Club Car 1998 DS Manual

DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 101968401
0199B0312A
1998-1999
MAINTENANCE
S E R V I C E
MANUAL
EDITION CODE

1998/1999 DS Golf Car Maintenance and Service Manual Page i
FORWARD
Club Car golf cars are designed and built to provide maximum efficiency and performance. However, proper
maintenance and repair is essential for achieving maximum service life and continued safe and reliable oper-
ation.This maintenance and service manual provides detailed procedures for the maintenance and repair of
those components that are common to all Club Car DS Golf Cars, and should be used in conjunction with the
appropriate maintenance and service supplement.The supplement will provide maintenance and repair pro-
cedures for those components specific to a particular type of vehicle.If you do not have the appropriate sup-
plement for your vehicle(s), you may obtain one of the following from your Club Car distributor:
This manual and the supplement should be read prior to servicing the vehicle.The procedures provided must
be properly implemented, and the CAUTION , WARNING , and DANGER statements must be heeded.
This manual was written for the vehicle mechanic who already possesses basic knowledge and skills in elec-
trical and mechanical repair. If the mechanic does not have such basic knowledge and skills, attempted ser-
vice or repairs to the vehicle may render it unsafe. For this reason, we advise that all repairs and/or service
be performed by an authorized Club Car distributor’s/dealer’s representative or by a Club Car factory trained
technician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service
knowledge and facilities so they can provide prompt and efficient service for vehicle owners.Regional techni-
cal representatives, golf car service seminars, periodic service bulletins, maintenance and service manuals,
and other service publications also represent Club Car’s continuing commitment to customer support.
This service manual, used in conjunction with the appropriate supplement, covers all aspects of typical DS
Golf Car service.However, unique situations do sometimes arise when servicing a golf car. If it appears that
a service question is not answered in this manual or the supplement, you may write to us at: Club Car, Inc.;
P.O. Box 204658; Augusta, GA 30917; Attention:Technical Services, or contact a Club CarTechnical Service
representative at [phone], extension 3580.
©1999, 2012 Club Car, Inc.
Club Car, Armorflex, PowerDrive, PowerDrive Plus,
and Tranquility are registered trademarks of Club Car, Inc.
This manual effective August 1, 1998
1998/1999 PowerDrive System 48 Vehicle Maintenance & Service Supplement Publication Part No. 101968404
1998/1999 PowerDrive Plus Vehicle Maintenance & Service Supplement Publication Part No. 101968405
1998/1999 V-Glide 36-Volt Vehicle Maintenance & Service Supplement Publication Part No. 101968406
1998/1999 FE 290 Gasoline Vehicle Maintenance & Service Supplement Publication Part No. 101968407

Page ii 1998/1999 DS Golf Car Maintenance and Service Manual
• 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.
• THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF
PUBLICATION. CLUB CAR, INC. IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR
VEHICLES 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 THIS 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
MAINTENANCE AS INSTRUCTED IN THE VEHICLE OWNER’S MANUAL), ACCIDENT OR
ALTERATION, INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY
SPECIFICATIONS OR MODIFICATIONS 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.
WARNING
NOTE

