................... 1
3 1014306 Washer, Flat, Type B, 1/4 ....................................................................... 2
E
4 1012412 Plate, Body Hinge .................................................................................. 2
5 332 Washer, Flat, 1/4 .................................................................................... 10
6 8233 Nut, Nylon Lock, 1/4-20 ......................................................................... 12
7 1013032 Door, Access – Black ............................................................................. 1
7 1013140 Door, Access – Beige ............................................................................. 1
8 1015525 Nut, Blind, 1/4-20 ................................................................................... 2
9 101692601 Body – Beige .......................................................................................... 1
9 101692602 Body – White .......................................................................................... 1
9 101692604 Body – Gray ........................................................................................... 1
9 101692606 Body – Red ............................................................................................ 1
9 101692609 Body – Pacific Blue (Royal Blue) ............................................................ 1
9 101692610 Body – Dark Green ................................................................................ 1
9 101692611 Body – Black .......................................................................................... 1
9 101692612 Body – Classic Blue (Navy) ................................................................... 1
9 101692613 Body – Burgundy ................................................................................... 1
10 101696208 Body with Taillight Opening – Beige ....................................................... 1
10 101696209 Body with Taillight Opening – White ....................................................... 1
10 101696211 Body with Taillight Opening – Gray ........................................................ 1
10 101696213 Body with Taillight Opening – Red ......................................................... 1
10 101696215 Body with Taillight Opening – Pacific Blue (Royal Blue) ......................... 1
10 101696216 Body with Taillight Opening – Dark Green ............................................. 1
10 101696219 Body with Taillight Opening – Black ....................................................... 1
10 101696220 Body with Taillight Opening – Classic Blue (Navy) ................................. 1
10 101696221 Body with Taillight Opening – Burgundy ................................................. 1
11 1017748 Clip, Body Keeper .................................................................................. 2
12 1012047 Screw, Self-Tapping, #8-32 x 3/8 ........................................................... 2
13 7847 Screw, Hex-Head Cap, 1/4-20 x 3/4 ....................................................... 4
14 1017936 Fender, Inner .......................................................................................... 2
15 1017141 Support, Front Body ............................................................................... 1
16 1015032 Mat, Floor ............................................................................................... 1
17 102221201 Pad, Wear .............................................................................................. 2

2003 DS Golf Cars Illustrated Parts List Page 1-7

1
G 4
TYPICAL
2 PLACES
17
1
E FRONT SEAT
SUPPORT
VERTICAL
STRUT
1
5
5
20 TYPICAL 1
2 PLACES
6 18

6
2 TYPICAL
2 PLACES

15
16

19

TYPICAL
2 PLACES

7 13
1

9 8
6

14 6
10

5 12 TYPICAL
EACH SIDE
TYPICAL OF VEHICLE
11 EACH SIDE
OF VEHICLE

Page 1-8 2003 DS Golf Cars Illustrated Parts List

 REAR BODY AND FENDER – ELECTRIC VEHICLE
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 8251 Screw, Phillips-Head, 1/4-20 x 1 ................................................................ 10

G
2 101904101 Plate, Body Kick ......................................................................................... 1
3 1017141 Support, Front Body ................................................................................... 1
E
4 1012412 Plate, Body Hinge ...................................................................................... 2
5 332 Washer, Flat, 1/4 ........................................................................................ 10
6 8233 Nut, Nylon Lock, 1/4-20 .............................................................................. 12
7 1017936 Fender, Inner .............................................................................................. 2
8 1014306 Washer, Flat, Type B, 1/4 ........................................................................... 2
9 1017814 Spacer, 1-7/8 .............................................................................................. 2
10 1012159 Screw, Hex-Head Cap, 1/4-20 x 2-3/4 ........................................................ 2
11 7479 Screw, Hex-Head Cap, 1/4-20 x 1-1/4 ........................................................ 2
12 1017815 Spacer, 1/2 ................................................................................................. 2
13 1017748 Clip, Body Keeper ...................................................................................... 2
14 1012047 Screw, Self-Tapping, #8-32 ........................................................................ 2
15 101693301 Body – Beige .............................................................................................. 1
15 101693302 Body – White .............................................................................................. 1
15 101693304 Body – Gray ............................................................................................... 1
15 101693306 Body – Red ................................................................................................ 1
15 101693309 Body – Pacific Blue (Royal Blue) ................................................................ 1
15 101693310 Body – Dark Green .................................................................................... 1
15 101693311 Body – Black .............................................................................................. 1
15 101693312 Body – Classic Blue (Navy) ........................................................................ 1
15 101693313 Body – Burgundy ....................................................................................... 1
16 101696201 Body with Taillight Opening – Beige ........................................................... 1
16 101696202 Body with Taillight Opening – White ........................................................... 1
16 101696204 Body with Taillight Opening – Gray ............................................................ 1
16 101696206 Body with Taillight Opening – Red ............................................................. 1
16 101696217 Body with Taillight Opening – Pacific Blue (Royal Blue) ............................. 1
16 101696218 Body with Taillight Opening – Dark Green ................................................. 1
16 101696222 Body with Taillight Opening – Black ........................................................... 1
16 101696223 Body with Taillight Opening – Classic Blue (Navy) ..................................... 1
16 101696224 Body with Taillight Opening – Burgundy ..................................................... 1
17 1013032 Door, Access – Black ................................................................................. 1
17 1013140 Door, Access – Beige ................................................................................. 1
18 1015525 Nut, Blind, 1/4-20 ....................................................................................... 2
19 1015032 Mat, Floor ................................................................................................... 1
20 102221201 Pad, Wear .................................................................................................. 2

2003 DS Golf Cars Illustrated Parts List Page 1-9

1
G
E

4 5

6
7 TYPICAL
8 PLACES
TYPICAL
8 PLACES
TYPICAL 10
2 PLACES

TYPICAL
8 PLACES

1 2

10

TYPICAL 8
2 PLACES

REFERENCE
TYPICAL
REAR BODY AND 9 4 PLACES
FENDER

Page 1-10 2003 DS Golf Cars Illustrated Parts List

 SEAT BOTTOM AND ARMREST
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 102174201 Assembly, Seat Bottom – Buff (includes items 2 and 3) ............................ 1 1

G
1 102174202 Assembly, Seat Bottom – White (includes items 2 and 3) .......................... 1 1
1 102174204 Assembly, Seat Bottom – Black (includes items 2 and 3) .......................... 1 1
E
1 102174205 Assembly, Seat Bottom – Gray (includes items 2 and 3) ........................... 1 1
2 101998201 Cover, Vinyl Seat Bottom – Buff ............................................................. 1 1
2 101998202 Cover, Vinyl Seat Bottom – White .......................................................... 1 1
2 101998204 Cover, Vinyl Seat Bottom – Black ........................................................... 1 1
2 101998205 Cover, Vinyl Seat Bottom – Gray ............................................................ 1 1
3 1010543 Insert, Wood ........................................................................................... 12 12
4 101987601 Armrest, Driver-Side .................................................................................. 1 1
5 101985501 Armrest, Passenger-Side ........................................................................... 1 1
6 1016916 Screw, Hex-Head Cap, 1/4-20 x 1-1/2 ........................................................ 8 8
7 332 Washer, Flat, Type A .................................................................................. 8 8
8 1011652 Plate, Seat Hinge, Stainless Steel ............................................................. 2 2
9 101954301 Screw, Hex-Head Cap, 1/4-20 x 3/4 (with patch) ....................................... 4 4
10 101998501 Gasket, Seat .............................................................................................. 2 2

2003 DS Golf Cars Illustrated Parts List Page 1-11

1
G 7

E
8

TYPICAL
9 2 PLACES

10

2
13
3 11
1 4
TYPICAL 12
2 PLACES

15
TYPICAL
5
4 PLACES

22

16 17
18
6 21 17
23
9 20
21
TYPICAL 2 PLACES

14 17
19
TYPICAL 2 PLACES
ON EACH SIDE OF VEHICLE TYPICAL 2 PLACES

Page 1-12 2003 DS Golf Cars Illustrated Parts List

 SEAT BACK AND BAG HOOP
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 102238301 Assembly, Seat Back – Buff (includes items 2 and 3) ................................ 1 1

G
1 102238302 Assembly, Seat Back – White (includes items 2 and 3) ............................. 1 1
1 102238304 Assembly, Seat Back – Black (includes items 2 and 3) .............................. 1 1
E
1 102238305 Assembly, Seat Back – Gray (includes items 2 and 3) ............................... 1 1
2 102060501 Cover, Vinyl, Seat Back – Buff ............................................................... 1 1
2 102060502 Cover, Vinyl, Seat Back – White ............................................................. 1 1
2 102060504 Cover, Vinyl, Seat Back – Black ............................................................. 1 1
2 102060505 Cover, Vinyl, Seat Back – Gray .............................................................. 1 1
3 102237001 Cap, Seat Back – Black ......................................................................... 1 1
4 102236601 Weldment, Support, Seat Back .................................................................. 2 2
5 102236703 Basket, Sweater ......................................................................................... 1 1
6 101910401 Screw, Self-Tapping, 5/16-18 x 1-1/4 ......................................................... 4 4
7 1010921 Screw, Hex-Head Cap, 5/16-18 x 2-1/2 ...................................................... 2 2
8 1015075 Washer, Flat, 5/16 ...................................................................................... 4 4
9 7473 Nut, Nylon Lock, 5/16-18 ............................................................................ 4 4
10 1013935 Assembly, Bag Hoop (includes items 11 - 13) ........................................... 1 1
11 1010434 Fastener, Plastic Barrel .......................................................................... 2 2
12 1010413 Strap, Bag .............................................................................................. 1 1
13 1013754 Buckle, Bag Strap .................................................................................. 2 2
14 1017774 Spacer, Body .............................................................................................. 4 4
15 102076701 Screw, SEMS (with patch) 1/4-20 x 1-3/4 .................................................. 4 4
16 8418 Screw, Phillips Truss-Head, 1/4-20 x 1-1/2 ................................................. 1 1
17 1015075 Washer, Flat, 5/16 ...................................................................................... 4 4
18 1014482 Spacer, Nylon ............................................................................................. 1 1
19 8233 Nut, Nylon Lock, 1/4-20 .............................................................................. 2 2
20 7479 Screw, Hex-Head Cap, 1/4-20 x 1-1/4 ........................................................ 2 2
21 1241 Washer, Flat, 5/16 ...................................................................................... 6 6
22 7818 Bolt, Carriage, 5/16-18 x 1-1/2 ................................................................... 2 2
23 102242401 Nut, Nylon Insert with Cap, 1/4-20 ............................................................. 1 1

2003 DS Golf Cars Illustrated Parts List Page 1-13

1
G
TYPICAL 2
PLACES
E
TYPICAL 2 PLACES
6

3
REF.

11 4
6 REF.
7

3
5
REFERENCE
SEAT BACK
SUPPORT
WELDMENT
1

4
REF.

F
NT O 8
FRO LE 9
IC
VEH

9
12 10
TYPICAL 4
PLACES
2

Page 1-14 2003 DS Golf Cars Illustrated Parts List

 CANOPY
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 1
1 2 3 4

1 102099101 Screw, SEMS (with patch) 5/16-18 x 1 ....................................................... 2 2

G
2 102155501 Kit, Support (includes items 3 - 10) ............................................................ 1 1
3 102063901 Weldment, Windshield ........................................................................... 1 1
E
4 102065501 Support, Rear Canopy (driver side) ....................................................... 1 1
5 102064601 Support, Rear Canopy (passenger side) ............................................... 1 1
6 102076701 Screw, SEMS, (with patch) 1/4-20 x 1-3/4 .............................................. 8 8
7 101835601 Nut, Flange, 1/4-20 ................................................................................ 8 8
8 324 Screw, Hex-Head Cap, 1/4-20 x 2-1/2 .................................................... 4 4
9 332 Washer, Flat, 1/4 .................................................................................... 8 8
10 8233 Nut, Lock, 1/4-20 .................................................................................... 4 4
11 102061301 Canopy – White .......................................................................................... 1 1
11 102061302 Canopy – Beige .......................................................................................... 1 1
12 102198301 Pad, Mounting (windshield frame) .............................................................. 2 2

2003 DS Golf Cars Illustrated Parts List Page 1-15

1
G
E
WHEELS AND TIRES 2
G
E
2
G
E

Club C
ar

19

1
6

4 18
3 10
9 13
2
12 16
15 22
21 25
24

17 23 26 20

5 11 14 8

STANDARD TREAD PERFORMANCE PREMIUM TREAD EXTRA TRACTION

Carlisle® GRADE TREAD Kenda® Duro
Duro®

Note: The performance grade tire has the wheel and tire matched and balanced at the Duro tire factory.

Page 2-2 2003 DS Golf Cars Illustrated Parts List

 WHEELS AND TIRES
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 2
1 2 3 4

1 1010984 Nut, Lug ..................................................................................................... 16 16

G
2 7310 Stem, Valve * .............................................................................................. 1 1
3 101570501 Assembly, Wheel and Standard Tire (includes items 4-5) .......................... 4 4
E
4 1015707 Wheel Rim – Beige ................................................................................ 1 1
5 727102 Tire, Unmounted, Standard Tread (18 x 8.50 - 8) (Carlisle®) ................. 1 1
6 101570507 Assembly, Wheel and Extra Traction Tire (includes items 7 - 8) ................. 2 2
7 1015707 Wheel Rim – Beige ................................................................................ 1 1
8 101769302 Tire, Unmounted, Extra Traction, 6-Ply Rated (18 x 8.50 - 8) (Duro®) ... 1 1
9 101570509 Assembly, Wheel and Performance Grade Tire (includes items 10 - 11) ... 4 4
10 1015707 Wheel Rim – Beige ................................................................................ 1 1
11 **** Tire, Unmounted, Performance Grade Tread (18 x 8.50 - 8) (Duro) ....... 1 1
12 101570513 Assembly, Wheel and Premium Grade Tire (includes items 13 - 14) ......... 4 4
13 1015707 Wheel Rim – Beige ................................................................................ 1 1
14 **** Tire, Unmounted, Premium Tread (18 x 8.50 - 8) (Kenda®) ................... 1 1
15 101651401 Assembly, Wheel and Standard Tire (includes items 16 - 17) .................... 4 4
16 1014771 Wheel Rim – White ................................................................................ 1 1
17 727102 Tire, Unmounted, Standard Tread (18 x 8.50 - 8) (Carlisle) .................... 1 1
18 101651407 Assembly, Wheel and Extra Traction Tire, (includes items 19 - 20) ............ 2 2
19 1014771 Wheel Rim – White ................................................................................ 1 1
20 101769302 Tire, Unmounted, Extra Traction, 6-Ply Rated (18 x 8.50 - 8) (Duro) ..... 1 1
21 101651409 Assembly, Wheel and Performance Grade Tire (includes items 22 - 23) ... 4 4
22 1014771 Wheel Rim – White ................................................................................ 1 1
23 **** Tire, Unmounted, Performance Grade Tread (18 x 8.50 - 8) (Duro) ....... 1 1
24 101651413 Assembly, Wheel and Premium Grade Tire (includes items 25 - 26) ........ 4 4
25 1014771 Wheel Rim – White ................................................................................ 1 1
26 **** Tire, Unmounted, Premium Tread (18 x 8.50 - 8) (Kenda) ..................... 1 1

* Note: Item 2 is a part of all wheel assemblies.

**** Special order item available upon request.

2003 DS Golf Cars Illustrated Parts List Page 2-3

2
G
E
DECALS 3
G
E
3
WARNING
G ROLLOVER OR FALLING OFF MAY CAUSE DEATH.
• Before using vehicle, read operating instructions.
• Remain seated and hold on to seat handle while moving.
OFF ON
OPERATING INSTRUCTIONS
• Do not start vehicle until all occupants are seated.
2
E • Two (2) persons per seat maximum.
• Operate from driver side only and not on public roads.
• Keep entire body inside vehicle while moving.
• Read Owner's Manual and safety warnings located on dash panel prior to driving.
• Study and understand controls.
• Make sure wheels are turned in desired direction.
• Drive slowly in turns and straight up and down slopes. • Turn key to “ON” position and be sure nothing is in your path.
• Do not leave children unattended on vehicle. • While vehicle is stopped, select direction by placing
• Never operate under the influence of alcohol or drugs. shift lever or switch in desired position:
• Use brakes to reduce speed when coasting downhill. 3 F – Forward N – Neutral R – Reverse (Buzzer will sound)
• Never stand in front of or behind vehicle. • Vehicle will start moving when accelerator pedal is depressed.
CCI 1019606-01
• Slowly depress accelerator pedal to increase speed. Park brake will
release when accelerator pedal is depressed.
• To stop, release accelerator pedal and depress brake pedal.
1 • After stopping the vehicle:
- Firmly depress park brake until it locks.
- Place Forward/Reverse switch in "NEUTRAL" position.
- Turn key “OFF” and remove key when not in use.
CCI 101621601

WARNING
CAN CAUSE SEVERE INJURY

Rotating parts
HOT
manifold & muffler
KEEP CLEAR CCI 1019605-01
WARNING
• GASOLINE EXPLOSION / FIRE. (ON STARTER/GENERATOR
• CAN CAUSE SEVERE INJURY OR DEATH. AND ENGINE)
• NO SMOKING, SPARKS, OR OPEN FLAME.
• STOP ENGINE, ALLOW TO COOL BEFORE REFUELING.
• TURN FUEL VALVE ( ) ON DURING OPERATION. 5
( ) OFF DURING STORAGE OR TRANSPORT. CCI 1015476-01

(ON VEHICLE FRAME NEAR FUEL TANK)

(ON VEHICLE FRAME NEAR BATTERY)

WARNING WARNING
Negative frame ground. Can cause severe injury. Excessive speed.
Do not contact positive (+) battery post or cable to frame. Can cause severe injury or death.
Disconnect negative battery lead first. Do not tamper with engine governor adjustment.
CCI 1019152-01

Page 3-2 2003 DS Golf Cars Illustrated Parts List

 DECALS – GASOLINE VEHICLE
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 3
1 2 3 4

1 101960601 Decal, Driver/Passenger Warning .............................................................. 1

G
2 101825101 Decal, Key Switch ...................................................................................... 1
3 101621601 Decal, Operating Instructions ..................................................................... 1
E
4 101547601 Decal, Gasoline Warning ........................................................................... 1
5 101960501 Decal, Rotating Parts and Hot Manifold Warning ....................................... 2
6 101915201 Decal, Frame Ground and Governor Warning ............................................ 1

2003 DS Golf Cars Illustrated Parts List Page 3-3

3
WARNING OFF ON
G ROLLOVER OR FALLING OFF MAY CAUSE DEATH.
• Before using vehicle, read operating instructions.
2 OPERATING INSTRUCTIONS
• Remain seated and hold on to seat handle while moving.
• Do not start vehicle until all occupants are seated.
• Read Owner's Manual and safety warnings located on dash panel prior to driving.

E • Two (2) persons per seat maximum.

• Operate from driver side only and not on public roads.
• Keep entire body inside vehicle while moving. 3
• Study and understand controls.
• Make sure wheels are turned in desired direction.
• Turn key to “ON” position and be sure nothing is in your path.
• Drive slowly in turns and straight up and down slopes.
• Do not leave children unattended on vehicle. • While vehicle is stopped, select direction by placing
• Never operate under the influence of alcohol or drugs. shift lever or switch in desired position:
• Use brakes to reduce speed when coasting downhill. F – Forward N – Neutral R – Reverse (Buzzer will sound)
• Never stand in front of or behind vehicle. • Vehicle will start moving when accelerator pedal is depressed.
CCI 101960601
• Slowly depress accelerator pedal to increase speed. Park brake will
release when accelerator pedal is depressed.
1 • To stop, release accelerator pedal and depress brake pedal.
• After stopping the vehicle:
- Firmly depress park brake until it locks.
- Place Forward/Reverse switch in "NEUTRAL" position.
- Turn key “OFF” and remove key when not in use.
CCI 101621601

(ON SPEED CONTROLLER COVER

IQ SYSTEM VEHICLE ONLY)

NOTICE
4 Do not operate vehicle without this cover properly installed.
Do not direct water stream in this area; will cause damage to components.
See vehicle maintenance and service manual before servicing. CCI 101931501
• Maximum vehicle speed is limited by motor braking during downhill operation
with accelerator pedal depressed.
IMPORTANT • If motor brake enabled, vehicle motor will brake when accelerator pedal is released.
8
• Beeping alarm indicates reduction in motor braking. Apply brakes to reduce speed.
NOTICE • System is activated only when tow switch is in the "RUN" position.
• DO NOT OPERATE VEHICLE
• When towing vehicle, tow switch must be in the "TOW" position. 101959902
WITHOUT COVER IN PLACE.
NOTICE • DO NOT DIRECT WATER
STREAM AT THIS SWITCH. CCI 1016109-01

(ON WIPER SWITCH COVER INSIDE

BATTERY COMPARTMENT)

6
WARNING HOT RESISTORS (COILED WIRE) CAN CAUSE SEVERE BURNS.

(ON FRAME UNDER SEAT ON

5
V-GLIDE 36 VOLT VEHICLE)

10
Club
Car F N

(ON TOW/RUN SWITCH BRACKET UNDER SEAT)

TOW RUN

Place Tow/Run switch in TOW position before: FAILURE TO HEED THIS 7

• Disconnecting or connecting batteries
WARNING COULD RESULT IN
• Towing
A BATTERY EXPLOSION OR
• Extended storage
• Servicing
SEVERE PERSONAL INJURY.
CCI 101908601

Page 3-4 2003 DS Golf Cars Illustrated Parts List

 DECALS – ELECTRIC VEHICLE
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 3
1 2 3 4

1 101960601 Decal, Driver/Passenger Warning .............................................................. 1

G
2 101825101 Decal, Key Switch ...................................................................................... 1
3 101621601 Decal, Operating Instructions ..................................................................... 1
E
4 101959902 Decal, Motor Braking (IQ System vehicle) ................................................. 1
5 1013496 Decal, Resistor Warning (V-Glide 36-Volt vehicles) ................................... 1
6 101610901 Decal, Potentiometer Caution (V-Glide 36-Volt vehicles) ........................... 1
7 101908601 Decal, Tow/Run Switch (IQ System vehicles) ............................................ 1
8 101931501 Decal, Electrical Component Cover (IQ System vehicle) ........................... 1
9 102259001 Emblem, IR, Gold ....................................................................................... 1
10 1014198 Nameplate, Gold ........................................................................................ 1

2003 DS Golf Cars Illustrated Parts List Page 3-5

3
G
E
 BRAKES, PEDAL,
AND CABLE ASSEMBLIES 4
G
E
4
G 6
10
TYPICAL 4

E TYPICAL 4
PLACES
PLACES

11

1
8

18

TYPICAL 2
PLACES
7 7
TYPICAL 2
PLACES
4
3
2

13

9
12

15
14

17 16
ELECTRIC GASOLINE
VEHICLE VEHICLE
SEE REAR SUSPENSION–
SECTION 6 FOR MOUNTING

Page 4-2 2003 DS Golf Cars Illustrated Parts List

 BRAKE ASSEMBLY
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 4
1 2 3 4

101823301 Cluster, Brake, Passenger-Side (includes items 1 - 9) ............................... 1 1

G
101823302 Cluster, Brake, Driver-Side (includes items 1 - 9) ...................................... 1 1
1 101824001 Assembly, Backing Plate, Passenger-Side (includes items 2 - 4) .......... 1 1
E
1 101824002 Assembly, Backing Plate, Driver-Side (includes items 2 - 4) .................. 1 1
2 101816501 Mechanism, Adjusting, Passenger-Side ............................................ 1 1
2 101816502 Mechanism, Adjusting, Driver-Side ................................................... 1 1
3 101823901 Washer .............................................................................................. 1 1
4 101823801 Washer, Plate .................................................................................... 1 1
5 1010850 Cover, Dust ............................................................................................ 1 1
6 101823201 Package, Brake Shoe (four pieces) ........................................................ 1 1
7 1011466 Kit, Shoe Retainer (four pieces) ............................................................. 1 1
8 101816301 Package, Brake Spring (four pieces) ...................................................... 1 1
9 101815501 Assembly, Lever, Passenger-Side .......................................................... 1 1
9 101815502 Assembly, Lever, Driver-Side ................................................................. 1 1
10 1013924 Nut, Hex Lock, Grade 8, 5/16-24 ............................................................... 8 8
11 1014153 Bolt, Brake Cluster Mounting, Grade 8, 5/16-24 x 7/8 ............................... 8 8
12 102022101 Kit, Brake Cable (includes items 13 -15) .................................................... 2 2
13 1010829 Pin, Clevis, 5/16 ..................................................................................... 2 2
14 1035 Pin, Cotter, 3/32 x 1 ............................................................................... 2 2
15 1011779 E-Clip, 1/2 .............................................................................................. 2 2
16 101900801 Hanger, Brake Cable (gasoline vehicle only) ............................................. 2
17 1013207 Hanger, Brake Cable (electric vehicle only) ............................................... 2
18 101791101 Drum, Brake ............................................................................................... 2 2

2003 DS Golf Cars Illustrated Parts List Page 4-3

4
G
E
ON
OFF

TYPICAL
2 PLACES
28

26

27
30
29 10

8
O P FLOORBOARD
REMOVED

S T TYPICAL 13
FOR CLARITY
4 PLACES
5 16 17

24
23 19 15
18 20

27 22
14
21 11
9
TYPICAL
3 PLACES
SERVICE PART
BRAKE PEDAL HAS
18 SECOND WELDMENT

TYPICAL
25 2 PLACES
12
TYPICAL
2 PLACES
2
5 7
2
TYPICAL
4 PLACES 3
4

31
1

Page 4-4 2003 DS Golf Cars Illustrated Parts List

 BRAKE PEDAL AND CABLE ASSEMBLY
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 4
1 2 3 4

1 101990801 Equalizer .................................................................................................... 1 1

G
2 1241 Washer, Flat, 5/16 ...................................................................................... 5 5
3 1013531 Spring, Brake Return ................................................................................. 1 1
E
4 1010921 Screw, Hex-Head Cap, 5/16-18 x 2-1/2 ...................................................... 4 4
5 7473 Nut, Nylon Lock, 5/16-18 ............................................................................ 5 5
6 102022101 Kit, Brake Cable (includes item 7, and items 13 and 14 on page 4-3) ....... 2 2
7 1011779 E-Clip, 1/2 .............................................................................................. 2 2
8 101878201 Kit, Brake Pedal (includes items 9 and 10) ................................................ 1 1
9 7716 Screw, Slotted Hex Washer-Head, #10-16 x 1/2 .................................... 3 3
10 1013869 Pad, Brake Pedal ................................................................................... 1 1
11 1010878 Bumper, Rubber ......................................................................................... 1 1
12 1028 Nut, Hex, 1/4-20 ......................................................................................... 1 1
13 101953101 Rod, Equalizer ............................................................................................ 1 1
14 102323201 Pin, Clevis, 5/16 (later style hardware) ...................................................... 1 1
15 102323101 Pin, Bow Tie Locking (later style hardware) ............................................... 1 1
16 101953001 Bolt, Hex-Head Shoulder, 3/8 x 1 (earlier style hardware) ......................... 1 1
17 7473 Nut, Nylon Lock, 5/16-18 (earlier style hardware) ...................................... 1 1
101187702 Kit, Park Brake Latch (includes items 18 - 22 and
item 26 on page 4-7) .................................................................................. 1 1
18 N/A Rod and Pawl ......................................................................................... 1 1
19 1017029 Pin, Cotter, 7/64 x 1/2 ............................................................................ 1 1
20 1010877 Nut, Push, 5/16 ...................................................................................... 1 1
21 1010805 Sleeve, Park Brake Rod ......................................................................... 1 1
22 1010932 Joint, Ball, 1/4-28 ................................................................................... 1 1
23 1010933 Spring, Park Brake Torsion ......................................................................... 1 1
24 1010927 Spacer, Park Brake .................................................................................... 1 1
25 1011402 Package, Brake Mounting Block (contains upper and lower
for driver and passenger sides) .................................................................. 1 1
26 1011418 Kit, Park Brake Pedal (includes items 27 - 30) ........................................... 1 1
27 1032 Bushing, Nylon ....................................................................................... 2 2
28 8626 Screw, Slotted Hex Washer-Head, #10-16 x 1/2 .................................... 2 2
29 1013876 Nut, Push, 3/8 ........................................................................................ 1 1
30 1013870 Pad, Park Brake ..................................................................................... 1 1
31 1242 Nut, Hex, 5/16-18 ....................................................................................... 1 1

2003 DS Golf Cars Illustrated Parts List Page 4-5

4
G
E
2 9
1 GO
21 11
5
12
TYPICAL 13
4 PLACES 14
3

5 10
4
6
8

20
19 15 16 17
18 18
19

20
TYPICAL
4 PLACES
22
23
24

7
TYPICAL
4 PLACES 25

21

24
OFF ON

26

Page 4-6 2003 DS Golf Cars Illustrated Parts List

 ACCELERATOR PEDAL ASSEMBLY
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 4
1 2 3 4

1 1017696 Sub-Assembly, Accelerator Pedal (includes items 2 and 3) ....................... 1 1

G
2 1013871 Pad, Accelerator Pedal ........................................................................... 1 1
3 7716 Screw, Slotted Hex Washer-Head, #10-16 x 1/2 .................................... 4 4
E
4 1624 Screw, Hex-Head Cap, 3/8-16 x 1-1/2 ........................................................ 1 1
5 334 Washer, Flat, 3/8 ........................................................................................ 2 2
6 102026001 Kit, Accelerator Pivot Rod (includes item 7) ............................................... 1 1
7 1011700 Spacer .................................................................................................... 1 1
8 101818801 Stud, Ball (for all vehicles except those equipped with MCOR) ................. 1 1
9 101862001 Screw, Hex-Head Cap, 1/4-20 x 1-3/8 (MCOR vehicles) ........................... 1
10 1017424 Bearing, Pivot Support ............................................................................... 1 1
11 101966901 Nut, Flange, 1/4-28 .................................................................................... 1 1
12 101817401 Retainer, Spring ......................................................................................... 1 1
13 101796201 Spring, Return ............................................................................................ 1 1
14 1017378 Cup, Spring ................................................................................................ 1 1
15 1017380 Bumper, Return Spring .............................................................................. 1 1
16 1241 Washer, Flat, 5/16 ...................................................................................... 1 1
17 7473 Nut, Nylon Lock, 5/16-18 ............................................................................ 1 1
18 101871901 Assembly, Accelerator Rod (V-Glide 36-Volt vehicle only)
(includes items 19 and 20) ......................................................................... 1
18 101912401 Assembly, Accelerator Rod (gasoline vehicle only)
(includes items 19 and 20) ......................................................................... 1
19 1011084 Nut, UNF Hex Jam, 1/4-28 ..................................................................... 2 2
20 1011734 Joint, Spring-Loaded Ball ....................................................................... 2 2
21 8754 Nut, Nylon Lock, 3/8-16 .............................................................................. 2 2
22 8233 Nut, Nylon Lock, 1/4-20 .............................................................................. 4 4
23 1014007 Washer, Flat, Type B, 1/4 ........................................................................... 4 4
24 1011694 Support, Accelerator Pivot Rod .................................................................. 2 2
25 101861901 Screw, Hex-Head Cap, 1/4-20 x 1-1/8 ........................................................ 4 4
101187702 Kit, Park Brake Latch (includes item 26, and items 18 - 22 on page 4-5) .. 1 1
26 N/A Ratchet, Park Brake ............................................................................... 1 1

