Club Car 1997 DS Manual

DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 1019345-04
PRINT CODE 0197C0398A
1997
MAINTENANCE
SERVICE
SUPPLEMENT

USING THIS SUPPLEMENT
The following pages are supplemental to the 1995-1996 DS Golf Car Maintenance and Service Manual (Club
Car Part No. 1019051-01). This supplement documents only those sections of the manual requiring changes
or additions describing features and procedures specific to 1997 DS Golf Cars. All other information in the
1995-1996 Maintenance and Service Manual pertaining to DS Golf Cars (unless noted as specific to another
particular vehicle) applies to 1997 DS Golf Cars as well. Sections 2, 4, 6, 9 (for gasoline vehicles only),
11, 12, 17, and 18 in the maintenance and service manual have been entirely superseded by sections
in this supplement. This supplement also includes updates to information in Sections 3, 13, 14, and
16. All other sections in the maintenance and service manual are unchanged. With the exception of sec-
tions 9, 10, 25, and 26, the placement of sections in this supplement corresponds to the placement of sec-
tions in the maintenance and service manual. References in this supplement refer to information elsewhere
within the supplement unless they state specifically that they refer to the 1995-1996 Maintenance and Ser-
vice Manual or other publication; for example, (See Figure 12-50, Page 12-37 in the Maintenance and Ser-
vice Manual) .
If you do not have a 1995-1996 DS Golf Car Maintenance and Service Manual, you may obtain one from
your Club Car dealer or distributor. This supplement and the manual should be thoroughly studied prior to
servicing the vehicle. The procedures provided must be properly implemented, and the NOTES, CAUTIONS,
WARNINGS, and DANGER statements must be heeded. This supplement and the manual were written for
the vehicle mechanic who already possesses basic knowledge and skills in electrical and mechanical repair.
If the mechanic does not have such basic knowledge and skills, attempted service or repairs to the vehicle
may render it unsafe. For this reason, we advise that all repairs and/or service be performed by an autho-
rized Club Car distributor/dealer representative or by a Club Car factory trained mechanic.
This supplement, in conjunction with the maintenance and service manual, covers all aspects of DS Golf Car
service. However, unique situations do sometimes arise when servicing golf cars. If it appears that a service
question is not answered in this supplement or in the manual, you may write to us or contact a Club Car tech-
nical service representative by phone at [phone], ext. 580.
©1996 Club Car, Inc.
Club Car, Armorflex, PowerDrive, PowerDrive Plus,
and Tranquility are registered trademarks of Club Car, Inc.
This manual effective August 1, 1996
• READ SECTION 1 - SAFETY - BEFORE ATTEMPTING ANY SERVICE ON THIS VEHICLE.
•BEFORE SERVICING VEHICLE, READ COMPLETE SECTION(S) AND ANY REFERENCED
INFORMATION RELEVANT TO SERVICE OR REPAIR TO BE PERFORMED.
WARNING

• THIS SUPPLEMENT REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF PUBLI-
CATION. CLUB CAR, INC. IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR VEHI-
CLES AND OTHER PRODUCTS. THESE IMPROVEMENTS MAY AFFECT SERVICING
PROCEDURES. ANY MODIFICATION AND/OR SIGNIFICANT CHANGE IN SPECIFICATIONS OR
PROCEDURES WILL BE FORWARDED TO ALL CLUB CAR DISTRIBUTORS AND DEALERS AND
WILL, WHEN APPLICABLE, APPEAR IN FUTURE EDITIONS OF THE MANUAL.
• DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR
WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED USE, OVERLOADING, ABUSE,
OR NEGLECT (INCLUDING FAILURE TO PROVIDE REASONABLE OR NECESSARY MAINTE-
NANCE AS INSTRUCTED IN THE VEHICLE OWNER’S MANUAL), ACCIDENT OR ALTERATION,
INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFI-
CATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF,
WILL VOID THE WARRANTY.
• CLUB CAR, INC. RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT
ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY
WHATSOEVER.
• THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS MANUAL. SEE THE LIMITED
WARRANTY FOUND IN THE VEHICLE OWNER’S MANUAL OR WRITE TO CLUB CAR, INC.
NOTE
!WARNING
Moving Parts
Practice Safety
Safety signs like you see above may at first seem shocking, but
their impact is mild compared with the reality of severe personal
injury.
Your safety and satisfaction are of the utmost importance to Club
Car. That is why we urge you to study this supplement and the
maintenance and service manual, and to read, understand, and
heed the warnings in this manual, as well as the safety decals on
your vehicle, before operating the vehicle.
Take time to understand the language of safety. It is a language
that can save your life.

