1963-1980 Harley-Davidson Golf Cart D, DF, DC, MGIV, DE4 Service Manual

Covers D, DC, DF, MGIV, MGV, MG2, MG3, DE4, DEF3, DEF4 models with procedures for chassis, engine, transmission, and electrical systems. Part Number 99496-80.

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Harley-Davidson Models Covered & Key Technical Specifications

Models: Harley-Davidson D, DC, DF, D4, DE3, DEF3, MGIV, MGV, MG2, MG3, DEF4
Sub-models / Variants: 3-wheel, 4-wheel, Gas Golf Car, Utilicar
Build Years: 1963–1980
Serial Numbers: 10000 and up (5 digits for 1978 D4 models)
Technical Data:

  • Engine type: 2-cycle-loop scavenged, 1-cylinder, air-cooled
  • Bore: 2.75 in. (69.8 mm)
  • Stroke: 2.50 in. (63.5 mm)
  • Displacement: 14.85 cu. in. (245.8 cc)
  • Compression ratio: 6.6:1 (low comp) or 9.5:1 (high comp)
  • Electrical system: 12-volt lead storage battery (6-volt standard operating voltage)
  • Fuel capacity (metal tank): 4.5 U.S. gallons
  • Fuel capacity (polyethylene tank): 8.5 U.S. gallons
  • Wheelbase: 70 inches
Technical Specifications
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Document Number / Seller:
29606 / George Perez
File Size:
59.96 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Golf Cart
Last updated / verified
Jan 17, 2025

Harley-Davidson Manual Features & Content Preview

Harley-Davidson 1963–1980 Golf Cart Technical Documentation

  • Covers the 1963–1980 Harley-Davidson Gas Golf Car and Utilicar series, including the 3-wheel D, DF, DC variants and 4-wheel D4 models
  • Official Columbia ParCar publication P/N 99496-80, issued January 2001
  • Contains 80+ exploded-view component diagrams and indexed assembly schematics for the chassis, engine, and drive systems
  • Accessible from your device as soon as the order is placed
  • Stored against your account so you can retrieve it after a hard-drive loss
  • Full-text search finds any part number in seconds
  • Laid out for standard letter and A4 printing
  • This reference captures the factory-authorized assembly specifications for the classic two-cycle D-series engine and drivetrain configuration

Component and Systems Documentation

The 1963–1980 Harley-Davidson golf cart service manual documents maintenance and overhaul procedures for the D, DF, DC, and D4 utility vehicles. It provides organized technical guidance across five primary sections: product identification, chassis maintenance, engine repair, transmission servicing, and electrical system diagnostics. Technical content outlines component-level inspection and adjustment standards, including frame alignment dimensions for 3-wheel and 4-wheel configurations.

Specification and Technical Preview

Engine specifications detail piston-to-cylinder clearances and ignition timing thresholds. The cylinder head mounting bolt torque is specified at 17–21 ft-lbs in the assembly tables. Crankcase assembly details confirm the maximum runout for mainshafts on bearings is documented at 0.002 in. for the fan side. Spark plug gap settings are listed at 0.020–0.022 in. within the ignition timing section. Differential lubrication maintenance intervals for late 1977 and later models require specific gear oil volumes to ensure longevity of the transmission drive units. This official Columbia ParCar service publication covers the complete 1963–1980 Harley-Davidson gas-powered golf cart fleet, providing essential technical data for the maintenance of chassis, engine, transmission, and electrical systems.

Manual FAQ, Purchase & Download Details

Can the manual be used to preview the coverage depth for the engine, transmission, and electrical systems in the 1963-1980 Harley-Davidson golf cart models? keyboard_arrow_down

Document covers the specified Harley-Davidson golf cart models with dedicated sections for the engine, transmission, chassis, and electrical systems. It includes detailed system information and component illustrations to support familiarity with the machine construction.

Which specific vehicle systems receive comprehensive coverage in the five main sections of this manual? keyboard_arrow_down

Manual is organized into five primary sections covering product specifications, chassis components, engine systems, transmission assemblies, and electrical circuitry.

What publication and identification markers are provided in this manual for the Harley-Davidson 1963-1980 golf cart series? keyboard_arrow_down

Service manual is identified by part number 99496-80 and was issued in January 2001. It contains information intended for the maintenance of the D, DF, DC, and D4 model golf cars. The document also includes patent notices and disclaimers provided by Columbia ParCar Corp.

Does this manual include diagrams and exploded views of components? keyboard_arrow_down

Manual contains numerous figures and illustrations that show components within the chassis, engine, and electrical sections.

Are reference tables and spec charts included for vehicle maintenance data? keyboard_arrow_down

Document includes comprehensive specification tables that detail fluid capacities, tire pressures, and engine dimensions for the covered models. It also features a metric conversion table and a maintenance interval chart for reference.

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