2003 DS Golf Cars Illustrated Parts List Page 4-7

4
G
E
 STEERING,
FRONT AND REAR SUSPENSION 5
G
E
5
30
G
E
28 26

27 29 23

21

25 19
20
24
17

22 18 13
12 15
18 16
5
14
17
21
19 TYPICAL 2
PLACES
11
7
9 8
20 7 10
TYPICAL 2
PLACES

TYPICAL 2
6 PLACES

2
3
TYPICAL 4
3 PLACES
1

Page 5-2 2003 DS Golf Cars Illustrated Parts List

 STEERING COLUMN
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 5
1 2 3 4

1 1013861 Joint, Compound Steering (includes items 2 and 3) .................................. 1 1

G
2 1017226 Screw, Hex-Head Cap, M8 x 1.25 x 30 mm ........................................... 3 3
3 7174 Washer, Lock, 5/16 ................................................................................ 3 3
E
4 101984801 Kit, Steering Column Mounting Bracket ..................................................... 1 1
5 1016663 Screw, Phillips, Type A, #12-11 x 5/8 ......................................................... 2 2
6 1016269 Screw, Hex Washer-Head Thread-Forming, 5/16-18 x 2 ............................ 2 2
7 334 Washer, Flat, 3/8 ........................................................................................ 4 4
8 1016183 Screw, Hex-Head Cap, 3/8-16 x 7 .............................................................. 2 2
9 8754 Nut, Nylon Lock, 3/8-16 .............................................................................. 2 2
10 1014288 Screw, Hex Washer-Head Thread-Forming, 5/16-18 x 3/4 ......................... 1 1
11 1011697 Washer, Flat, 5/16 ...................................................................................... 1 1
12 102278001 Boot, Steering Column ............................................................................... 1 1
13 1016181 Assembly, Steering Column (includes items 14 - 22) ................................. 1 1
14 1012605 Ring, Retaining ...................................................................................... 1 1
15 1012604 Washer, Steel, 5/8 .................................................................................. 1 1
16 1014217 Spring, Compression ............................................................................. 1 1
17 1014125 Wedge .................................................................................................... 2 2
18 1014213 Assembly, Bearing ................................................................................. 2 2
19 1014126 Seat, Bearing ......................................................................................... 2 2
20 1015545 Shaft, Steering Column .......................................................................... 1 1
21 1016622 Column, Aluminum Steering .................................................................. 1 1
22 1014214 Ring, Retaining ...................................................................................... 1 1
23 1016263 Cover, Steering Column ............................................................................. 1 1
24 1016156 Wheel, Steering ......................................................................................... 1 1
25 1017273 Nut, Nylon Lock, 5/8-18 .............................................................................. 1 1
26 1016219 Assembly, Scorecard Plate (includes items 27 - 30) .................................. 1 1
27 1012565 Screw, Round-Head, #12-14 x 1 ............................................................ 2 2
28 1012566 Spring, Tapered Compression ................................................................ 2 2
29 1016214 Grip, Pencil ............................................................................................. 1 1
30 1016154 Clip, Scorecard ....................................................................................... 1 1

1014216 Kit, Steering Column Rebuild (not shown) ................................................. A/R A/R

2003 DS Golf Cars Illustrated Parts List Page 5-3

5
G 23

22 28
E 1

25 2 3
4
27
26

21
24
11

10

8
5
6 7

12 13
14 15

29
30
TYPICAL
3 PLACES

31
TYPICAL
3 PLACES

19
16 20

17
18

Page 5-4 2003 DS Golf Cars Illustrated Parts List

 STEERING GEAR ASSEMBLY
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 5
1 2 3 4

101878302 Assembly, Steering Gear Box (includes items 1 - 20) ................................ 1 1

G
1 1013035 Seal, Dust, Passenger-Side ................................................................... 1 1
2 8990 Tie, Wire ................................................................................................. 2 2
E
3 101880201 Assembly, Inner Ball Joint ...................................................................... 1 1
4 101880301 Washer, Tab ........................................................................................... 1 1
5 N/A Box, Steering Gear ................................................................................ 1 1
6 N/A Bearing, Lower Pinion ............................................................................ 1 1
7 N/A Pinion, Steering ...................................................................................... 1 1
8 101879401 Bearing, Upper Pinion ............................................................................ 1 1
9 101879901 Ring, C-Type Stop .................................................................................. 1 1
10 1013051 Ring, Snap ............................................................................................. 1 1
11 1013052 Seal, Dust, Steering Pinion .................................................................... 1 1
12 101879701 Guide, Steering Rack ............................................................................. 1 1
13 101879801 Spring, Yoke ........................................................................................... 1 1
14 1013044 Nut, Lock, Rack Screw ........................................................................... 1 1
15 N/A Screw, Rack Guide ................................................................................. 1 1
16 N/A Rack, Steering ....................................................................................... 1 1
17 101879501 Washer, Stop .......................................................................................... 1 1
18 101879601 Ring, C-Type Stop .................................................................................. 1 1
19 101880001 Seal, Dust, Driver-Side .......................................................................... 1 1
20 101880101 Ring, Retaining ...................................................................................... 1 1
21 1035 Pin, Cotter, 3/32 x 1 ................................................................................... 1 1
22 7540 Ball Joint, Left-Hand Thread (includes items 23, 24 and 25) ..................... 1 1
23 1015597 Fitting, Thread-Forming Grease, 1/4-28 ................................................. 1 1
24 7602 Nut, Hex Slotted, 3/8-24 ......................................................................... 1 1
25 1011930 Boot, Dust .............................................................................................. 1 1
26 7555 Nut, Hex, Left-Hand Thread, 1/2-20 ........................................................... 1 1
27 1012467 Link, Rack and Pinion Drag ........................................................................ 1 1
28 1013042 Nut, Hex, M12 x 1.75 ................................................................................. 1 1
29 1624 Screw, Hex-Head Cap, 3/8-16 x 1-1/2 ........................................................ 3 3
30 334 Washer, Flat, 3/8 ........................................................................................ 3 3
31 8754 Nut, Nylon Lock, 3/8-16 .............................................................................. 3 3

2003 DS Golf Cars Illustrated Parts List Page 5-5

5
TYPICAL
2 PLACES
G 5
8
E REFERENCE
STEERING GEAR
15 TYPICAL 4
14 PLACES
7
21
5
10
12
15

11
9 13

16 2

18 TYPICAL 19
2 PLACES

5
10
4
2 3
2

18
5 TYPICAL
2 1
2 PLACES
4
2

20

6
TYPICAL 4
PLACES

17
TYPICAL
2 PLACES
22

Page 5-6 2003 DS Golf Cars Illustrated Parts List

 FRONT SUSPENSION, UPPER
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 5
1 2 3 4

1 1016353 Assembly, Delta A-Plate (includes items 2, 3 and 4) ................................. 2 2

G
2 1016346 Bushing, Urethane ................................................................................. 6 6
3 1016350 Sleeve, Delta Outer ................................................................................ 1 1
E
4 1016349 Sleeve, Delta Inner ................................................................................. 2 2
5 8754 Nut, Nylon Lock, 3/8-16 .............................................................................. 10 10
6 1010200 Screw, Hex-Head Cap, 3/8-16 x 4-1/4 ........................................................ 4 4
7 1308 Nut, Hex, 1/2-20 ......................................................................................... 1 1
8 8861 Screw, Hex-Head Cap, 3/8-16 x 1-3/4 ........................................................ 2 2
9 1624 Nut, Dimpled Lock, 3/8-16 .......................................................................... 2 2
10 2402 Screw, Hex-Head Cap, 3/8-16 x 2-1/4 ........................................................ 4 4
11 1010219 Rod, Tie ...................................................................................................... 1 1
12 7555 Nut, Hex, Left-Hand Thread, 1/2-20 ........................................................... 1 1
13 7540 Ball Joint, Left-Hand Thread (includes items 15, 16 and 17) ..................... 1 1
14 7539 Ball Joint (includes items 15, 16 and 17) ................................................... 1 1
15 1015597 Fitting, Thread-Forming Grease, 1/4-28 ................................................. 1 1
16 1011930 Boot, Dust .............................................................................................. 1 1
17 7602 Nut, Slotted Hex, 3/8-24 ......................................................................... 1 1
18 1017266 Strap, A-Plate ............................................................................................. 2 2
19 1014235 Shock Absorber, Front ............................................................................... 2 2
20 1010124 Plate, Spring Mounting ............................................................................... 1 1
21 1016385 Assembly, Delta Shock and Gear Support ................................................. 1 1
22 1035 Pin, Cotter, 3/32 x 1 ................................................................................... 3 3

2003 DS Golf Cars Illustrated Parts List Page 5-7

5
G
E REFERENCE
STEERING GEAR
ASSEMBLY

15

17

PASSENGER 2
SIDE ONLY
14 16 18

3
29
TYPICAL
4 PLACES
5
1
DRIVER TYPICAL
SIDE ONLY 4 PLACES
25 24
26 11
20
14
4
27 23
19 21
7
12
8 10
26
9
10
22
TYPICAL 13
4 PLACES 6
30
28
31

Page 5-8 2003 DS Golf Cars Illustrated Parts List

 FRONT SUSPENSION, LOWER
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 5
1 2 3 4

1 1010348 Assembly, Spindle, Driver-Side (includes items 3, 4 and 5) ....................... 1 1

G
2 1010347 Assembly, Spindle, Passenger-Side (includes items 3, 4 and 5) ............... 1 1
3 8067 Bushing, Bronze Spindle ........................................................................ 1 1
E
4 7048 Bushing, Bronze ..................................................................................... 1 1
5 1015597 Fitting, Grease, 1/4-28 ........................................................................... 1 1
6 1012030 Spring, Tapered Leaf .................................................................................. 1 1
7 8745 Assembly, Eccentric ................................................................................... 1 1
8 706 Nut, Hex, 3/8-16 ......................................................................................... 1 1
9 1011892 Assembly, Hub (includes items 10 - 13) ..................................................... 2 2
10 1011393 Package, Hub Bearing ........................................................................... 2 2
11 1011304 Stud, Lug, 1/2-20 ................................................................................... 4 4
12 1013135 Seal, Double Lip ..................................................................................... 1 1
13 1011887 Cover, Dust ............................................................................................ 1 1
14 8754 Nut, Nylon Lock, 3/8-16 .............................................................................. 4 4
15 1016387 Screw, Hex-Head Cap, 3/8-16 x 2-3/4 ........................................................ 2 2
16 1016384 Clevis, Upper Delta .................................................................................... 2 2
17 101903101 Nut, Nylon Lock, 1/2-20 .............................................................................. 2 2
18 1010150 Bearing, Thrust ........................................................................................... 2 2
19 1016389 Washer, Kingpin Wave ............................................................................... 2 2
20 1010984 Nut, Lug ..................................................................................................... 8 8
21 1010005 Washer, Flat, 3/4 ........................................................................................ 2 2
22 7840 Nut, Hex Slotted, 3/4-16 ............................................................................. 2 2
23 7910 Pin, Cotter, 5/32 x 1 ................................................................................... 2 2
24 8755 Screw, Hex-Head Cap, 3/8 - 16 x 3-3/8 ...................................................... 2 2
25 1016386 Kingpin ....................................................................................................... 2 2
26 1015583 Bushing, Urethane ..................................................................................... 4 4
27 1012303 Bushing, Steel ............................................................................................ 2 2
28 1014276 Plate, Front Spring Retainer ....................................................................... 1 1
29 1624 Screw, Hex-Head Cap, 3/8-16 x 1-1/2 ........................................................ 4 4
30 357 Washer, Lock, 3/8 ...................................................................................... 4 4
31 706 Nut, Hex, 3/8-16 ......................................................................................... 4 4

2003 DS Golf Cars Illustrated Parts List Page 5-9

5
G BRAKE CABLE
HANGER MOUNTING—
TYPICAL ON
E GASOLINE VEHICLE ONLY EACH SIDE
OF VEHICLE

TYPICAL ON
17
EACH SIDE
OF VEHICLE
BRAKE CABLE
16 HANGER MOUNTING—
ELECTRIC VEHICLE ONLY

14 4
3
14
2 11
4

3 4
12 7 2
1 14
6

9
15 4
10 3
13
10 8
4
TYPICAL 2
9 PLACES

Page 5-10 2003 DS Golf Cars Illustrated Parts List

 REAR SUSPENSION
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 5
1 2 3 4

1 1012304 Shackle, Rear Spring (gasoline vehicle) .................................................... 4

G
1 7569 Shackle, Rear Spring (electric vehicle) (not shown) .................................. 4
2 8754 Nut, Nylon Lock, 3/8-16 .............................................................................. 6 6
E
3 1012303 Bushing, Steel ............................................................................................ 6 6
4 1015583 Bushing, Urethane ..................................................................................... 12 12
5 1010145 Nut, UNF Hex, 3/8-24 ................................................................................. 4 4
6 1013164 Kit, Shock Absorber (includes items 7, 9, and 10) ..................................... 1 1
7 1014236 Shock Absorber, Rear ............................................................................ 2 2
8 1011415 Kit, Shock Absorber Cushion (includes 2 each of items 9 and 10) ............. 4 4
9 N/A Retainer, Shock Absorber Cushion ........................................................ 8 8
10 N/A Cushion, Shock Absorber ...................................................................... 8 8
11 1012180 U-Bolt ......................................................................................................... 2 2
12 1012324 Spring, Rear Leaf (gasoline vehicle) .......................................................... 2
12 1010974 Spring, Rear Leaf (electric vehicle) ............................................................ 2
13 1014555 Nut, Nylon Lock, 7/16-24 ............................................................................ 4 4
14 8755 Screw, Hex-Head Cap, 3/8-16 x 3-3/8 ........................................................ 6 6
15 1012182 Pad, Spring, Driver-Side ............................................................................ 1 1
15 1012181 Pad, Spring, Passenger-Side ..................................................................... 1 1
16 101900801 Hanger, Brake Cable (gasoline vehicle) ..................................................... 2
17 1013207 Hanger, Brake Cable (electric vehicle) ....................................................... 2

2003 DS Golf Cars Illustrated Parts List Page 5-11

5
G
E
ELECTRICAL SYSTEM –
GASOLINE VEHICLE 6
G
E
6
G
4 14
E 3

13
FORWARD / REVERSE
CK
B LA ASSEMBLY
FRAME
GROUND LIMIT
RE D
E SWITCHES
BL U
TE CK CK
WHI BLA B LA
E / M- 2
WHIT M+
CK
2 BLA 1
HITE NG E
D/W
1 KEY O RA EN
RE SWITCH GRE
ITE
LOW 3 / WH
YE L RED
LOW 5
YEL
E
WHIT
REVERSE 6
LOW OIL BUZZER
ITE
2 WARNING / WH LIMIT
LIGHT RED CK
BLA EEN
GR SWITCHES
1 15
RED / WHITE

NGE
K ORA
LAC
BLUE

TE/B 7
WHI
WHITE

CK
/ BLA
CK W H IT E
BL A
WH I
TE 4 BL A
CK

E
BL U FRAME
GROUND

SOLENOID 16
VOLTAGE
R ED RED ITE
WH
REGULATOR IRE
ND W WIR
E
G ROU UND
RE D
RED

IDED RO
WHITE / BLACK

E BRA IDED G K
BL U BRA LAC
R ED E/B
NGE WHIT
O RA
TE
WH I
FUSE STARTER /
BLOCK GENERATOR
8 17 18 F2
BLACK

YELLOW
RED

A1 DF
9 F1
A2
N
RPM LIMITER EE
YELLOW

GR
YELLOW

YELLOW
YE L L O W ENGINE
WHITE OIL
/ BLACK LEVEL
BLACK BLACK SENSOR
YELLO
YELLOW W
10 BLA C K WHITE

FRAME
BATTERY GROUND
19
12

Page 6-2 2003 DS Golf Cars Illustrated Parts List

 WIRING – GASOLINE VEHICLE
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

101889302 Wire Harness (includes items 1 - 11) .................................................................... 1

G
1 N/A Wire Assembly, #18 Red/White ......................................................................... 1
2 N/A Wire Assembly, #18 Yellow ................................................................................ 1
E
3 N/A Wire Assembly, #18 Yellow and #16 Blue .......................................................... 1
4 N/A Wire Assembly, #18 White/Black and #18 White ............................................... 1
5 N/A Wire Assembly, #18 Green ............................................................................... 1
6 N/A Wire Assembly, #18 Black ................................................................................. 1
7 1015769 Wire Assembly, #6 White .................................................................................. 1
8 N/A Wire Assembly, #16 Red and #16 Orange ........................................................ 1
9 N/A Wire Assembly, #16 Yellow ................................................................................ 1
10 1014119 Wire Assembly, #6 Red ..................................................................................... 1
11 N/A Wire Assembly, #18 Yellow ................................................................................ 1
12 1012382 Wire Assembly, #6 Black ....................................................................................... 1
13 N/A Wire Assembly, #18 Black ..................................................................................... 1
14 N/A Wire Assembly, #18 Black (part of reverse buzzer kit) .......................................... 1
15 N/A Wire Assembly, #16 Orange (part of the electrical component box) ..................... 1
16 1015920 Wire Assembly, #6 Braided Ground ...................................................................... 1
17 1015737 Wire Assembly, #10 Red (part of the electrical component box) .......................... 1
18 1015332 Wire Assembly, #10 Braided Ground .................................................................... 1
19 101837301 Wire Assembly, #6 Green ..................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 6-3

6
G
E 22 TYPICAL 4
PLACES
23

21 2
3
24 4
9
1 5
6
CO
M
NO
NC

25 8 8 2
11
13
26 10
12
14
20
19
7

27 18 17 16

15
28
20
19
24

29

Clu
bC
ar

TYPICAL 3
30 PLACES

Club
Car
Club
Car

Page 6-4 2003 DS Golf Cars Illustrated Parts List

 FORWARD/REVERSE SHIFTER ASSEMBLY –
GASOLINE VEHICLE
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

1016947 Assembly, Forward/Reverse Shifter (includes items 1 - 17) .................................. 1

G
1 1012594 Screw, Machine, #4-40 x 1-1/2 .......................................................................... 2
2 8057 Nut, Hex, #4-40 ................................................................................................. 4
E
3 1012431 Washer, Flat, #4 ................................................................................................ 4
4 101979101 Switch, Limit ...................................................................................................... 1
5 1014807 Switch, Limit ...................................................................................................... 1
6 8058 Washer, Lock, #4 .............................................................................................. 2
7 1013591 Pin, Roll, 1/8 ...................................................................................................... 1
8 1014145 Bushing, Bronze ................................................................................................ 2
9 1014727 Washer, Nylon Flat, #4 ...................................................................................... 2
10 1016342 Base, Forward/Reverse Shifter ......................................................................... 1
11 1014089 Kit, Neutral Lockout Cam (includes item 12) ..................................................... 1
12 1014065 Washer, Flat ................................................................................................. 1
13 1013590 Spring, Forward/Reverse Cam .......................................................................... 1
14 1013589 Ring, Retaining ................................................................................................. 1
15 8717 Nut, Nylon Lock, 1/4-28 .................................................................................... 1
16 1013587 Weldment, Forward/Reverse Bell Crank ........................................................... 1
17 1010954 Stud, Ball, 1/4-28 x 1/4 ...................................................................................... 1
18 101951501 Cable, Transmission (includes items 19 and 20) ................................................... 1
19 7893 Nut, Hex, #10-32 ............................................................................................... 2
20 1012333 Joint, Ball .......................................................................................................... 2
21 1013198 Screw, Phillips Oval Countersunk Machine, #8-32 x 5/8 ....................................... 1
22 1012987 Handle, Forward/Reverse Switch .......................................................................... 1
23 8248 Screw, Phillips Truss-Head, 1/4-20 x 3/4 ............................................................... 4
24 8233 Nut, Nylon Lock, 1/4-20 ......................................................................................... 8
25 1016201 Washer, Wave, 3/8 ................................................................................................ 1
26 8251 Screw, Phillips-Head, 1/4-20 x 1 ............................................................................ 4
27 101855801 Retainer, Cable ..................................................................................................... 1
28 332 Washer, Flat, 1/4 ................................................................................................... 4
29 101922601 Bracket, Transmission Cable Support ................................................................... 1
30 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 3

2003 DS Golf Cars Illustrated Parts List Page 6-5

6
G 2

1
E 10
TYPICAL 2
PLACES
11
REFERENCE
ACCELERATOR CABLE
12
3
13
ORANGE WIRE 19
ASSEMBLY 15 10 TYPICAL 2
TYPICAL 2 PLACES
PLACES 20
14 4
17
2
TYPICAL 2
18 5 PLACES

16
TYPICAL 2 29
PLACES

21
22
23

10
26

5
TO FRAME 25 24
GROUND 2
6 TYPICAL 2
PLACES
REFERENCE
FRO ACCELERATOR ROD
NT
VEH OF
ICLE
TYPICAL 2 7
PLACES

8
28 27 9

Page 6-6 2003 DS Golf Cars Illustrated Parts List

 ELECTRICAL COMPONENT BOX – GASOLINE VEHICLE
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

101992601 Box, Electrical Component, Complete (includes items 1 - 25) .............................. 1

G
1 1015372 Cover, Electrical Component Box ..................................................................... 1
2 1015752 Screw, Hex Washer-Head Hi-Lo, #12-16 x 5/8 .................................................. 5
E
3 1013589 Ring, Retaining ................................................................................................. 1
4 1015373 Cam, Electrical Box ........................................................................................... 1
5 1014145 Bushing, Bronze ................................................................................................ 2
6 1014065 Washer, Flat ...................................................................................................... 1
7 1010954 Stud, Ball, 1/4-28 .............................................................................................. 1
8 1015345 Assembly, Bell Crank and Shaft ........................................................................ 1
9 8717 Nut, Nylon Lock, 1/4-28 .................................................................................... 1
10 8057 Nut, Hex, #4-40 ................................................................................................. 4
11 8058 Washer, Lock, #4 .............................................................................................. 2
12 1014807 Switch, Limit ...................................................................................................... 1
13 1014808 Switch, Limit ...................................................................................................... 1
14 1012431 Washer, Flat, #4 ................................................................................................ 2
15 N/A Wire Assembly, #16 Orange ............................................................................. 1
16 1015878 Screw, Hex-Head Machine, #4-40 x 1-5/8 ........................................................ 2
17 101856102 Screw, Hex Washer-Head Hi-Lo, 1/4-15 x 1-1/2 ............................................... 1
18 1015777 Assembly, Voltage Regulator ............................................................................ 1
19 7893 Nut, Hex, #10-32 ............................................................................................... 2
20 1242 Nut, Hex, 5/16-18 .............................................................................................. 2
21 1013609 Solenoid, 12-Volt ............................................................................................... 1
22 1012295 Fuse, 10-Amp ................................................................................................... 1
23 1015737 Wire Assembly, #10 Red ................................................................................... 1
24 1015741 Block, Fuse ....................................................................................................... 1
25 1015371 Box, Electrical Component ................................................................................ 1
26 1015405 Bolt, Carriage, 5/16-18 x 2 .................................................................................... 1
27 1241 Washer, Flat, 5/16 ................................................................................................. 2
28 7473 Nut, Nylon Lock, 5/16-18 ....................................................................................... 2
29 7818 Bolt, Carriage, 5/16-18 x 1-1/2 .............................................................................. 1

2003 DS Golf Cars Illustrated Parts List Page 6-7

6
G AS SEEN
FROM FRONT
DRIVER SIDE

E 5 6
OF VEHICLE,
BODY
REMOVED

M- 1
2

M+

10
ON
OFF

12
11
4
8 9
2 7
TYPICAL
3 4 PLACES
1

OFF ON

13

14
TYPICAL
3 PLACES

Page 6-8 2003 DS Golf Cars Illustrated Parts List

 ELECTRICAL COMPONENTS, FRONT BODY –
GASOLINE VEHICLE
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

1 1016859 Kit, Reverse Buzzer (includes items 2, 3 and 4) ................................................... 1

G
2 1016849 Screw, Pan-Head Hi-Lo, #4-24 x 5/16 ............................................................... 2
3 1016851 Buzzer, Reverse ................................................................................................ 1
E
4 N/A Wire Assembly, #18 Black ................................................................................. 1
5 1011229 Nut, K Lock, #6-32 ................................................................................................ 1
6 1015720 Screw, Hex Washer-Head, #6-32 x 1/2 ................................................................. 1
7 101830601 Assembly, Screw and Washer ............................................................................... 4
8 101826301 Switch, Key ........................................................................................................... 1
9 101851101 Washer .................................................................................................................. 1
10 101830701 Nut, Key Switch ..................................................................................................... 1
11 101834502 Cap, Key Switch (black) ........................................................................................ 1
12 1012505 Key (pair) ............................................................................................................... 1
12 AM10079 Key (bag of 50) * ................................................................................................... 1
13 1016630 Light, Low Oil Warning .......................................................................................... 1
14 101900901 Retainer, Harness ................................................................................................. 3

* Must order in multiples of 50.

2003 DS Golf Cars Illustrated Parts List Page 6-9

6
TYPICAL 26 TYPICAL

G 3 PLACES 24 29 2 PLACES
TYPICAL
4 PLACES
15
TYPICAL
4 PLACES

21 28 TYPICAL
14
E 27
2 PLACES
AT F1 AND
TYPICAL F2 TERMINALS
2 PLACES
18
DF
20 TERMINAL

19 17

TYPICAL
2 PLACES
AT A1 AND 16
A2 TERMINALS

23
22
30
TYPICAL
25 TYPICAL 4 PLACES
2 PLACES

TYPICAL
2 PLACES

12
8
TYPICAL 11
3 PLACES
1
9

5 7 10

2 3
4

13 31

Page 6-10 2003 DS Golf Cars Illustrated Parts List

 STARTER/GENERATOR ASSEMBLY
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

101833701 Starter/Generator (clockwise rotation) (includes items 1 - 30) .............................. 1

G
1 101875201 Housing, Field Coil ............................................................................................ 1
2 101875101 Assembly, Armature (includes items 3 - 6) ........................................................ 1
E
3 101875001 Retainer, Bearing ......................................................................................... 1
4 1013001 Ball Bearing, Output Shaft ............................................................................ 1
5 1013005 Commutator, Ball Bearing ............................................................................ 1
6 101939901 Spacer, 5/16 ................................................................................................. 1
7 1013003 Key, Woodruff .................................................................................................... 1
8 101876501 Kit, Pulley Nut and Screw (includes items 9 - 12) ............................................. 1
9 N/A Washer, Lock, M14 ....................................................................................... 1
10 N/A Nut, Hex, M14 x 2 ......................................................................................... 1
11 N/A Screw, Cross-Recessed, M5 x .8 x 18 mm .................................................. 3
12 101896501 Screw, Cross-Recessed, M5 x .8 x 16 mm (with lock washer) ..................... 2
13 101874901 End Bell, Output Shaft ...................................................................................... 1
14 101875301 Set, Pole (set of 4) ............................................................................................ 1
15 101875401 Screw, Pole Piece (set of 4) .............................................................................. 1
16 101875501 Coil, Field .......................................................................................................... 1
17 101875601 Insulator, F Terminal .......................................................................................... 2
18 101877601 Package, Terminal Hardware (F1 and F2) ........................................................ 2
19 101875701 Insulator, DF Terminal ....................................................................................... 1
20 101877701 Package, Terminal Hardware (DF) .................................................................... 1
21 101301102 Holder, Brush (includes item 22) ....................................................................... 1
22 101878101 Spring, Brush ............................................................................................... 4
23 101876001 Package, Terminal Hardware (A1 and A2) ........................................................ 2
24 101876301 Cover, Brush Inspection Port (set of 4) (includes item 25) ................................ 1
25 1017653 Cover, Brush Inspection Port, with Drain ...................................................... 1
26 101876402 End Bell, Commutator ....................................................................................... 1
27 101879001 Bolt, Clamp, M6 x 1 x 180 mm .......................................................................... 2
28 101869302 Package, Brush (includes 4 brushes, 4 screws, 4 washers) ............................. 1
29 101876202 Connector, Brush .............................................................................................. 2
30 101875802 A Connector (set of 2) ....................................................................................... 1
31 1014289 Pulley .................................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 6-11

6
G 16
17
FRAME
CONNECTION

E 15

14
AS VIEWED FROM
A1 TERMINAL DRIVER SIDE
OF VEHICLE

F1
TERMINAL

A2 TERMINAL

TYPICAL
2 PLACES
7
8
5
13
9

F2

DF

4
12
9
AS VIEWED FROM
PASSENGER SIDE OF VEHICLE 11
10

Page 6-12 2003 DS Golf Cars Illustrated Parts List

 STARTER/GENERATOR MOUNTING
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

1 101833701 Starter/Generator (clockwise rotation) .................................................................. 1

G
2 101524001 Bracket, Mounting, FE290 ..................................................................................... 1
3 101916701 Belt, Starter/Generator .......................................................................................... 1
E
4 1016883 Bracket, Adjusting ................................................................................................. 1
5 8754 Nut, Nylon Lock, 3/8-16 ......................................................................................... 2
6 1015075 Washer, Flat, 5/16 ................................................................................................. 1
7 705 Screw, Hex-Head Cap, 3/8-16 x 1-1/4 ................................................................... 2
8 1012830 Screw, Hex-Head Cap, M8 x 1.25 x 22 mm .......................................................... 2
9 7174 Washer, Lock, 5/16 ............................................................................................... 3
10 1016074 Screw, Torx-Head, M8 x 1.25 x 18 mm ................................................................. 1
11 1015932 Bolt, Carriage, 5/16-18 x 1 .................................................................................... 1
12 1242 Nut, Hex, 5/16-18 .................................................................................................. 1
13 101837301 Wire Assembly, #6 Green ..................................................................................... 1
14 1015920 Wire Assembly, #6 Braided Ground ...................................................................... 1
15 7473 Nut, Nylon Lock, 5/16-18 ....................................................................................... 1
16 1241 Washer, Flat, 5/16 ................................................................................................. 1
17 7173 Screw, Hex-Head Cap, 5/16-18 x 3/4 .................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 6-13

6
G NEW-STYLE BATTERY
WITH NEW HARDWARE
E 4
2 1

3 AS SEEN FROM THE

PASSENGER SIDE
OF VEHICLE

New-style battery
does not require
spacer (4). 3

6
5 TO NEGATIVE
BATTERY POST
TERMINAL 7

10

8
9
8 AS SEEN FROM
DRIVER SIDE
OF VEHICLE
9

Page 6-14 2003 DS Golf Cars Illustrated Parts List

 BATTERY – GASOLINE VEHICLE
ITEM PART NO. DESCRIPTION QTY 6
1 2 3 4

1 1012328 Battery, 12-Volt ...................................................................................................... 1

G
2 102355301 Washer, Lock, Stainless Steel, 3/8* ...................................................................... 2
3 1014375 Screw, Hex-Head Cap, Stainless Steel, 3/8-16 x 1/2 ............................................ 2
E
4 1014374 Spacer, Battery Terminal Bolt* .............................................................................. 2
5 1010934 Screw, Hex-Head Cap, 5/16-18 x 1 ....................................................................... 1
6 101898001 Clamp, Battery ...................................................................................................... 1
7 7173 Screw, Hex Cap, 5/16-18 x 3/4 .............................................................................. 1
8 1241 Washer, Flat, 5/16 ................................................................................................. 2
9 7473 Nut, Nylon Lock, 5/16-18 ....................................................................................... 2
10 1014288 Screw, Thread-Forming, 5/16-16 x 3/4 .................................................................. 1

*NOTE: When ordering a new battery, you must order the new stainless
steel lockwasher (2). Lockwasher cannot be used if battery terminal
spacer (4) is required by battery design.

