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Club Car VILLAGER 4 User Manual

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

Table of Contents

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Club Car VILLAGER 4 Specifications

General IconGeneral
BrandClub Car
ModelVILLAGER 4
CategoryGolf Cars
LanguageEnglish

Summary

SECTION 1 – SAFETY

General Warning

Critical safety warnings, precautions, and hazard definitions for vehicle service.

SECTION 2 – VEHICLE SPECIFICATIONS

Vehicle Specifications Overview

Detailed specifications for various Club Car models, including power, dimensions, and capacities.

SECTION 3 – GENERAL INFORMATION

Storage Procedures

Covers storage preparation and returning vehicles to service for gasoline and electric models.

SECTION 4 – BODY AND TRIM

Front Body Procedures

Details the removal and installation of the front body assembly.

Body Repair Techniques

Explains repair methods for stress lines, scratches, dents, and gouges on body panels.

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP

Brake Pedal and Park Brake Procedures

Covers removal and installation of brake pedal and park brake assemblies.

Accelerator Pedal Procedures

Details removal and installation of accelerator pedals for gasoline and electric vehicles.

Pedal Group Adjustment

Provides procedures for adjusting pedal height, park brake engagement, and accelerator linkage.

SECTION 6 – WHEEL BRAKE ASSEMBLIES

Brake Shoe Removal

Steps for removing rear brake shoes and drums, including special procedures.

Brake Assembly Cleaning

Instructions for cleaning brake assemblies for self-adjusting and manually-adjusted brakes.

Brake Adjustment

Procedures for adjusting self-adjusting and manually-adjusted brake systems.

Brake Cable Procedures

Details the removal and installation of front and rear brake cables.

SECTION 7 – STEERING AND FRONT SUSPENSION

Steering Wheel Procedures

Covers removal, installation, and maintenance of the steering wheel.

Rack and Pinion Procedures

Covers removal, disassembly, assembly, and installation of the rack and pinion steering gear.

Front Suspension Procedures

Covers lubrication, wheel alignment, camber, toe-in, and leaf spring procedures.

SECTION 8 – WHEELS AND TIRES

Wheel Procedures

Covers wheel removal and installation, including lug nut tightening.

Tire Procedures

Details tire removal, repair, installation, and air pressure recommendations.

SECTION 9 – REAR SUSPENSION

Shock Absorber Procedures

Covers inspection, removal, and installation of rear shock absorbers.

Multi-Leaf Spring Procedures

Details the removal and installation of multi-leaf springs.

Stabilizer Bar Procedures

Details the removal and installation of the stabilizer bar on specific gasoline models.

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