Club Car Villager 6 Owner's Manual
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Club Car Villager 6 Owner's Manual

Electric and gasoline
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Villager 6 and 8
Owner's Manual
Electric and Gasoline
[Refer to back cover for applicable build code range]

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  • Page 1 Villager 6 and 8 Owner’s Manual Electric and Gasoline [Refer to back cover for applicable build code range]...
  • Page 3 Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
  • Page 4 Services, P.O. Box 204658, Augusta, Georgia 30917-4658 USA. We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehicle, please include the manual so that the next owner will have the important operating, safety, and maintenance information it contains.

  • Page 5: Table Of Contents

    Fueling Instructions – Gasoline Vehicle ........................ 49 Cleaning the Vehicle ............................50 Accessories ............................... 51 Subsequent Owner Registration .......................... 51 Vehicle Specifications ............................52 Warranties................................60 EC Declaration of Conformity ..........................67 Villager 6 and 8 Owner’s Manual Page 3...

  • Page 6: Safety Decal And Feature Identification

    Decal, Tow/Run Switch Warning (on Tow/Run 102845101 switch plate, under seat) 103205401 Decal, Rollover Warning (on instrument panel) 103210301 Decal, Forward/Reverse (on instrument panel) 103783001 Decal, Operating Instructions (on steering wheel) Serial Number Page 4 Villager 6 and 8 Owner’s Manual...
  • Page 7 Decal, Falling Off Warning (on rear-facing seat Decal, 4 Gauge Wire Warning (on frame in battery 101705701 hand rail and/or on back side of forward-facing 102967601 compartment) seat backs) Decal, Component Cover Notice (on electrical 102518301 component cover) Villager 6 and 8 Owner’s Manual Page 5...
  • Page 8 Decal, Falling Off Warning (on rear-facing seat Decal, 4 Gauge Wire Warning (on frame in battery 101705701 hand rail and/or on back side of forward-facing 102967601 compartment) seat backs) Decal, Component Cover Notice (on electrical 102518301 component cover) Page 6 Villager 6 and 8 Owner’s Manual...
  • Page 9 101825102 Decal, On/Off/Start Key Switch (above key switch) 103205401 Decal, Rollover Warning (on instrument panel) Decal, Maintenance/Operate Warning (on 103205501 Maintenance/Operate switch plate, under seat) 103210201 Decal, Forward/Reverse (on instrument panel) Villager 6 and 8 Owner’s Manual Page 7...
  • Page 10 Safety Decal and Feature Identification GASOLINE VILLAGER 6 AND 8, CONTINUED CCI 1019152-01 2919 Decal, Frame Ground/Governor Warning (on 101915201 105082301 vehicle frame near battery) Decal, Gasoline Fuel Warning (on fuel tank) Decal, Rotating Parts/Hot Manifold Warning (on 101960501 starter/generator)
  • Page 11 Safety Decal and Feature Identification GASOLINE VILLAGER 6 AND 8, CONTINUED 2920 Decal, Falling Off Warning (on rear-facing seat 101705701 hand rail and/or on back side of forward-facing seat backs) Villager 6 and 8 Owner’s Manual Page 9...

  • Page 12: Practice Safety

    PROPOSITION 65 – STATE OF CALIFORNIA WARNING • This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm. Page 10 Villager 6 and 8 Owner’s Manual...

  • Page 13: Safety Details

    • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.
  • Page 14 • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle or battery charger. • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. Page 12 Villager 6 and 8 Owner’s Manual...

  • Page 15: Disabling The Vehicle

    Connect battery cables in reverse order. Figure 2 Battery Cable Removal – Gasoline Vehicle Figure 3 Battery Cable Removal – 8x6-Volt Battery Configuration – Villager 6 and 8 IQ Plus Electric Vehicles Villager 6 and 8 Owner’s Manual Page 13...
  • Page 16 Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...

  • Page 17: General Information

    International Safety Symbols on Batteries GENERAL INFORMATION This manual features Villager 6 and 8 vehicles. The electric Villager is equipped with the IQ Plus electrical system. The gasoline Villager is equipped with a Subaru engine and accompanying powertrain and has a key-start configuration.