2003 DS Golf Cars Illustrated Parts List Page 6-15

6
G
E
FE290 ENGINE 7
G
E
7
G
E REF. REF. 3 8 TYPICAL 6 PLACES
FOR ITEM 9

1 2 4
TYPICAL 4
9 PLACES
FOR ITEM 18

17

4
TYPICAL 4
PLACES
FOR ITEM 3

7
6 CARBURETOR
REMOVED
TYPICAL 2 FOR CLARITY
PLACES
18

5 2
TYPICAL 2 1
PLACES
15

10 5

TYPICAL 3 PLACES
FOR ITEM 10

4
16

14

13
12
11
4
TYPICAL 2
PLACES

Page 7-2 2003 DS Golf Cars Illustrated Parts List

 FE290 ENGINE – SHROUDS AND BRACKETS
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

101953901 FE290 OHV Gasoline Engine (clockwise rotation) Without Automatic

G
Compression Release (w/o ACR) with Carburetor
(does not include items 15 - 18) ............................................................................ 1 E
1 1016507 Bolt, 2-Ended, M6 x 1 x 29 mm ......................................................................... 1
2 1016512 Washer, Flat, 6 mm ........................................................................................... 1
3 1016524 Shroud, Engine, FE290 ..................................................................................... 1
4 1016456 Bolt, Flanged, M6 x 1 x 12 mm ......................................................................... 15
5 1016547 Nut, Flange, M6 x 1 ........................................................................................... 3
6 101909701 Bolt, 2-Ended, M6 x 1 x 27 mm ......................................................................... 2
7 1016526 Shroud, Engine, FE290 (lower) ......................................................................... 1
8 1017221 Bolt, 2-Ended, M6 x 1 x 46 mm ......................................................................... 1
9 101915601 Housing, Fan ..................................................................................................... 1
10 1016525 Shroud, Engine, FE290 (upper) ........................................................................ 1
11 1016443 Bracket .............................................................................................................. 1
12 1016539 O-Ring ............................................................................................................... 1
13 1016536 Tube, Oil Filler, FE290 ....................................................................................... 1
14 1016531 Dipstick ............................................................................................................. 1
15 101887601 Nut, Nylon Lock, M6 x 1 ........................................................................................ 1
16 1015332 Wire Assembly, #10 Braided Ground .................................................................... 1
17 1015969 Screw, Pan-Head, M6 x 1 x 14 mm ....................................................................... 4
18 1015649 Shroud, Fan .......................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 7-3

7
G
E
12 11

13 10

9 TYPICAL 2
8 PLACES

19
18
16
24
1
23
22 2

21 25
TYPICAL 3
17 20 PLACES

15
14
TYPICAL 2
PLACES

Page 7-4 2003 DS Golf Cars Illustrated Parts List

 FE290 ENGINE –
IGNITION COMPONENTS AND FLYWHEEL
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

1 101915701 Flywheel ............................................................................................................ 1

G
2 101915801 Fan, Flywheel, Gray .......................................................................................... 1
3 1017448 Screw, Flanged Hex-Head, M6 x 1 x 10 mm ..................................................... 3
E
4 1016548 Washer, Flat, 16 mm ......................................................................................... 1
5 1016505 Nut, Hex, M16 x 1.5 .......................................................................................... 1
6 1017455 Plate, Flywheel Fan ........................................................................................... 1
7 1016562 Key .................................................................................................................... 1
8 1016455 Bolt, Flanged, M5 x .8 x 25 mm ........................................................................ 2
9 101909201 Coil, Ignition (with internal igniter) ..................................................................... 1
10 1016578 Grommet ........................................................................................................... 1
11 1016588 Tube, 7 mm x 70 mm ........................................................................................ 1
12 1016493 Assembly, Plug Cap .......................................................................................... 1
13 101881101 Plug, Spark, OHV .............................................................................................. 1
14 1016456 Bolt, Flanged, M6 x 1 x 12 mm ......................................................................... 2
15 1012981 Clamp ................................................................................................................ 1
16 1016579 Band, RPM Limiter Mount ................................................................................. 1
17 1016586 Damper, RPM Limiter ........................................................................................ 1
18 101909401 Limiter, RPM, OHV ............................................................................................ 1
19 1016445 Bracket, RPM Limiter ........................................................................................ 1
20 101909501 Clamp ................................................................................................................ 1
21 1016497 Screw, Cross Pan-Head, M5 x .8 x 8 mm ......................................................... 1
22 1016544 Screw, Cross Pan-Head Self-Tapping, M5 x .8 x 12 mm .................................. 1
23 1016561 Clamp ................................................................................................................ 1
24 1016587 Clamp ................................................................................................................ 1
25 101909301 Wire, Lead ......................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 7-5

7
G
E

5
15
TYPICAL 2 14
PLACES
13
4

12 11
10
9

3
TYPICAL 2
PLACES

7
2
6
8
1 TYPICAL 6
PLACES

Page 7-6 2003 DS Golf Cars Illustrated Parts List

 FE290 ENGINE – OIL CIRCULATION
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

1 1016467 Oil Filter ............................................................................................................. 1

G
2 1016502 Bracket, Oil Filter ............................................................................................... 1
3 1016457 Bolt, Flanged Hex-Head, M6 x 1 x 40 mm ........................................................ 2
E
4 1017507 Plug ................................................................................................................... 2
5 1016570 O-Ring, Oil Filter Mount .................................................................................... 1
6 1016576 Plug, Drain, FE290 ............................................................................................ 1
7 1016432 Gasket, Drain Plug ............................................................................................ 1
8 1017456 Screw, Flanged Hex-Head, M6 x 1 x 12 mm ..................................................... 6
9 1016484 Cover, Pump ..................................................................................................... 1
10 1016435 Gasket, Oil Pump .............................................................................................. 1
11 1016473 Plate, Oil Pump ................................................................................................. 1
12 101648203 Pump, Oil and Rotor .......................................................................................... 1
13 1016429 Seat, Valve ........................................................................................................ 1
14 1016537 Ball, Steel, Pressure Relief ............................................................................... 1
15 1016581 Spring ................................................................................................................ 1

2003 DS Golf Cars Illustrated Parts List Page 7-7

7
G
E

5
6
7 TYPICAL 2
PLACES
8
9
10
14
1 15
2 12
13
EXHAUST

16
18 INTAKE
19
20 17

22 11
TYPICAL 2 TYPICAL 2
PLACES
AT EXHAUST PLACES
CONNECTION
21

3
4
TYPICAL 2
PLACES
23

25
26
24
27
TYPICAL 2
PLACES TYPICAL 6
PLACES 28

Page 7-8 2003 DS Golf Cars Illustrated Parts List

 FE290 ENGINE – CYLINDER HEAD
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

1 1016442 Case, Rocker .................................................................................................... 1

G
2 1016436 Gasket, Rocker Case ........................................................................................ 1
3 1016583 Bolt, Flanged, M6 x 1 x 35 mm ......................................................................... 2
E
4 1016569 O-Ring ............................................................................................................... 2
5 1016545 Nut, Hex, M5 x .8 .............................................................................................. 2
6 1016542 Screw, Stud, M5 x .8 ......................................................................................... 2
7 1016451 Arm, Rocker ...................................................................................................... 2
8 1016450 Collet ................................................................................................................. 4
9 1016449 Retainer, Valve Spring ....................................................................................... 2
10 1016523 Spring, Engine Valve ......................................................................................... 2
11 1016431 Assembly, Cylinder Head, OHV (includes items 12 and 13) ............................. 1
12 1016560 Ring, Snap .................................................................................................... 2
13 1016519 Guide, Valve ................................................................................................. 2
14 1016479 Seat, Spring ...................................................................................................... 2
15 1016566 Seal, Valve ........................................................................................................ 2
16 1016448 Valve, Exhaust .................................................................................................. 1
17 1016447 Valve, Intake ...................................................................................................... 1
18 1016544 Screw, Cross Pan-Head Self-Tapping, M5 x .8 x 12 mm .................................. 1
19 1016474 Plate .................................................................................................................. 1
20 1016483 Valve ................................................................................................................. 1
21 1016563 Pin ..................................................................................................................... 2
22 1016489 Bolt, Stud, M8 x 1.25 x 29 mm .......................................................................... 2
23 1016452 Shaft, Rocker .................................................................................................... 1
24 1016471 Rod, Push ......................................................................................................... 2
25 1016549 Washer, Flat, M12 ............................................................................................. 1
26 1016517 Circlip, Type E ................................................................................................... 1
27 1016458 Bolt, Flanged, M8 x 1.25 x 45 mm .................................................................... 6
28 1016430 Gasket, Head .................................................................................................... 1

102304701 Kit, Gasket, FE290 (not shown) (contains one each of all internal gaskets for
the FE290 engine) ................................................................................................ 1

2003 DS Golf Cars Illustrated Parts List Page 7-9

7
G
E

TYPICAL 2
PLACES

CLAMP
2 ONLY
4
3

18
17
16
15 TYPICAL 2
PLACES
7 14 TYPICAL 3
PLACES
13

12
TYPICAL 2
11 PLACES
10
20

19
9
TYPICAL 6
8 PLACES
TYPICAL 2
PLACES

Page 7-10 2003 DS Golf Cars Illustrated Parts List

 FE290 ENGINE –
CRANKCASE, CAMSHAFT AND OIL SENSOR
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

1 1016535 Connector, Cord ................................................................................................ 1

G
2 1016538 O-Ring ............................................................................................................... 1
3 1016506 Clamp ................................................................................................................ 1
E
4 1016544 Screw, Cross Pan-Head Self-Tapping, M5 x .8 x 12 mm .................................. 1
5 1016564 Pin ..................................................................................................................... 2
6 1016565 Bearing, Ball ...................................................................................................... 1
7 1016567 Seal, Crankshaft ............................................................................................... 1
8 1016584 Bolt, 2-Ended, M8 x 1.25 x 69 mm .................................................................... 2
9 1016458 Bolt, Flanged, M8 x 1.25 x 45 mm .................................................................... 6
10 1016520 Cover, Crankcase .............................................................................................. 1
11 1016446 Gasket, Crankcase Cover ................................................................................. 1
12 1016456 Bolt, Flanged, M6 x 1 x 12 mm ......................................................................... 2
13 1016510 Bracket, Oil Level Switch ................................................................................... 1
14 1016494 Sensor, Oil Level ............................................................................................... 1
15 1016496 Screw, Cross Pan-Head, M4 x .7 x 8 mm ......................................................... 3
16 1016454 Bolt, Flanged, M5 x .8 x 8 mm .......................................................................... 2
17 1016472 Plate, Oil Filter Screen ...................................................................................... 1
18 1016521 Screen, Oil Filter ............................................................................................... 1
19 101915401 Camshaft, Complete ......................................................................................... 1
20 1016453 Tappet ............................................................................................................... 2

2003 DS Golf Cars Illustrated Parts List Page 7-11

7
G
E
6

3
4
1
2 8
TYPICAL 2
PLACES
3
5

7
7

14

16
12
13

12

17 13
TYPICAL 4
PLACES
11
20 21 10
TYPICAL 4 15
PLACES
19
18

Page 7-12 2003 DS Golf Cars Illustrated Parts List

 FE290 ENGINE – CRANKCASE AND CRANKSHAFT
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

1 1016568 Seal, Oil ............................................................................................................ 1

G
2 101915501 Crankcase, OHV ............................................................................................... 1
3 1016558 Ring, Snap ........................................................................................................ 2
E
4 1016460 Pin, Piston ......................................................................................................... 1
5 101645901 Piston, Standard ............................................................................................... 1
5 101645902 Piston, .25 mm Oversized ................................................................................. 1
5 101645903 Piston, .50 mm Oversized ................................................................................. 1
6 101646101 Ring Set, Piston, Standard ................................................................................ 1
6 101646102 Ring Set, Piston, .25 mm Oversized ................................................................. 1
6 101646103 Ring Set, Piston, .50 mm Oversized ................................................................. 1
7 101647501 Assembly, Connecting Rod, Standard (includes 2 each of item 8) ................... 1
7 101647502 Assembly, Connecting Rod, .50 mm Undersized
(includes 2 each of item 8) ................................................................................ 1
8 1016509 Screw, Hex-Head Cap, M7 x 1 x 36 mm ...................................................... 2
9 101922301 Crankshaft, FE290 (left-hand thread)
(includes items 10, 11 and one each of item 12) .............................................. 1
10 1016533 Gear, Helical ................................................................................................. 1
11 1016532 Gear, Spur .................................................................................................... 1
12 1016516 Assembly, Rod (includes one each of item 13) ............................................ 2
13 1016580 Bearing, Plain .......................................................................................... 2
14 1016562 Key .................................................................................................................... 1
15 101655001 Shim, Crankshaft, 1.13 mm Thick ..................................................................... A/R
15 101655002 Shim, Crankshaft, 1.18 mm Thick ..................................................................... A/R
15 101655003 Shim, Crankshaft, 1.23 mm Thick ..................................................................... A/R
15 101655004 Shim, Crankshaft, 1.28 mm Thick ..................................................................... A/R
15 101655005 Shim, Crankshaft, 1.33 mm Thick ..................................................................... A/R
15 101655006 Shim, Crankshaft, 1.38 mm Thick ..................................................................... A/R
15 101655007 Shim, Crankshaft, 1.43 mm Thick ..................................................................... A/R
15 101655008 Shim, Crankshaft, 1.48 mm Thick ..................................................................... A/R
15 101655009 Shim, Crankshaft, 1.53 mm Thick ..................................................................... A/R
16 1016559 Spacer ............................................................................................................... 1
17 1016541 Bolt, Stud, M6 x 1 x 22 mm ............................................................................... 4
18 1016547 Nut, Flanged, M6 x 1 ......................................................................................... 4
19 1016470 Shaft, Counterbalance Guide ............................................................................ 1
20 1016571 O-Ring ............................................................................................................... 1
21 1016469 Weight, Counterbalance ................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 7-13

7
G FR
O
VE NT O
HIC F
E LE

REFERENCE
ENGINE

TYPICAL
2 PLACES

TYPICAL 8
4 PLACES 9
5 Clu
bC
ar

1
TYPICAL
2 PLACES 6
2 TYPICAL
2 PLACES

TYPICAL
4 PLACES
2
3
TYPICAL
7 4 PLACES

4
10
TYPICAL
4 PLACES

11
TYPICAL
4 PLACES

12

Clu
bC
ar

TYPICAL
2 PLACES

13 5

6
TYPICAL
4 PLACES
REFERENCE
UNITIZED TRANSAXLE—
SECTION 11

Page 7-14 2003 DS Golf Cars Illustrated Parts List

 ENGINE MOUNTING
ITEM PART NO. DESCRIPTION QTY 7
1 2 3 4

1 1012164 Snubber ................................................................................................................. 1

G
2 1013924 Nut, Hex Lock, 5/16-24, UNF ................................................................................ 6
3 101834601 Bracket, Snubber ................................................................................................... 1
E
4 101827101 Plate, Mounting ..................................................................................................... 1
5 101833001 Nut, Flange, M8 x 1.25 .......................................................................................... 6
6 101884801 Screw, Hex Washer-Head, 5/16-24 x 7/8 .............................................................. 6
7 101833301 Screw, Hex-Head Cap, M10 x 1.25 x 30 mm ........................................................ 4
8 101833201 Stud, M8 x 1.25 x 60 mm ...................................................................................... 2
9 101832101 Spacer ................................................................................................................... 2
10 101832901 Nut, Flange, M10 x 1.25 ........................................................................................ 4
11 1012571 Washer, Heavy Flat, 5/16 ...................................................................................... 4
12 101855901 Screw, Hex-Head Cap, M8 x 1.25 x 43 mm .......................................................... 4
13 101832701 Stiffener, Flywheel Side ......................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 7-15

7
G
E
 FUEL, INTAKE,
AND GOVERNOR SYSTEMS 8
G
E
8
8
G 7
5
7
4

3 2
6
E 10

11

5
1

17

ENGINE REMOVED
FOR CLARITY

19 18 22
21
20
21 21

SEE ITEM SIX

21 ABOVE

19
12
13

21

21

19
23
14 16

15
19

19 5
21
20 21
21
TO ENGINE CRANKCASE

Page 8-2 2003 DS Golf Cars Illustrated Parts List

 FUEL SYSTEM
ITEM PART NO. DESCRIPTION QTY 8
1 2 3 4

1 1016003 Kit, Fuel Tank (includes items 2 - 8) ...................................................................... 1

G
2 1015188 Cap, Fuel Tank, Nonvented ............................................................................... 1
3 1015143 Assembly, Fuel Tank Vent .................................................................................. 1
E
4 1015139 Grommet, Insulation .......................................................................................... 1
5 1015137 Line, Bulk Vent (available by the foot) ............................................................... A/R
6 101896901 Valve, Fuel Pickup Tube with Shut-Off .............................................................. 1
7 1013746 Clamp, Hose ..................................................................................................... 2
8 101824401 Barb, Vent .......................................................................................................... 1
9 101824401 Barb, Vent .............................................................................................................. 1
10 1014928 Assembly, Rear Fuel Strap .................................................................................... 1
11 1013746 Clamp, Hose ......................................................................................................... 2
12 1014523 Pump, Fuel Impulse ............................................................................................... 1
13 1014524 Rebuild Kit, Fuel Impulse Pump ............................................................................ 1
14 1017203 Bolt, Carriage, 1/4-20 x 1 ...................................................................................... 2
15 101987701 Clamp, Plastic ....................................................................................................... 1
16 8233 Nut, Nylon Lock, 1/4-20 ......................................................................................... 2
17 1014116 Nut, U-Type Speed, 1/4-20 ................................................................................... 2
18 1011988 Screw, Phillips Truss-Head, 1/4-20 x 2 .................................................................. 1
19 1013692 Line, Bulk Fuel (available by the foot) ................................................................... A/R*
20 102003201 Filter, Fuel .............................................................................................................. 2
21 1012649 Clamp, Hose (red) ................................................................................................. 9
22 8248 Screw, Phillips Truss-Head, 1/4-20 x 3/4 ............................................................... 1
23 1013687 Clamp, Hose, 3/8 .................................................................................................. 1

* The total fuel line length for the DS Golf Car is 47 inches (119.4 cm).

2003 DS Golf Cars Illustrated Parts List Page 8-3

8
G
E

4 1

8
6

9
7
10

11

Page 8-4 2003 DS Golf Cars Illustrated Parts List

 CARBURETOR ASSEMBLY
ITEM PART NO. DESCRIPTION QTY 8
1 2 3 4

1 101905601 Assembly, Carburetor (includes items 2 - 11) ....................................................... 1

G
2 1016501 Assembly, Idle Screw ........................................................................................ 1
3 N/A Assembly, Pilot Air Screw .................................................................................. 1
E
4 101973101 Jet, Pilot, #40 .................................................................................................... 1
5 1016486 Assembly, Float ................................................................................................. 1
6 101973201 Nozzle, Main ..................................................................................................... 1
Standard Jetting:
7 101642582 Jet, Main, 0 - 3,000 feet .................................................................................... 1
7 101642580 Jet, Main, 3,000 - 5,000 feet ................................................................................. A/R
7 101642578 Jet, Main, 5,000 - 8,000 feet ................................................................................. A/R
7 101642575 Jet, Main, 8,000 - 10,000 feet ............................................................................... A/R
7 101642572 Jet, Main, 10,000 Feet and Above ........................................................................ A/R
8 1016437 Gasket, Float Chamber ..................................................................................... 1
9 1017461 Assembly, Float Chamber (includes item 10) .................................................... 1
10 1016499 Assembly, Screw .......................................................................................... 1
11 1016585 Assembly, Bolt ................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 8-5

8
G 7

6
E 5

1
2
3

12 10
14
12

11

15 13

16

17
TYPICAL 18
2 PLACES

Page 8-6 2003 DS Golf Cars Illustrated Parts List

 CARBURETOR INSTALLATION
ITEM PART NO. DESCRIPTION QTY 8
1 2 3 4

1 1016440 Gasket, Insulator ................................................................................................... 1

G
2 101648102 Insulator, Carburetor ............................................................................................. 1
3 1016439 Gasket, Carburetor Insulator to Throttle Bracket ................................................... 1
E
4 1016444 Bracket, Throttle .................................................................................................... 1
5 101820201 Guard, Governor ................................................................................................... 1
6 1011697 Washer, Flat, 5/16 ................................................................................................. 1
7 101887601 Nut, Nylon Lock, M6 x 1 ........................................................................................ 1
8 1016441 Gasket, Throttle Bracket to Carburetor .................................................................. 1
9 1016582 Spring, Throttle Return .......................................................................................... 1
10 101905601 Assembly, Carburetor ............................................................................................ 1
11 1013746 Clamp, Hose (gray) ............................................................................................... 1
12 1017466 Clamp, Hose (bronze) ........................................................................................... 2
13 1015137 Line, Bulk Vent (available by the foot) ................................................................... A/R
14 1016572 Tube, Crankcase Vent ........................................................................................... 1
15 1016438 Gasket, Carburetor to Intake Manifold .................................................................. 1
16 1016480 Pipe, Intake ........................................................................................................... 1
17 101649002 Screw, 2-Ended Stud, M6 x 1 x 90 mm ................................................................. 2
18 1016547 Nut, Flanged, M6 x 1 ............................................................................................. 2

2003 DS Golf Cars Illustrated Parts List Page 8-7

8
10
G EARLIER
STYLE
E
3 17
3 9

1
2
LATER STYLE

16
8
TYPICAL
2 PLACES 15

11
10

EARLIER
STYLE
12
13
EARLIER
STYLE
10
11
18
4
3

6
4
3
12

14
5

6
LATER STYLE
19

Page 8-8 2003 DS Golf Cars Illustrated Parts List

 GOVERNOR AND ACCELERATOR CABLES
ITEM PART NO. DESCRIPTION QTY 8
1 2 3 4

1 1013700 Clamp, Cable Retaining ........................................................................................ 2

G
2 1016546 Nut, Flanged Hex, M8 x 1.25 ................................................................................ 2
3 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 4
E
4 101903501 Screw, Hex-Head Cap, M8 x 1.25 x 24 mm .......................................................... 1
5 7174 Washer, Lock, 5/16 ............................................................................................... 1
6 1011697 Washer, Flat, 5/16 ................................................................................................. 1

Earlier style cables (early 2003 models)*:

7 101832501 Cable, Accelerator ................................................................................................. 1
8 101832401 Cable, Governor .................................................................................................... 1
9 101832301 Bracket, Accelerator Support ................................................................................ 1
10 1016202 E-Ring ................................................................................................................... 3
11 1015408 Pin, Governor Cable Clevis ................................................................................... 2
12 1014413 Pin, Hair Spring Cotter, 1/8 I.D. x 5/8 .................................................................... 2
13 101832201 Bracket, Support ................................................................................................... 1
14 1015845 Bracket, Governor Cable Engine ........................................................................... 1

Later style cables (beginning mid-model year 2003)*:

15 102336101 Cable, Accelerator, Snap-in .................................................................................. 1
16 102336001 Cable, Governor, Snap-in ...................................................................................... 1
17 101832302 Bracket, Accelerator Support ................................................................................ 1
18 101832202 Bracket, Support ................................................................................................... 1
19 101584502 Bracket, Governor Cable Engine............................................................................ 1

* Brackets and cables must be of the same style.

2003 DS Golf Cars Illustrated Parts List Page 8-9

8
G REFERENCE
CARBURETOR
17
18
E 1 15 5

TYPICAL 16 6
2 PLACES 2

3
15

TYPICAL
3 PLACES
4
17

19 10
20 7
21
22 8
9

11

12

13

25
26
26 TYPICAL
14 3 PLACES
14

14

23

24

14

Page 8-10 2003 DS Golf Cars Illustrated Parts List

 INTAKE DUCT, CHOKE, AND AIR BOX ASSEMBLY
ITEM PART NO. DESCRIPTION QTY 8
1 2 3 4

101821501 Assembly, Air Box (includes items 1 - 13) ............................................................. 1

G
1 101804301 Screw, Hex-Head Hi-Lo, #8-1/2 ......................................................................... 2
2 101881701 Washer, Stainless Steel, #8 .............................................................................. 2
E
3 101925701 Latch, Wire ........................................................................................................ 2
4 101972801 Assembly, Air Box Top (includes items 5 - 10) .................................................. 1
5 101813001 E-Clip ............................................................................................................ 1
6 101917601 Lever, Choke ................................................................................................ 1
7 N/A O-Ring, 5/16 (red) ........................................................................................ 1
8 N/A O-Ring, 3/8 (green) ...................................................................................... 1
9 N/A Valve, Choke ................................................................................................ 1
10 101812301 Spring, Return .............................................................................................. 1
11 1015426 Filter, Air ............................................................................................................ 1
12 101811901 Bottom, Air Box ................................................................................................. 1
13 101921501 Seal, Intake ....................................................................................................... 1
14 183 Washer, Flat, #10 .................................................................................................. 4
15 101971301 Clamp, Hose (air Intake) ....................................................................................... 2
16 101837101 Hose, Intake .......................................................................................................... 1
17 101850301 Screw, Hex Washer-Head Hi-Lo, #12 x 1/2 ........................................................... 4
18 101917701 Positioner, Choke .................................................................................................. 1
19 101805701 Assembly, Choke Button (includes items 20, 21 and 22) ...................................... 1
20 101811501 Guide, Choke Lever .......................................................................................... 1
21 101856201 Spring, Compression ........................................................................................ 1
22 101811401 Lever, Choke ..................................................................................................... 1
23 332 Washer, Flat, 1/4 ................................................................................................... 3
24 1015752 Screw, Hex Washer-Head Hi-Lo, #12-16 x 5/8 ...................................................... 3
25 101958101 Assembly, Air Duct ................................................................................................ 1
26 1606 Rivet, Pop, 3/16 ..................................................................................................... 2
101971001 Air Duct Repair Kit (not shown) ............................................................................. A/R

2003 DS Golf Cars Illustrated Parts List Page 8-11

8
G
E
EXHAUST SYSTEM 9
G
E
9
G
TYPICAL 2
PLACES
E 10
11

8 6

12

5
4
3
TYPICAL 2
1 PLACES

REFERENCE
ENGINE MOUNTING
SECTION 7

Page 9-2 2003 DS Golf Cars Illustrated Parts List

 EXHAUST SYSTEM
ITEM PART NO. DESCRIPTION QTY 9
1 2 3 4

1 101859301 System, Exhaust ................................................................................................... 1

G
2 1015814 Bracket, Muffler Mounting ..................................................................................... 1
3 332 Washer, Flat, 1/4 ................................................................................................... 2
E
4 451 Washer, Lock, 1/4 ................................................................................................. 2
5 7847 Screw, Hex-Head Cap, 1/4-20 x 3/4 ...................................................................... 2
6 1017689 Clamp, Muffler ....................................................................................................... 1
7 1012830 Screw, Hex-Head Cap, M8 x 1.25 x 22 mm .......................................................... 1
8 7174 Washer, Lock, 5/16 ............................................................................................... 1
9 1015075 Washer, Flat, 5/16 ................................................................................................. 1
10 1012528 Nut, Hex, M8 x 1.25 .............................................................................................. 2
11 1013734 Washer, Lock, 8 mm ............................................................................................. 2
12 1015330 Gasket, Exhaust .................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 9-3