CONTENTS
SECTION 1 - SAFETY 1
SECTION 2 - VEHICLE SPECIFICATIONS 3
Section 2 in this supplement supersedes Section 2 in the 1995-1996 DS Maintenance and Service
Manual.
SECTION 3 - GENERAL INFORMATION 5
Use this supplement for current information on the subjects listed below. See Section 3 in the
1995-1996 DS Golf Car Maintenance and Service Manual for all other information.
Pre-Operation Checklist .................................................................................................................... 5
SECTION 4 - PERIODIC MAINTENANCE 6
Section 4 in this supplement supersedes Section 2 in the 1995-1996 DS Maintenance and Service
Manual.
Lubrication - Gasoline Vehicles ......................................................................................................... 7
Lubrication - Electric Vehicles ........................................................................................................... 8
Vehicle Capacities ............................................................................................................................ 9
Periodic Service - Gasoline Vehicles ................................................................................................ 10
Periodic Service - Electric Vehicles ................................................................................................... 12
SECTION 5 - BODY AND TRIM 14
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 6 - ACCELERATOR AND BRAKE PEDAL GROUP 15
Section 6 in this supplement supersedes Section 6 in the 1995-1996 DS Maintenance and Service
Manual.
General Information .......................................................................................................................... 15
Pedal Group Adjustment ................................................................................................................... 16
Pedal Group Disassembly and Assembly.......................................................................................... 25
SECTION 7 - WHEEL BRAKE ASSEMBLIES
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 8 - STEERING AND FRONT SUSPENSION
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 9 - WHEELS AND TIRES
See Section 10 in the 1995-1996 DS Golf Car Maintenance and Service Manual.

SECTION 10 - UNITIZED TRANSAXLE AND GOVERNOR 35
For gasoline vehicles only , Section 10 in this supplement supersedes Section 9 and Section 17
in the 1995-1996 DS Maintenance and Service Manual.
General Information .......................................................................................................................... 35
Axle Shaft .......................................................................................................................................... 37
Removing the Unitized Transaxle ...................................................................................................... 41
Unitized Transaxle Disassembly ........................................................................................................ 47
Component Disassembly................................................................................................................... 51
Component Assembly........................................................................................................................ 55
Unitized Transaxle Assembly ............................................................................................................. 60
Unitized Transaxle Installation ........................................................................................................... 67
Forward and Reverse Shifter Cable................................................................................................... 71
SECTION 11 - TROUBLESHOOTING THE GASOLINE VEHICLE 75
Section 11 in this supplement supersedes Section 11 in the 1995-1996 DS Maintenance and Ser-
vice Manual.
Troubleshooting Guide ...................................................................................................................... 75
SECTION 12 - ELECTRICAL SYSTEM, GASOLINE VEHICLE 81
Section 12 in this supplement supersedes Section 12 in the 1995-1996 DS Maintenance and Ser-
vice Manual.
General Information .......................................................................................................................... 82
FE 290 Gasoline Vehicle Electrical Circuit ........................................................................................ 82
Circuit Testing .................................................................................................................................... 87
Test Procedures ................................................................................................................................ 94
Electrical System Components ......................................................................................................... 107
Starter/Generator .......................................................................................................................... 107
Voltage Regulator .......................................................................................................................... 118
Key Switch .................................................................................................................................... 119
Solenoid ........................................................................................................................................ 119
Fuse .............................................................................................................................................. 120
Accelerator Starter Limit Switch .................................................................................................... 121
Kill Limit Switch .............................................................................................................................. 121
Neutral Lock-out Limit Switch......................................................................................................... 122
Neutral Lock-out Cam ................................................................................................................... 123
Reverse Warning Buzzer ............................................................................................................... 124
Reverse Buzzer Limit Switch ......................................................................................................... 124
Oil Warning Light ........................................................................................................................... 125
Battery ........................................................................................................................................... 126
SECTION 13 - FE 290 ENGINE 135
Use this supplement for current information on the subjects listed below. See Section 13 in the
1995-1996 DS Golf Car Maintenance and Service Manual for all other information.
General Information .......................................................................................................................... 135