1998/1999 DS Golf Car Maintenance and Service Manual Page iii
CONTENTS
SAFETY SECTION
General Warning ............................................................................................................................... 1-1
VEHICLE SPECIFICATIONS SECTION
General Information .......................................................................................................................... 2-1
GENERAL INFORMATION SECTION
Model Identification ........................................................................................................................... 3-1
Safety Committee ............................................................................................................................. 3-1
Pre-Operation Checklist .................................................................................................................... 3-2
Controls ............................................................................................................................................ 3-3
Driving Instructions ........................................................................................................................... 3-9
Towing ............................................................................................................................................... 3-11
Transporting on a Trailer ................................................................................................................... 3-11
Storage - Gasoline Vehicle ............................................................................................................... 3-12
Storage - Electric Vehicle .................................................................................................................. 3-13
BODY AND TRIM SECTION
General Information .......................................................................................................................... 4-2
Front and Rear Body Repair ............................................................................................................. 4-2
Seat .................................................................................................................................................. 4-4
Front Body ........................................................................................................................................ 4-4
Rear Body ......................................................................................................................................... 4-6
Floormat ............................................................................................................................................ 4-8
ACCELERATOR AND BRAKE PEDAL GROUP SECTION
General Information .......................................................................................................................... 5-1
Pedal Group Adjustment.................................................................................................................... 5-2
Pedal Group Disassembly and Assembly ......................................................................................... 5-8
WHEEL BRAKE ASSEMBLIES SECTION
Removal and Cleaning of Wheel Brake Assemblies ......................................................................... 6-3
Installing the Brake Shoes ................................................................................................................ 6-5
Adjusting the Brakes ......................................................................................................................... 6-8
Removal and Installation of Brake Assembly .................................................................................... 6-8
1
2
3
4
5
6

Page iv 1998/1999 DS Golf Car Maintenance and Service Manual
STEERING AND FRONT SUSPENSION SECTION
General Information - Steering........................................................................................................... 7-1
Steering Wheel ................................................................................................................................. 7-2
Steering Column ............................................................................................................................... 7-2
Steering Adjustment .......................................................................................................................... 7-6
Rack and Pinion ................................................................................................................................ 7-7
Tie Rod and Drag Link ...................................................................................................................... 7-10
Front Suspension .............................................................................................................................. 7-12
Front Suspension Components ........................................................................................................ 7-14
Front Wheel Bearings and Hubs ....................................................................................................... 7-18
WHEELS AND TIRES SECTION
General Information........................................................................................................................... 8-1
Wheel Removal, Repair and Installation ........................................................................................... 8-2
REAR SUSPENSION SECTION
General Information .......................................................................................................................... 9-1
Shock Absorbers ............................................................................................................................... 9-3
Leaf Springs ...................................................................................................................................... 9-3
7
8
9

1998/1999 DS Golf Car Maintenance and Service Manual Page 1-1
1
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.
GENERALWARNING
The following safety procedures must be followed whenever the vehicle is being operated, repaired,
or serviced. Service technicians should become familiar with these general statements, which will be
found frequently throughout this manual. Also, other specific warnings appear throughout this man-
ual and on the vehicle.
• A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
• A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
• A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH MAY RESULT IN
PRODUCT OR PROPERTY DAMAGE OR MINOR PERSONAL INJURY.
• A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY
UNDERSTOOD.
• BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM
THE VEHICLE. VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS
WEAR A 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 WATER. FOLLOW WITH MILK OF MAGNESIA
OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL A PHYSICIAN IMMEDIATELY.
DANGER
WARNING
CAUTION
NOTE
DANGER

SAFETY General Warning
Page 1-2 1998/1999 DS Golf Car Maintenance and Service Manual
1
GeneralWarning, Continued:
• GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES
AWAY FROM VEHICLE AND SERVICE AREA. SERVICE ONLY IN A WELL-VENTILATED AREA.
• DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER
VENTILATION. THE ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS,
DEADLY POISON.
• A GOLF CAR WILL NOT PROVIDE PROTECTION FROM LIGHTNING, FLYING OBJECTS, OR
OTHER STORM RELATED HAZARDS. IF CAUGHT IN A STORM WHILE DRIVING A GOLF CAR,
EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY
GUIDELINES FORYOUR LOCATION.
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
ELECTRICAL AND MECHANICAL REPAIR.
• FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND HEED DANGER ,
WARNING , AND CAUTION STATEMENTS LISTED IN THIS MANUAL AS WELL AS THOSE
AFFIXED TO THE VEHICLE.
• IMPROPER USE OF THE VEHICLE OR FAILURE TO PROPERLY MAINTAIN IT, COULD RESULT
IN DECREASED VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY.
• ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR
HANDLING OF THE VEHICLE, OR INCREASES MAXIMUM VEHICLE SPEED BEYOND FACTORY
SPECIFICATIONS, COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
• CHECK THE VEHICLE OWNER’S MANUAL FOR PROPER LOCATION OF ALL VEHICLE
WARNING DECALS AND MAKE SURE THAT THEY ARE IN PLACE AND ARE EASY TO READ.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHEN SERVICING THE
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• 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.
• ALWAYS USE INSULATED TOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL
CONNECTIONS.
• LIFT ONLY ONE END OF 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 VEHICLE.
• TURN THE KEY SWITCH TO OFF , REMOVE THE KEY, CHOCK THE WHEELS, PLACE THE
FORWARD AND REVERSE SWITCH IN NEUTRAL , AND DISCONNECT BATTERY(IES) PRIOR
TO SERVICING THE VEHICLE.
WARNING CONTINUED ON NEXT PAGE:
DANGER
WARNING