9
G
E
TORQUE CONVERTER 10
G
E
10
G
1
E 2
3
TYPICAL
3 PLACES

10
14
13
12
11
4
5
8
6

16
7 16
15

18
9 19 17

21

20

23

22

Page 10-2 2003 DS Golf Cars Illustrated Parts List

 DRIVE CLUTCH
ITEM PART NO. DESCRIPTION QTY 10
1 2 3 4

101833902 Assembly, Drive Clutch (includes items 1 - 19) ..................................................... 1

G
1 1016801 Kit, Drive Clutch Weight .................................................................................... 1
2 101929801 Assembly, Fixed Face ....................................................................................... 1
E
3 1014049 Bearing, Idler ..................................................................................................... 1
4 1014050 Retainer, Spring ................................................................................................ 1
5 1014051 Spring, Drive Clutch – Black ............................................................................. 1
6 1016289 Spacer, Fixed Face Shaft .................................................................................. 1
7 1014057 Ring, Retaining ................................................................................................. 1
8 1014059 Assembly, Drive Hub ......................................................................................... 1
9 N/A Plug, Drive Clutch ............................................................................................. 3
10 1014453 Kit, Drive Clutch Button (includes item 11 - 14) ................................................ 1
11 1014287 Spring, Drive Button ..................................................................................... 3
12 1014062 Driver, Drive Clutch ...................................................................................... 3
13 183 Washer, Flat, #10, Type A ............................................................................ 3
14 8450 Screw, Hex-Head, #10-24 x .5 ...................................................................... 3
15 1014058 Washer, Thrust .................................................................................................. 1
16 1014056 Ring, Spiral Back-Up ......................................................................................... 2
17 1014052 Assembly, Movable Face (includes items 18 and 19) ....................................... 1
18 N/A Bushing ........................................................................................................ 1
19 1014055 Retainer ........................................................................................................ 1
20 1016203 Belt, Drive .............................................................................................................. 1
21 101916701 Belt, Starter/Generator .......................................................................................... 1
22 101916501 Screw, Hex-Head Cap, 3/8-24 x 5-1/2 (left-hand threads) .................................... 1
23 1017328 Washer, Drive Clutch – Green .............................................................................. 1

2003 DS Golf Cars Illustrated Parts List Page 10-3

10
G
8
E 7

6
TYPICAL 3
PLACES
2

10

12
11
1

Page 10-4 2003 DS Golf Cars Illustrated Parts List

 DRIVEN CLUTCH
ITEM PART NO. DESCRIPTION QTY 10
1 2 3 4

1 101834001 Assembly, Driven Clutch (includes items 2 - 8) ..................................................... 1

G
2 1014080 Ring, Retaining ................................................................................................. 1
3 1014078 Key .................................................................................................................... 1
E
4 1017686 Cam .................................................................................................................. 1
5 101836201 Spring – Green .................................................................................................. 1
6 1014454 Kit, Driven Clutch Button (includes 3 screws and 3 buttons) ............................ 1
7 1014072 Assembly, Moveable Face with Bushing ........................................................... 1
8 1014070 Face, Fixed ........................................................................................................ 1
9 1016203 Belt, Drive .............................................................................................................. 1
AM10419 Kit, Driven Clutch Hardware Repair (includes items 10 - 12) ................................ 1
10 101833401 Key, Square Transmission ................................................................................. 1
11 102242101 Screw, Hex-Head Cap, Thread-Locking, 5/16-18 x 3/4 ..................................... 1
12 1017327 Washer, Driven Clutch ...................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 10-5

10
G
E
UNITIZED TRANSAXLE 11
G
E
11
5
3
G 7
4 11
E 8
6 12
REFERENCE FORWARD/
9 13
REVERSE SHIFTER—
GASOLINE SECTION
14
10
15 27

16 17

21 19
20
31 29
1 30

2 22
28
18

23

24
Clu
bCa
r 32
25
REFERENCE AXLE
TUBES

26

ClubC
ar
Club
Car

Page 11-2 2003 DS Golf Cars Illustrated Parts List

 UNITIZED TRANSAXLE – GEAR CASES AND BRACKETS
ITEM PART NO. DESCRIPTION QTY 11
1 2 3 4

1 101922601 Bracket, Transmission Cable Support ................................................................... 1

G
2 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 3
3 1013061 Nut, Nylon Lock, #10-32 ........................................................................................ 1
E
4 183 Washer, Flat, #10 .................................................................................................. 1
5 1010954 Stud, Ball, 1/4-28 x 9/16 ........................................................................................ 1
6 1016341 Lever, Transmission Shifter ................................................................................... 1
7 1017082 Screw, Hex Washer-Head, #10-32 x 3/4 ............................................................... 1
8 8717 Nut, Nylon Lock, 1/4-28 ......................................................................................... 1
9 1017231 Key, Woodruff ........................................................................................................ 1
10 101834801 Arm, Governor Lever ............................................................................................. 1
11 101886101 Screw, Square-Head, 1/4-20 x 1 ........................................................................... 1
12 1014007 Washer, Type B, 1/4 .............................................................................................. 1
13 8233 Nut, Nylon Lock, 1/4-20 ......................................................................................... 1
101833601 Unitized Transaxle (includes items 14 - 88) ........................................................... 1
14 101890201 Shaft, Shifter ..................................................................................................... 1
15 101927301 Ring, Snap ........................................................................................................ 1
16 101892901 Washer, Flat ...................................................................................................... 1
17 101927201 Seal, Oil ............................................................................................................ 1
18 101890101 Lever, Shifter ..................................................................................................... 1
19 1012752 Pin, Roll ............................................................................................................. 1
20 101928601 Pin, Cotter ......................................................................................................... 1
21 1016513 Washer, Flat ...................................................................................................... 1
22 101927101 Seal, Oil ............................................................................................................ 1
23 101893801 Washer .............................................................................................................. 1
24 101891301 Arm, Pivot ......................................................................................................... 1
25 101890601 Gear Case (passenger side) ............................................................................. 1
26 101890501 Gear Case (driver side) ..................................................................................... 1
27 101926901 Bolt, Flanged, M8 x 1.25 x 40 mm .................................................................... 15
28 1012896 Pin, Dowel ......................................................................................................... 2
29 1013759 Plug, Drain (includes item 30) ........................................................................... 2
30 1016432 Gasket .......................................................................................................... 1
31 1012711 Breather ............................................................................................................ 1
32 101928701 Gasket, Liquid, 8.8 oz. (250 grams) .................................................................. A/R

2003 DS Golf Cars Illustrated Parts List Page 11-3

11
G
33
E 36
35 48
47

49
34 46
41
45
44 46
43
42
48
41
40
39 55
38 54
37 39
53
52
43
41
45
51
50

59
58
57

56
38
64
63
REFERENCE
DRIVER SIDE 64
CASE

62
61
60 REFERENCE
PASSENGER SIDE
CASE

Clu
bC
ar

Page 11-4 2003 DS Golf Cars Illustrated Parts List

 UNITIZED TRANSAXLE –
F&R TRANSMISSION AND GEAR REDUCTION
ITEM PART NO. DESCRIPTION QTY 11
1 2 3 4

33 101892001 Rod, Shift .......................................................................................................... 1

G
34 101890001 Fork, Shift .......................................................................................................... 1
35 1012748 Spring ................................................................................................................ 1
E
36 1012747 Ball, Steel .......................................................................................................... 1
37 101889401 Guide ................................................................................................................ 1
38 AM10080 Bearing, Ball ...................................................................................................... 2
39 1016338 Washer, Spring ................................................................................................. 2
40 101892401 Gear, Spur ......................................................................................................... 1
41 101892201 Plate, Thrust ...................................................................................................... 3
42 101980901 Gear Assembly, Input, 28 Tooth (16°) ............................................................... 1
43 101927601 Bearing, Needle ................................................................................................ 3
44 101927501 Bearing, Needle ................................................................................................ 1
45 101981001 Ring, Synchronizer (16°) ................................................................................... 2
46 1012741 Spring, Synchronizer ......................................................................................... 2
47 101928001 Hub, Synchronizer Clutch ................................................................................. 1
48 1012740 Insert, Synchronizer .......................................................................................... 3
49 101927901 Sleeve, Synchronizer ........................................................................................ 1
50 101927701 Pin, Dowel ......................................................................................................... 1
51 101889901 Shaft, Input ........................................................................................................ 1
52 101980801 Gear Assembly, Input, 25 Tooth (16°) ............................................................... 1
53 1016337 Washer, Thrust .................................................................................................. 1
54 AM10081 Bearing, Ball ...................................................................................................... 1
55 1012714 Seal, Oil, Input Shaft ......................................................................................... 1
56 101892601 Gear, 17 Tooth ................................................................................................... 1
57 101893201 Key .................................................................................................................... 1
58 101892501 Gear, 61 Tooth ................................................................................................... 1
59 101928101 Bearing, Ball ...................................................................................................... 1
60 101893901 Washer .............................................................................................................. 1
61 101892301 Governor Assembly ........................................................................................... 1
62 101891601 Sleeve ............................................................................................................... 1
63 101891901 Gear, Cluster Idler ............................................................................................. 1
64 7335 Bearing, Ball ...................................................................................................... 2

2003 DS Golf Cars Illustrated Parts List Page 11-5

11
G
73
E

71 76
69
75
67
REFERENCE
PASSENGER SIDE
72 CASE
70
78
68
65
86

83

87 88

77
88 79
80
87

Clu
bC
82
ar
83
84 72
85 75
81

77
76

REFERENCE
DRIVER SIDE
CASE

74
66

68
69
70
71
67

Page 11-6 2003 DS Golf Cars Illustrated Parts List

 UNITIZED TRANSAXLE – DIFFERENTIAL AND AXLES
ITEM PART NO. DESCRIPTION QTY 11
1 2 3 4

65 101891501 Axle Assembly, Driver-Side (Includes items 67 - 71) ........................................ 1

G
66 101891401 Axle Assembly, Passenger-Side (includes items 67 - 71) ................................. 1
67 1013787 Stud, Lug ...................................................................................................... 4
E
68 1013792 Ring, Retaining ............................................................................................. 1
69 1011291 Bearing, Outer Axle Tube ............................................................................. 1
70 1014207 Collar, 25 mm I. D. ........................................................................................ 1
71 1016672 Ring, Retaining ............................................................................................. 1
72 1013794 Seal, Oil ............................................................................................................ 2
73 101891001 Assembly, Axle Tube, Driver-Side ..................................................................... 1
74 101890901 Assembly, Axle Tube, Passenger-Side .............................................................. 1
75 1013790 Bolt, M10 x 1.5 x 30 mm ................................................................................... 14
76 1013791 Washer, Lock, M10 ........................................................................................... 14
77 7330 Bearing, Inner Axle Tube ................................................................................... 2
78 101928301 Bolt, M8 x 1.25 x 37 mm ................................................................................... 8
79 101892701 Gear, Output ..................................................................................................... 1
80 1014193 Pin, Dowel ......................................................................................................... 1
81 101910501 Kit, Differential Gear Case (includes items 82 - 85) .......................................... 1
82 1013768 Case, Gear Carrier ....................................................................................... 1
83 1013774 Plate, Thrust (idler gear) ............................................................................... 2
84 1013773 Plate, Thrust (differential gear) ..................................................................... 1
85 1013769 Cover, Gear Case ......................................................................................... 1
86 1013772 Pin, Differential .................................................................................................. 1
87 1013770 Gear, Differential Idler ....................................................................................... 2
88 1013771 Gear, Differential ............................................................................................... 2

2003 DS Golf Cars Illustrated Parts List Page 11-7

11
G
E
ELECTRICAL SYSTEM –
ELECTRIC VEHICLE 12
G
E
12
G
E
AS SEEN
FROM FRONT TYPICAL ON
DRIVER SIDE 2 PLACES OFF
OF VEHICLE,
BODY 4
REMOVED

9
8
7
3
5 6

2
1

OFF ON

11
12
TYPICAL
2 PLACES
10

POWERDRIVE SYSTEM 48
AND IQ SYSTEM VEHICLES
V-GLIDE 36-VOLT
VEHICLE

Page 12-2 2003 DS Golf Cars Illustrated Parts List

 ELECTRICAL COMPONENTS, FRONT BODY –
ELECTRIC VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 1016859 Kit, Reverse Buzzer (includes items 2 and 3) ....................................................... 1

G
2 1016849 Screw, Pan-Head Hi-Lo, #4-24 x 5/16 ............................................................... 2
3 1016851 Buzzer, Reverse ................................................................................................ 1
E
4 101830601 Assembly, Screw and Washer ............................................................................... 2
5 101826201 Switch, Key ........................................................................................................... 1
6 101851101 Washer, Key Switch .............................................................................................. 1
7 101830701 Nut, Key Switch ..................................................................................................... 1
8 101834502 Cap, Key Switch .................................................................................................... 1
9 1012505 Key (pair) ............................................................................................................... 1
9 AM10079 Key (bag of 50) * ................................................................................................... 1
10 101802601 Plug, Hole (V-Glide 36-Volt vehicle only) ............................................................... 1
11 101935501 Light, Battery Warning (amber) (PowerDrive System 48 and IQ System) ............. 1
12 8990 Tie, Wire ................................................................................................................ 2

* Must order in multiples of 50.

2003 DS Golf Cars Illustrated Parts List Page 12-3

12
G
22 UE
BL
E 20
RE
D 2
1

16
ITE
WH E KEY
G
AN SWITCH
OR
BR
OW
REVERSE N
PU
BUZZER FORWARD / GR RP
EE LE
N
REVERSE LIMIT RED
SWITCH SWITCH
15 1
UE
BL

RE
D 24 D K
YE RE LAC
LL B SNUBBER
WH OW
ITE
WH
21 ITE

WH
IT E 12
DIODE
N
EE
GR SOLENOID 23
FUSE AND EE
N 17
GR 10
RECEPTACLE N GE
RA
O 13
BL
25 BL
AC
K
RE K UE ITE
D AC GR WH
BL EE D
N RE N
BULLET EE
- CK CONNECTOR GR
BL
A 5
+

SPEED
WHITE 6
SWITCH
18
WHITE

7
14 2
9
BLACK

D
RE RE
GREEN

BLUE
YELLOW

D
19
+ - 11 8
ORANGE

GR
- AY
1 +
WHITE

G
RE
EN
+
2
W

BATTERY
H
IT

BANK
E

+ -

+ -
- 3
- 4 RESISTOR 4
6 + 26 BOARD
G
R
BL

LE
AY

TYPICAL A2 RP
AC

BL PU
K

AC 5 PLACES
5 K N
S2 OW
BR
A1
S1 1
MOTOR

Page 12-4 2003 DS Golf Cars Illustrated Parts List

 WIRING – V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 1016070 Wire Assembly, #6 Brown ..................................................................................... 1

G
2 1016069 Wire Assembly, #6 Purple ..................................................................................... 1
3 1012651 Wire Assembly, #6 Black ....................................................................................... 1
E
4 1016068 Wire Assembly, #6 Gray ........................................................................................ 1
5 1014036 Wire Assembly, #6 Black, 6th Speed ..................................................................... 1
6 1014035 Wire Assembly, #6 Blue, 5th Speed ...................................................................... 1
7 1014034 Wire Assembly, #6 Green, 4th Speed ................................................................... 1
8 1014033 Wire Assembly, #6 Yellow, 3rd Speed ................................................................... 1
9 1014032 Wire Assembly, #6 Orange, 2nd Speed ................................................................ 1
10 1014029 Wire Assembly, #6 White ...................................................................................... 1
11 1014030 Wire Assembly, #6 White, 1st Speed .................................................................... 1
12 1014828 Wire Assembly, #6 Green ..................................................................................... 1
13 N/A Wire Assembly, #18 Black ..................................................................................... 1
14 1013092 Wire Assembly, #10 Red ....................................................................................... 1
15 N/A Wire Assembly, #18 Orange .................................................................................. 1
16 N/A Wire Assembly, #18 White .................................................................................... 1
17 N/A Wire Assembly, #18 Green ................................................................................... 1
18 102018001 Wire Assembly, #10 Red ....................................................................................... 1
19 1011010 Wire Assembly, #10 White .................................................................................... 1
20 N/A Wire Assembly, #18 Red ....................................................................................... 1
21 1014039 Wire Assembly, #6 White ...................................................................................... 1
22 N/A Wire Assembly, #18 Blue ...................................................................................... 1
23 1011069 Wire Assembly, #6 Red ......................................................................................... 1
24 N/A Wire Assembly, #18 Yellow .................................................................................... 1
25 N/A Wire Assembly, #18 Black ..................................................................................... 1
26 1010958 Wire Assembly, #6 Black ....................................................................................... 5

2003 DS Golf Cars Illustrated Parts List Page 12-5

12
G 3
9
E TYPICAL 2
PLACES
2

10 TYPICAL 2
4 PLACES

TYPICAL 3
PLACES
1
11

15
TYPICAL 3
13 14
PLACES
TYPICAL 2
PLACES
SEAT SUPPORT
FRONT PANEL
12 TYPICAL 3
PLACES

8
TYPICAL 3 7
PLACES
6

Page 12-6 2003 DS Golf Cars Illustrated Parts List

 FORWARD/REVERSE SWITCH –
V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 1011997 Assembly, Forward/Reverse Switch (includes items 2 - 5) .................................... 1

G
2 1014808 Switch, Limit ...................................................................................................... 1
3 8057 Nut, Hex, #4-40 ................................................................................................. 2
E
4 8058 Washer, Lock, #4 .............................................................................................. 2
5 1016896 Screw, Hex-Head Machine, #4-40 x 1-1/8 ........................................................ 2
6 1028 Nut, Hex, 1/4-20 .................................................................................................... 3
7 451 Washer, Lock, 1/4 ................................................................................................. 3
8 304 Screw, Hex-Head Cap, 1/4-20 x 1 ......................................................................... 3
9 1012987 Handle, Forward/Reverse Switch .......................................................................... 1
10 1013198 Screw, Phillips-Head Machine, #8-32 x 5/8 ........................................................... 1
11 1016845 Screw, Phillips Truss-Head, 1/4-20 x 2-1/8 ............................................................ 3
12 8233 Nut, Nylon Lock, 1/4-20 ......................................................................................... 3
13 8049 Washer, Internal Tooth Lock, #10 .......................................................................... 2
14 8450 Screw, Hex-Head Machine, #10-24 x 1/2 .............................................................. 2
15 1014528 Washer, Plastic, 1/4 .............................................................................................. 3

2003 DS Golf Cars Illustrated Parts List Page 12-7

12
TYPICAL
G TYPICAL
8 PLACES

26 5 PLACES 32
E 25
22 21 1
32 33

REF.
TYPICAL 17 23 SEE PAGE 4-6
2 PLACES 5
3 7
20
19 NO
TI
9
C

E
18

17 6

16 8
15
14
27
4
13
33

4
12 2
TYPICAL
2 PLACES
9
4 28
24
10

31
Club 29
Car TYPICAL
2 PLACES
30

MOUNTING
DETAIL

11

Page 12-8 2003 DS Golf Cars Illustrated Parts List

 WIPER SWITCH – V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1014735 Assembly, V-Glide Wiper Switch and Resistor Group

G
(includes Wiper Switch Assembly listed below,
Resistor and Board Assembly – items 1 - 11 on page 12-11, and E
connecting wires – items 5 - 11 on page 12-5) ...................................................... 1
1016140 Assembly, V-Glide Wiper Switch (includes items 1 - 27) ................................... 1
1 1014999 Assembly, Wiper Switch Case, 6-Speed (includes items 2 and 3) ............... 1
2 1014414 Bumper, Wiper Switch .............................................................................. 1
3 101610901 Decal, Wiper Switch Warning ................................................................... 1
4 1014253 Nut, Brass Hex Jam, 1/4-20 ......................................................................... 3
5 7473 Nut, Nylon Lock, 5/16-18 .............................................................................. 1
6 1012353 Stud, Short Ball, 1/4-28 ................................................................................ 1
7 1014003 Crank, Bell .................................................................................................... 1
8 8449 Nut, Dimpled Lock, 1/4-28 ............................................................................ 1
9 1012903 Bearing, Bronze, 3/8 x 1/2 ............................................................................ 2
10 1014189 Screw, Bronze Hex-Head Cap, 1/4-20 x 2 .................................................... 1
11 1013886 Cover, Wiper Switch Case ............................................................................ 1
12 1013061 Nut, Nylon Lock, #10-32 ............................................................................... 1
13 1014017 Carrier, Wiper Switch Arm ............................................................................ 1
14 1013998 Spring, Wiper Switch Brush .......................................................................... 1
15 1014000 Stud, Wiper Switch Adjusting ....................................................................... 1
16 1014019 Screw, Self-Tapping, #4-40 x 3/8 .................................................................. 1
17 8058 Washer, Lock, #4 .......................................................................................... 3
18 1013887 Arm, Speed Switch ....................................................................................... 1
19 1013860 Assembly, Switch Brush ............................................................................... 1
20 8056 Screw, Round-Head Machine, #4-40 x 3/4 ................................................... 2
21 1014807 Switch, Limit ................................................................................................. 1
22 1014010 Grommet, Split ............................................................................................. 1
23 8057 Nut, Hex, #4-40 ............................................................................................ 2
24 451 Washer, Lock, 1/4 ......................................................................................... 1
25 N/A Wire Assembly, #18 Black ............................................................................ 1
26 N/A Wire Assembly, #18 Green ........................................................................... 1
27 1017692 Cap, Protector .............................................................................................. 1
28 1014109 Bolt, Carriage, #10-24 x 1 ..................................................................................... 2
29 1016175 Washer, Lock, #10 ................................................................................................ 2
30 1017 Nut, Hex, #10-24 ................................................................................................... 2
31 101949201 Shim, Wiper Switch ............................................................................................... 1
32 1028 Nut, Hex, 1/4-20 .................................................................................................... 13
33 451 Washer, Lock, 1/4 ................................................................................................. 9

2003 DS Golf Cars Illustrated Parts List Page 12-9

12
G R 12
TYPICAL
2 PLACES
OF CA
FRONT
E
13
7
8
9
10
11

TYPICAL
2 6 PLACES
TYPICAL
6 PLACES
4

5
6

2
TYPICAL
6 PLACES
1

TYPICAL 12
2 PLACES

Page 12-10 2003 DS Golf Cars Illustrated Parts List

 RESISTOR AND BOARD ASSEMBLY –
V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 1028 Nut, Hex, 1/4-20 .................................................................................................... 12

G
2 451 Washer, Lock, 1/4 ................................................................................................. 12
3 1011931 Washer, Flat, 1/4 ................................................................................................... 6
E
4 1014045 Stand-Off, Resistor Coil ........................................................................................ 6
5 1014728 Board, Resistor Mounting ..................................................................................... 1
6 332 Washer, Flat, 1/4 ................................................................................................... 6
7 1014476 Coil, Resistor, 5th Speed, .182 Inch Wire Diameter, 3-Coil ................................... 1
8 1014012 Coil, Resistor, 4th Speed, .162 Inch Wire Diameter, 3-Coil ................................... 1
9 1014013 Coil, Resistor, 3rd Speed, .144 Inch Wire Diameter, 3-Coil .................................. 1
10 1014014 Coil, Resistor, 2nd Speed, .128 Inch Wire Diameter, 4-Coil .................................. 1
11 1014729 Coil, Resistor, 1st Speed, .128 Inch Wire Diameter, 6-Coil ................................... 1
12 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 4
13 1013971 Shield, Resistor ..................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 12-11

12
VEHICLE
G 26
BODY
TYPICAL
TYPICAL
2 PLACES

TYPICAL
2 PLACES 31 TYPICAL
E 4 PLACES
26
2 PLACES

28 27

16

18 23

19
17
20 30 TYPICAL
2 PLACES

22 29

25
TYPICAL 21
2 PLACES
24 14 TYPICAL
TYPICAL 1 22 2 PLACES
6 PLACES
TYPICAL 15
3 PLACES
2 TYPICAL
3 12 PLACES
6 TYPICAL TYPICAL 11
5 PLACES 2 PLACES 13
8
4
32
TYPICAL 35 33
6 PLACES
34

12
TYPICAL
2 PLACES

7
5
TYPICAL
6 PLACES

10

Page 12-12 2003 DS Golf Cars Illustrated Parts List

 BATTERIES, CHARGER RECEPTACLE, SOLENOID –
V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 1015072 Nut, Nylon Lock, Stainless Steel, 5/6-18 ............................................................... 6

G
2 1011578 Washer, Flat, Type B Wide, 5/16 ........................................................................... 6
3 101090801 Hold-Down, Battery ............................................................................................... 3
E
4 1013683 J-Bolt ..................................................................................................................... 6
5 101661601 Battery, 6-Volt ........................................................................................................ 6
5 101661602 Battery, 6-Volt, Dry ................................................................................................ 6
6 1010958 Wire Assembly, #6 Black ....................................................................................... 5
7 101831401 Cap, 6-Volt Battery ................................................................................................ 6
8 1014304 Nut, Hex, Stainless Steel, 5/6-18 .......................................................................... 12
9 1012022 Clamp, Cable ........................................................................................................ 2
10 1606 Rivet, Pop, 3/16 ..................................................................................................... 2
11 101975901 Solenoid, 36-Volt ................................................................................................... 1
12 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 2
13 7893 Nut, Hex, #10-32 ................................................................................................... 2
14 1010521 Nut, Hex, 5/16-24 .................................................................................................. 2
15 7174 Washer, Lock, 5/16 ............................................................................................... 2
16 101342501 Kit, Fuse and Receptacle (includes items 17 - 31) ............................................... 1
17 1014516 Kit, Fuse (includes items 18 - 22) ..................................................................... 1
18 N/A Lens, Fuse .................................................................................................... 1
19 N/A Fuse, 80-Amp ............................................................................................... 1
20 N/A Holder, Fuse ................................................................................................. 1
21 1016 Washer, Lock, #10 ........................................................................................ 2
22 8797 Nut, Brass, #10-32 ....................................................................................... 4
23 4107 Receptacle, Charger, 2-Prong .......................................................................... 1
24 1013092 Wire Assembly, #10 Red ................................................................................... 1
25 1013628 Bracket, Fuse and Receptacle Mounting .......................................................... 1
26 8796 Screw, Phillips Pan-Head Self-Tapping, #7-19 x 3/4 ......................................... 6
27 8795 Screw, Phillips Pan-Head Self-Tapping, #7-19 x 1-3/4 ...................................... 2
28 1013649 Bezel, Charger Receptacle ............................................................................... 1
29 8797 Nut, Brass, #10-32 ............................................................................................ 2
30 1016 Washer, Lock, #10 ............................................................................................ 2
31 1013266 Screw, Phillips Pan-Head Self-Tapping, #8-18 x 1/2 ......................................... 2
32 1014948 Diode ..................................................................................................................... 1
33 102047201 Snubber ................................................................................................................. 1
34 102048301 Base, Mounting ..................................................................................................... 1
35 8639 Tie, Wire ................................................................................................................ 1

2003 DS Golf Cars Illustrated Parts List Page 12-13

12
G 5 TYPICAL 2
PLACES

11 ANTI-ARCING
E SEAT SUPPORT
LIMIT SWITCH

FRONT PANEL REVERSE BUZZER

LIMIT SWITCH

CO
2
12 NO
M

HALF-SPEED
NC

CO
M
LIMIT SWITCH
4 NO
NC

3
TYPICAL 3
PLACES

13 6
7
TYPICAL 2
10 PLACES
9 TYPICAL 2
PLACES
15
TYPICAL
17 4 PLACES 16
TYPICAL 3
PLACES

1
8
TYPICAL
2 PLACES TYPICAL 3
PLACES
14

COM
NO
COM
NC
NO
NC

Page 12-14 2003 DS Golf Cars Illustrated Parts List

 FORWARD/REVERSE SWITCH –
POWERDRIVE SYSTEM 48 VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 101753005 Assembly, Forward/Reverse Switch (includes items 2 - 10) .................................. 1

G
2 102250201 Switch, Limit, Sealed ......................................................................................... 1
3 101979101 Switch, Limit, Sealed ......................................................................................... 1
E
4 1014808 Switch, Limit ...................................................................................................... 1
5 8057 Nut, Hex, #4-40 ................................................................................................. 2
6 8058 Washer, Lock, #4 .............................................................................................. 2
7 1014871 Screw, Hex Washer-Head, #4-40 x 2 ................................................................ 2
8 1017799 Bar, Bus ............................................................................................................. 2
9 451 Washer, Lock, 1/4 ............................................................................................. 4
10 1028 Nut, Hex, 1/4-20 ................................................................................................ 4
11 1012987 Handle, Forward/Reverse Switch .......................................................................... 1
12 1013198 Screw, Phillips-Head Machine, #8-32 x 5/8 ........................................................... 1
13 1016845 Screw, Phillips Truss-Head, 1/4-20 x 2-1/8 ............................................................ 3
14 8233 Nut, Nylon Lock, 1/4-20 ......................................................................................... 3
15 8049 Washer, Internal Tooth Lock, #10 .......................................................................... 2
16 8450 Screw, Hex-Head Machine, #10-24 x 1/2 .............................................................. 2
17 1014528 Washer, Plastic, 1/4 .............................................................................................. 3

2003 DS Golf Cars Illustrated Parts List Page 12-15

12
11
G TYPICAL
4 PLACES

E
10

6
TYPICAL
5 7 2 PLACES

TYPICAL 8
6 PLACES
TYPICAL
3 PLACES
17 TYPICAL
18 3 PLACES
19
16 TYPICAL 2
12 PLACES
3
15 9
14 1 4
TYPICAL
5 PLACES

TYPICAL
6 PLACES

13

COM
NO
COM
NC
NO
NC

12
TYPICAL
6 PLACES

Page 12-16 2003 DS Golf Cars Illustrated Parts List

 BATTERIES, CHARGER RECEPTACLE –
POWERDRIVE SYSTEM 48 VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 101802101 Kit, Fuse and Receptacle (includes items 2 - 9) ................................................... 1

G
2 101796501 Bezel, Receptacle ............................................................................................. 1
3 N/A Wire Assembly, Sense Lead, Gray .................................................................... 1
E
4 N/A Wire Assembly, #10 Red ................................................................................... 1
5 N/A Wire Assembly, #10 Black ................................................................................. 1
6 101796801 Assembly, Fuse, 48-Volt (includes item 7) ........................................................ 1
7 1013061 Nut, Nylon Lock, #10 .................................................................................... 2
8 1017705 Screw, Phillips Pan-Head, #8 Type AB .............................................................. 3
9 101894901 Fuse, 3/8-Amp .................................................................................................. 1
10 101801001 Plate, Receptacle Backing .................................................................................... 1
11 101832001 Screw, Phillips Pan-Head, #7-18 x 3/4 .................................................................. 4
12 101797701 Battery, 8-Volt PowerDrive (includes item 13) ....................................................... 6
12 101797702 Battery, 8-Volt PowerDrive, Dry (includes item 13) ............................................... 6
13 101797801 Cap, Battery, 4-Port Gang ................................................................................. 1
14 101795701 Wire Assembly, #6 Black ....................................................................................... 5
15 1014304 Nut, Hex, Stainless Steel, 5/16-18 ........................................................................ 12
16 101090801 Hold-Down, Battery ............................................................................................... 3
17 1015072 Nut, Nylon Lock, Stainless Steel, 5/16-18 ............................................................. 6
18 1011578 Washer, Flat, Type B Wide, 5/16 ........................................................................... 6
19 1013683 J-Bolt ..................................................................................................................... 6