SECTION 13 - FE 290 ENGINE, CONTINUED:
Engine Mounting Plate ..................................................................................................................... 137
Installation of Remaining Engine Components.................................................................................. 137
Engine Removal ................................................................................................................................ 137
Engine Assembly............................................................................................................................... 137
SECTION 14 - FUEL SYSTEM 137
Use this supplement for current information on the subjects listed below. See Section 14 in the
1995-1996 DS Golf Car Maintenance and Service Manual for all other information.
Carburetor ......................................................................................................................................... 137
Procedure for Changing Main Jet ...................................................................................................... 137
Accelerator Rod................................................................................................................................. 138
Governor Cable ................................................................................................................................. 139
Accelerator Cable .............................................................................................................................. 140
SECTION 15 - EXHAUST SYSTEM
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 16 - TORQUE CONVERTER 142
Use this supplement for current information on the subjects listed below. See Section 16 in the
1995-1996 DS Golf Car Maintenance and Service Manual for all other information.
General Information .......................................................................................................................... 142
Drive Clutch Disassembly.................................................................................................................. 143
Drive Clutch Assembly....................................................................................................................... 144
Assembly of the Driven Clutch .......................................................................................................... 146
Clutch Alignment ............................................................................................................................... 146
SECTION 17 - TRANSMISSION AND GOVERNOR
Section 10 in this supplement supersedes Section 17 in the 1995-1996 DS Maintenance and Ser-
vice Manual.
SECTION 18 - REAR SUSPENSION - GASOLINE VEHICLE 147
Section 18 in this supplement supersedes Section 18 in the 1995-1996 DS Maintenance and Ser-
vice Manual.
General Information .......................................................................................................................... 147
Shock Absorbers .............................................................................................................................. 148
Mono-Leaf Springs ........................................................................................................................... 149
The Snubber ..................................................................................................................................... 150
SECTION 19A - ELECTRICAL SYSTEM,
V-GLIDE 36 VOLT VEHICLE
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 19B - ELECTRICAL COMPONENTS,
V-GLIDE 36 VOLT VEHICLE
See 1995-1996 DS Golf Car Maintenance and Service Manual.

SECTION 20A - ELECTRICAL SYSTEM,
POWERDRIVE SYSTEM 48
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 20B - ELECTRICAL COMPONENTS,
POWERDRIVE SYSTEM 48 VEHICLE
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 21A - ELECTRICAL SYSTEM,
POWERDRIVE PLUS
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 21B - ELECTRICAL COMPONENTS,
POWERDRIVE PLUS
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 22 - BATTERIES
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 23A - ACCU-POWER BATTERY CHARGER
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 23B - POWERDRIVE BATTERY CHARGER
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 24 - MOTOR
See 1995-1996 DS Golf Car Maintenance and Service Manual.
SECTION 25 - TRANSAXLE, ELECTRIC VEHICLE
See Section 9 in the 1995-1996 DS Golf Car Maintenance and Service Manual. Disregard information
pertaining to gasoline vehicles.
SECTION 26 - REAR SUSPENSION, ELECTRIC VEHICLE
See Section 25 in the 1995-1996 DS Golf Car Maintenance and Service Manual.

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SECTION
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SECTION 1 - SAFETY
To insure the safety of those servicing Club Car DS Golf Cars, and to protect the vehicles from possible dam-
age resulting from improper service or maintenance, the procedures in this manual must be followed. It is
important to note that throughout this manual there are statements which are contained within boxes labeled
DANGER , WARNING , or CAUTION . These special statements relate to specific safety issues, and must be
read, understood, and heeded before proceeding with procedures. There are also boxes labeled NOTE,
which provide other essential service or maintenance information.
Service technicians should become familiar with the following general safety statements. These will be found
frequently throughout this manual:
•ADANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER-
SONAL INJURY OR DEATH.
• A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PER-
SONAL INJURY.
• A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR
PERSONAL INJURY, OR DAMAGE TO THE VEHICLE OR OTHER PROPERTY.
• A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDER-
STOOD OR IMPLEMENTED.
•GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES
AWAY FROM THE VEHICLE SERVICE AREA.
•DO NOT OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION. ENGINE PRO-
DUCES CARBON MONOXIDE, WHICH IS AN ODORLESS, DEADLY POISON.
•BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY. VEN-
TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL FACE
SHIELD WHEN WORKING ON OR NEAR BATTERIES.
•BATTERY - POISON! CONTAINS ACID! CAUSES SEVERE BURNS. AVOID CONTACT WITH
SKIN, EYES, OR CLOTHING. ANTIDOTES:
- EXTERNAL: FLUSH WITH WATER. CALL A PHYSICIAN IMMEDIATELY.
-INTERNAL: DRINK LARGE QUANTITIES OF MILK OR WATER. FOLLOW WITH MILK OF MAG-
NESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY.
DANGER
WARNING
CAUTION
NOTE
DANGER