SAFETY General Warning
1998/1999 DS Golf Car Maintenance and Service Manual Page 1-3
1
GASOLINEVEHICLES ONLY:
• TO AVOID UNINTENTIONALLY STARTING THE VEHICLE:
- DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST (FIGURE 1-1) .
- DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
• FRAME GROUND - DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT
FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING. NEVER
ALLOW A POSITIVE WIRE TO TOUCH VEHICLE FRAME, ENGINE, OR METAL COMPONENT.
ELECTRICVEHICLES ONLY:
• TO AVOID UNINTENTIONALLY STARTINGTHE VEHICLE, DISCONNECT BATTERIES AS SHOWN
(FIGURES 1-2 OR 1-3) .
• ON POWERDRIVE PLUS VEHICLES, PLACE TOW SWITCH IN THE TOW POSITION BEFORE
DISCONNECTING BATTERIES.
• ON POWERDRIVE SYSTEM 48 VEHICLES, DISCHARGE THE CONTROLLER AS FOLLOWS
AFTER DISCONNECTING BATTERIES:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE 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.
Figure 1-1 GasolineVehicle Figure 1-2 PowerDrive Vehicles
Figure 1-3 V-Glide 36-VoltVehicle
WARNING
FRONT
OF VEHICLE
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
REMOVE
NEGATIVE
CABLE FIRST
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE
DS POWERDRIVE SYSTEM 48
AND POWERDRIVE PLUS
BATTERY DISCONNECT
1
2
3
4
6
5
FRONT
OF VEHICLE
REMOVE
NEGATIVE
CABLE FIRST
DISCONNECT
BATTERY CABLES HERE
1
2
3
4
6
5
DISCONNECT
BATTERY CABLES HERE
FRONT
OF VEHICLE

1

1998/1999 DS Golf Car Maintenance and Service Manual Page 2-1
2
SECTION 2–VEHICLE SPECIFICATIONS
GENERAL INFORMATION
Club Car, Inc. reserves the right to change vehicle specifications and design of either gasoline or electric
vehicles at any time 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 unitized
transaxle.
•
Ignition: Transistor electronic ignition with electronic RPM limiter. •
UnitizedTransaxle: Fully synchronized forward and reverse with neutral
and reduced speed reverse (11.8:1 forward, 17.1:1 reverse).
•
Transaxle: Double reduction helical gear with 12.28:1 direct drive axle. •••
Electrical System: Battery - 12 volt, 500 cold cranking amps at 0°, 650
cranking amps at 32°, 85 minute reserve 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: Matched paint finish 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 •• • •
FuelTank: 7 gallons (26.5 liters), unleaded gasoline only. •
Specifications Continued on Next Page.