  • Page 18: Controls And Indicators

    • Key-start vehicles: Do not shift the Forward/Reverse handle while the accelerator pedal is pressed. Shift the handle only when the vehicle is at a complete stop and the engine is at idle. Failure to heed this caution can result in damage to the transaxle. Page 16 Villager 6 and 8 Owner’s Manual...
  • Page 19 NEUTRAL, with neither side down, the vehicle will not operate if the accelerator pedal is pressed. Club Car vehicles operate at reduced speed in reverse. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in the REVERSE position.
  • Page 20 30 minutes. However, the vehicle should be charged at the first opportunity. If the warning light comes on and the vehicle is unable to operate for 30 minutes, have your Club Car distributor/dealer check the vehicle for a possible battery or electrical system problem.
  • Page 21 If indicator display does not reset back to full after recharging, there may be a problem with the battery charger or with one of the batteries. In either case the vehicle should be checked by a Club Car dealer or a trained technician. LOW OIL WARNING LIGHT...
  • Page 22 • When batteries are fully charged, a warning buzzer will sound during motor braking to alert the driver that motor braking is operating at a reduced level of performance. When this occurs, use the brake pedal to control vehicle speed. Page 20 Villager 6 and 8 Owner’s Manual...
  • Page 23 PARK BRAKE marked on top of it (Figure 10). To set the park brake, press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot (Figure 11). See following WARNING. Villager 6 and 8 Owner’s Manual Page 21...
  • Page 24 • For Long Term Storage: Place the Tow/Run switch in the TOW position to turn off power to the vehicle electrical system, thus preventing vehicle electrical components from discharging the batteries. Page 22 Villager 6 and 8 Owner’s Manual...
  • Page 25 If the circuit breaker trips again when vehicle operation is resumed, contact a local Club Car distributor/dealer. NEUTRAL LOCKOUT Gasoline Vehicles Only Figure 13 Neutral Lockout Switch Villager 6 and 8 Owner’s Manual Page 23...

  • Page 26: Pre-Operation And Daily Safety Checklist

    Forward/Reverse handle in either the FORWARD or REVERSE position. PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
  • Page 27 • Steering: The vehicle should be easy to steer and should not have any play in the steering wheel. • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle ride and performance. Have a Club Car distributor/dealer or a trained technician investigate anything unusual. Electric Vehicles •...

  • Page 28: Driving Instructions

    An experienced operator should accompany each first-time driver on a test drive before allowing him/her to operate the vehicle alone. To ensure safe operation of the vehicle, follow all procedures exactly as written. Read and understand all instructions prior to driving the vehicle. Page 26 Villager 6 and 8 Owner’s Manual...
  • Page 29 • Press the brake pedal as necessary and partially press the accelerator when descending a hill. With the accelerator pedal partially pressed, the governor will cause the engine to assist the brakes in controlling downhill speed. Villager 6 and 8 Owner’s Manual Page 27...

  • Page 30: Transporting On A Trailer

    • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer.

  • Page 31: Storage - Electric Vehicles

    Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse switch in the NEUTRAL position during storage. If so installed, turn off all accessories, including GPS units, fans, etc. Villager 6 and 8 Owner’s Manual Page 29...
  • Page 32 RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE If necessary, connect batteries. See Connecting the Batteries – Electric Vehicles on page 14. Fully charge batteries. Page 30 Villager 6 and 8 Owner’s Manual...

  • Page 33: Storage - Gasoline Vehicles

    Sta-Bil ® 3.2. Disconnect fuel vent line from fuel tank vent nipple. 3.3. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap. Villager 6 and 8 Owner’s Manual Page 31...

  • Page 34: Maintenance

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. WARNING •...

  • Page 35: Periodic Service Schedules

    Both the Periodic Service Schedules and Periodic Lubrication Schedules must be followed to keep vehicle in optimum operating condition. Villager 6 and 8 Owner’s Manual Page 33...
  • Page 36 Batteries Section in the appropriate Annual service by trained technician only maintenance and service manual. (or every 100 hours of operation, whichever comes first) Check safety decals. Replace if damaged or Safety Decals illegible. Page 34 Villager 6 and 8 Owner’s Manual...
  • Page 37 Check safety decals. Replace if damaged or Safety Decals illegible. Two-year service by trained technician only (or every 200 hours of operation, whichever Engine Check and adjust valve lash as needed. comes first) Villager 6 and 8 Owner’s Manual Page 35...