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General Safety Statements, Continued:
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY
AND HEED ALL WARNINGS STATED IN THIS MANUAL.
• IMPROPER USE OF THIS VEHICLE, OR FAILURE TO MAINTAIN IT PROPERLY, COULD RESULT
IN DECREASED PERFORMANCE OR SEVERE PERSONAL INJURY.
• ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY, OR
INCREASES THE SPEED BEYOND FACTORY SPECIFICATIONS, COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
• CHECK THE OWNER’S MANUAL FOR PROPER LOCATION OF ALL VEHICLE WARNING
DECALS AND MAKE SURE THAT THEY ARE IN PLACE AND ARE EASILY READ.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
• HOT! - DO NOT ATTEMPT TO SERVICE HOT MOTOR, RESISTORS, ENGINE, OR EXHAUST
SYSTEMS. FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS.
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
GASOLINE VEHICLES ONLY:
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, ALWAYS BEFORE SERVICING:
- DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
- DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
• FRAME GROUND - DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT
FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING. NEVER
ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, OR OTHER METAL
COMPONENT.
ELECTRIC VEHICLES ONLY:
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS
SHOWN IN FIGURE 22-5 OR 22-6, PAGE 22-5 IN THE MAINTENANCE AND SERVICE MANUAL.
THEN DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE
REVERSE POSITION.
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
WARNING

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SECTION 2 - VEHICLE SPECIFICATIONS
Club Car, Inc. reserves the right to change specifications and design of either gasoline or electric vehicles at
any time without notice and without obligation to make these changes on units previously sold.
SPECIFICATIONS
DS
GASOLINE
POWERDRIVE
SYSTEM 48
ELECTRIC
POWERDRIVE
PLUS
ELECTRIC
DS
36 VOLT
ELECTRIC
POWER SOURCE
Engine: 4 cycle, OHV, 286 cc, 9.0 hp rated, single cylinder, air cooled,
with pressure lubrication system.
•
Drive Motor: Direct drive, 48 volts DC, series wound, 3.1 hp. •
Drive Motor: Direct drive, 48 volts DC, shunt wound, 3.2 hp. •
Drive Motor: Direct drive, 36 volts DC, series wound, 2.97 hp. •
Fuel System: Side draft carburetor with float bowl, fixed jets, fuel filter,
and impulse fuel pump.
•
Governor: Automatic ground speed sensing, internally geared in the unit-
ized transaxle.
•
Ignition: Transistor electronic ignition with electronic RPM limiter. •
Unitized Transaxle: Fully synchronized forward and reverse with neutral
(11.8:1 forward, 17.1:1 reverse).
•
Transaxle: Double reduction helical gear with 12.28:1 direct drive axle. •••
Electrical System: 12 volt, 460 cold cranking amp battery and 35 amp
charging capacity.
•
Electrical System: 48 volts DC, reduced speed reverse. ••
Electrical System: 36 volts DC, reduced speed reverse. •
Batteries: High capacity, deep cycle, Trojan PowerDrive 8 volt, 117 min.
capacity. ••
Batteries: High capacity, deep cycle, Trojan 6 volt, 115 min. capacity. •
Charger: Automatic, 17 amp PowerDrive; UL and CSA listed. ••
Charger: Automatic, 21 amp Accu-Power; UL and CSA listed. •
Torque Converter: Automatic, variable speed, dry type. •
STEERING/SUSPENSION/BRAKES
Steering: Self-adjusting rack and pinion. ••••
Suspension: Front and rear tapered mono-leaf springs with dual hydrau-
lic shocks. ••••
Brakes: Dual rear wheel self-adjusting brakes with cast iron drums and
single brake pedal with automatic-release park brake. ••••
BODY/CHASSIS
Frame/Chassis: Twin I-Beam welded aluminum. ••••
Front and Rear Body: Armorflex® ••••
Body Finish: Protective coat over molded-in color. ••••
Tires: 18.00 x 8.50 - 8.00 tubeless, 4 ply rated. ••••
SEATING CAPACITY/FUEL CAPACITY
Standard Seating Capacity: 2 persons ••••
Fairway Villager Seating Capacity: 4 persons ••N/A N/A
Fuel Tank: 7 gallons (26.5 liters), unleaded gasoline only. •
Specifications Continued on Next Page.