VEHICLE SPECIFICATIONS General Information
Page 2-2 1998/1999 DS Golf Car Maintenance and Service Manual
2
DIMENSIONS/WEIGHT
Overall Length
91-1/2"
(232 cm) 91-1/2" (232 cm) 91-1/2" (232 cm) 91-1/2" (232 cm)
OverallWidth
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)
FrontWheelTread
34-1/2"
(88 cm) 34-1/2" (88 cm 34-1/2" (88 cm 34-1/2" (88 cm
RearWheelTread
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) 477 lbs. (216 kg) 448 lbs. (203 kg)
Weight: FairwayVillager electric vehicle (without batteries) 495 lbs.
(225 kg) 517 lbs. (235 kg) N/A
Weight: Standard gasoline powered vehicle (dry, without battery) 598 lbs.
(271 kg.)
Weight: FairwayVillager gasoline powered vehicle (dry) 638 lbs.
(289 kg.)
Forward Speed: At 2700 rpm 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

1998/1999 DS Golf Car Maintenance and Service Manual Page 3-1
3
SECTION 3–GENERAL INFORMATION
There are four DS Golf Car models: the DS gasoline powered vehicle, the DS V-Glide 36-volt electric powered
vehicle, the DS PowerDrive System 48 (48-volt) electric vehicle, and the DS PowerDrive Plus (48-volt) electric
vehicle with motor braking.Throughout this manual, important features unique to each model are highlighted.We
urge the owner/operator to read and understand this manual, and to pay special attention to the features specific
to his/her vehicle(s).
MODEL IDENTIFICATION
The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the
accelerator pedal (Example: A9801-123456 for Electric or AG9801-123456 for Gasoline). See Figure 3-1,
Page 3-1 . There is also a second serial number decal mounted on the front body frame behind the center
dash panel.The center dash panel must be removed to access this decal (Figure 3-2, Page 3-1) .
SAFETY COMMITTEE
If the golf car is to be rented or is part of a fleet, Club Car, Inc. recommends a safety committee be
appointed. One of the main concerns of this committee should be the safe operation of the golf cars.
This should include at a minimum:
• Where golf cars should be driven.
• Ensuring that proper warnings of driving hazards are displayed and visible.
• Who should and who should not drive golf cars.
• ALWAYS HAVE THE VEHICLE SERIAL NUMBER AT HAND WHEN ORDERING PARTS OR
MAKING INQUIRIES.
Figure 3-1 Serial Number Decal Figure 3-2 Serial Number Decal Behind Dash
• SIGNS SUCH AS STEEP HILL AND SHARP TURN ARE AVAILABLE FROM THE GOLF CAR
MANUFACTURERS ASSOCIATION MEMBERS.
NOTE
This vehicle is covered by one or more of the
following U.S. Patents as applicable: D271008
D292899, 4343503, 4539162, 4637270, 4821827
4826467, 5042519, 5083736 and other
patents pendings.
Club
GO
GO
SERIAL NUMBER
A9801-123456
P O BOX 204658
AUGUSTA GA 30917
Club Car R
l
Help spee
d
up p
l
ay.
l
Dispose of litter properly.
Club Car, Inc.
SERIAL NUMBER
DECAL
SERIAL NUMBER
A9812-583947
P O BOX 204658
AUGUSTA GA 30917
Club Car
R
REAR OF CENTER
DASH VIEWED FROM
THE FRONT OF
THE VEHICLE
(FRONT BODY
REMOVED)
SERIAL NUMBER DECAL
NOTE