2003 DS Golf Cars Illustrated Parts List Page 12-17

12
G TYPICAL
2 PLACES
7 9

8
E
2 SOLENOID
TYPICAL
2 PLACES 3

12 TYPICAL
4 PLACES

5
TYPICAL
TYPICAL 21
2 PLACES
2 PLACES 12 TYPICAL
4
1 2 PLACES
22
13
CONTROLLER 14

20
ONBOARD 16
COMPUTER
10 14
11
11 15
17
14
12
14 10
TYPICAL 14
2 PLACES
11

18
14
19
15

COM
NO
COM
NC
NO
NC

Page 12-18 2003 DS Golf Cars Illustrated Parts List

 COMPUTER, CONTROLLER, AND SOLENOID –
POWERDRIVE SYSTEM 48 VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 101965201 Plate, Component Mounting .................................................................................. 1

G
2 1014288 Screw, Thread-Forming, 5/16-18 x 3/4 .................................................................. 2
3 101908701 Solenoid, 48-Volt (with diode) (includes items 4 - 8) ............................................. 1
E
4 1011558 Nut, Hex, #6-32 ................................................................................................. 2
5 N/A Washer, Flat ...................................................................................................... 2
6 N/A Washer, Lock .................................................................................................... 2
7 1012528 Nut, Hex, M8 ..................................................................................................... 2
8 7174 Washer, Lock, 5/16 ........................................................................................... 2
9 1014947 Assembly, Resistor ................................................................................................ 1
10 1242 Nut, Hex, 5/16-18 .................................................................................................. 3
11 7174 Washer, Lock, 5/16 ............................................................................................... 3
12 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 8
13 101840201 Controller, 48-Volt (225-amp) ................................................................................ 1
14 1241 Washer, Flat, 5/16 ................................................................................................. 6
15 7173 Screw, Hex-Head Cap, 5/16-18 x 3/4 .................................................................... 2
16 1218 Screw, Hex-Head Cap, 5/16-18 x 1-1/4 ................................................................. 1
17 101909901 Computer, Onboard (includes item 18) ................................................................. 1
18 101942301 Kit, 3-Pin Receptacle ........................................................................................ 1
19 101920101 Kit, 3-Pin Plug Assembly ....................................................................................... 1
20 101827801 Kit, Wire and Terminal, #6 Black ........................................................................... 1
21 1014948 Assembly, Diode (Service Part replacement for existing diode that
comes standard with solenoid) ............................................................................. 1
22 101910401 Screw, Thread-Forming, 5/16-18 x 1-1/4 ............................................................... 2

2003 DS Golf Cars Illustrated Parts List Page 12-19

12
G 1

2
4

5
OFF ON

Page 12-20 2003 DS Golf Cars Illustrated Parts List

 MOTOR CONTROLLER OUTPUT REGULATOR (MCOR)
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 102101101 Regulator, Motor Controller Output (MCOR) ......................................................... 1

G
2 102101001 Bar, Drive .............................................................................................................. 1
3 1015752 Screw, Hex Washer-Head Hi-Lo, #12-16 x 5/8 ...................................................... 2
E
4 101936801 Kit, 2-Pin Plug Assembly ....................................................................................... 1
5 101920101 Kit, 3-Pin Plug Assembly ....................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 12-21

12
N 2
EE 1
G GR

R
D
RE E
AN
G
ITE
KEY
SWITCH
O H
G E/W
AN
E BR
OW
N
OR
REVERSE
29
BUZZER 9
FORWARD /
BATTERY REVERSE
WARNING SWITCH
1

E
U
LIGHT

BL
BL 10
UE
OR
AN
GE
MOTOR BL
UE
CONTROLLER
2
BL WH
OUTPUT UE ITE
REGULATOR 8 LIMIT
SWITCHES
K 1
AC
BL E 2
ITE
/
HIT
E HIT
7 WH N /W E D/W GE 3
5 GR
EE R AN
EE
N
OR
GR
6 ITE
WH
GR
EE
N/
12
W
BR
3 HI
TE 11
OW K UE
OR
AN N
YE
4 BL
AC BL
14 GE LL
O
22

ORANGE
RE BL W
D PU
GR RP AC
EE LE K LE 21

BLUE
RP

WHITE
N
15 PU

WHITE/ BLACK
FUSE AND

GRE
RECEPTACLE 16

RED

RED
EN
24

RE
17

PURPLE
RED/WHITE
20
BLK

- K OW
AC AY LL
+
BL GR YE
RE
FUSE D SOLENOID
RE
D +
RE
D 23

RED
-
GRAY

26
BLACK

+ 18
GREEN
BROWN
RED
YELLOW

-
19
YELLOW

2
D YELLOW
BLUE

RE
TYPICAL
BATTERY 5 PLACES 1 3
+ 2
BANK 1
-
M- B- CONTROLLER
+ + 3
-
-
+
5 -
4 B+ LE
RP HIT
E
THREE PIN PU D/W
CONNECTOR R E OW
L L
YE
BLACK

ITE
WH
BLACK

6 BL
UE
GREEN
GE
AN
OR
A2

BL S2
AC
K 13 A1
S1 27
ONBOARD 25
COMPUTER
28 MOTOR

Page 12-22 2003 DS Golf Cars Illustrated Parts List

 WIRING – POWERDRIVE SYSTEM 48 VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

102162101 Wire Harness (includes items 1 - 18) .................................................................... 1

G
1 N/A Wire Assembly, #18 Brown ............................................................................... 1
2 N/A Wire Assembly, #18 Blue .................................................................................. 1
E
3 N/A Wire Assembly, #18 Purple ............................................................................... 1
4 N/A Wire Assembly, #18 Yellow ................................................................................ 1
5 N/A Wire Assembly, #18 Green/White ..................................................................... 1
6 101883002 Wire Assembly, #18 Black (includes resistor and #18 white wire) .................... 1
7 N/A Wire Assembly, #18 Green ............................................................................... 1
8 N/A Wire Assembly, #18 White/Black and #18 Red ................................................. 1
9 101901401 Wire Assembly, #6 Blue .................................................................................... 1
10 101901201 Wire Assembly, #6 Orange ............................................................................... 1
11 101901501 Wire Assembly, #6 White .................................................................................. 1
12 N/A Wire Assembly, #18 Red/White ......................................................................... 1
13 101901301 Wire Assembly, #6 Blue .................................................................................... 1
14 N/A Wire Assembly, #18 Green ............................................................................... 1
15 N/A Wire Assembly, #18 Red ................................................................................... 1
16 N/A Wire Assembly, #18 Orange ............................................................................. 1
17 N/A Wire Assembly, #18 Red ................................................................................... 1
18 N/A Wire Assembly, #18 Yellow ................................................................................ 1
19 101795701 Wire Assembly, #6 Black ....................................................................................... 5
20 N/A Wire Assembly, #10 Black (part of onboard computer assembly) ......................... 1
21 1014947 Assembly, Resistor ................................................................................................ 1
22 101902801 Wire Assembly, #6 Red ......................................................................................... 1
23 101903001 Wire Assembly, #6 Yellow ...................................................................................... 1
24 N/A Wire Assembly, #18 Gray (part of onboard computer assembly) .......................... 1
25 N/A Wire Assembly, #10 Black (part of onboard computer assembly) ......................... 1
26 N/A Wire Assembly, #10 Red (part of fuse and receptacle assembly) ......................... 1
27 101902901 Wire Assembly, #6 Green ..................................................................................... 1
28 N/A Wire Assembly, #6 Black (part of onboard computer assembly) ........................... 1
29 N/A Wire Assembly, #18 Orange/White (part of battery warning light) ........................ 1

2003 DS Golf Cars Illustrated Parts List Page 12-23

12 TOW/RUN
2 FORWARD / SWITCH

G GR
EE
N 2
KEY
SWITCH
REVERSE
SWITCH
R
D
RE

E HI
TE 1 F

BL AC
/W 3 TWO-PIN

AC K
BL
E
NG 2

BLUE
CONNECTOR

K
RA 1 THREE-PIN
O
ORANGE/WHITE

CONNECTOR
REVERSE N
EE
BUZZER OR BLU GR LUE
BR A E G HT HT B
I
BATTERY OW NGE L LIG LIG
N PI HT
NK
WARNING FOUR-PIN BL
BROWN

UE
LIGHT MOTOR CONNECTOR
CONTROLLER
OUTPUT W
REGULATOR W LLO
OW W LO E RE
E LL ELLO/YEL CK/Y D
Y
N/ E/Y RED BL A
RED

EE LU +
GR B D
GREEN

- RE
BLUE

E
B LU +
HT E N
LIG NG OW -
U ORA BR
E
BLUE

BL 2
SONIC
WELD 8
1
3 RE
D BATTERY +

RED
PINK
BANK -
+ +
N -
EE - SONIC
T GR 3
GH WELD
LI +
5 - 4 D
E RE
A NG
BLACK/YELLOW

OR
RED/YELLOW

K
4 AC
GREEN/YELLOW

BL 10
BLUE/YELLOW
PURPLE/WHITE

SONIC
BROWN/WHITE
ORANGE/WHITE

WELD 6
YELLOW

TAN
GREEN

BROWN
WHITE

BLUE
WHITE
GRAY

PINK
FUSE AND
BLK

RED
RECEPTACLE 15
-

LIGHT BLUE
+ BL
GR AC 5 TERMINAL B–
RE AY K K
D AC
BL S1
FUSE K M–
AC S2
BR BL
OW
N/
6
W B+ OW
W HI K LL
HI TE AC YE
TE C K BL
B LA
SIX-PIN E
HIT
BLACK

CONNECTOR /W
UE
BL SOLENOID
D E
RE BLU HT
. 1 14
LT RN/W
G YEL

ONBOARD AY L
GR BL IGH RE
COMPUTER AC T G D
11 K/ R
W EE
HI N
TE

12 GR
EE
N G R
7 BL RE ED
(PIN 9) GRAY WIRE 9 1 (PIN 1) WHITE WIRE AC EN
K
(PIN 10) TAN WIRE 10 2 (PIN 2) YELLOW WIRE W
OR BL
UE
HI
TE
13
11 3 (PIN 3) PURPLE/WHITE WIRE AN A2
GE
(PIN 12) BLUE/WHITE WIRE 12 4 (PIN 4) GREEN/WHITE WIRE
(PIN 13) BLACK/WHITE WIRE 13 5 (PIN 5) LIGHT BLUE WIRE F2
9 A1
(PIN 14) LIGHT GREEN WIRE 14 6 (PIN 6) GREEN WIRE
(PIN 7) ORANGE/WHITE WIRE F1
(PIN 15) RED WIRE 15 7
(PIN 16) BLUE WIRE 16 8 (PIN 8) BROWN WIRE

MOTOR

Page 12-24 2003 DS Golf Cars Illustrated Parts List

 WIRING – IQ SYSTEM VEHICLE WITH
MOTOR CONTROLLER OUTPUT REGULATOR (MCOR)
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 102196601 Wire Harness ....................................................................................................... 1

G
2 N/A Wire Assembly, #18 Orange/White (part of battery warning light) ........................ 1
3 N/A Wire Assembly, #10 Red (part of fuse and receptacle assembly) ......................... 1
E
4 N/A Wire Assembly, #6 Black ....................................................................................... 1
5 N/A Wire Assembly, #10 Black (part of onboard computer assembly) ......................... 1
6 N/A Wire Assembly, #18 Gray (part of onboard computer assembly) .......................... 1
7 N/A Wire Assembly, #10 Black (part of onboard computer assembly) ......................... 1
8 101795701 Wire Assembly, #6 Black ....................................................................................... 5
9 101978101 Wire Assembly, #10 Orange .................................................................................. 1
10 102199601 Wire Assembly, #6 Red ......................................................................................... 1
11 101978201 Wire Assembly, #10 Blue ...................................................................................... 1
12 101968701 Wire Assembly, #6 White ...................................................................................... 2
13 101978001 Wire Assembly, #6 Green ..................................................................................... 1
14 101920001 Wire Assembly, #6 Yellow ...................................................................................... 1
15 102263601 Wire, Assembly, #10 Black .................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 12-25

12
G
E 1

6
2 8
9
7
F
4

10
3 REFERENCE
19 DECALS– 21
TYPICAL SECTION 3 20
14 3 PLACES

16
17
18 RUN
13 15 TOW
WARNING
12
5
11
22
24
23

F 25

25

Page 12-26 2003 DS Golf Cars Illustrated Parts List

 FORWARD/REVERSE SWITCH, TOW/RUN SWITCH –
IQ SYSTEM VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 101856001 Switch, Forward/Reverse ...................................................................................... 1

G
2 101855002 Case, Forward/Reverse Switch ............................................................................. 1
3 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 3
E
4 101942301 Kit, 3-Pin Receptacle and Wedge Lock ................................................................. 1
5 101932401 Kit, 4-Pin Receptacle and Wedge Lock ................................................................. 1
6 102266601 Wire Assembly, Forward/Reverse Switch (includes items 7 - 10) ......................... 1
7 101920101 Kit, 3-Pin Plug and Wedge Lock ........................................................................ 1
8 N/A Wire Assembly, #18 Blue .................................................................................. 1
9 N/A Wire Assembly, #18 Orange ............................................................................. 1
10 N/A Wire Assembly, #18 Brown ............................................................................... 1
11 102266701 Wire Assembly, IQDM Port (includes items 12 - 18) ............................................. 1
12 101932501 Kit, 4-Pin Plug and Wedge Lock ........................................................................ 1
13 N/A Wire Assembly, #18 Red/Yellow ........................................................................ 1
14 N/A Wire Assembly, #18 Black/Yellow ...................................................................... 1
15 N/A Wire Assembly, #18 Blue/Yellow ....................................................................... 1
16 N/A Wire Assembly, #18 Green/Yellow .................................................................... 1
17 N/A Cap, Dust .......................................................................................................... 1
18 N/A Connector, 4-Pin ............................................................................................... 1
19 8248 Screw, Phillips Truss-Head, 1/4-20 x 3/4 ............................................................... 2
20 101922501 Bracket, Tow/Run Switch (without decal) .............................................................. 1
21 101908401 Boot, Tow/Run Switch (with nut) ............................................................................ 1
22 332 Washer, Flat, 1/4 ................................................................................................... 2
23 8233 Nut, Nylon Lock, 1/4-20 ......................................................................................... 2
24 101908101 Switch, Tow/Run .................................................................................................... 1
25 8990 Tie, Wire ................................................................................................................ A/R

2003 DS Golf Cars Illustrated Parts List Page 12-27

12
G 11
TYPICAL
4 PLACES

10
TYPICAL
2 PLACES
6
5 7
TYPICAL
3 PLACES

TYPICAL 8
3 PLACES

16 TYPICAL
12 PLACES TYPICAL
5 PLACES
17 15 2
14
3
TYPICAL
6 PLACES
18 4 9
1
19
TYPICAL
6 PLACES

13

F
12
TYPICAL
6 PLACES

Page 12-28 2003 DS Golf Cars Illustrated Parts List

 BATTERIES, CHARGER RECEPTACLE –
IQ SYSTEM VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 101802101 Kit, Fuse and Receptacle (includes items 2 - 9) ................................................... 1

G
2 101796501 Bezel, Receptacle ............................................................................................. 1
3 N/A Wire Assembly, Sense Lead, Gray .................................................................... 1
E
4 N/A Wire Assembly, #10 Red ................................................................................... 1
5 N/A Wire Assembly, #10 Black ................................................................................. 1
6 101796801 Assembly, Fuse, 48-Volt (includes item 7) ........................................................ 1
7 1013061 Nut, Nylon Lock, #10 .................................................................................... 2
8 1017705 Screw, Phillips Pan-Head, #8 Type AB .............................................................. 3
9 101894901 Fuse, 3/8-Amp .................................................................................................. 1
10 101801001 Plate, Receptacle Backing .................................................................................... 1
11 101832001 Screw, Phillips Pan-Head, #7-18 x 3/4 .................................................................. 4
12 101797701 Battery, 8-Volt PowerDrive (includes item 13) ....................................................... 6
12 101797702 Battery, 8-Volt PowerDrive, Dry (includes item 13) ............................................... 6
13 101797801 Cap, Battery, 4-Port Gang ................................................................................. 1
14 101795701 Wire Assembly, #6 Black ....................................................................................... 5
15 1014304 Nut, Hex, Stainless Steel, 5/16-18 ........................................................................ 12
16 101090801 Hold-Down, Battery ............................................................................................... 3
17 1015072 Nut, Nylon Lock, Stainless Steel, 5/16-18 ............................................................. 6
18 1011578 Washer, Flat, Type B Wide, 5/16 ........................................................................... 6
19 1013683 J-Bolt ..................................................................................................................... 6

2003 DS Golf Cars Illustrated Parts List Page 12-29

12
G
E
8 25
24
9
TYPICAL
2 PLACES
4
TYPICAL
3 PLACES

TYPICAL
2 PLACES 16
10 15
17 1

14

11 18 19
3 3
TYPICAL
2 PLACES TYPICAL
3 PLACES

12
6
5
13 7
3 TYPICAL
F 2 PLACES

21
TYPICAL 23
2 PLACES
22

20

TYPICAL 3
2 PLACES

Page 12-30 2003 DS Golf Cars Illustrated Parts List

 COMPUTER, CONTROLLER, AND SOLENOID –
IQ SYSTEM VEHICLE
ITEM PART NO. DESCRIPTION QTY 12
1 2 3 4

1 101956501 Controller, 48-Volt (250-amp) ................................................................................ 1

G
1 101956502 Controller, 48-Volt (250-amp) (customized programming) ..................................... 1
2 102240501 Screw, Hex Washer-Head, M8 x 1-1/4 x 12 mm ................................................... 3
E
3 1012285 Screw, Hex, Type TT, 1/4-20 x 5/8 ......................................................................... 9
4 102266501 Kit, Connector, IQ Controller ................................................................................. 1
5 102240601 Cover, Controller (includes items 6 and 7) ............................................................ 1
6 102240801 Gasket, Controller ............................................................................................. 1
7 101931501 Decal, Electrical Component Cover .................................................................. 1
8 101965202 Plate, Component Mounting .................................................................................. 1
9 1014288 Screw, Thread-Forming, 5/16-18 x 3/4 .................................................................. 2
10 101910401 Screw, Thread-Forming, 5/16-18 x 1-1/4 ............................................................... 2
11 101909902 Computer, Onboard (includes item 12) ................................................................. 1
12 101932601 Kit, 6-Pin Receptacle ........................................................................................ 1
13 101932701 Kit, 6-Pin Plug Assembly ....................................................................................... 1
14 101827801 Kit, Wire and Terminal, #6 Black ........................................................................... 1
15 102259801 Block, Terminal (controller) .................................................................................... 1
16 102263601 Wire Assembly, #10 Black ..................................................................................... 1
17 102263701 Screw, Phillips, Thread-Forming, #10-24 x 3/4 ..................................................... 1
18 7174 Washer, Lock, 5/16 ............................................................................................... 1
19 1242 Nut, Hex, 5/16-18 .................................................................................................. 1
20 101908701 Solenoid, 48-Volt (with diode) (includes items 21 and 22) .................................... 1
21 1012528 Nut, M8 x 1-1/4 ................................................................................................. 2
22 1013734 Washer, Lock, 8 mm .......................................................................................... 2
23 1014947 Assembly, Resistor ................................................................................................ 1
24 8639 Tie, Wire ................................................................................................................ 1
25 **** Z-Bracket, Controller Cover ................................................................................... 1

**** Special order item available upon request.

2003 DS Golf Cars Illustrated Parts List Page 12-31

12
G
E
ELECTRIC MOTOR 13
G
E
13
TYPICAL
2 PLACES
G 12
11
9
13
E TYPICAL
2 PLACES

14
10

7
17
8
TYPICAL
4 PLACES

15
16

20
21
22

6
5
4
3

19 2
18
TYPICAL
3 PLACES

REFERENCE
TRANSAXLE–
SECTION 14

Page 13-2 2003 DS Golf Cars Illustrated Parts List

 MOTOR – V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 13
1 2 3 4

102237401 Assembly, 36-Volt Motor, 2.97-hp (includes items 1 - 17) ..................................... 1

G
1 1017944 Shield, End ........................................................................................................ 1
2 1017945 Assembly, Stator Shell and Winding ................................................................. 1
E
3 1017947 Package, Hardware (includes items 4 - 7) ........................................................ 1
4 N/A Bushing, Insulator ......................................................................................... 2
5 N/A Washer, Flat, 5/16 ........................................................................................ 4
6 N/A Nut, Hex, 5/16-18 ......................................................................................... 4
7 N/A Bushing, Insulator ......................................................................................... 2
8 1017952 Screw, Clamp .................................................................................................... 4
9 1017953 Screw, Bearing Retainer ................................................................................... 2
10 1017951 Shield, End ........................................................................................................ 1
11 1017949 Screw, Brush Holder ......................................................................................... 2
12 1017948 Rigging, Brush .................................................................................................. 1
13 1017946 Package, Brush (2 pieces) (includes 4 brushes) ............................................... 1
14 1011411 Package, Brush Spring (4 pieces) ..................................................................... 1
15 1011290 Bearing, Ball ...................................................................................................... 1
16 1017950 Retainer, Bearing .............................................................................................. 1
17 N/A Armature ........................................................................................................... 1
18 1014201 Screw, Hex-Head Cap, 1/4-20 x 2-1/4 ................................................................... 3
19 451 Washer, Lock, 1/4 ................................................................................................. 3
20 1010934 Screw, Hex-Head Cap, 5/16-18 x 1 ....................................................................... 1
21 7174 Washer, Lock, 5/16 ............................................................................................... 1
22 102235201 Bumper, Motor ...................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 13-3

13
TYPICAL
11 2 PLACES
G 12
9
13
E TYPICAL
2 PLACES
14
10

7
17
8
TYPICAL
4 PLACES

15
16

21 20
22

6
5
4

19 3
18

TYPICAL 2
3 PLACES

REFERENCE
TRANSAXLE–
SECTION 14

Page 13-4 2003 DS Golf Cars Illustrated Parts List

 MOTOR – POWERDRIVE SYSTEM 48 VEHICLE
ITEM PART NO. DESCRIPTION QTY 13
1 2 3 4

102237701 Assembly, 48-Volt Motor, 3.10-hp (includes items 1 - 17) ..................................... 1

G
1 1017944 Shield, End ........................................................................................................ 1
2 1017958 Assembly, Stator Shell and Winding ................................................................. 1
E
3 1017947 Package, Hardware (includes items 4 - 7) ........................................................ 1
4 N/A Bushing, Insulator ......................................................................................... 2
5 N/A Washer, Flat, 5/16 ........................................................................................ 4
6 N/A Nut, Hex, 5/16-18 ......................................................................................... 4
7 N/A Bushing, Insulator ......................................................................................... 2
8 1017961 Screw, Clamp .................................................................................................... 4
9 1017953 Screw, Bearing Retainer ................................................................................... 2
10 1017951 Shield, End ........................................................................................................ 1
11 1017949 Screw, Brush Holder ......................................................................................... 2
12 1017948 Rigging, Brush .................................................................................................. 1
13 1017946 Package, Brush (2 pieces) (includes 4 brushes) ............................................... 1
14 1011411 Package, Brush Spring (4 pieces) ..................................................................... 1
15 1011290 Bearing, Ball ...................................................................................................... 1
16 1017950 Retainer, Bearing .............................................................................................. 1
17 N/A Armature ........................................................................................................... 1
18 1014201 Screw, Hex-Head Cap, 1/4-20 x 2-1/4 ................................................................... 3
19 451 Washer, Lock, 1/4 ................................................................................................. 3
20 1010934 Screw, Hex-Head Cap, 5/16-18 x 1 ....................................................................... 1
21 7174 Washer, Lock, 5/16 ............................................................................................... 1
22 102235201 Bumper, Motor ...................................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 13-5

13
TYPICAL
29
G 2 PLACES
9
19 TYPICAL

E 22
2 PLACES

23
12
21
13
20

14 11

16
15

8
18
TYPICAL
4 PLACES

7 10

17

2
27
28
A2

F2
24
F11
A

6
5
4
26
25 3
TYPICAL
3 PLACES

REFERENCE
TRANSAXLE–
SECTION 14

Page 13-6 2003 DS Golf Cars Illustrated Parts List

 MOTOR – IQ SYSTEM VEHICLE
ITEM PART NO. DESCRIPTION QTY 13
1 2 3 4

102240102 Assembly, 48-Volt IQ Motor, 3.20-hp (includes items 1 - 23) ................................ 1

G
1 1017944 Shield, End ........................................................................................................ 1
2 102265501 Assembly, Stator Shell and Winding ................................................................. 1
E
3 1017947 Package, Hardware (includes items 4 - 7) ........................................................ 1
4 N/A Bushing, Insulator ......................................................................................... 2
5 N/A Washer, Flat, 5/16 ........................................................................................ 4
6 N/A Nut, Hex, 5/16-18 ......................................................................................... 4
7 N/A Bushing, Insulator ......................................................................................... 2
8 102266101 Screw, Clamp, #10-32 x 8-1/4 ........................................................................... 4
9 1017953 Screw, Bearing Retainer, #8-32 x 7/8 ............................................................... 2
102265901 Assembly, End Shield (includes items 10 - 13) ................................................. 1
10 102266001 Shield, End ................................................................................................... 1
11 102265601 Sensor, Motor Speed (includes item 12) ...................................................... 1
12 101942301 Housing, Female 3-Wire, Gray ................................................................. 1
13 102267001 Screw, Steel Hex, Thread-Rolling, #8 x 3/8 .................................................. 1
14 102265701 Kit, Bearing and Magnet (includes items 15 and 16) ........................................ 1
15 N/A Bearing, Ball ................................................................................................. 1
16 N/A Magnet ......................................................................................................... 1
17 1017950 Retainer, Bearing .............................................................................................. 1
18 N/A Armature ........................................................................................................... 1
19 102327801 Assembly, Brush Rigging (includes items 20 - 22) ............................................ 1
20 1011411 Package, Brush Spring (4 pieces) ................................................................ 1
21 102251901 Package, Brush (2 pieces) (includes 4 brushes) .......................................... 1
22 1017948 Rigging, Brush .............................................................................................. 1
23 1017949 Screw, Brush Holder, #6-32 x 1/2 ..................................................................... 2
24 102235201 Bumper, Motor ...................................................................................................... 1
25 1014201 Screw, Hex-Head Cap, 1/4-20 x 2-1/4 ................................................................... 3
26 451 Washer, Lock, 1/4 ................................................................................................. 3
27 1010934 Screw, Hex-Head Cap, 5/16-18 x 1 ....................................................................... 1
28 7174 Washer, Lock, 5/16 ............................................................................................... 1
29 101920101 Kit, 3-Pin Plug Assembly, Gray ............................................................................. 1

2003 DS Golf Cars Illustrated Parts List Page 13-7

13
G
E
TRANSAXLE – ELECTRIC VEHICLE 14
G
E
14
G
E
REFERENCE
MOTOR–
SECTION 13 8

6
5
4
3
1

16
12
20

32

10
12 13
11 15
12

14 17
19

18
21
28

30
32
22 9

29
31 11

26

27
9
24 4
26 2
23 5
25
32 3
23

Page 14-2 2003 DS Golf Cars Illustrated Parts List

 TRANSAXLE, TYPE G – ELECTRIC VEHICLE
ITEM PART NO. DESCRIPTION QTY 14
1 2 3 4

101896001 Transaxle, Type G (includes items 1 - 32) ............................................................. 1

G
1 101895801 Axle Assembly, Passenger-Side (includes item 3) ............................................ 1
2 101895901 Axle Assembly, Driver-Side (includes item 3) ................................................... 1
E
3 101922201 Stud, Lug ...................................................................................................... 4
4 101976001 Bolt, M10 x 1.5 x 35 mm ................................................................................... 10
5 101897901 Washer, Lock .................................................................................................... 10
6 101923501 Seal, Oil, Input Shaft ......................................................................................... 1
7 101895501 Gear Case, Passenger-Side ............................................................................. 1
8 101897201 Breather ............................................................................................................ 1
9 7330 Bearing, Differential .......................................................................................... 2
10 101895601 Assembly, Axle Tube, Passenger-Side .............................................................. 1
11 1013794 Seal, Oil, Axle Shaft .......................................................................................... 2
12 7335 Bearing, Input Gear ........................................................................................... 3
13 101923701 Shaft, Input ........................................................................................................ 1
14 7336 Bearing, Intermediate Gear .............................................................................. 1
15 101906901 Assembly, Intermediate Gear ............................................................................ 1
16 101895401 Gear Case, Driver-Side ..................................................................................... 1
17 101972201 Plug, Fill ............................................................................................................ 1
18 101972101 Plug, Magnetic .................................................................................................. 1
19 101923201 Gasket, Plug ..................................................................................................... 2
20 101897001 Bolt, M8 x 1.25 x 60 mm ................................................................................... 11
21 101897601 Pin, Dowel ......................................................................................................... 2
22 101923601 Housing, Differential .......................................................................................... 1
23 101923901 Gear, Differential ............................................................................................... 2
24 101903601 Plate, Thrust (idler gear) ................................................................................... 2
25 101923001 Gear, Differential Idler ....................................................................................... 2
26 101903701 Plate, Thrust ...................................................................................................... 2
27 101922101 Pin, Differential .................................................................................................. 1
28 101906201 Gear, Output ..................................................................................................... 1
29 101897401 Bolt, M10 x 1.5 x 25 mm ................................................................................... 4
30 101972401 Pin, Dowel ......................................................................................................... 1
31 101895701 Assembly, Axle Tube, Driver-Side ..................................................................... 1
32 101928701 Gasket, Liquid, 8.8 oz. (250 g) .......................................................................... A/R

2003 DS Golf Cars Illustrated Parts List Page 14-3

14
G
E

REFERENCE
MOTOR–
SECTION 13 12

11
13

10
9
8
3
1

TYPICAL 10
24 PLACES

18 26
19
18
7
17 15

16 18
4 23
5
6 21
20
25
TYPICAL
2 PLACES

30 28 27
22 29 14
41
6

31 5
4
37
38
17
40
37 7
36

14 39
33
34
8
35 9
34 32 2
15 3

Page 14-4 2003 DS Golf Cars Illustrated Parts List

 TRANSAXLE, TYPE K – ELECTRIC VEHICLE
ITEM PART NO. DESCRIPTION QTY 14
1 2 3 4

N/A Transaxle, Type K (includes items 1 - 41) .............................................................. 1

G
1 1013785 Axle Assembly, Passenger-Side (includes items 3 - 7) ..................................... 1
2 1013786 Axle Assembly, Driver-Side (includes items 3 - 7) ............................................ 1
E
3 1013787 Stud, Lug ...................................................................................................... 4
4 1014207 Bushing, 25 mm I. D. .................................................................................... 1
5 1011291 Bearing, Outer Axle Tube ............................................................................. 1
6 1013792 Circlip, Type C .............................................................................................. 1
7 1016672 Ring, Retaining ............................................................................................. 1
8 1013790 Bolt, M10 x 1.5 x 30 mm ................................................................................... 10
9 1013791 Washer, Lock .................................................................................................... 10
10 1013775 Seal, Input Shaft Oil .......................................................................................... 1
11 1013756 Gear Case, Passenger-Side ............................................................................. 1
12 1012711 Breather ............................................................................................................ 1
13 1013758 Gasket, Case .................................................................................................... 1
14 7330 Bearing, Inner Axle Tube ................................................................................... 2
15 101928701 Gasket, Liquid, 8.8 oz. (250 g) .......................................................................... 2
16 1017704 Assembly, Axle Tube, Passenger-Side .............................................................. 1
17 1013794 Seal, Axle Shaft Oil ........................................................................................... 2
18 7335 Bearing, Input Gear ........................................................................................... 3
19 1013764 Shaft, Input ........................................................................................................ 1
20 7336 Bearing, Intermediate Gear .............................................................................. 1
21 1013766 Gear, Intermediate, Small ................................................................................. 1
22 1013780 Key, Sunk .......................................................................................................... 1
23 1013765 Gear, Intermediate, Large ................................................................................. 1
24 1013757 Gear Case, Driver-Side ..................................................................................... 1
25 1013759 Plug, Fill, with Gasket ....................................................................................... 2
26 1013763 Bolt, M6 x 1 x 50 mm ........................................................................................ 10
27 1012710 Pin, Dowel ......................................................................................................... 2
28 1013779 Bolt, M8 x 1.25 x 37 mm ................................................................................... 8
29 1013782 Plate, Lock ........................................................................................................ 4
30 1013767 Gear, Output ..................................................................................................... 1
31 1013772 Pin, Differential .................................................................................................. 1
32 101910501 Kit, Differential Gear Case (includes items 33 - 36) .......................................... 1
33 1013768 Gear Case, Differential (driver side) ............................................................. 1
34 1013773 Plate, Thrust (differential gear) ..................................................................... 2
35 1013774 Plate, Thrust (idler gear) ............................................................................... 2
36 1013769 Gear Case, Differential (passenger side) ..................................................... 1
37 1013771 Gear, Differential ............................................................................................... 2
38 1013770 Gear, Differential Idler ....................................................................................... 2
39 1013781 Shim .................................................................................................................. 1
40 1017703 Assembly, Axle Tube, Driver-Side ..................................................................... 1
41 1014193 Pin, Dowel ......................................................................................................... 1
Note: Transaxle type is identified by orientation of gear case bolts (item 26).
The Type K Transaxle has gear case bolt heads facing toward the driver side
of the vehicle.