  • Page 38: Periodic Lubrication Schedules

    (or every 100 hours of operation, whichever comes Inspect front wheel bearings (Repack Chassis Lube – EP NLGI Grade 2 first) as necessary) 2822 Figure 14 Lubrication Points – Electric Vehicles Page 36 Villager 6 and 8 Owner’s Manual...
  • Page 39 200 Change engine oil 5W-30 grade SE or higher. hours of operation or annually, See also Figure 24, Page 49. whichever comes first. 2823 Figure 15 Lubrication Points – Gasoline Vehicles Villager 6 and 8 Owner’s Manual Page 37...

  • Page 40: Batteries - Electric Vehicle

    WATER QUALITY Water purity is the most important factor in the performance and lifespan of the vehicle batteries. Club Car has, therefore, placed an increased importance on battery maintenance.
  • Page 41 Water testing, however, is expensive, and water quality can change from day to day depending on additives, water main leaks, etc. Due to the cost and labor of performing water quality tests, Club Car recommends the use of distilled water or a deionizer.
  • Page 42 The hold-down straps should be tight enough so that the batteries do not move while the vehicle is in motion, but not so tight as to crack or buckle the battery case. For Villager 6 and 8 vehicles, tighten hold-down retaining nuts to 55 in·lb (6.2 N·m).

  • Page 43: Battery Charger, Iq Plus - Electric Vehicle

    WARNING • Only trained technicians should repair or service the charger. Contact a Club Car distributor/dealer. • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.
  • Page 44 National Electrical Code and all local codes and ordinances. See the owner’s manual supplied with the battery charger for specific operating instructions before using the charger. Page 42 Villager 6 and 8 Owner’s Manual...
  • Page 45 Club Car battery chargers interact with the vehicle onboard computer. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing operation of the vehicle as well as the possibility of subsequent damage to the charger and the vehicle.
  • Page 46 • If the receptacle fuse link is blown, determine the source of the problem and correct it before replacing the fuse. • Never modify wiring to bypass the gray sense lead fuse (Figure 19). Page 44 Villager 6 and 8 Owner’s Manual...

  • Page 47: Battery - Gasoline Vehicle

    – Eyes: Flush with water for 15 minutes. Call a physician immediately. WARNING • Do not jump-start a dead battery using another battery and jumper cables. The battery in a Club Car gasoline vehicle is a 12-volt, low-maintenance battery that requires infrequent watering (Figure 20). Villager 6 and 8 Owner’s Manual...

  • Page 48: Engine Oil - Gasoline Vehicle

    Vehicle should be on a level surface when checking oil. Do not overfill with oil. ENGINE OIL LEVEL CHECK Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (Figure 22). See following CAUTION. Page 46 Villager 6 and 8 Owner’s Manual...
  • Page 49 Access the engine compartment. Disconnect battery and spark plug wire. See Disconnecting the Battery – Gasoline Vehicles on page 13. Position a pan designed for oil changes under the drain plug (1) (Figure 23). Villager 6 and 8 Owner’s Manual Page 47...
  • Page 50 The engine requires 40.5 fl-oz (1.2 L) of oil per change. 10W-30 or 5W-30 grade SE or higher is recommended. Refer to oil viscosity guidelines for selection of oil grade (Figure 24). Replace the dipstick. Page 48 Villager 6 and 8 Owner’s Manual...

  • Page 51: Fueling Instructions - Gasoline Vehicle

    Use of these fuels in this vehicle will void the warranty. • Do not repeatedly attempt to start a vehicle when the fuel pump is dry (no gas in tank). Doing so can damage the fuel pump. Villager 6 and 8 Owner’s Manual Page 49...

  • Page 52: Cleaning The Vehicle

    A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has an ArmorFlex rear body that has been removed) will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.

  • Page 53: Accessories

    SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. Please send your name, address, and serial number(s) of the vehicle(s) to Club Car, LLC, P.O.