GENERAL INFORMATION Pre-Operation Checklist
Page 3-2 1998/1999 DS Golf Car Maintenance and Service Manual
3
Safety Committee, Continued:
• Instructing first time drivers.
• Maintaining golf cars in a safe driving condition.
• How various rules are to be enforced.
The safety committee should include all these items and such others as the committee feels necessary or
appropriate.
PRE-OPERATION CHECKLIST
Each Club Car vehicle is thoroughly inspected and adjusted at the factory and by a Club Car distributor/dealer.
However, upon receipt of any new Club Car vehicle, become familiar with the controls and vehicle operation.
Carefully inspect each vehicle to be satisfied it is in proper working condition before accepting delivery.
Use the following checklist as a guide to inspect the new vehicle. This checklist may also be used in
conjunction with the Daily Pre-operation Safety Checklist (Periodic Maintenance, Section 10,
Maintenance and Service Supplement) . Any problems should be corrected by a Club Car distributor/
dealer or a trained mechanic.
• General: All 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 starter belt for tightness.
• Warning Decals: Check to ensure that all warning and operation decals are in place. See the Vehicle
Identification Pages at the beginning of the Vehicle Owner’s Manual.
• Tires: Check for proper tire pressure. SeeVehicle Capacities, Section 10, Maintenance and Service
Supplement .
• Batteries (electric vehicles): Check electrolyte to ensure that it is at its proper level. See Section 13,
Maintenance and Service Supplement . Check battery posts.Wires should be tight and free of corro-
sion. Charge batteries fully before first use of vehicle.
• Multi-Step Potentiometer (48 volt electric vehicles) and V-Glide Wiper Switch (36 volt electric
vehicles): Be sure accelerator switch cover is properly secured prior to operating the vehicle.
• Engine (gasoline vehicles): Check for proper engine oil level. See Engine Oil, Section 10, Mainte-
nance and Service Supplement .
• Fuel (gasoline vehicles): Check fuel level. See Fueling Instructions, Section 10, Maintenance and
Service Supplement .
PERFORMANCE INSPECTION
After becoming familiar with the vehicle’s controls and after reading and understanding the driving
instructions, take the vehicle for a test drive.Use the following checklist as a guide to inspect the new vehicle.
Any problems should be corrected by a CLUB CAR distributor/dealer or a trained technician.
All vehicles:
• Brakes: Be sure the brakes function properly. When brake pedal is fully depressed under moderate
pressure, it should not go more than halfway to the floor, and vehicle should come to a smooth, straight
stop within 14 feet. If the pedal goes more than halfway to the floor, or if the vehicle swerves or fails to
stop within 14 feet, have the brake system checked and adjusted as required. Brake adjustment must
be maintained so that the brake pedal cannot be depressed to the floor under any circumstances.
• BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE
OPERATING THE VEHICLE. FAILURE TO DO SO MAY RESULT IN A FIRE, PROPERTY
DAMAGE, PERSONAL INJURY, OR DEATH.
WARNING