2003 DS Golf Cars Illustrated Parts List Page 14-5

14
G
E
BATTERY CHARGER 15
G
E
15
G 1

8
9
7

10
11 14

12 13

Page 15-2 2003 DS Golf Cars Illustrated Parts List

 ACCU-POWER BATTERY CHARGER, DOMESTIC –
V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

101646401 Charger, Accu-Power, Domestic, 120-V AC, 36-V DC, 60-Hz

G
(model number 13800-11) (includes items 1 - 14)
108-inch DC cord, 72-inch AC cord ...................................................................... 1 E
1 1015907 Assembly, Case (includes fasteners) ................................................................ 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. 10
3 1015912 Assembly, Transformer ...................................................................................... 1
4 1015914 Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... 1
5 1015905 Ammeter (includes mounting hardware) ........................................................... 1
6 1015911 Relay, 36-V DC ................................................................................................. 1
7 1015910 Capacitor ........................................................................................................... 1
8 101643301 Cordset, DC, 108-Inch Long (standard) 12-AWG ............................................. 1
8 101643302 Cordset, DC, 146-Inch Long, 10-AWG .............................................................. 1
8 101643303 Cordset, DC, 242-Inch Long, 10-AWG .............................................................. 1
9 1012101 Assembly, Fuse (Includes Hardware) ............................................................... 1
10 1012098 Bushing, Strain Relief, 12-AWG DC Cord ......................................................... 1
10 1012042 Bushing, Strain Relief, 10-AWG DC Cord ......................................................... 1
11 1015917 Bushing, Strain Relief, AC Cord ........................................................................ 1
12 101591601 Cordset, AC, 72-Inch Long (standard) .............................................................. 1
12 101591602 Cordset, AC, 108-Inch Long .............................................................................. 1
13 1015906 Assembly, Timer Kit (includes mounting hardware) .......................................... 1
14 1015913 Assembly, Control Cable ................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 15-3

15
G
1
E
2

8
9
1

10
11 14

13
12

Page 15-4 2003 DS Golf Cars Illustrated Parts List

ACCU-POWER BATTERY CHARGER, EXPORT, 230-VOLT –
V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

101643401 Charger, Accu-Power, Export, 230-V AC, 36-V DC, 50-Hz

G
(model number 14410-11) (includes items 1 - 14)
108-inch DC cord, 108-inch AC cord ..................................................................... 1 E
1 N/A Assembly, Case ................................................................................................ 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. 10
3 1015936 Assembly, Transformer ...................................................................................... 1
4 1015914 Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... 1
5 1015905 Ammeter (includes mounting hardware) ........................................................... 1
6 1015911 Relay, 36-V DC ................................................................................................. 1
7 1015910 Capacitor ........................................................................................................... 1
8 101643301 Cordset, DC, 108-Inch Long, 12-AWG (standard) ............................................ 1
8 101643302 Cordset, DC, 146-Inch Long, 10-AWG .............................................................. 1
8 101643303 Cordset, DC, 242-Inch Long, 10-AWG .............................................................. 1
9 1012101 Assembly, Fuse (includes mounting hardware) ................................................ 1
10 1012098 Bushing, Strain Relief, 12-AWG DC Cord ......................................................... 1
10 1012042 Bushing, Strain Relief, 10-AWG DC Cord ......................................................... 1
11 1015917 Bushing, Strain Relief, AC Cord ........................................................................ 1
12 1014696 Cordset, AC, 108-Inch Long (standard) ............................................................ 1
13 1015906 Assembly, Timer Kit (includes mounting hardware) .......................................... 1
14 1015913 Assembly, Control Cable ................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 15-5

15
G 1

E
2

9
1

10
11
14

12
13

Page 15-6 2003 DS Golf Cars Illustrated Parts List

ACCU-POWER BATTERY CHARGER, EXPORT, 100-VOLT –
V-GLIDE 36-VOLT VEHICLE
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

101646201 Charger, Accu-power, Export, 100-V AC, 36-V DC, 50-Hz

G
(model number 14900) (includes items 1 - 14)
108-inch DC cord, 108-inch AC cord .................................................................... 1 E
1 N/A Assembly, Case ................................................................................................ 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. 10
3 1016336 Assembly, Transformer ...................................................................................... 1
4 1015914 Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... 1
5 1015905 Ammeter (Includes Mounting Hardware) .......................................................... 1
6 1015911 Relay, 36-V DC ................................................................................................. 1
7 1015939 Capacitor ........................................................................................................... 1
8 101643301 Cordset, DC, 108-Inch Long, 12-AWG (standard) ............................................ 1
8 101643302 Cordset, DC, 146-Inch Long, 10-AWG .............................................................. 1
8 101643303 Cordset, DC, 242-Inch Long, 10-AWG .............................................................. 1
9 1012101 Assembly, Fuse (includes mounting hardware) ................................................ 1
10 1012098 Bushing, Strain Relief, 12-AWG DC Cord ......................................................... 1
10 1012042 Bushing, Strain Relief, 10-AWG DC Cord ......................................................... 1
11 1015917 Bushing, Strain Relief, AC Cord ........................................................................ 1
12 1016282 Cordset, AC, 108-Inch Long .............................................................................. 1
13 1015906 Assembly, Timer Kit (includes mounting hardware) .......................................... 1
14 1015913 Assembly, Control Cable ................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 15-7

15
G
E 1

3
5

7
8
9

C
lu
b
C
ar
R

11

10

13 14

1
12

Page 15-8 2003 DS Golf Cars Illustrated Parts List

 POWERDRIVE BATTERY CHARGER, DOMESTIC
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

PowerDrive chargers can be used with PowerDrive System 48

G
and IQ System vehicles.
E
101802201 Charger, Battery, PowerDrive, Domestic 120-V AC 48-V DC 60-Hz
(model number 17930-11) (includes items 1 - 14)
103-inch DC cord with male 3-pin plug, 12-AWG
74-inch AC cord with male grounded plug ............................................................ 1
101802202 Charger, Battery, PowerDrive 120-V AC 48-V DC 60-Hz
(model number 17930-18) (includes items 1 - 14)
144-inch DC cord with male 3-pin plug, 12-AWG
108-inch AC cord with male grounded plug .......................................................... 1
101802203 Charger, Battery, PowerDrive 120-V AC 48-V DC 60-Hz
(model number 17930-19) (includes items 1 - 14)
240-inch DC cord with male 3-pin plug, 12-AWG
108-inch AC cord with male grounded plug ........................................................... 1
1 101828301 Assembly, Case (includes fasteners) ................................................................ 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. 10
3 101819701 Assembly, Transformer ...................................................................................... 1
4 1015914 Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... 1
5 101828501 Ammeter (includes mounting hardware) ........................................................... 1
6 101831101 Kit, Wire Assembly ............................................................................................ 1
7 101828901 Cordset, DC, 113-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
7 101828902 Cordset, DC, 154-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
7 101828903 Cordset, DC, 250-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
8 1012101 Assembly, Fuse (includes mounting hardware) ................................................ 1
9 1012098 Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ 1
10 101914401 Assembly, Voltage Suppressor .......................................................................... 1
11 CCX8506 Breaker, Circuit, 15-Amp, 120-V AC ................................................................. 1
12 101828601 Relay, Power, 48-V DC ...................................................................................... 1
13 101828801 Cordset, AC, 80-Inch Long ................................................................................ 1
13 101828802 Cordset, AC, 116-Inch Long .............................................................................. 1
14 1015917 Bushing, Strain Relief, AC Cord ........................................................................ 1

2003 DS Golf Cars Illustrated Parts List Page 15-9

15
G 2
14

5 4

9 2

13
10

7 15
11 1
12

Page 15-10 2003 DS Golf Cars Illustrated Parts List

 POWERDRIVE 2 BATTERY CHARGER, DOMESTIC
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

PowerDrive 2 chargers can be used with PowerDrive System 48

G
and IQ System vehicles.
E
101802204 Charger, Battery, PowerDrive 2, Domestic 120-V AC 48-V DC 60-Hz
(model number 22110-11) (includes items 1 - 15)
103-inch DC cord with male 3-pin plug, 12-AWG
74-inch AC cord with male grounded plug ............................................................ 1
101802205 Charger, Battery, PowerDrive 2 120-V AC 48-V DC 60-Hz
(model number 22110-18) (includes items 1 - 15)
144-inch DC cord with male 3-pin plug, 12-AWG
108-inch AC cord with male grounded plug .......................................................... 1
101802206 Charger, Battery, PowerDrive 2 120-V AC 48-V DC 60-Hz
(model number 22110-19) (includes items 1 - 15)
240-inch DC cord with male 3-pin plug, 12-AWG
108-inch AC cord with male grounded plug ........................................................... 1
1 102273201 Assembly, Case (includes item 2) ..................................................................... 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .............................................. 12
3 102273301 Assembly, Transformer (includes rivets) ............................................................ 1
4 102273401 Plate, Heatsink ................................................................................................. 1
5 102273501 Assembly, Diode with Heatsink Film (includes mounting hardware) ................. 1
6 102273601 Kit, Wire Assembly (not shown) ........................................................................ 1
7 101828904 Cordset, DC, 113-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
7 101828905 Cordset, DC, 154-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
7 101828906 Cordset, DC, 250-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
8 102273701 Assembly, Fuse, 30-Amp (includes terminal hardware) .................................... 1
9 102273801 Ammeter (includes mounting hardware) ........................................................... 1
10 102273901 Bushing, Strain Relief, AC Cord ........................................................................ 1
11 1012098 Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ 1
12 CCX8506 Breaker, Circuit, 15-Amp, 120-V AC ................................................................. 1
13 101828801 Cordset, AC, 80-Inch Long ................................................................................ 1
13 101828802 Cordset, AC, 116-Inch Long .............................................................................. 1
14 102274001 Handle, PowerDrive 2 Charger (with four screws) ............................................ 1
15 101828601 Relay, Power, 48-V DC ...................................................................................... 1

2003 DS Golf Cars Illustrated Parts List Page 15-11

15
G
E
1

6
5 8

9
10

11 12
13

C
lu
b
C
ar
R

14

1
15 16

Page 15-12 2003 DS Golf Cars Illustrated Parts List

 POWERDRIVE BATTERY CHARGER, EXPORT
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

PowerDrive chargers can be used with PowerDrive System 48

G
and IQ System vehicles.
E
101831503 Charger, Battery, PowerDrive, Export with 4-Position Switch
100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz
(model number 18780-11) (includes items 1 - 16)
103-inch DC cord with male 3-pin plug, 12-AWG
74-inch AC cord with no plug ................................................................................ 1
101831504 Charger, Battery, PowerDrive Export with 4-Position Switch
100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz
(model number 18780-18) (includes items 1 - 16)
144-inch DC cord with male 3-pin plug, 12-AWG
108-inch AC cord with no plug .............................................................................. 1
1 N/A Assembly, Case ................................................................................................ 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. 10
3 101838201 Assembly, Transformer ...................................................................................... 1
4 1015914 Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... 1
5 101914401 Assembly, Voltage Suppressor .......................................................................... 1
6 101838501 Kit, Wire Assembly ............................................................................................ 1
7 101828501 Ammeter (includes hardware) ........................................................................... 1
8 101838301 Relay, Power, 48-V DC (includes mounting hardware) ..................................... 1
9 101838701 Bracket, Power Relay Mounting ........................................................................ 1
10 101838601 Switch, 4-Position Slide ..................................................................................... 1
11 101828901 Cordset, DC, 113-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
11 101828902 Cordset, DC, 154-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
11 101828903 Cordset, DC, 250-Inch Long with Male 3-Pin Plug, 12-AWG ............................ 1
12 1012101 Assembly, Fuse (includes hardware) ................................................................ 1
13 1012098 Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ 1
14 101838401 Breaker, Circuit, 10-Amp ................................................................................... 2
15 101831701 Cordset, AC, 80-Inch Long with Leads (no plug) .............................................. 1
15 101831702 Cordset, AC, 116-Inch Long with Leads (no plug) ............................................ 1
16 1015917 Bushing, Strain Relief, AC Cord ........................................................................ 1

2003 DS Golf Cars Illustrated Parts List Page 15-13

15
G 15

E
2
5

1
4

8 21
18
9

1
10 11
12

C
lu
b
C
ar
R

14

13

16

17

Page 15-14 2003 DS Golf Cars Illustrated Parts List

 POWERDRIVE BATTERY CHARGER, EUROPEAN
ITEM PART NO. DESCRIPTION QTY 15
1 2 3 4

PowerDrive chargers can be used with PowerDrive System 48

G
and IQ System vehicles.
E
101956201 Charger, Battery, PowerDrive, European with 4-Position Switch
100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz
(model number 20300) (includes items 1 - 15)
103-inch (261 cm) DC cord with male 3-pin plug, 12-AWG ................................... 1
101956202 Charger, Battery, PowerDrive European with 4-Position Switch
100 - 200 - 220 - 240 V AC, 48-V DC 50/60-Hz
(model number 20310) (includes items 1 - 15)
144-inch (366 cm) DC cord with male 3-pin plug, 12-AWG .................................. 1
1 N/A Assembly, Case ................................................................................................ 1
2 7577 Screw, Pan-Head, Self-Tapping, #10-16 x 1/2 .................................................. 10
3 **** Assembly, Transformer ...................................................................................... 1
4 1015914 Assembly, Heatsink, with Diodes (includes mounting hardware) ...................... 1
5 **** Assembly, AC Voltage Suppressor..................................................................... 1
6 **** Kit, Wire Assembly ............................................................................................ 1
7 101976601 Ammeter (includes hardware) ........................................................................... 1
8 101987501 Relay, Power, 48-V DC (includes mounting hardware) ..................................... 1
9 101838601 Switch, 4-Position Slide ..................................................................................... 1
10 101828901 Cordset, DC, 103-Inch (261 cm) Long with Male 3-Pin Plug, 12-AWG ............. 1
10 101828902 Cordset, DC, 144-Inch (366 cm) Long with Male 3-Pin Plug, 12-AWG ............. 1
10 101828903 Cordset, DC, 250-Inch (635 cm) Long with Male 3-Pin Plug, 12-AWG ............. 1
11 1012101 Assembly, Fuse (includes hardware) ................................................................ 1
12 1012098 Bushing, Strain Relief, DC Cord, 12-AWG ........................................................ 1
13 101838401 Breaker, Circuit, 10-Amp ................................................................................... 2
14 101973501 Receptacle, AC Cord ........................................................................................ 1
15 **** Assembly, Current Limiter ................................................................................. 1
16 101958301 Cordset, AC, Continental Europe, 96-Inch (244 cm) Long
(with male 2-pin plug) ............................................................................................ 1
17 101958201 Cordset, AC, U.K., 96-Inch (244 cm) Long (with male 3-pin plug) ........................ 1
18 N/A Wire, Jumper.......................................................................................................... 1

**** Special order item available on request

2003 DS Golf Cars Illustrated Parts List Page 15-15

15
G
E
MAINTENANCE AND
SERVICE TOOLS 16
G
E
16
G
E AC
PE CE

Loctite®
DA LE
L RA
HE TO
IG R
HT

1 2
3 4 5 6

8 9 10
7
BR
EQ AK
U E
AL C
IZ AB
AT LE
IO
N CALIBRATION & TEST MODULE
INSTRUCTIONS
SPEED CONTROL
SET POWER SWITCH TEST
TO "ON".
PEDAL CIRCUIT
POT CALIBRATION: SET MODE SWITCH TO "POT".
CHECK INTERNAL 4.30±.03 VOLT SIGNAL BY PRESSING "TEST" BUTTON.
CONNECT TEST SOCKET TO POT PLUG, CONNECT GREEN LEAD TO GREEN/
WHITE POT LIMIT SWITCH LEAD, CONNECT BLUE LEAD TO BATTERY
POSITIVE. ILLUMINATION OF THE L.E.D. INDICATES A CLOSED
PEDAL LIMIT SWITCH, READ THE POTENTIOMETER SET VOLTAGE FROM THE
L.C.D. DISPLAY. SEE SERVICE MANUAL FOR ADJUSTMENT PROCEDURE.
SPEED SENSOR TEST: SET MODE SWITCH TO "SSAM", CONNECT TEST
SOCKET TO MOTOR SPEED SENSOR PLUG, ROTATE MOTOR. L.E.D. SHOULD
PULSE ON AND OFF INDICATING SPEED SENSOR IS FUNCTIONAL.

SEE OPERATING INSTRUCTIONS FOR MORE DETAIL

R
POWER MODE

BR ON Club Car SSAM

OFF POT

AK
H EP
EI E
G DA
H L
T
12
13 14
11

15 18 19
16 17

COMMUNICATION
DISPLAY MODULE
DISPLAY FUNCTIONS:
PRESS AND HOLD
BUTTON TO SHOW
FUNCTION NUMBER.
WARNING
RELEASE BUTTON TO
SHOW FUNCTION VALUE.
Func1 - Battery voltage.
Func2 - Energy units removed since last charge cycle.
Func3 - Total accumulated energy units removed.
Func4 - Last charge termination type (1 = Incomplete,
2 = DVDT, 4 = Normal, 8 = Max. timer).
R
POWER
ON
OFF
Club Car
PART #17075

20 21 22 23

Page 16-2 2003 DS Golf Cars Illustrated Parts List

 MAINTENANCE AND SERVICE TOOLS
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 16
1 2 3 4

The following tool list includes all tools available from Club Car for
G
maintenance and service procedures for gasoline and/or electric
vehicles, both past and present models. Be sure to carefully examine E
the tool list for applicability to your vehicle before ordering.

1 101871001 Accelerator Pedal Adjustment Tool ............................................................ 1 1

2 101813202 Adhesive, Guide Ring, 3-Gram Tube .......................................................... 1 1
3 101831901 Battery Discharge Machine, 36/48 Volt ...................................................... 1
4 1014305 Battery Terminal Protector Spray ............................................................... 1 1
5 1011767 Battery Thermometer ................................................................................. 1
6 1016417 Bearing and Oil Seal Remover Assembly .................................................. 1 1
7 1016416 Bearing Driver Set ...................................................................................... 1 1
8 1012811 Bearing Puller ............................................................................................ 1 1
9 1012812 Bearing Puller Wedge Attachment ............................................................. 1 1
10 1013582 Brake Adjustment Tool (used only on vehicles with
manually adjusted mechanical brakes) ...................................................... 1 1
102249901 Brake Pedal Adjustment Tool Kit (used for the Carryall electric ................. 1
industrial truck only) (includes items 11 and 12)
11 **** Brake Pedal Adjustment Tool ................................................................. 1
12 **** Brake Pedal Tension Tool ....................................................................... 1
13 101887101 Calibration Test Module .............................................................................. 1
14 101808401 Cam Installation Tool .................................................................................. 1
1014510 Clutch Tool Kit (includes items 15 - 21) ...................................................... 1
15 1014498 Clutch Alignment Tool (for pre-unitized transaxle
vehicles built prior to 1997 model year) ................................................. 1
16 1014496 Drive Clutch Puller ................................................................................. 1
17 1014497 Drive Clutch Hub Puller .......................................................................... 1
18 1014508 Driven Clutch Cam Puller ....................................................................... 1
19 1014507 Driven Clutch Puller Plug ....................................................................... 1
20 1015524 Drive Clutch Holder Tool Assembly ........................................................ 1
21 101809101 Press Weldment ..................................................................................... 1
22 101831801 Communication Display Module ................................................................. 1
23 101641002 Compression Gauge and Adapter ............................................................. 1

Please refer to the maintenance and service manual

for proper tool application.

**** Special order item available upon request

2003 DS Golf Cars Illustrated Parts List Page 16-3

16
G
E

24 25 26 27 28 29

30

33
Gasket

1 3
Liquid

31 32 34
35 36

37

38 39 40 41 42 43 44 45

Page 16-4 2003 DS Golf Cars Illustrated Parts List

 MAINTENANCE AND SERVICE TOOLS, CONTINUED
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 16
1 2 3 4

24 1011273 Continuity Tester ......................................................................................... 1 1

G
25 1012151 Dry Moly Lubricant ..................................................................................... 1 1
26 1016627 Flywheel Puller Kit ..................................................................................... 1
E
27 1016418 Gear Yoke ................................................................................................... 1 1
28 101933101 Governor Shaft Installation Tool ................................................................. 1
29 102169401 Hydraulic Brake Adjuster (for vehicles equipped
with hydraulic brakes) ................................................................................. 1
30 1011478 Hydrometer ................................................................................................ 1 1
31 1013593 Internal Retaining Ring Pliers .................................................................... 1 1
32 102248803 IQ Display Module (IQDM) Kit (for IQ System vehicles only) ..................... 1
(includes items 33 and 34)
33 102241502 Cable, IQDM .......................................................................................... 1
34 102251501 Adaptor, Cable ........................................................................................ 1
35 101928701 Liquid Gasket (transaxle case) ................................................................... 1 1
36 102243402 Moly-Teflon Lubricant (4-oz. (113-gram) tube) ........................................... 1
37 1016414 Piston Ring Compressor Kit (FE290, FE350 and FE400 engines) ............ 1
38 1016415 Piston Ring Pliers ....................................................................................... 1
39 1012549 Retaining Ring Pliers, 45° External ............................................................ 1 1
40 1012560 Retaining Ring Pliers, 90° Internal ............................................................. 1 1
41 101823101 Safety First Card (50 per pack) .................................................................. 1 1
42 1012809 Seal Puller .................................................................................................. 1 1
43 102330901 Spanner Wrench (for coil over shock front suspension vehicles only) ........ 1
44 1014264 Steering Column Bearing Press Tool ......................................................... 1 1
45 1014259 Steering Column Retaining Ring Tool ........................................................ 1 1

Please refer to the maintenance and service manual

for proper tool application.

2003 DS Golf Cars Illustrated Parts List Page 16-5

16
G
E PULSE ENGINE TACHOMETER
PET-1000

POSTION RESET

46 47 48
49 50

56
51 52 53 54 55

- +
V
eh
ic
le
C
ar
e
K
it

WAVETEK 5XL
V OFF V
1000 500

200 200

20 200

2 2m

200 20
m m

200
2000
k m

200k
20k 200
Ω 2k A

Ve
hicl
45° 45° eC
are
Kit

V Ω ! COM ! 200nA
MAX
1000 ---
FUSED
750V

57 58
59 60

61

Page 16-6 2003 DS Golf Cars Illustrated Parts List

 MAINTENANCE AND SERVICE TOOLS, CONTINUED
QTY QTY
ITEM PART NO. DESCRIPTION
GAS ELEC 16
1 2 3 4

46 102061201 Steering Wheel Puller Tool ......................................................................... 1 1

G
47 1016112 Tachometer ................................................................................................ 1
48 101997201 Paint, Touch-Up – Beige ............................................................................. 1 1
E
48 101997202 Paint, Touch-Up – White ............................................................................. 1 1
48 101997203 Paint, Touch-Up – Red ............................................................................... 1 1
48 101997204 Paint, Touch-Up – Gray ............................................................................... 1 1
48 101997205 Paint, Touch-Up – Dark Gray ...................................................................... 1 1
48 101997206 Paint, Touch-Up – Pacific Blue (Royal Blue) ............................................... 1 1
48 101997207 Paint, Touch-Up – Black ............................................................................. 1 1
48 101997209 Paint, Touch-Up – Dark Green ................................................................... 1 1
48 101997211 Paint, Touch-Up – Classic Blue (Navy) ...................................................... 1 1
48 101972012 Paint, Touch-Up – Burgundy ...................................................................... 1 1
49 1014115 Transmission Tool Kit .................................................................................. 1
50 1014161 Transaxle Pinion Seal Tool ......................................................................... 1
51 1014162 Transaxle Axle Seal Tool ............................................................................ 1
52 1016413 Valve Clearance Adjuster Screw Holder (for FE290 engines only) ............ 1
53 101641201 Valve Guide Reamer .................................................................................. 1
54 101641202 Arbor .......................................................................................................... 1
55 1016551 Valve Seat Cutter T-Wrench ....................................................................... 1
56 1016552 Valve Seat Cutter Guide ............................................................................. 1
57 1016553 Valve Seat Cutter, 45° (32 mm diameter) (for FE290 engines only) ........... 1
58 1016554 Valve Seat Cutter, 45°/30° (35 mm diameter) ............................................ 1
59 101641101 Valve Spring Compressor .......................................................................... 1
60 AM10021 Vehicle Care Kit .......................................................................................... 1 1
61 1011480 Volt Ohm Meter .......................................................................................... 1 1
62 101611003 Tune-Up Kit, All OHV (includes air filter, spark plug,
oil filter, fuel filters) (not shown) .................................................................. 1

Please refer to the maintenance and service manual

for proper tool application.

