BODY
Read section A and B completely prior to operation or repair of golf car
K-2
In the following text, there are references to removing/installing bolts etc. Additional hardware
(nuts, washers etc.) that are removed must always be installed in original position unless
otherwise specified. Non-specified specifications are as shown in the table contained in
Section A.
General
BODY COMPONENT REPLACEMENT.
Batteries should always be removed before any servicing that could generate sparks or repairs
that require welding or cutting.
In general, body component replacement can be finished with a minimum of specialized tools. Most body
components are held in place with conventional removable hardware (nuts, bolts, washers, and screws).
Some components are mounted with “pop” rivets which require that the rivet head be removed in order
to push out the shank of the rivet. The rivet head is easily removed by drilling into the head with a sharp
drill bit that is slightly larger than the shank of the rivet (Ref Fig. K1). Care must be exercised when
drilling to prevent the drill from being forced through the plastic body components where it could damage
components located immediately behind the rivet. The best way to prevent this from occurring is to use a
sharp drill bit that requires very little pressure to cut successfully and to place a piece of protective sheet
metal between the surface being drilled and components directly behind it.
Fig. K1: Drill Out Metal Rivet
The body components can be replaced by removing the securing hardware, replacing the component
and securing with hardware in the same orientation as removed. The illustrations on the following pages
indicate the assembly methods for the various components.