GENERAL INFORMATION Controls
1998/1999 DS Golf Car Maintenance and Service Manual Page 3-3
3
• Park Brake: When latched, the park brake should lock the wheels and hold the vehicle stationary (on
incline of 20% or less). It should release when either the accelerator or brake pedal is depressed.
• Reverse Buzzer: The reverse buzzer should sound as a warning when the vehicle is in REVERSE.
• Steering: The vehicle should be easy to steer and should not have any play in the steering wheel.
• Accelerator: With the key switch ON and the Forward/Reverse handle in the FORWARD position; as
the accelerator pedal is depressed, the engine or motor should start and the vehicle should come up
smoothly to full speed.When pedal is released it should return to the original position and the engine or
motor should stop. All DS (gasoline and electric) vehicles run at reduced speed in REVERSE.
• Governor (gasoline vehicles): Check maximum speed of the vehicle.The vehicle should run at 12-15
mph (19-24 kph) on a level surface.
• General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle ride and perfor-
mance.Have a CLUB CAR distributor/dealer or a trained mechanic investigate anything unusual.
DS PowerDrive PlusVehicles with Motor Braking:
• Zero Speed Detect: With the vehicle parked on level ground and the park brake disengaged, place the
tow switch in the RUN position and attempt to push the vehicle. It should resist rolling (moving at no
more than 1 or 2 mph) with the Forward/Reverse handle in any position.
• “Pedal Up” Motor Braking: Accelerate the vehicle to full speed and then release the accelerator
pedal.Motor braking should quickly and smoothly slow the vehicle to approximately 9 mph.Motor brak-
ing will disengage when vehicle slows to 9 mph.
• “Pedal Down” Motor Braking: Accelerate down an incline with the accelerator pedal depressed.
When the vehicle reaches approximately 15 mph, motor braking should engage and moderate vehicle
speed between 15 and 16 mph, depending upon the grade of the hill.
CONTROLS
• DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER
VENTILATION. GASOLINE ENGINES PRODUCE CARBON MONOXIDE GAS, WHICH IS AN
ODORLESS, DEADLY POISON.
• IF RENTING OR LOANING THE VEHICLE, MAKE SURE DRIVER IS FAMILIAR WITH ALL CONTROLS
AND OPERATING PROCEDURES BEFORE ALLOWING THE VEHICLE TO BE DRIVEN.
• DO NOT TAMPER WITH THE GASOLINE VEHICLE GOVERNOR. DOING SO WILL VOID THE
WARRANTY, AS WELL AS DAMAGE THE ENGINE AND OTHER COMPONENTS, AND COULD
RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH DUE TO ACCIDENT AT
UNSAFE SPEED.
• DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY WHICH MIGHT AFFECT ITS
STABILITY OR HANDLING, OR INCREASE MAXIMUM SPEED BEYOND FACTORY
SPECIFICATIONS.PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH COULD RESULT.
• DO NOT SHIFT THE FORWARD/REVERSE HANDLE WHILE THE VEHICLE IS MOVING. TO
AVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE, ALWAYS
BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING THE SWITCH. A BUZZER WILL
SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE .
• RELEASE THE ACCELERATOR PEDAL AND THEN DEPRESS THE BRAKE PEDAL FIRMLY
UNTIL THE VEHICLE STOPS. TO AVOID UNINTENTIONALLY STARTING OR ROLLING THE
VEHICLE, SET THE PARK BRAKE, TURN THE KEY SWITCH TO OFF , AND REMOVE THE KEY
WHEN LEAVING THE VEHICLE.
DANGER
WARNING

GENERAL INFORMATION Controls
Page 3-4 1998/1999 DS Golf Car Maintenance and Service Manual
3
Controls, Continued:
KEY SWITCH
The key switch is mounted on the dash to the right of the steering column (Figure 3-3, Page 3-4) . It has two
positions, OFF and ON, which are clearly labeled.
FORWARD/REVERSE CONTROL
DS Gasoline, DS V-Glide Electric, and DS PowerDrive System 48
The Forward/Reverse shift handle is located on the seat support panel, below and to the right of the driver’s
right knee (Figure 3-4, Page 3-4) . The handle has three distinct positions: F (forward), N (neutral), and R
(reverse). Rotate the handle towards the driver, F (forward), to run the vehicle in the FORWARD direction, or
towards the passenger, R (reverse), to run the vehicle in REVERSE.When the handle is in the straight up, or
N (neutral) position, the vehicle will not run.The engine on the DS gasoline vehicle will stop if it is shifted to
this position while running. DS electric and gasoline vehicles operate at reduced speed in REVERSE.When
the vehicle is in REVERSE, the reverse warning buzzer will sound.
DS PowerDrive PlusWith Motor Braking
The Forward/Reverse rocker switch is located in the same place as the Forward/Reverse shift handle on all
other DS models; on the seat support panel below and to the right of the driver’s right knee.The Forward (F)
and Reverse (R) positions are clearly marked on the switch. Push down the F (forward) side of the switch to
run the vehicle in the FORWARD direction, or push down the R (reverse) side of the switch to run the vehicle
in REVERSE.When the switch is positioned with neither side down, the vehicle is in the NEUTRAL position
and the vehicle will not run if the accelerator pedal is depressed (Figure 3-5, Page 3-5) .
ACCELERATOR PEDAL
The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 3-6, Page 3-5) .
• THE KEY CAN BE REMOVED WHEN THE KEY SWITCH IS IN THE OFF POSITION ONLY.
Figure 3-3 Key Switch Figure 3-4 Forward and Reverse Handle
• THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE .
NOTE
OFF ON
NOTE

