Street Legal Club Car Villager 4

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txbonds

New Member
I purchased this 2004 Club Car Villager 4 a few days ago. I think it's half way to street legal now, as it has head lights and tail lights installed, as well as a center rear view mirror.

I think I will need (in Florida) an orange triangle for rear, a driver side mirror, a turn signal kit and horn to finish it off.

I think my biggest question is how to best, and easiest, add the turn signal kit to a setup that already has the CC headlight/tail light installation on it?

My model has the IQ setup and 48v battery system via six new 8v batteries, if that matters.
 
HotRodCarts

HotRodCarts

Cartaholic
Welcome to Cartaholics.

Sharp cart! Check the tail lights and see if they use the dual element bulb. If they do you should have a extra wire on both tail lights. The extra wire would be for brake lights and turn signals. You will need a turn signal switch for the column, a flasher receptacle and a brake light switch if you want brake lights. Most of the online cart sites sell kits to wire the turn signals/brake lights.
 
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txbonds

New Member
Thanks for the comments and tips.

I know I have brake lights and not just running lights, as the switch bracket and switches are wired up onto the pedal and my wife verified they work. I don't know if I have dual element bulbs with a 3rd wire though and will check.

That said, I placed an order for a kit. Not sure if that is everything I need or not, but should give me a good start and includes the horn pieces too.

If it turns out my rear tail lights don't have the 3rd wire, do I just swap them out for different ones, or does the harness in the kit I ordered include a new wire for that?

Also, I'm thinking I'd like a 3rd brake light / running light on the back, either on the rear of the top or on the rear passenger handle. Any idea how I would wire that in? I'm guessing it would be tapped into the wiring for running and brake lights if my harness has a separate 3rd wire for tail lights?

Sorry for all the questions. Just wait though, as I'm sure I'll have tons more as I slowly make changes to the cart. :)
 
HotRodCarts

HotRodCarts

Cartaholic
If you already have brake lights you have the dual element sockets so your good there. The kit you ordered looks like it has everything you need. As far a a third brake light goes just tap into the the existing brake light wiring. Don't worry about asking questions, that's why we're here. :D
 
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txbonds

New Member
Weird thing is that my 2004 villager DS, according to the serial number, has the features of a pre 2000 DS. The split rear seat backs and the silver top framing appear to be older features, but the Serial number search and manual show mine is a 2004 cart.
 
JRay

JRay

Cartaholic
I have been thinking about your cart. I thought all the villagers were street legal from the factory, so the wiring should be there for turn signals etc. That split front seat back is original i think, lots of villager owners on here to tell me if i am wrong. They are nice carts, i have been looking for one for awhile. Thats a good looking cart you have. Just thinking someone has removed some of the factory stuff? Hang in here someone will figure it all out.
 
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StreetGlide

New Member
The villager during that time frame came with the different parts. It doesn't show-up in the parts book of a standard DS because of it. The different parts are covered in the Transporter-4's, documentation. Also, if you want to match-up the black and clear aluminum winshield, roof and seat supports club car has the black coversion parts available. I just painted some of mine until deciding on a new cart, which I didn't get at the time and paint still looks good. The electrical system is wired differently too. I had the DS wiring diagram and I couldn't believe the differences. I re-wired most of the electrical system (several posts with complaints, pictures, etc in the forums under CC electrics) before I got the correct wiring diagram, what a pain. Also, no, the Villager didn't come street legal. It did come with factory lights, brake lights and horn.
 
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txbonds

New Member
Thanks. I did a little investigation last night and found that behind each front light there are two wires with connectors hanging there. I'm guessing the harness is plug and play for the turn signals, so I may have wasted some money buying a kit with a whole new harness. There is also a larger molex looking connector on the drivers side just above the front wheel. I'm thinking this may be to connect the horn into but don't know since mind didn't come with the horn.

Either way, I think with the turn signal kit I ordered, I should be able to get this into good shape for lighting for road usage.


On the top, as best I can tell about my cart, the frame and body is basically a 2000+ DS with the IQ system installed and a 19mph setting programmed into it. It has the regen motor setup.