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DIMENSIONS/WEIGHT
Overall Length 91-1/2”
(232 cm) 91-1/2” (232 cm) 91-1/2” (232 cm) 91-1/2” (232 cm)
Overall Width 47-1/4”
(120 cm) 47-1/4” (120 cm) 47-1/4” (120 cm) 47-1/4” (120 cm)
Overall Height: At Steering Wheel. 48”
(122 cm) 48” (122 cm) 48” (122 cm) 48” (122 cm)
Wheelbase 65-1/2”
(166 cm) 65-1/2” (166 cm) 65-1/2” (166 cm) 65-1/2” (166 cm)
Ground Clearance 4-1/2”
(11 cm) 4-1/2” (11 cm) 4-1/2” (11 cm) 4-1/2” (11 cm)
Front Wheel Tread 34-1/2”
(88 cm) 34-1/2” (88 cm) 34-1/2” (88 cm) 34-1/2” (88 cm)
Rear Wheel Tread 38-1/2”
(98 cm) 38-1/2” (98 cm) 38-1/2” (98 cm) 38-1/2” (98 cm)
Weight: Standard electric vehicle (without batteries) 455 lbs.
(206 kg) 455 lbs. (206 kg) 448 lbs. (203 kg)
Weight: Fairway Villager electric vehicle (without batteries) 495 lbs.
(225 kg) N/A N/A
Weight: Standard gasoline powered vehicle (dry) 593 lbs.
(269 kg.)
Weight: Fairway Villager gasoline powered vehicle (dry) 633 lbs.
(287 kg.)
Forward Speed 12 - 15 mph
(19 - 24 kph) 12 - 15 mph (19 - 24 kph) 12 - 15 mph (19 - 24 kph) 12 - 15 mph (19 - 24 kph)
Clearance Circle (diameter) 17’-6”
(533 cm) 17’-6” (533 cm) 17’-6” (533 cm) 17’-6” (533 cm)
Braking Distance: At 12 mph (19 kph). 14’
(427 cm) 14’ (427 cm) 14’ (427 cm) 14’ (427 cm)
SPECIFICATIONS DS
GASOLINE
POWERDRIVE
SYSTEM 48
ELECTRIC
POWERDRIVE
PLUS
ELECTRIC
DS
36 VOLT
ELECTRIC

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SECTION 3 - GENERAL INFORMATION
Because continuously variable potentiometers were used on some early 1997 DS PowerDrive System 48
and PowerDrive Plus Golf Cars, the Pre-Operation Checklist on Page 3-2 in the 1995-1996 DS Maintenance
and Service Manual should read as follows:
PRE-OPERATION CHECKLIST
Your CLUB CAR has been thoroughly inspected and adjusted at the factory, and also by your CLUB CAR
distributor/dealer. However, upon arrival of your new CLUB CAR(s), you should become familiar with its con-
trols and operation, and carefully inspect each vehicle to be satisfied that it is in proper working condition
before accepting delivery.
Use the following checklist as a guide to inspect your new vehicle. Any problems should be corrected only by
your CLUB CAR distributor/dealer or a trained technician.
• General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screws
are tight. On the DS Gasoline vehicle, check all hose clamps for tight fit as well as the starter belt for
tightness.
•Warning Labels: Check to ensure that all warning and operation labels are in place (See Vehicle
Identification pages at the beginning of vehicle Owner’s Manual).
• Tires: Check for proper tire pressure (See Capacities, Page 9 in this supplement).
•DS Electric Batteries (all models): Check electrolyte to ensure that it is at its proper level (See Fig-
ure 22-7, Section 22, Page 6, in the Maintenance and Service Manual). Check battery posts. Wires
should be tight and free of corrosion. Charge batteries fully before first use of vehicle.
•DS V-Glide Speed Switch and PowerDrive System 48 Multi-step Potentiometer: Be sure speed
switch or potentiometer cover is properly secured prior to operating the vehicle.
•DS Gasoline Engine: Check for proper engine oil level (See Section 13, Page 47 in the Maintenance
and Service Manual).
• DS Gasoline Fuel: Check fuel level.
•SEVERAL VEHICLE SAFETY DECALS HAVE BEEN RELOCATED FROM BENEATH THE SEAT
ON THE VEHICLE FRONT BODY TO THE VEHICLE FRAME INSIDE THE ENGINE OR BATTERY
COMPARTMENT.
•CONTINUOUSLY VARIABLE POTENTIOMETERS WERE STANDARD ON EARLY 1997 DS POW-
ERDRIVE SYSTEM 48 VEHICLES. ON DS POWERDRIVE SYSTEM 48 VEHICLES SERIAL NO.
9711-564736 AND LATER, THE MULTI-STEP POTENTIOMETER IS STANDARD.
•BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERAT-
ING THE VEHICLE. FAILURE TO DO SO COULD RESULT IN A FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
NOTE
NOTE
DANGER