GENERAL INFORMATION Controls
1998/1999 DS Golf Car Maintenance and Service Manual Page 3-5
3
BRAKE PEDAL
The brake pedal is the large pedal on the left with the word STOP molded into it (Figure 3-6, Page 3-5) . To
slow or stop the vehicle, depress the brake pedal with your right foot (Figure 3-7, Page 3-6) .
PARK BRAKE PEDAL
The park brake pedal is the small raised portion in the upper left corner of the brake pedal. It has the word
PARK molded into it and the words PARK BRAKE marked on top of it (Figure 3-7, Page 3-6) . To set the
park brake, depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot
(Figure 3-8, Page 3-6) .
GASOLINEVEHICLES ONLY
Neutral Lock-out
The vehicle has a neutral lock-out circuit that prevents the driver from starting the vehicle in NEUTRAL.If the
vehicle is started in FORWARD or REVERSE and then shifted to NEUTRAl, the engine will stop running. For
the convenience of the trained mechanic, there is a neutral lock-out cam located on the back of the Forward/
Reverse handle.If the neutral lock-out cam is pulled out approximately 3/8 in. (10 mm) and then rotated one-
half turn until it snaps into place, the cam will be in the SERVICE position (Figure 3-9, Page 3-7) .
• THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN
AUTOMOBILE. WHEN THE KEY SWITCH IS ON , AND THE SHIFT HANDLE IS IN EITHER
FORWARD OR REVERSE , DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY
RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION
SELECTED ( FORWARD OR REVERSE ). AS THE ACCELERATOR PEDAL IS DEPRESSED,
SPEED WILL INCREASE UNTIL FULL SPEED IS REACHED. WHEN THE ACCELERATOR IS
RELEASED, POWER WILL BE CUT OFF AND THE ENGINE OR MOTOR WILL STOP RUNNING.
• POWERDRIVE PLUS VEHICLES ONLY: SEE “PEDAL-UP” AND “PEDAL-DOWN” MOTOR
BRAKING ON PAGE 3-3.
Figure 3-5 PowerDrive Plus Forward/Reverse Switch Figure 3-6 Accelerator and Brake Pedals
• THE PARK BRAKE WILL RELEASE AUTOMATICALLY WHEN EITHER THE ACCELERATOR OR
BRAKE PEDAL IS DEPRESSED. THE PARK BRAKE HAS MULTIPLE LOCKING POSITIONS AND
SHOULD BE FIRMLY PRESSED AND LOCKED TO PREVENT THE VEHICLE FROM ROLLING.
NOTE
R
F
WARNING