2003 DS Golf Cars Illustrated Parts List Page 16-7

16
G
E
 INDEX

Part Number and Page 7910 5-9 1011019 1-3

7973 1-3 1011069 12-5
AM10021 16-7
8049 12-7, 12-15 1011084 4-7
AM10079 6-9, 12-3
8056 12-9 1011229 6-9
AM10080 11-5
8057 6-5, 6-7, 12-7, 12-9, 12-15 1011273 16-5
AM10081 11-5
8058 6-5, 6-7, 12-7, 12-9, 12-15 1011290 13-3, 13-5
AM10419 10-5
8067 5-9 1011291 11-7, 14-5
CCX8506 15-9, 15-11
8233 1-7, 1-9, 1-13, 1-15, 4-7, 6-5, 8-3, 1011304 5-9
183 8-11, 10-3
12-7, 12-15, 12-27 1011382 1-3
304 12-7
8248 6-5, 8-3, 12-27 1011393 5-9
324 1-15
8251 1-7, 1-9, 6-5 1011394 1-5
332 1-7, 1-9, 1-11, 1-15, 6-5, 8-11, 9-3,
8418 1-13 1011402 4-5
12-11, 12-27
8449 12-9 1011411 13-3, 13-5, 13-7
334 4-7, 5-3, 5-5
8450 10-3, 12-7, 12-15 1011415 5-11
357 5-9
8626 4-5 1011418 4-5
451 9-3, 12-7, 12-9, 12-11, 12-15, 13-3,
13-5, 13-7 8639 12-13, 12-31 1011466 4-3
705 6-13 8717 6-5, 6-7 1011478 16-5
706 5-9 8745 5-9 1011480 16-7
1016 12-13 8754 4-7, 5-3, 5-5, 5-7, 5-9, 5-11, 6-13 1011558 12-19
1017 12-9 8755 5-9 1011578 12-13, 12-17, 12-29
1028 4-5, 12-7, 12-9, 12-11, 12-15 8795 12-13 1011652 1-11
1032 4-5 8796 12-13 1011694 4-7
1035 4-3, 5-5, 5-7 8797 12-13 1011697 1-3, 5-3, 8-7, 8-9
1218 12-19 8861 5-7 1011700 4-7
1241 1-5, 1-13, 4-5, 4-7, 6-7, 6-13, 6-15, 8990 5-5, 12-3, 12-27 1011734 4-7
12-19 8755 5-11 1011767 16-3
1242 4-5, 6-7, 6-13, 12-19, 12-31 1010005 5-9 1011779 4-3, 4-5
1308 5-7 1010124 5-7 101187702 4-5, 4-7
1606 8-11, 12-13 1010145 5-11 1011887 5-9
1620 1-3 1010150 5-9 1011892 5-9
1624 4-7, 5-5, 5-7, 5-9 1010200 5-7 1011930 5-5, 5-7
2402 5-7 1010219 5-7 1011931 12-11
4107 12-13 1010347 5-9 1011988 8-3
7048 5-9 1010348 5-9 1011997 12-7
7173 6-13, 6-15, 12-19 1010413 1-13 1012022 12-13
7174 5-3, 6-13, 8-9, 9-3, 12-13, 12-19, 1010434 1-3, 1-13 1012030 5-9
12-31, 13-3, 13-5, 13-7 1010435 1-5 1012042 15-3, 15-5, 15-7
7251 1-5 1010521 12-13 1012047 1-7, 1-9
7310 2-3 1010543 1-11 1012098 15-3, 15-5, 15-7, 15-9, 15-11,
7330 11-7, 14-3, 14-5 1010805 4-5 15-13, 15-15
7335 11-5, 14-3, 14-5 1010829 4-3 1012101 15-3, 15-5, 15-7, 15-9, 15-13,
7336 14-3, 14-5 1010850 4-3 15-15
7473 1-3, 1-5, 1-13, 4-5, 4-7, 6-7, 6-13, 1010877 4-5 1012151 16-5
6-15, 12-9 1010878 4-5 1012159 1-9
7479 1-9, 1-13 101090801 12-13, 12-17, 12-29 1012164 7-15
7539 5-7 1010921 1-13, 4-5 1012180 5-11
7540 5-5, 5-7 1010927 4-5 1012181 5-11
7555 5-5, 5-7 1010932 4-5 1012182 5-11
7569 5-11 1010933 4-5 1012285 6-5, 8-9, 12-11, 12-13, 12-19,
7577 15-3, 15-5, 15-7, 15-9, 15-11, 15-13, 1010934 6-15, 13-3, 13-5, 13-7 12-27, 12-31
15-15 1012295 6-7
1010954 6-5, 6-7, 11-3
7602 5-5, 5-7 1012303 5-9, 5-11
1010958 12-5, 12-13
7716 4-5, 4-7 1012304 5-11
1010974 5-11
7818 1-13, 6-7 1012324 5-11
1010984 2-3, 5-9
7840 5-9 1012328 6-15
1011010 12-5
7847 1-3, 1-7, 9-3 1012333 6-5
1011014 1-5
7893 6-5, 6-7, 12-13 1012353 12-9
1011017 1-5

2003 DS Golf Cars Illustrated Parts List Page i-1

 INDEX
1012382 6-3 1013587 6-5 1014007 4-7
1012412 1-7, 1-9 1013589 6-5, 6-7 1014010 12-9
1012431 6-5, 6-7 1013590 6-5 1014012 12-11
1012467 5-5 1013591 6-5 1014013 12-11
1012505 6-9, 12-3 1013593 16-5 1014014 12-11
1012528 9-3, 12-19, 12-31 1013609 6-7 1014017 12-9
1012549 16-5 1013628 12-13 1014019 12-9
1012560 16-5 1013649 12-13 1014029 12-5
1012565 5-3 1013683 12-13, 12-17, 12-29 1014030 12-5
1012566 5-3 1013687 8-3 1014032 12-5
1012571 7-15 1013692 8-3 1014033 12-5
1012594 6-5 1013700 8-9 1014034 12-5
1012604 5-3 1013734 9-3, 12-31 1014035 12-5
1012605 5-3 1013746 8-3, 8-7 1014036 12-5
1012649 8-3 1013754 1-13 1014039 12-5
1012651 12-5 1013756 14-5 1014045 12-11
1012710 14-5 1013757 14-5 1014049 10-3
1012711 11-3, 14-5 1013758 14-5 1014050 10-3
1012714 11-5 1013759 11-3, 14-5 1014051 10-3
1012740 11-5 1013763 14-5 1014052 10-3
1012741 11-5 1013764 14-5 1014055 10-3
1012747 11-5 1013765 14-5 1014056 10-3
1012748 11-5 1013766 14-5 1014057 10-3
1012752 11-3 1013767 14-5 1014058 10-3
1012809 16-5 1013768 11-7, 14-5 1014059 10-3
1012811 16-3 1013769 11-7, 14-5 1014062 10-3
1012812 16-3 1013770 11-7, 14-5 1014065 6-5, 6-7
1012830 6-13, 9-3 1013771 11-7, 14-5 1014070 10-5
1012903 12-9 1013772 11-7, 14-5 1014072 10-5
1012981 7-5 1013773 11-7, 14-5 1014078 10-5
1012987 6-5, 12-7, 12-15 1013774 11-7, 14-5 1014080 10-5
1013001 6-11 1013775 14-5 1014089 6-5
1013003 6-11 1013779 14-5 1014109 12-9
1013005 6-11 1013780 14-5 1014115 16-7
101301102 6-11 1013781 14-5 1014116 8-3
1013032 1-7, 1-9 1013782 14-5 1014119 6-3
1013035 5-5 1013785 14-5 1014125 5-3
1013042 5-5 1013786 14-5 1014126 5-3
1013044 5-5 1013787 11-7, 14-5 1014145 6-5, 6-7
1013051 5-5 1013790 11-7, 14-5 1014153 4-3
1013052 5-5 1013791 11-7, 14-5 1014161 16-7
1013061 12-9, 12-17, 12-29 1013792 14-5 1014162 16-7
1013092 12-5, 12-13 1013794 11-7, 14-3, 14-5 1014189 12-9
1013135 5-9 1013860 12-9 1014193 11-7, 14-5
1013140 1-7, 1-9 1013861 5-3 1014198 1-5, 3-5
1013164 5-11 1013869 4-5 1014201 13-3, 13-5, 13-7
1013198 6-5, 12-7, 12-15 1013870 4-5 1014207 11-7, 14-5
1013207 4-3, 5-11 1013871 4-7 1014213 5-3
1013266 12-13 1013876 4-5 1014214 5-3
1013343 1-3 1013886 12-9 1014216 5-3
1013344 1-3 1013887 12-9 1014217 5-3
101342501 12-13 1013924 4-3, 7-15 1014235 5-7
101347501 1-5 1013935 1-13 1014236 5-11
1013494 1-3 1013971 12-11 1014253 12-9
1013496 3-5 1013998 12-9 1014259 16-5
1013531 4-5 1014000 12-9 1014264 16-5
1013582 16-3 1014003 12-9 1014276 5-9

Page i-2 2003 DS Golf Cars Illustrated Parts List

 INDEX
1014287 10-3 101547601 3-3 101621601 3-3, 3-5
1014288 5-3, 6-15, 12-19, 12-31 1015524 16-3 1016219 5-3
1014289 6-11 1015525 1-7, 1-9 1016263 5-3
1014304 12-13, 12-17, 12-29 1015545 5-3 1016269 5-3
1014305 16-3 1015583 5-9, 5-11 1016282 15-7
1014306 1-7, 1-9 1015597 5-5, 5-7, 5-9 1016289 10-3
1014374 6-15 1015649 7-3 1016336 15-7
1014375 6-15 101570501 2-3 1016337 11-5
1014413 8-9 101570507 2-3 1016338 11-5
1014414 12-9 101570509 2-3 1016341 11-3
1014453 10-3 101570513 2-3 1016342 6-5
1014454 10-5 1015707 2-3 1016346 5-7
1014476 12-11 1015720 6-9 1016349 5-7
1014482 1-13 1015737 6-3, 6-7 1016350 5-7
1014496 16-3 1015741 6-7 1016353 5-7
1014497 16-3 1015752 6-7, 8-11, 12-21 1016379 1-3
1014498 16-3 1015769 6-3 1016384 5-9
1014507 16-3 1015777 6-7 1016385 5-7
1014508 16-3 1015814 9-3 1016386 5-9
1014510 16-3 1015845 8-9 1016387 5-9
1014516 12-13 101584502 8-9 1016389 5-9
1014523 8-3 1015878 6-7 101641002 16-3
1014524 8-3 1015905 15-3, 15-5, 15-7 101641101 16-7
1014528 12-7, 12-15 1015906 15-3, 15-5, 15-7 101641201 16-7
1014555 5-11 1015907 15-3 101641202 16-7
1014645 1-3 1015910 15-3, 15-5 1016413 16-7
1014696 15-5 1015911 15-3, 15-5, 15-7 1016414 16-5
1014727 6-5 1015912 15-3 1016415 16-5
1014728 12-11 1015913 15-3, 15-5, 15-7 1016416 16-3
1014729 12-11 1015914 15-3, 15-5, 15-7, 15-9, 15-13, 1016417 16-3
1014735 12-9 15-15 1016418 16-5
1014771 2-3 101591601 15-3 101642572 8-5
1014807 6-5, 6-7, 12-9 101591602 15-3 101642575 8-5
1014808 6-7, 12-7, 12-15 1015917 15-3, 15-5, 15-7, 15-9, 15-13 101642578 8-5
1014828 12-5 1015920 6-3, 6-13 101642580 8-5
1014871 12-15 1015932 6-13 101642582 8-5
1014928 8-3 1015936 15-5 1016429 7-7
1014947 12-19, 12-23, 12-31 1015939 15-7 1016430 7-9
1014948 12-13, 12-19 1015969 7-3 1016431 7-9
1014999 12-9 1016003 8-3 1016432 7-7, 11-3
1015032 1-3, 1-5, 1-7, 1-9 1016068 12-5 101643301 15-3, 15-5, 15-7
1015072 12-13, 12-17, 12-29 1016069 12-5 101643302 15-3, 15-5, 15-7
1015075 1-13, 6-13, 9-3 1016070 12-5 101643303 15-3, 15-5, 15-7
1015137 8-3, 8-7 1016074 6-13 101643401 15-5
1015139 8-3 101610901 3-5, 12-9 1016435 7-7
1015143 8-3 101611003 16-7 1016436 7-9
1015188 8-3 1016112 16-7 1016437 8-5
101524001 6-13 1016140 12-9 1016438 8-7
1015330 9-3 1016154 5-3 1016439 8-7
1015332 6-3, 7-3 1016156 5-3 1016440 8-7
1015345 6-7 1016175 12-9 1016441 8-7
1015371 6-7 1016181 5-3 1016442 7-9
1015372 6-7 1016183 5-3 1016443 7-3
1015373 6-7 1016201 6-5 1016444 8-7
1015405 6-7 1016202 8-9 1016445 7-5
1015408 8-9 1016203 10-3, 10-5 1016446 7-11
1015426 8-11 1016214 5-3 1016447 7-9

2003 DS Golf Cars Illustrated Parts List Page i-3

 INDEX
1016448 7-9 1016519 7-9 1016583 7-9
1016449 7-9 1016520 7-11 1016584 7-11
1016450 7-9 1016521 7-11 1016585 8-5
1016451 7-9 1016523 7-9 1016586 7-5
1016452 7-9 1016524 7-3 1016587 7-5
1016453 7-11 1016525 7-3 1016588 7-5
1016454 7-11 1016526 7-3 101660404 1-3
1016455 7-5 1016531 7-3 101661601 12-13
1016456 7-3, 7-5, 7-11 1016532 7-13 101661602 12-13
1016457 7-7 1016533 7-13 1016622 5-3
1016458 7-9, 7-11 1016535 7-11 1016627 16-5
101645901 7-13 1016536 7-3 1016630 6-9
101645902 7-13 1016537 7-7 1016663 5-3
101645903 7-13 1016538 7-11 1016672 11-7, 14-5
1016460 7-13 1016539 7-3 1016801 10-3
101646101 7-13 1016541 7-13 1016845 12-7, 12-15
101646102 7-13 1016542 7-9 1016849 6-9, 12-3
101646103 7-13 1016544 7-5, 7-9, 7-11 1016851 6-9, 12-3
101646201 15-7 1016545 7-9, 12-19 1016859 6-9, 12-3
101646401 15-3 1016546 8-9 1016868 1-5
1016467 7-7 1016547 7-3, 7-13, 8-7 1016875 1-3
1016469 7-13 1016548 7-5 1016876 1-3
1016470 7-13 1016549 7-9 1016883 6-13
1016471 7-9 101655001 7-13 1016896 12-7
1016472 7-11 101655002 7-13 1016916 1-11
1016473 7-7 101655003 7-13 101692501 1-5
1016474 7-9 101655004 7-13 101692502 1-5
101647501 7-13 101655005 7-13 101692504 1-5
101647502 7-13 101655006 7-13 101692506 1-5
1016479 7-9 101655007 7-13 101692509 1-5
1016480 8-7 101655008 7-13 101692510 1-5
101648102 8-7 101655009 7-13 101692511 1-5
101648203 7-7 1016551 16-7 101692512 1-5
1016483 7-9 1016552 16-7 101692513 1-5
1016484 7-7 1016553 16-7 101692601 1-7
1016486 8-5 1016554 16-7 101692602 1-7
1016489 7-9 1016558 7-13 101692604 1-7
101649002 8-7 1016559 7-13 101692606 1-7
1016493 7-5 1016560 7-9 101692609 1-7
1016494 7-11 1016561 7-5 101692610 1-7
1016496 7-11 1016562 7-5, 7-13 101692611 1-7
1016497 7-5 1016563 7-9 101692612 1-7
1016499 8-5 1016564 7-11 101692613 1-7
1016501 8-5 1016565 7-11 101693301 1-9
1016502 7-7 1016566 7-9 101693302 1-9
1016505 7-5 1016567 7-11 101693304 1-9
1016506 7-11 1016568 7-13 101693306 1-9
1016507 7-3 1016569 7-9 101693309 1-9
1016509 7-13 1016570 7-7 101693310 1-9
1016510 7-11 1016571 7-13 101693311 1-9
1016512 7-3 1016572 8-7 101693312 1-9
101651401 2-3 1016576 7-7 101693313 1-9
101651407 2-3 1016578 7-5 101693901 1-5
101651409 2-3 1016579 7-5 101693902 1-5
101651413 2-3 1016580 7-13 101693904 1-5
1016516 7-13 1016581 7-7 101693906 1-5
1016517 7-9 1016582 8-7 101693908 1-5

Page i-4 2003 DS Golf Cars Illustrated Parts List

 INDEX
101693909 1-5 1017704 14-5 101823201 4-3
101693910 1-5 1017705 12-17, 12-29 101823301 4-3
101693911 1-5 1017748 1-7, 1-9 101823302 4-3
101693912 1-5 1017774 1-13 101823801 4-3
1016947 6-5 1017799 12-15 101823901 4-3
1016952 1-3 1017814 1-9 101824001 4-3
101696201 1-9 1017815 1-9 101824002 4-3
101696202 1-9 101791101 4-3 101824401 8-3
101696204 1-9 1017936 1-7, 1-9 101825101 3-3, 3-5
101696206 1-9 1017944 13-3, 13-5, 13-7 101826201 12-3
101696208 1-7 1017945 13-3 101826301 6-9
101696209 1-7 1017946 13-3, 13-5 101827101 7-15
101696211 1-7 1017947 13-3, 13-5, 13-7 101827801 12-19, 12-31
101696213 1-7 1017948 13-3, 13-5, 13-7 101828301 15-9
101696215 1-7 1017949 13-3, 13-5, 13-7 101828501 15-9, 15-13
101696216 1-7 1017950 13-3, 13-5, 13-7 101828601 15-9, 15-11
101696217 1-9 1017951 13-3, 13-5 101828801 15-9, 15-11
101696218 1-9 1017952 13-3 101828802 15-9, 15-11
101696219 1-7 1017953 13-3, 13-5, 13-7 101828901 15-9, 15-13, 15-15
101696220 1-7 101795701 12-17, 12-23, 12-25, 12-29 101828902 15-9, 15-13, 15-15
101696221 1-7 1017958 13-5 101828903 15-9, 15-13, 15-15
101696222 1-9 1017961 13-5 101828904 15-11
101696223 1-9 101796201 4-7 101828905 15-11
101696224 1-9 101796501 12-17, 12-29 101828906 15-11
1016967 1-5 101796801 12-17, 12-29 101830601 6-9
1017029 4-5 101797701 12-17, 12-29 101830701 6-9, 12-3
101706702 1-3 101797702 12-17, 12-29 101831101 15-9
1017079 1-3 101797801 12-17, 12-29 101831401 12-13
1017080 1-5 101801001 12-17, 12-29 101831503 15-13
101708301 1-3 101802101 12-17, 12-29 101831504 15-13
1017141 1-7, 1-9 101802201 15-9 101831701 15-13
1017203 8-3 101802202 15-9 101831702 15-13
1017221 7-3 101802203 15-9 101831801 16-3
1017226 5-3 101802204 15-11 101831901 16-3
1017231 11-3 101802205 15-11 101832001 12-17, 12-29
1017266 5-7 101802206 15-11 101832101 7-15
1017273 5-3 101802601 1-3, 12-3 101832201 8-9
1017327 10-5 101804301 8-11 101832202 8-9
1017328 10-3 101805701 8-11 101832301 8-9
1017378 4-7 101808401 16-3 101832302 8-9
1017380 4-7 101809101 16-3 101832401 8-9
1017424 4-7 101811401 8-11 101832501 8-9
1017448 7-5 101811501 8-11 101832701 7-15
1017455 7-5 101811901 8-11 101832901 7-15
1017456 7-7 101812301 8-11 101833001 7-15
1017461 8-5 101813202 16-3 101833201 7-15
1017466 8-7 101815501 4-3 101833301 7-15
1017507 7-7 101815502 4-3 101833401 10-5
101753005 12-15 101816301 4-3 101833601 11-3
1017653 6-11 101816501 4-3 101833701 6-11, 6-13
101768202 1-3 101816502 4-3 101833902 10-3
1017686 10-5 101817401 4-7 101834001 10-5
1017689 9-3 101818801 4-7 101834502 6-9, 12-3
1017692 12-9 101819701 15-9 101834601 7-15
101769302 2-3 101820201 8-7 101834801 11-3
1017696 4-7 101821501 8-11 101835601 1-15
1017703 14-5 101823101 16-5 101836201 10-5

2003 DS Golf Cars Illustrated Parts List Page i-5

101837101 8-11 101884801 7-15 101906201 14-3
101837301 6-3, 6-13 101887101 16-3 101906901 14-3
101838201 15-13 101887601 7-3, 8-7 101908101 12-27
101838301 15-13 101887901 12-31 101908401 12-27
101838401 15-13, 15-15 101889302 6-3 101908601 3-5
101838501 15-13 101889401 11-5 101908701 12-19, 12-31
101838601 15-13, 15-15 101889901 11-5 101909201 7-5
101838701 15-13 101890001 11-5 101909301 7-5
101840201 12-19 101890101 11-3 101909401 7-5
101850301 8-11 101890201 11-3 101909501 7-5
101851101 6-9 101890601 11-3 101909701 7-3
101855002 12-27 101890901 11-7 101909901 12-19
101855801 6-5 101891001 11-7 101909902 12-31
101855901 7-15 101891301 11-3 101910401 1-13, 12-19, 12-31
101856001 12-27 101891401 11-7 101910501 11-7, 14-5
101856102 6-7 101891501 11-7 101912401 4-7
101856201 8-11 101891601 11-5 101914401 15-9, 15-13
101859301 9-3 101891901 11-5 101915201 3-3
101861901 4-7 101892001 11-5 101915401 7-11
101862001 4-7 101892201 11-5 101915501 7-13
101869302 6-11 101892301 11-5 101915601 7-3
101871001 16-3 101892401 11-5 101915701 7-5
101871901 4-7 101892501 11-5 101915801 7-5
101874901 6-11 101892601 11-5 101916501 10-3
101875001 6-11 101892701 11-7 101916701 6-13, 10-3
101875101 6-11 101893201 11-5 101917601 8-11
101875201 6-11 101894901 12-17, 12-29 101917701 8-11
101875301 6-11 101895401 14-3 101920001 12-25
101875401 6-11 101895501 14-3 101920101 12-19, 12-21, 12-27, 13-7
101875501 6-11 101895601 14-3 101921501 8-11
101875601 6-11 101895701 14-3 101922101 14-3
101875701 6-11 101895801 14-3 101922201 14-3
101875802 6-11 101895901 14-3 101922301 7-13
101876001 6-11 101896001 14-3 101922501 12-27
101876202 6-11 101896501 6-11 101922601 6-5, 11-3
101876301 6-11 101896901 8-3 101923001 14-3
101876402 6-11 101897001 14-3 101923201 14-3
101876501 6-11 101897201 14-3 101923501 14-3
101877601 6-11 101897401 14-3 101923601 14-3
101877701 6-11 101897601 14-3 101923701 14-3
101878101 6-11 101897901 14-3 101923901 14-3
101878201 4-5 101898001 6-15 101925701 8-11
101878302 5-5 101900801 4-3, 5-11 101927101 11-3
101879001 6-11 101900901 6-9 101927201 11-3
101879401 5-5 101901201 12-23 101927501 11-5
101879501 5-5 101901301 12-23 101927601 11-5
101879601 5-5 101901401 12-23 101927901 11-5
101879701 5-5 101901501 12-23 101928001 11-5
101879801 5-5 101902801 12-23 101928101 11-5
101879901 5-5 101902901 12-23 101928301 11-7
101880001 5-5 101903001 12-23 101928701 11-3, 14-3, 14-5, 16-5
101880101 5-5 101903101 5-9 101929801 10-3
101880201 5-5 101903501 8-9 101931501 3-5
101880301 5-5 101903601 14-3 101932401 12-27
101881101 7-5 101903701 14-3 101932501 12-27
101881701 8-11 101904101 1-7, 1-9 101932601 12-31
101883002 12-23 101905601 8-5, 8-7 101932701 12-31
 INDEX
101933101 16-5 101997211 16-7 102249901 16-3
101935501 12-3 101997212 16-7 102250201 12-15
101936801 12-21 101998201 1-11 102251501 16-5
101939901 6-11 101998202 1-11 102251901 13-7
101942301 12-19, 12-27, 13-7 101998204 1-11 102259001 1-5, 3-5
101949201 12-9 101998205 1-11 102259801 12-31
101951501 6-5 101998501 1-11 102263601 12-25, 12-31
101953001 4-5 102003201 8-3 102263701 12-31
101953101 4-5 102018001 12-5 102265501 13-7
101953901 7-3 102022101 4-3, 4-5 102265601 13-7
101954301 1-11 102026001 4-7 102265701 13-7
101956201 15-15 102047201 12-13 102265901 13-7
101956202 15-15 102048301 12-13 102266001 13-7
101958101 8-11 102060501 1-13 102266101 13-7
101958201 15-15 102060502 1-13 102266501 12-31
101958301 15-15 102060504 1-13 102266601 12-27
101959902 3-5 102060505 1-13 102266701 12-27
101960501 3-3 102061201 16-7 102267001 13-7
101960601 3-3, 3-5 102061301 1-15 102273201 15-11
101965201 12-19, 12-31 102061302 1-15 102273301 15-11
101965602 12-31 102063901 1-15 102273401 15-11
101966901 4-7 102064601 1-15 102273501 15-11
101968701 12-25 102065501 1-15 102273601 15-11
101971001 8-11 102076701 1-13, 1-15 102273701 15-11
101971301 8-11 102099101 1-15 102273801 15-11
101972101 14-3 102101001 12-21 102273901 15-11
101972201 14-3 102101101 12-21 102274001 15-11
101972401 14-3 102155501 1-15 102278001 5-3
101972801 8-11 102162101 12-23 102304701 7-9
101973101 8-5 102169401 16-5 102310701 1-5
101973201 8-5 102174201 1-11 102323101 4-5
101973501 15-15 102174202 1-11 102323201 4-5
101975901 12-13 102174204 1-11 102327801 13-7
101976001 14-3 102174205 1-11 102330901 16-5
101976601 15-15 102196601 12-25 102336001 8-9
101978001 12-25 102198301 1-15 102336101 8-9
101978101 12-25 102199601 12-25 102355301 6-15
101978201 12-25 102221201 1-3, 1-7, 1-9 727102 2-3
101979101 6-5, 12-15 102235201 13-3, 13-5, 13-7
101980801 11-5 102236601 1-13 A
101980901 11-5 102236703 1-13 ac voltage suppressor 15-15
101981001 11-5 102237001 1-13 accelerator pedal 4-7
101984801 5-3 102237401 13-3 accelerator pedal adjustment tool 16-3
101985501 1-11 102237701 13-5 accelerator pedal return spring cup 4-7
101987501 15-15 102238301 1-13 accelerator pivot rod 4-7
101987601 1-11 102238302 1-13 accelerator rod 4-7
101987701 8-3 102238304 1-13 access door 1-7, 1-9
101990801 4-5 102238305 1-13 accu-power charger 15-3, 15-5, 15-7
101992601 6-7 102240102 13-7 a-connector (starter/generator) 6-11
101997201 16-7 102240501 12-31 adaptor, cable (IQDM) 16-5
101997202 16-7 102240601 12-31 adhesive, guide ring 16-3
101997203 16-7 102240801 12-31 adjuster, hydraulic brake 16-5
101997204 16-7 102241502 16-5 adjusting stud 12-9
101997205 16-7 102242101 10-5 air box 8-11
101997206 16-7 102242401 1-13 air duct 8-11
101997207 16-7 102243402 16-5 air duct repair kit 8-11
101997209 16-7 102248803 16-5 air filter 8-11

2003 DS Golf Cars Illustrated Parts List Page i-7

 INDEX
ammeter 15-3, 15-5, 15-7, 15-9, 15-11, seat back 1-13 15-15
15-13, 15-15 seat bottom 1-11 battery charger, PowerDrive 2 15-11
a-plate strap 5-7 spindle 5-9 battery clamp 6-15
arbor 16-7 stator shell 13-3, 13-5, 13-7 battery hold-down 12-13, 12-17, 12-29
arm steering column 5-3 battery warning light 12-3
governor lever 11-3 steering gearbox 5-5 battery, 12-volt 6-15
pivot 11-3 switch brush 12-9 bearing
rocker 7-9 timer 15-3, 15-5, 15-7 ball (crankshaft) 7-11
speed switch 12-9 transformer 15-3, 15-5, 15-7, 15-9, ball (motor) 13-3, 13-5, 13-7
armature 6-11, 13-3, 13-5, 13-7 15-11, 15-13, 15-15 ball, input shaft 11-5
armrest 1-11 v-glide wiper switch 12-9 ball, output shaft 6-11
assembly voltage regulator 6-7 bronze 12-9
3-pin plug 13-7 voltage suppressor 15-9, 15-13 differential 14-3
6-pin plug 12-31 wheel and tire 2-3 idler (drive clutch) 10-3
36-volt motor 13-3 wire 6-3, 6-7, 6-9, 6-13, 7-3, 12-5, 12-9, inner axle tube 11-7, 14-5
48-volt motor 13-5 12-13, 12-17, 12-23, 12-25, input gear 14-3, 14-5
ac voltage suppressor 15-15 12-29, 12-31, 15-11, 15-13,
intermediate gear 14-3, 14-5
15-15
accelerator rod 4-7 lower pinion 5-5
wire, sense lead 12-17, 12-29
air box top 8-11 needle 11-5
axle 11-7, 14-3, 14-5
air duct 8-11 outer axle tube 11-7, 14-5
axle shaft seal 14-3
armature 6-11 pivot support 4-7
axle tube 11-7, 14-3, 14-5
axle 11-7, 14-3, 14-5 plain (counterbalance rod) 7-13
axle tube oil seal 14-5
axle tube 14-3, 14-5 thrust 5-9
bag hoop 1-13 upper pinion 5-5
bearing (steering column) 5-3
B
bearing and oil seal remover 16-3
bell crank and shaft 6-7 backing plate (brake) 4-3
bearing driver set 16-3
bolt (float chamber) 8-5 bag hoop 1-13
bearing puller 16-3
brush rigging 13-7 bag strap 1-13
bearing puller wedge 16-3
carburetor 8-5 bag strap buckle 1-13
bearing retainer 13-3, 13-5, 13-7
charger case 15-3, 15-5, 15-7, 15-9, bagwell protector 1-3
bearing retainer (starter/generator) 6-11
15-11, 15-13, 15-15 ball bearing, output shaft 6-11
bearing retainer screw 13-3, 13-5
control cable 15-3, 15-5, 15-7 ball joint 6-5
bell crank 12-9
current limiter 15-15 ball joint (tie rod) 5-7
bell crank and shaft 6-7
cylinder head 7-9 ball joint, inner 5-5
bell crank, forward/reverse 6-5
delta a-plate 5-7 ball joint, left-hand thread 5-5, 5-7
belt, drive 10-3, 10-5
diode 12-19 ball stud 6-5, 6-7
belt, starter/generator 6-13, 10-3
diode with heatsink film 15-11 ball stud (shifter lever) 11-3
bezel, receptacle 12-13, 12-17, 12-29
drive hub 10-3 ball stud, accelerator pedal 4-7
block
driven clutch 10-5 ball, steel (shift fork retainer) 11-5
brake pedal mounting 4-5
eccentric 5-9 ball, steel, pressure relief 7-7
fuse 6-7
end shield 13-7 band, rpm limiter mount 7-5
terminal (controller) 12-31
float (carburetor) 8-5 bar, bus 12-15
board, resistor mounting 12-11
float chamber 8-5 bar, drive 12-21
body (rear) 1-7, 1-9
forward/reverse shifter 6-5 barb, vent 8-3
body hinge plate 1-7, 1-9
forward/reverse switch 12-7, 12-15, barrel fastener 1-13
body keeper clip 1-7, 1-9
12-27 barrel, plastic 1-3
body kick plate 1-7, 1-9
fuel strap, rear 8-3 base, forward/reverse shifter 6-5
body spacer 1-13
heatsink 15-3, 15-5, 15-7, 15-9, 15-13, base, mounting 12-13
body support 1-7, 1-9
15-15 basket, sweater 1-13
body, front 1-5
hub 5-9 battery
bolt, brake cluster mounting 4-3
idle screw 8-5 6-volt 12-13
bolt, j- 12-13, 12-17, 12-29
lever (brake) 4-3 8-volt 12-17, 12-29
boot
moveable face (driven clutch) 10-5 discharge machine 16-3
dust 5-5, 5-7
pilot air screw 8-5 terminal protector spray 16-3
steering column 5-3
resistor 12-19, 12-23, 12-31 thermometer 16-3
tow/run switch 12-27
rod (counterbalance) 7-13 battery cap 12-13, 12-17, 12-29
box, electrical component 6-7
screw (float chamber) 8-5 battery charger, PowerDrive 15-9, 15-13,
bracket