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SECTION 4 - PERIODIC MAINTENANCE
It is important to implement and follow a Preventive Maintenance program for your vehicle(s). Preventive
Maintenance consists of the regular performance of scheduled vehicle service and maintenance procedures,
and is the only way to insure that the vehicle provides the safe, reliable, and economical service that it is
designed to deliver. The following charts provide recommended service intervals for the lubrication and main-
tenance of DS vehicles. Note that critical areas such as brake operation, accelerator operation, steering and
tires should be performed daily. Any car that is not functioning properly should be removed from use until it is
properly repaired.
•IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE, DO NOT
OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE. FAILURE TO MAKE NECESSARY
REPAIRS COULD RESULT IN FIRE, PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR
DEATH.
•ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
•ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY
AND HEED ALL WARNINGS STATED IN THIS SUPPLEMENT AND IN THE MANUAL.
•TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
•MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
•HOT! - DO NOT ATTEMPT TO SERVICE HOT MOTOR, RESISTORS, ENGINE, OR EXHAUST
SYSTEM. FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS.
•ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
GASOLINE VEHICLES ONLY:
•TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING:
-DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
-DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
•FRAME GROUND - DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT
FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING. NEVER
ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, OR OTHER METAL
COMPONENT.
ELECTRIC VEHICLES ONLY:
•TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS
SHOWN IN THE MAINTENANCE AND SERVICE MANUAL; FIGURE 22-5, PAGE 22-5 FOR V-
GLIDE VEHICLES, OR FIGURE 22-6, PAGE 22-5 FOR POWERDRIVE VEHICLES. THEN DIS-
CHARGE THE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES AS FOLLOWS:
-TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE
REVERSE POSITION .
-SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
WARNING

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LUBRICATION - GASOLINE VEHICLES
*See Figure 4-1 below.
PERIODIC LUBRICATION SCHEDULE - GASOLINE VEHICLE
REGULAR INTERVAL SERVICE PLACE*RECOMMENDED LUBRICANT
Quarterly by Owner
or Trained Technician
Brake shaft bearings 1. Dry Moly Lube - Club Car Part No. 1012151
Brake Linkage and Pivots 2. Dry Moly Lube - Club Car Part No. 1012151
Accelerator push rod pivots and
shifter cable pivots 3. Dry Moly Lube - Club Car Part No. 1012151
Front Suspension (5 fittings) 4. Chassis Lube
Annually by Trained
Technician Only
(Every 200 rounds or
100 hours of operation)
Check/fill unitized transaxle to plug
level 5. 27 oz. (.8 liter) 80-90 WT. API Class GL-5 or 80-90 WT. AGMA Class EP Gear Lube
Inspect front wheel bearings
(Repack as necessary) 6. Chassis Lube
First Change 100 Hours -
Additional Change Every
400 Rounds or Every 200
Hours of Operation,
or Annually -
Whichever Comes First
Change engine oil and oil filter 7. 32 oz. (.97 liter) without filter; 38 oz. (1.16
liters) with filter. SAE 30 above 32°F (0°C)
or SAE 5W20 below 32°F (0°C) API Class
SE, SF, or SG Oil (or higher)
FIGURE 4-1
DS GASOLINE VEHICLE
LUBRICATION POINTS
7
3
3
4
4
2
2
1
1
6
6
4
4
4
3
5