The bottom seat cushion is a 2000+ style setup, but the upper seat backs are the pre-2000 style.

The top and frame is also a pre-2000 style.


If I understood your post correctly, I could order one of the newer black frames for the top and it would fit? I've found them onling that come precoated in the black textured looking powder coating for about $99 or so. I'm still looking for a source for the rear top bracket one to match in the black color that would fit my seat bracket. In the end, I might end up just painting it as well.

Also, I'm looking into the one piece windshield with a windshield wiper installed. Seems to be a very nice way to meet the impact rating requirement for the front windshield for road use, as well as the wiper requirement.
 
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txbonds

New Member
Just as an FYI, here is sort of what I've got in my mind for cart direction. Not sure on a lift or not yet, but am thinking a woody kit would look nice with some different rims for starters. Also painting all of the silver aluminum tube framing black. Any thoughts on the look?
 
HotRodCarts

HotRodCarts

Cartaholic
I'll be honest I'm not a big fan of the woody look. Your cart is very sharp the way it sits. I don't think I'd do much to it at all. Maybe some fine detail here and there but overall the cart looks real good right now. These are just my opinions and don't let them discourage you from doing what you want to do with the cart.
 
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txbonds

New Member
Understood. I realize the look would be a personal decision. I think the two biggest things I don't like about the current cart are the silver top frame and trim pieces and the solid chrome wheels. If I could break them up with some black, it would probably appeal more to me as is.

I'll probably start with just painting the silver parts satin black and go from there. That way I can take little steps until it gets to a point I like.
 
E

essness

New Member
I'm with HRC on the woody thing. I think you got a great color and I like the wheels. I do think the black on the roof supports would look great And maybe some seat covers????
 
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StreetGlide

New Member
When I painted mine I cleaned the aluminum with brass wool, blew off with leaf blower, then soap and water, then mineral spirits. Let dry, wiped it down and painted with flat black rustoleam (sp?). Used artist brushes. Took two coats. The paint flowed nicely and it eneded-up better than I thought it would.

Club Car web page under accessories have the black pieces listed separately. A few CC dealers have them listen, but don't remember which ones. The prices were not near as bad as the local dealer or I thought they would be. May want to check them on web.

You have a great looking cart! :thumbsup:
 
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txbonds

New Member
Thanks guys. I guess I'm the only one that doesn't like the solid chrome wheels. I was just telling my wife, I've never liked them since they started coming out back in the 70's and 80's by Craiger or who ever it was that was so popular back then on trucks/cars. I am pretty sure I'm going ahead with the black paint on the roof frame, a new windshield and eventually some new rims. I'm really interested in a mild lift as well to be able to do a little off pavement driving from time to time.


On a separate note, I discovered one of my rear brake linkages was missing the clevis pin. Prior owner indicated the brakes needed replacing since it was a little slow to stop. Replaced the clevis pin and it will stop on a dime and screech the tires now. It was simply only using one brake without that pin.

And, on one more separate note, I took it out today with the GPS for the first time and was astounded to see that on the stock motor and fresh batteries, I was averaging 20mph flat and 14mph up hill. Wow. I thought it was fast, but didn't really think it was that fast.

What would say a 6" lift and 22" or larger tires do to that performance though?
 
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txbonds

New Member
Maybe, but I'll probably just order a tire/wheel combo whenever I change them out. Have to first decide if I'm lifting it or not.

Any advice on the following:

Will any of the lift kits improve the ride over bumpy ground? Currently everything is very bumpy and rattling whenever I try to go off pavement.

How badly will they affect my top speed and acceleration, as well as hill climb speed? Currently 20mph top and 14mph uphill with good acceleration.

What is difference in spindle, A-Arm and Long Travel lifts and which would suit me best to provide a most comfy ride when off road, but also still be practical when on road? I'll be on pavement 90% of use and off 10%. Off road use would be dirt roads and trails, not anything serious.

I don't want to have to change out motor/controller/etc for this if possible. Thanks.
 
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