Page i-8 2003 DS Golf Cars Illustrated Parts List

 INDEX
accelerator support 8-9 bronze 5-9, 6-5, 6-7 charger, PowerDrive battery 15-9, 15-13,
adjusting (starter/generator) 6-13 drive clutch 10-3 15-15
engine shroud 7-3 insulator 13-3, 13-5, 13-7 choke button 8-11
fe290 mounting 6-13 stain relief 15-3, 15-13 choke valve 8-11
fuse and receptacle mounting 12-13 steel 5-9, 5-11 choke valve o-ring 8-11
governor cable engine 8-9 strain relief 15-5, 15-7, 15-9, 15-11, circuit breaker (15-amp) 15-9, 15-11
muffler mounting 9-3 15-15 clamp
oil filter 7-7 urethane 5-7, 5-9, 5-11 battery 6-15
oil level switch 7-11 bushing (axle) 14-5 cable 12-13
power relay mounting 15-13 buzzer, reverse 12-3 cable retaining 8-9
rpm limiter 7-5 hose (air intake) 8-11
snubber 7-15 C hose (bronze) 8-7
steering column mounting 5-3 cable hose (fuel) 8-3
support 8-9 accelerator 8-9 hose (gray) 8-3, 8-7
throttle 8-7 accelerator, snap-in 8-9 hose (red) 8-3
tow/run switch 12-27 brake 4-3, 4-5 muffler 9-3
transmission cable support 6-5, 11-3 control 15-3, 15-5, 15-7 plastic (fuel line) 8-3
brake adjusting mechanism 4-3 governor 8-9 clamp (oil sending wire) 7-11
brake adjustment tool 16-3 governor, snap-in 8-9 clamp (wire) 7-5
brake cable 4-3, 4-5 IQDM 16-5 clamp screw 13-3, 13-5, 13-7
brake cable equalizer 4-5 transmission 6-5 clevis, upper delta 5-9
brake cable hanger 4-3, 5-11 cable retainer 6-5 clip 5-3
brake cluster 4-3 calibration test module 16-3 clip, body keeper 1-7, 1-9
brake cluster mounting bolt 4-3 cam (driven clutch) 10-5 cluster, brake 4-3
brake drum 4-3 cam installation tool 16-3 clutch alignment tool 16-3
brake pedal 4-5 cam, electrical box 6-7 clutch tool kit 16-3
brake pedal adjustment tool 16-3 cam, neutral lockout 6-5 clutch, drive 10-3
brake pedal mounting block 4-5 camshaft 7-11 clutch, driven 10-5
brake pedal pad 4-5 canopy 1-15 coil
brake pedal stop bumper 4-5 canopy support kit 1-15 field 6-11
brake pedal tension tool 16-3 cap ignition 7-5
brake shoe 4-3 6-volt battery 12-13 resistor 12-11
brake spring 4-3 battery (4-port) 12-17, 12-29 collar (axle shaft) 11-7
breaker, circuit, 10-amp 15-13, 15-15 dust 12-27 collet 7-9
breaker, circuit, 15-amp 15-9, 15-11 fuel tank 8-3 column, steering 5-3
breather 14-3, 14-5 key switch 6-9, 12-3 communication display module 16-3
breather, transaxle case 11-3 protector 12-9 component mounting plate 12-19, 12-31
bronze bushing 6-5, 6-7 seat back 1-13 compression gauge 16-3
brush 6-11, 13-3, 13-5, 13-7 capacitor 15-3, 15-5, 15-7 compressor, piston ring 16-5
brush connector 6-11 carburetor 8-5, 8-7 compressor, valve spring 16-7
brush holder 6-11 carburetor insulator 8-7 computer, onboard 12-19, 12-31
brush holder screw 13-3, 13-5 card, safety first 16-5 connecting rod 7-13
brush inspection port cover 6-11 care kit, vehicle 16-7 connector
brush rigging 13-3 carrier, wiper switch arm 12-9 4-pin 12-27
brush spring 6-11, 12-9, 13-3, 13-5, 13-7 case cord 7-11
brush, switch 12-9 charger 15-3, 15-5, 15-7, 15-9, 15-11, IQ controller 12-31
buckle, bag strap 1-13 15-13, 15-15 continuity tester 16-5
bumper forward/reverse switch 12-27 control cable 15-3, 15-5, 15-7
brake pedal stop 4-5 gear carrier 11-7 controller, 48-volt (225-amp) 12-19
front 1-5 rocker arm 7-9 controller, 48-volt (250-amp) 12-31
motor 13-3, 13-5, 13-7 wiper switch 12-9 cord connector 7-11
rear 1-3 case gasket 14-5 cordset, ac 15-3, 15-5, 15-7, 15-9, 15-11,
return spring 4-7 charger case 15-3, 15-5, 15-7, 15-9, 15-11, 15-13, 15-15
side guard trim 1-5 15-13, 15-15 cordset, dc 15-3, 15-5, 15-7, 15-9, 15-11,
charger, accu-power, battery 15-3, 15-5, 15-13, 15-15
wiper switch 12-9
15-7 counterbalance guide shaft 7-13
bus bar 12-15
charger, PowerDrive 2 battery 15-11 counterbalance weight 7-13
bushing

2003 DS Golf Cars Illustrated Parts List Page i-9

 INDEX
cover drink holder 1-3 fuel 8-3
brush inspection port 6-11 drive bar 12-21 oil 7-7
controller 12-31 drive belt 10-3, 10-5 fitting, grease 5-9
crankcase 7-11 drive clutch 10-3 fitting, thread-forming grease 5-5, 5-7
dust 4-3, 5-9 drive clutch button 10-3 fixed face (drive clutch) 10-3
electrical component box 6-7 drive clutch holder tool 16-3 fixed face (driven clutch) 10-5
gear case 11-7 drive clutch hub puller 16-3 float (carburetor) 8-5
oil pump 7-7 drive clutch puller 16-3 float chamber 8-5
seat back 1-13 drive hub 10-3 floor mat 1-3, 1-5, 1-7, 1-9
seat bottom 1-11 driven clutch 10-5 flywheel 7-5
steering column 5-3 driven clutch cam puller 16-3 flywheel fan 7-5
wiper switch case 12-9 driven clutch puller plug 16-3 flywheel puller 16-5
crank, bell 12-9 driver, drive clutch 10-3 fork, shift 11-5
crankcase 7-13 drum, brake 4-3 forward/reverse bell crank 6-5
crankcase cover 7-11 dry moly lubricant 16-5 forward/reverse handle 6-5
crankshaft 7-13 dust boot 5-5, 5-7 forward/reverse shifter 6-5
crankshaft seal 7-11 dust cap 12-27 forward/reverse shifter base 6-5
crankshaft shim 7-13 dust cover 4-3, 5-9 forward/reverse switch 12-7, 12-15, 12-27
cup, accelerator pedal return spring 4-7 forward/reverse switch case 12-27
current limiter 15-15 E forward/reverse switch handle 12-7, 12-15
cutter, valve seat 16-7 8-volt battery 12-17, 12-29 front body 1-5
cylinder head 7-9 80-amp fuse 12-13 front spring retainer plate 5-9
eccentric 5-9 f-terminal insulator 6-11
D e-clip (air box top) 8-11 fuel filter 8-3
damper, rpm limiter 7-5 electrical box cam 6-7 fuel impulse pump 8-3
dash panel, center 1-3 electrical component box 6-7 fuel line 8-3
dash, driver side 1-3 emblem, IR 1-5, 3-5 fuel pickup tube (valve) 8-3
dash, passenger side 1-3 end bell, commutator 6-11 fuel strap, rear 8-3
decal end bell, output shaft 6-11 fuel tank 8-3
driver/passenger warning 3-3, 3-5 end shield 13-3, 13-5, 13-7 fuse
electrical component cover 3-5, 12-31 engine shroud 7-3 10-amp 6-7
frame ground and governor warning 3-3 engine valve spring 7-9 3/8-amp 12-17, 12-29
gasoline warning 3-3 engine, fe290 ohv gasoline 7-3 30-amp 15-11
key switch 3-3, 3-5 equalizer rod 4-5 80-amp 12-13
motor braking 3-5 equalizer, brake cable 4-5 charger 15-3, 15-5, 15-7, 15-9, 15-13,
15-15
operating instructions 3-3, 3-5 exhaust gasket 9-3
fuse block 6-7
potentiometer caution 3-5 exhaust system 9-3
fuse holder 12-13
resistor warning 3-5 exhaust valve 7-9
fuse lens 12-13
rotating parts and hot manifold
warning 3-3 F
tow/run switch 3-5
4-pin plug and wedge lock 12-27
G
wiper switch warning 12-9 gasket
4-pin receptacle and wedge lock 12-27
delta a-plate 5-7 carburetor insulator 8-7
48-volt motor, 3.10-hp 13-5
delta shock and gear support 5-7 case 14-5
48-volt motor, 3.20-hp 13-7
delta sleeve 5-7 controller 12-31
48-volt solenoid 12-19, 12-31
differential bearing 14-3 crankcase cover 7-11
fan housing 7-3
differential gear 11-7, 14-3, 14-5 drain plug 7-7, 11-3
fan shroud 7-3
differential gear case 11-7, 14-5 exhaust 9-3
fan, flywheel 7-5
differential housing 14-3 fe290 7-9
fastener, barrel 1-13
differential idler gear 11-7, 14-3, 14-5 float chamber 8-5
fe290 ohv gasoline engine 7-3
differential pin 11-7, 14-3 head 7-9
fender, inner 1-7, 1-9
diode 12-13, 12-19 insulator 8-7
field coil (starter/generator) 6-11
dipstick 7-3 intake pipe 8-7
fill plug 14-3
door, access 1-7, 1-9 liquid 14-3, 14-5, 16-5
fill plug with gasket 14-5
double lip seal 5-9 liquid (transaxle case) 11-3
filter
drag link, rack and pinion 5-5 oil pump 7-7
air 8-11
drain plug (crankcase) 7-7 plug 14-3

Page i-10 2003 DS Golf Cars Illustrated Parts List

 INDEX
rocker arm case 7-9 hose, intake 8-11 key (vehicle) 6-9, 12-3
seat 1-11 housing key switch 6-9, 12-3
throttle bracket 8-7 differential 14-3 key switch cap 6-9
gauge, compression 16-3 fan 7-3 key switch nut 6-9, 12-3
gear female 3-wire 13-7 kingpin 5-9
cluster idler 11-5 field coil (starter/generator) 6-11 kingpin wave washer 5-9
differential 11-7, 14-3, 14-5 hub 5-9 kit
differential idler 11-7, 14-3, 14-5 hub, drive 10-3 2-pin plug 12-21
helical (crankshaft) 7-13 hub, synchronizer clutch 11-5 3-pin plug 12-19, 12-21, 13-7
input 11-5 hydraulic brake adjuster 16-5 3-pin plug and wedge lock 12-27
intermediate 14-3, 14-5 hydrometer 16-5 3-pin receptacle 12-19
intermediate, small 14-5 3-pin receptacle and wedge lock 12-27
output 11-7, 14-3, 14-5 I 4-pin plug and wedge lock 12-27
spur (crankshaft) 7-13 idle screw 8-5 4-pin receptacle and wedge lock 12-27
spur (transaxle) 11-5 ignition coil 7-5 6-pin plug 12-31
gear case 11-3, 14-3, 14-5 inner axle tube bearing 14-5 6-pin receptacle 12-31
gear yoke 16-5 inner fender 1-7, 1-9 accelerator pivot rod 4-7
governor 11-5 input gear bearing 14-3, 14-5 air duct repair 8-11
governor guard 8-7 input shaft 14-3, 14-5 bagwell protector 1-3
governor lever arm 11-3 input shaft oil seal 14-3, 14-5 bearing and magnet 13-7
governor shaft installation tool 16-5 insert, synchronizer 11-5 brake cable 4-3, 4-5
grease fitting 5-5, 5-7, 5-9 insert, wood 1-11 brake pedal 4-5
grip, pencil 5-3 insulator bushing 13-3, 13-5 brake pedal adjustment tool 16-3
grommet 7-5 insulator gasket 8-7 canopy support 1-15
grommet, insulation 8-3 insulator, carburetor 8-7 differential gear case 11-7
grommet, split 12-9 insulator, f-terminal 6-11 drink holder 1-3
guard, governor 8-7 intake hose 8-11 drive clutch weight 10-3
guard, scuff 1-3 intake pipe 8-7 driven clutch button 10-5
guide intake valve 7-9 fuel impulse pump rebuild 8-3
choke lever 8-11 intermediate gear 14-3, 14-5 fuse and receptacle 12-13, 12-17,
oil (transaxle) 11-5 12-29
intermediate gear bearing 14-5
steering rack 5-5 gasket 7-9
internal retaining ring pliers 16-5
valve 7-9 IQ controller connector 12-31
IQ display module (IQDM) 16-5
valve seat cutter 16-7 IQ display module (IQDM) 16-5
IR emblem 1-5, 3-5
guide ring adhesive 16-3 park brake pedal 4-5
pulley nut and screw 6-11
J
H j-bolt 12-13, 12-17, 12-29
reverse buzzer 6-9
shock absorber cushion 5-11
handle jet, main 8-5
shock absorber, rear 5-11
forward/reverse 6-5 jet, pilot 8-5
snap washer (dash mounting) 1-3
forward/reverse switch 12-7, 12-15 joint
steering column mounting bracket 5-3
PowerDrive 2 15-11 ball 4-5, 6-5
steering column rebuild 5-3
hanger, brake cable 4-3, 5-11 ball (tie rod) 5-7
tune-up 16-7
hardware, terminal (starter/generator) 6-11 compound steering 5-3
vehicle care 16-7
harness retainer 6-9 inner ball 5-5
harness, wire 6-3, 12-23, 12-25 left-hand thread ball 5-5, 5-7
head gasket 7-9 spring-loaded ball 4-7
L
heatsink 15-3, 15-5, 15-7, 15-9, 15-11, latch, park brake 4-5, 4-7
15-13, 15-15 latch, wire (air box) 8-11
K
helical gear (crankshaft) 7-13 lead wire 7-5
key
hold-down, battery 12-13, 12-17, 12-29 lens, fuse 12-13
square 10-5
holder, drink 1-3 lever
sunk 14-5
holder, fuse 12-13 choke 8-11
woodruff 6-11, 11-3
hole plug 12-3 shifter 11-3
key (crankshaft) 7-13
hose clamp 8-3 transmission shifter 11-3
key (driven clutch) 10-5
hose clamp (bronze) 8-7 lever (brake) 4-3
key (flywheel) 7-5
hose clamp (gray) 8-7 light, battery warning 12-3
key (transmission shaft) 11-5
hose clamp (red) 8-3 light, low oil warning 6-9

2003 DS Golf Cars Illustrated Parts List Page i-11

 INDEX
limit switch 6-5, 6-7, 12-7, 12-9, 12-15 o-ring (counterbalance shaft) 7-13 component mounting 12-19, 12-31
limiter, rpm, ohv 7-5 o-ring (oil sending connector) 7-11 flywheel fan 7-5
line, fuel 8-3 o-ring (rocker case hardware) 7-9 front spring retainer 5-9
line, vent (fuel) 8-3, 8-7 o-ring, choke valve 8-11 heatsink 15-11
link, rack and pinion drag 5-5 o-ring, oil filter mount 7-7 lock 14-5
liquid gasket 14-3, 14-5, 16-5 outer axle tube bearing 14-5 mounting (engine) 7-15
lock plate 14-5 output gear 14-3, 14-5 mounting (rear bumper) 1-3
low oil warning light 6-9 oil filter screen 7-11
lower pinion bearing 5-5 P oil pump 7-7
lubricant, dry moly 16-5 package, brush 6-11, 13-3, 13-5 oil valve 7-9
lubricant, moly-teflon 16-5 package, hub bearing 5-9 receptacle backing 12-17, 12-29
lug nut 2-3 pad scorecard 5-3
lug stud 5-9, 11-7, 14-3, 14-5 accelerator pedal 4-7 seat hinge 1-11
brake pedal 4-5 spring mounting 5-7
M mounting (windshield frame) 1-15 thrust 11-5, 11-7, 14-5
magnet 13-7 park brake 4-5 thrust (idler gear) 14-3
magnetic plug 14-3 spring 5-11 pliers
main jet 8-5 wear 1-3, 1-7, 1-9 internal retaining ring 16-5
mat, floor 1-3, 1-5, 1-7, 1-9 paint, touch-up 16-7 piston ring 16-5
MCOR (motor controller output panel, center dash 1-3 retaining ring 16-5
regulator) 12-21 park brake latch 4-5, 4-7 plug
mechanism, brake adjusting 4-3 park brake pedal 4-5 2-pin 12-21
meter, volt ohm 16-7 park brake ratchet 4-7 3-pin 12-19, 12-21, 13-7
module, calibration test 16-3 park brake rod sleeve 4-5 6-pin 12-31
module, communication display 16-3 park brake torsion spring 4-5 cap 7-5
moly-teflon lubricant 16-5 pawl 4-5 drain (crankcase) 7-7
motor pedal drain (transaxle) 11-3
36-volt 13-3 accelerator 4-7 drive clutch 10-3
48-volt 13-5 brake 4-5 driven clutch puller 16-3
48-volt IQ 13-7 park brake 4-5 fill 14-3
motor bumper 13-5, 13-7 pencil grip 5-3 fill with gasket 14-5
mounting base 12-13 pilot air screw 8-5 filter bracket 7-7
mounting block, brake pedal 4-5 pilot jet 8-5 hole 12-3
mounting bracket, fuse and pin hole (dash board) 1-3
receptacle 12-13 differential 11-7, 14-3, 14-5 magnetic 14-3
mounting pad (windshield frame) 1-15 governor cable clevis 8-9 spark 7-5
mounting plate (engine) 7-15 head locating 7-9 plug gasket 14-3
mounting plate (rear bumper) 1-3 piston 7-13 pole set (starter/generator) 6-11
movable face 10-3 roll (shifter lever) 11-3 positioner, choke 8-11
moveable face (driven clutch) 10-5 pin (crankcase cover locating) 7-11 power relay 15-9, 15-11, 15-13
muffler clamp 9-3 pin, bow tie locking 4-5 PowerDrive 2 battery charger 15-11
pin, clevis 4-5 PowerDrive battery charger 15-9, 15-13,
N pinion, steering 5-5
15-15
nameplate 1-5, 3-5 press weldment 16-3
pipe, intake 8-7
neutral lockout cam 6-5 pressure relief ball 7-7
piston 7-13
nozzle, main 8-5 protector cap 12-9
piston pin 7-13
nut, key switch 6-9, 12-3 protector spray, battery terminal 16-3
piston pin retaining ring 7-13
nut, lug 2-3 protector, bagwell 1-3
piston ring compressor 16-5
puller
piston ring pliers 16-5
bearing 16-3
O piston ring set 7-13
drive clutch 16-3
oil filler tube 7-3 pivot arm 11-3
drive clutch hub 16-3
oil filter screen 7-11 pivot support bearing 4-7
driven clutch cam 16-3
oil level sensor 7-11 plastic barrel 1-3
flywheel 16-5
oil pump and rotor 7-7 plate
seal 16-5
oil seal (crankshaft) 7-13 backing (brake) 4-3
pulley (starter/generator) 6-11
oil sending wire clamp 7-11 body hinge 1-7, 1-9
pulley nut and screw (starter/
onboard computer 12-19 body kick 1-7, 1-9

Page i-12 2003 DS Golf Cars Illustrated Parts List

 INDEX
generator) 6-11 rocker arm case 7-9 seat bottom 1-11
pump, fuel impulse 8-3 rocker arm shaft 7-9 seat bottom cover 1-11
push rod 7-9 rod seat hinge plate 1-11
accelerator 4-7 sensor, motor speed 13-7
R accelerator pivot 4-7 sensor, oil level 7-11
rack, steering 5-5 connecting 7-13 set, pole 6-11
ratchet, park brake 4-7 equalizer 4-5 shackle, rear spring 5-11
reamer, valve guide 16-7 push 7-9 shaft
rear bumper 1-3 shift 11-5 counterbalance guide 7-13
rear leaf spring 5-11 tie 5-7 input 11-5, 14-3, 14-5
rear spring shackle 5-11 rod (counterbalance) 7-13 rocker arm 7-9
receptacle rod and pawl 4-5 shifter 11-3
3-pin 12-19 rpm limiter bracket 7-5 steering column 5-3
6-pin 12-31 rpm limiter damper 7-5 shield, end 13-3, 13-5, 13-7
ac cord 15-15 rpm limiter mount band 7-5 shield, resistor 12-11
charger, 2-prong 12-13 rpm, ohv limiter 7-5 shift fork 11-5
receptacle (fuse) 12-13, 12-17, 12-29 shift rod 11-5
receptacle backing plate 12-17, 12-29 S shifter lever 11-3
receptacle bezel 12-13, 12-17, 12-29 6-pin plug 12-31 shifter shaft 11-3
regulator, motor controller output 6-pin receptacle 12-31 shifter, forward/reverse 6-5
(MCOR) 12-21 6-volt battery 12-13 shim (axle) 14-5
relay, 36-vdc 15-3, 15-5, 15-7 safety first card 16-5 shim, crankshaft 7-13
relay, 48-vdc power 15-9, 15-11, 15-13, scorecard 5-3 shim, wiper switch 12-9
15-15 scorecard clip 5-3 shock absorber 5-7
remover, bearing and oil seal 16-3 scorecard plate 5-3 shock absorber cushion 5-11
resistor 12-19, 12-23, 12-31 screen, oil filter 7-11 shock absorber cushion retainer 5-11
resistor coil 12-11 screw shock absorber, rear 5-11
resistor coil stand-off 12-11 bearing retainer 13-3, 13-5, 13-7 shoe retainer 4-3
resistor mounting board 12-11 brush holder 13-3, 13-5 shoe, brake 4-3
resistor shield 12-11 clamp 13-3, 13-5, 13-7 shroud, engine 7-3
retainer idle 8-5 shroud, fan 7-3
bearing 13-3, 13-5, 13-7 pilot air 8-5 side guard trim bumper 1-5
bearing (starter/generator) 6-11 pole piece (starter/generator) 6-11 sleeve
cable 6-5 valve clearance adjuster 16-7 delta 5-7
harness 6-9 scuff guard 1-3 park brake rod 4-5
shock absorber cushion 5-11 seal synchronizer 11-5
spiral ring 10-3 axle tube oil 14-5 sleeve (transaxle) 11-5
spring 4-7, 10-3 crankshaft 7-11 slide switch, 4-position 15-13, 15-15
valve spring 7-9 double lip 5-9 small intermediate gear 14-5
retaining ring (driven clutch) 10-5 dust (steering gear box) 5-5 snap ring 5-5
retaining ring pliers 16-5 dust, steering pinion 5-5 snubber 7-15, 12-13
return spring bumper 4-7 input shaft oil 14-5 snubber bracket 7-15
reverse buzzer 6-9, 12-3 intake (air box) 8-11 solenoid
rigging, brush 13-3, 13-5, 13-7 oil (axle shaft) 11-7 12-volt 6-7
rim, tire 2-3 oil (crankshaft) 7-13 36-volt 12-13
ring oil (governor pivot) 11-3 48-volt 12-19, 12-31
c-type stop 5-5 oil (shifter shaft) 11-3 spacer
piston (set) 7-13 oil, axle shaft 14-3 1/2 (fender mounting) 1-9
piston pin retaining 7-13 oil, input shaft 11-5, 14-3 1-7/8 (fender mounting) 1-9
retaining (driven clutch) 10-5 valve 7-9 battery terminal bolt 6-15
retaining (steering column) 5-3 seal puller 16-5 body 1-13
retaining (steering gear box) 5-5 seat fixed face shaft 10-3
snap 5-5, 11-3 bearing 5-3 nylon (sweater basket) 1-13
spiral back-up 10-3 spring 7-9 park brake 4-5
synchronizer 11-5 valve 7-7 spacer (accelerator pivol rod) 4-7
rivet, blind 1-5 seat back 1-13 spacer (crankshaft) 7-13
rocker arm 7-9 seat back support 1-13 spacer (engine) 7-15

2003 DS Golf Cars Illustrated Parts List Page i-13

 INDEX
spanner wrench 16-5 body 1-7, 1-9 governor shaft installation 16-5
speed switch arm 12-9 canopy 1-15 steering column bearing press 16-5
spindle 5-9 delta shock and gear 5-7 steering column retaining ring 16-5
spray, battery terminal protector 16-3 seat back 1-13 steering wheel puller 16-7
spring sweater basket 1-13 transaxle axle seal 16-7
accelerator pedal retainer 4-7 switch transaxle pinion seal 16-7
brake shoe 4-3 4-position slide 15-13, 15-15 transmission 16-7
brush 6-11, 13-3, 13-5, 13-7 brush 12-9 tool kit, clutch 16-3
compression 5-3 forward/reverse 12-7, 12-15, 12-27 top, air box 8-11
compression (choke button) 8-11 key 6-9, 12-3 touch-up paint 16-7
drive button 10-3 limit 6-5, 6-7, 12-7, 12-9, 12-15 tow/run switch 12-27
drive clutch 10-3 limit sealed 12-15 transaxle 14-3, 14-5
engine valve 7-9 tow/run 12-27 transaxle axle seal tool 16-7
forward/reverse cam 6-5 v-glide wiper 12-9 transaxle pinion seal tool 16-7
oil pressure relief 7-7 synchronizer clutch hub 11-5 transaxle, unitized 11-3
park brake torsion 4-5 synchronizer ring 11-5 transformer 15-3, 15-5, 15-7, 15-9, 15-11,
rear leaf 5-11 system, exhaust 9-3 15-13, 15-15
return 4-7 transmission cable 6-5
return (air box) 8-11 T transmission tool 16-7
shift fork retainer 11-5 trim, front body 1-5
12-volt battery 6-15
synchronizer 11-5 tube
2-pin plug 12-21
tapered compression 5-3 axle 11-7
2-prong charger receptacle 12-13
tapered leaf 5-9 crankcase vent 8-7
3-pin plug 12-19, 12-21, 13-7
throttle return 8-7 oil filler 7-3
3-pin plug and wedge lock 12-27
wiper switch brush 12-9 tune-up kit 16-7
3-pin receptacle 12-19
yoke 5-5 3-pin receptacle and wedge lock 12-27
spring mounting plate 5-7 3/8-amp fuse 12-17, 12-29 U
spring seat 7-9 30-amp fuse 15-11 u-bolt 5-11
spur gear (crankshaft) 7-13 36-volt motor, 2.97-hp 13-3 unitized transaxle 11-3
stain relief bushing 15-3 36-volt solenoid 12-13 upper pinion bearing 5-5
stand-off, resistor coil 12-11 10-amp fuse 6-7 urethane bushing 5-7, 5-9, 5-11
starter/generator 6-11, 6-13 12-volt solenoid 6-7
stator shell 13-3, 13-5, 13-7 tachometer 16-7 V
steel bushing 5-9, 5-11 tapered compression spring 5-3 valve
steering column 5-3 tapered leaf spring 5-9 choke 8-11
steering column bearing press tool 16-5 tappet 7-11 exhaust 7-9
steering column mounting bracket 5-3 terminal block (controller) 12-31 fuel pickup tube 8-3
steering column retaining ring tool 16-5 terminal hardware (starter/generator) 6-11 intake 7-9
steering column shaft 5-3 tester, continuity 16-5 oil 7-9
steering gearbox 5-5 thermometer, battery 16-3 valve clearance adjuster screw 16-7
steering wheel 5-3 throttle bracket 8-7 valve guide 7-9
steering wheel puller tool 16-7 throttle return spring 8-7 valve guide reamer 16-7
stem, valve 2-3 thrust bearing 5-9 valve seal 7-9
stiffener, flywheel side 7-15 thrust plate (differential) 14-5 valve seat 7-7
strap tie rod 5-7 valve seat cutter 16-7
a-plate 5-7 tie, wire 5-5, 12-3, 12-13, 12-27, 12-31 valve seat cutter guide 16-7
bag 1-13 timer 15-5, 15-7 valve seat t-wrench 16-7
rear fuel 8-3 tire 2-3 valve spring compressor 16-7
stud t-nut, slab base 1-5 valve spring retainer 7-9
ball 4-7, 6-5, 6-7, 11-3 tool valve spring, engine 7-9
lug 5-9, 11-7, 14-3, 14-5 accelerator pedal adjustment 16-3 valve, stem 2-3
short ball 12-9 brake adjustment 16-3 vehicle care kit 16-7
wiper switch adjusting 12-9 brake pedal adjustment 16-3 vent barb 8-3
stud (engine mounting) 7-15 brake pedal tension 16-3 vent line (fuel) 8-3, 8-7
sunk key 14-5 cam installation 16-3 vent, fuel tank 8-3
support clutch alignment 16-3 v-glide wiper switch 12-9
accelerator pivot rod 4-7 drive clutch holder 16-3 volt ohm meter 16-7

Page i-14 2003 DS Golf Cars Illustrated Parts List

 INDEX
voltage regulator 6-7
voltage suppressor 15-9, 15-13

W
warning light, low oil 6-9
washer
key switch 12-3
kingpin wave 5-9
mounting 10-3, 10-5
snap washer kit (dash mounting) 1-3
spring 11-5
thrust (transaxle) 11-5
wave 6-5
wear pad 1-3, 1-7, 1-9
wedge (steering column) 5-3
wedge, bearing puller 16-3
weight, counterbalance 7-13
weight, drive clutch 10-3
weldment, press 16-3
wheel 2-3
wheel rim 2-3
wheel, steering 5-3
windshield frame 1-15
wiper switch arm carrier 12-9
wiper switch bumper 12-9
wiper switch case 12-9
wiper switch shim 12-9
wiper switch, v-glide 12-9
wire and terminal 12-31
wire assembly 6-3, 6-7, 6-9, 6-13, 7-3,
12-5, 12-9, 12-13, 12-17, 12-23, 12-25,
12-29, 12-31, 15-9, 15-11, 15-13, 15-15
wire assembly, forward/reverse
switch 12-27
wire assembly, IQDM port 12-27
wire assembly, sense lead 12-17, 12-29
wire clamp 7-5
wire harness 6-3, 12-23, 12-25
wire terminal 12-19
wire tie 5-5, 12-3, 12-13, 12-27, 12-31
wire, jumper 15-15
wire, lead 7-5
wood insert 1-11
woodruff key 6-11, 11-3
wrench, spanner 16-5

Y
yoke spring 5-5
yoke, gear 16-5

Z
z-bracket 12-31

2003 DS Golf Cars Illustrated Parts List Page i-15

2003 DS Golf Cars Illustrated Parts List
Golf Cars
Club Car Inc.
P.O. Box 204658
Augusta, GA 30917-4658