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LUBRICATION - ELECTRIC VEHICLES
*See Figure 4-2 below, and Figure 4-3 on Page 9.
PERIODIC LUBRICATION SCHEDULE - ELECTRIC VEHICLES
REGULAR INTERVAL SERVICE PLACE* RECOMMENDED LUBRICANT
Quarterly by Owner
or Trained Technician
Brake shaft bearings 1. Dry Moly Lube - Club Car Part No. 1012151
Brake Linkage and Pivots 2. Dry Moly Lube - Club Car Part No. 1012151
Accelerator pivots 3. Dry Moly Lube - Club Car Part No. 1012151
Forward and reverse switch shaft and
contacts, charger receptacle
(Do not lubricate forward and reverse
switch on PowerDrive Plus vehicles)
4. WD-40®
Front Suspension (5 fittings) 5. Chassis Lube
Anually by Trained
Technician Only
(Every 200 rounds or
100 hours of operation)
Check/fill transaxle to plug level 6. 22 oz. (.67 liter) SAE 30 WT. API
Class SE, SF, or SG Oil (or higher)
Inspect front wheel bearings
(Repack as necessary)
7. Chassis Lube
FIGURE 4-2
3
3
4
2
2
1
1
7
45
5
55
5
7
6
POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES
WITH CONTINUOUSLY VARIABLE POTENTIOMETERS
LUBRICATION POINTS
DO NOT LUBRICATE
FORWARD & REVERSE
SWITCH ON
POWERDRIVE PLUS
VEHICLES

Page 9
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VEHICLE CAPACITIES
FIGURE 4-3
CAPACITIES
GASOLINE VEHICLES ELECTRIC VEHICLES
Engine Crankcase without filter 32 oz. (.98 liters)
Engine Crankcase with filter 38 oz. (1.16 liters)
Unitized Transaxle (gas vehicle) 27 oz. (.8 liters)
Transaxle (electric vehicle) 22 oz. (.67 liters)
Gasoline Tank 7 gallons (26.5 liters)
Tire Pressure 12-14 psi (83-96 kPa) 18-20 psi (124-138 kPa)
•IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE, DO NOT
OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE. FAILURE TO MAKE NECESSARY
REPAIRS COULD RESULT IN FIRE, PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR
DEATH.
3
2
2
1
1
7
5
5
5
4
5
5
7
3
6
POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES WITH
MULTI-STEP POTENTIOMETERS, AND V-GLIDE 36 VOLT VEHICLES
LUBRICATION POINTS
4
DO NOT LUBRICATE
FORWARD & REVERSE
SWITCH ON
POWERDRIVE PLUS
VEHICLES
WARNING

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PERIODIC SERVICE - GASOLINE VEHICLES
•IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE, DO NOT
OPERATE VEHICLE UNTIL REPAIRS ARE MADE. FAILURE TO MAKE NECESSARY REPAIRS
COULD RESULT IN FIRE, PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.
•ALL SERVICE, REPAIRS, AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THIS
MANUAL.
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE
REGULAR INTERVAL SERVICE
Daily Service by Owner
Accelerator Pedal/Rod Check for proper operation (See Performance Inspection, Page 3-2 in the Maintenance & Service
Manual). Adjust as necessary.
Accelerator/Governor Linkage and Cables Check for proper operation (See Performance Inspec- tion, Page 3-2 in the Maintenance & Service Manual).
Adjust as necessary.
Brake System Check for proper operation (See Performance Inspec- tion, Page 3-2 in the Maintenance & Service Manual).
Adjust as necessary.
Choke Check for proper operation (See Section 14).
Engine Check for proper operation (See Section 13).
Engine Air Intake System Check air filter element, clean as necessary.
Engine Cooling Air Intake Check for clogging, clean as necessary.
Fuel System Check fuel tank, lines, cap, pump, and carburetor for
fuel leakage.
Park Brake Check proper operation. (See Performance Inspec-
tion, Page 3-2 in Maintenance & Service Manual).
Reverse Warning Buzzer Check for proper operation (See NOTE, Page 3-4 in
the Maintenance and Service Manual).
Steering and Linkages Check for proper operation (See Performance Inspec-
tion, Page 3-2 in the Maintenance & Service Manual).
Tires Check for wear and damage.
Unitized Transaxle Check shift linkage for proper operation.
Vehicle Warning Decals Make sure all are in place (See Gasoline Vehicle
Feature Identification, in DS Owner’s Manual).
Weekly Service by Owner
Battery Clean terminals and wash dirt from casing, check
electrolyte level (See Section 22).
Electrical Wiring and Connections Check for tightness and damage.
Torque Converter Rinse with water.
General Vehicle
Check for loose hardware and tighten
as required.
Check maximum speed of vehicle. Maximum vehicle
speed should be 12-15 mph (19-24 kph).
Wash engine compartment and underside
of vehicle.
Check all daily items listed above.
Periodic Service Schedule Continued on Next Page.
WARNING