  • Page 54: Vehicle Specifications

    (122 cm) Vil.6: 98.5 in (250 cm) Wheelbase Vil.8: 131.5 in (334 4.5 in Ground clearance (11 cm) 34.5 in Front wheel tread (88 cm) 38.5 in Rear wheel tread (98 cm) Page 52 Villager 6 and 8 Owner’s Manual...
  • Page 55 (207 to 234 kPa) NOISE AND VIBRATION 69.1 dBA Drive-by noise level to operator Test method: EN 12053:2001 Uncertainty: 2 dBA 56 m/s Vibration at driver’s seat Test method: SAE J1013 Uncertainty: 0.20 m/s Villager 6 and 8 Owner’s Manual Page 53...
  • Page 56 240 in (609.6 cm) Weight 31.0 lb (14.1 kg) 31.0 lb (14.1 kg) 31.0 lb (14.1 kg) MOUNTING CONFIGURATION Mounting: Set on shelf, wall mount with keyhole, or hang securely from ceiling. ● ● ● Page 54 Villager 6 and 8 Owner’s Manual...
  • Page 57 Case – Overall height 9.5 in (24.1 cm) AC cord length 17 ft (5.2 m) (retractable) DC cord length 22.0 in (55.8 cm) Weight 37.0 lb (16.8 kg) MOUNTING CONFIGURATION Mounting: Onboard ● Villager 6 and 8 Owner’s Manual Page 55...
  • Page 58 103 in (261.6 cm) 144 in (365.8 cm) Weight 34.8 lb (15.8 kg) 35.3 lb (16.0 kg) MOUNTING CONFIGURATION Mounting: Set on shelf, wall mount with keyhole, or hang securely from ceiling. ● ● Page 56 Villager 6 and 8 Owner’s Manual...
  • Page 59 9.5 in (24.1 cm) AC cord length 17 ft (5.2 m) (retractable) DC cord length 21.5 in (54.6 cm) Weight 37.0 lb (16.8 kg) MOUNTING CONFIGURATION Mounting: Onboard (secured to the vehicle) ● Villager 6 and 8 Owner’s Manual Page 57...
  • Page 60 Vil. 6: 98.5 in (250 cm) Wheelbase Vil. 8: 131.5 in (334 cm) 4.5 in Ground clearance (11 cm) 34.5 in Front wheel tread (88 cm) 38.5 in Rear wheel tread (98 cm) Page 58 Villager 6 and 8 Owner’s Manual...
  • Page 61 Unknown at time of printing. Drive-by noise level to operator Test method: EN 12053:2001 Uncertainty: 2 dBA Unknown at time of printing. Vibration at driver’s seat Test method: SAE J1013 Uncertainty: 0.20 m/s Villager 6 and 8 Owner’s Manual Page 59...

  • Page 62: Warranties

    4 YEARS EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance, neglect, abuse, accident and collision, maintenance adjustments, unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment including Club Car approved or non-approved GPS systems, non-approved alteration and acts of God.
  • Page 63 A vehicle not having an operational charger on a circuit that has the parameters specified in the vehicle owner’s manual. (Number of operational chargers must equal the number of operational vehicles.) Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle.
  • Page 64 To make a warranty claim under this limited warranty, you must present the vehicle or defective component with evidence of proof of purchase date and number of amp-hours (if applicable) to an authorized CLUB CAR dealer. For warranty-related communication, contact Warranty Services, Club Car, 4125 Washington Rd., Evans, GA 30809, USA, 706.863.3000.
  • Page 65 (excluding the states with high-altitude areas). • CLUB CAR will either pay for the shipping costs of replacement parts to and from an authorized service center. • Or CLUB CAR will provide for a service technician to come to the owner to make the warranty repair.
  • Page 66 As the engine owner, you should however be aware that CLUB CAR may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 67 CLUB CAR recommends that you retain all receipts covering maintenance on your vehicle engine, but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 68 The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part.

  • Page 69: Ec Declaration Of Conformity

    B-1932 S int-S te ve ns -Woluwe , Be lgium _______________________________________________ Ge off S te wa rt S e pte mbe r 17, 2013 Dire ctor, P roduct S a fe ty Eva ns , Ge orgia , US A Villager 6 and 8 Owner’s Manual Page 67...
  • Page 72 BC56607 BC56607 Publication Part Number 105062706 Edition Code 1113A00000 This manual is valid for vehicles with build codes between 56658 and the one indicated at the top of this page.

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