Page 11
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Monthly Service by Owner
or Trained Mechanic
Battery Wash battery top with baking soda/water solution
(See Section 22).
Brake System
Check brake cables for damage; replace as required.
Check for proper operation (See Performance Inspec-
tion, Page 3-2 in the Maintenance & Service Manual).
Check brake pedal free play. Adjust as necessary
(See Section 6).
Engine
Make sure that both ground wires are tight
and properly connected.
Check engine oil level - change as required
(See Gas Vehicle Lubrication Chart on Page 7).
Exhaust System Check for leaks.
Tires
Check for wear and damage.
Check air pressure and adjust as necessary
(See Vehicle Capacities Chart on Page 9).
Check all daily and weekly items listed above
Quarterly Service
by Owner
or Trained Mechanic
Engine Check engine oil level - change as required
(See Gas Vehicle Lubrication Chart on Page 7).
Engine Air Intake Hose Check clamps for tightness; check hose for cracks.
Accelerator Pedal/Rod Check for proper operation, adjust as necessary
(See Section 6).
Accelerator/Governor Linkage
and Cables Check for proper operation, adjust as necessary.
Steering Lubricate per Gas Vehicle Lubrication Chart
on Page 7.
General Vehicle Lubricate per Gas Vehicle Lubrication Chart
on Page 7.
Check all daily, weekly, and monthly items listed above.
Semi-annual Service by
Trained Mechanic Only
(Every 100 rounds or
50 hours of operation)
Brake System
Check for proper operation (See Performance Inspec-
tion, Page 3-2 in the Maintenance & Service Manual).
Check brake pedal free play. Adjust as necessary
(See Section 6).
Check brake shoes, replace if necessary.
Lubricate slide plates with graphite (See Section 7).
Drive Belt Check for cracks, wear, or glazing, replace if neces-
sary.
Electrical Wiring Check for cracked or worn insulation.
Engine Check spark plug wire and boot for damage and
proper routing (See Section 13).
Exhaust System
Check head and exhaust/header pipe flange connec-
tion gasket for leaks.
Check muffler condition.
Front Wheel Alignment and Camber Check and adjust as required (See Section 8).
Periodic Service Schedule Continued on Next Page.
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE
REGULAR INTERVAL SERVICE

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PERIODIC SERVICE - ELECTRIC VEHICLES
Semi-annual Service by
Trained Mechanic Only
(Every 100 rounds or
50 hours of operation),
Continued:
Torque Converter/Drive Belt Check for proper operation. Inspect belt and replace
as required (See Section 16).
Starter/Generator Belt
Check for cracks, wear, and glazing, replace if neces-
sary.
Check belt tension, adjust as required (Section 12).
General Vehicle Lubricate per Gas Vehicle Lubrication Chart, Page 7.
Check all daily, weekly, monthly, and quarterly items listed above.
Annual Service by
Trained Mechanic Only
(Every 200 rounds or
100 hours of operation)
Engine
Check engine oil level - change as required
(See Gas Vehicle Lubrication Chart, Page 7).
Check for leaks around gaskets, fill plugs, etc.
Inspect, clean, and regap spark plug; replace if
necessary.
Engine Air Intake Check air filter element, clean or replace.
Fuel Filters Replace.
Front Wheel Bearings Check front wheels for free play. Inspect and replace or repack wheel bearings with chassis lube as neces-
sary.
Starter/Generator Check brush length (remove excess carbon dust);
replace as necessary (See Section 12).
Unitized Transaxle Check/fill transaxle to plug level (See Gas Vehicle
Lubrication Chart on Page 7).
General Vehicle Lubricate per Gas Vehicle Lubrication Chart
on Page 7.
Check all daily, weekly, monthly, quarterly, and semi-annual items listed above.
•IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE, DO NOT
OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE. FAILURE TO MAKE NECESSARY
REPAIRS COULD RESULT IN FIRE, PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR
DEATH.
•ALL SERVICE, REPAIRS, AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THIS
MANUAL.
PERIODIC SERVICE SCHEDULE - ELECTRIC VEHICLES
REGULAR INTERVAL SERVICE
Daily Service by Owner
Accelerator Pedal/Rod Check for proper operation (See Section 6). Adjust as
necessary.
Accelerator Switch
(Wiper Switch or Continuously Variable
Potentiometer)
Check for proper operation (See Performance Inspec-
tion, Page 3-2 in the Maintenance & Service Manual).
Periodic Service Schedule Continued on Next Page.
PERIODIC SERVICE SCHEDULE - GASOLINE VEHICLE
REGULAR INTERVAL SERVICE
WARNING