GENERAL INFORMATION Controls
Page 3-6 1998/1999 DS Golf Car Maintenance and Service Manual
3
Neutral Lock-out, Continued:
This will allow the mechanic to run the engine in NEUTRAL for certain maintenance procedures. With the
cam in this position, the vehicle will not operate if Forward/Reverse handle is placed in either FORWARD or
REVERSE position.To put cam back into the OPERATE position, pull the cam out approximately 3/8 in. (10
mm) and rotate one-half turn until it snaps into place (Figure 3-10, Page 3-7). See following WARNING.
Choke
The choke is located on the seat support panel below and to the left of the driver’s left knee (Figure 3-11,
Page 3-7) . If the vehicle is hard to start in cool or cold temperatures, simply push in the choke button with
your left hand.Hold it during start up and release the choke cover after the engine starts and runs smoothly.
Oil Light
The DS Gasoline golf car is equipped with a low oil warning light, located on the dash panel just above the
steering column (Figure 3-12, Page 3-7) . If the oil warning light comes on, oil should be checked and added
to the engine as necessary before continuing to use the vehicle.The vehicle should never be driven with oil
warning light remaining on. If the oil warning light goes on and off, you may proceed, but oil should be added
at the first opportunity. If oil level is correct and the light stays on, have a trained mechanic check the vehicle.
• WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING, THE VEHICLE MAY
MOVE SUDDENLY IF THE FORWARD/REVERSE HANDLE IS SHIFTED OR ACCIDENTALLY
BUMPED.TO PREVENT THIS, CHOCK THE FRONT AND REAR WHEELS AND ALWAYS FIRMLY
SET THE PARK BRAKE BEFORE SERVICING OR LEAVING THE VEHICLE.
• BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE
VEHICLE, OR IT WILL NOT RUN WITH THE FORWARD/REVERSE HANDLE IN EITHER THE
FORWARD OR REVERSE POSITION.
Figure 3-7 Brake and Park Brake Pedals Figure 3-8 Depress Park Brake Pedal
• FAILURE TO ADD OIL IMMEDIATELY WHEN THE OIL WARNING LIGHT STAYS ON MAY
RESULT IN PERMANENT ENGINE DAMAGE.
WARNING
NOTE
CAUTION

GENERAL INFORMATION Controls
1998/1999 DS Golf Car Maintenance and Service Manual Page 3-7
3
POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS ELECTRIC VEHICLES ONLY
Battery Warning Light
PowerDrive System 48 and PowerDrive Plus vehicles feature a dash mounted warning light that, when vehicle
is in operation, indicates low battery voltage, or, when vehicle is being charged, indicates a charging problem
(Figure 3-12, Page 3-7) .The battery warning light is controlled by the PowerDrive onboard computer.
When the vehicle is in operation, the warning light will come on and remain illuminated if:
• Batteries’ voltage drops below 48 when there is no load on the batteries (the vehicle is stopped and
there are no accessories on).
• Batteries have discharged to less than 25% of their capacity.
If the warning light comes on during a round of golf, there is enough power remaining to finish the round, but
the car should be charged before being used again. If the warning light comes on and the vehicle is unable to
finish the round, have a Club Car distributor/dealer check the vehicle for a possible battery or electrical
system problem.
When the batteries receive an incomplete charge because 1) the DC power cord is disconnected, 2) AC
power to the charger is interrupted, 3) automatic charger shut-off occurs after 16 hours of operation, or 4) the
charger malfunctions, the warning light will indicate as follows:
• The warning light will not come on if the charge is 90% or more complete.The onboard computer will
retain in memory the amount of charge needed to fully replenish the batteries and will complete the
charge during the next charge cycle.
Figure 3-9 Neutral Lock-out Cam - Service Figure 3-10 Neutral Lock-out Cam - Operate
Figure 3-11 Choke Button Figure 3-12 DashWarning Light
NEUTRAL FORWARD NEUTRAL FORWARD
CHOKE
OIL LIGHT (Gasoline Vehicles)
BATTERY WARNING LIGHT
(48-Volt Vehicles) +

GENERAL INFORMATION Controls
Page 3-8 1998/1999 DS Golf Car Maintenance and Service Manual
3
Battery Warning Light, Continued:
•When the charger is unplugged, the warning light will come on and remain illuminated for 10 seconds if
the charge is less than 90% complete but the car has enough power to complete 36 holes of golf.This
will alert the fleet operator that the car may be used, but that it must be charged to completion as soon
as possible.
•The warning light will repeatedly illuminate for 10 seconds, with 4 second intervals, if the charger times
out at 16 hours (see charger manual) and the batteries are not sufficiently charged. This indicates an
abnormal charge cycle. Charger and batteries should be checked by your Club Car distributor/dealer.
•The warning light will repeatedly illuminate for 10 seconds, with 4 second intervals, during a charge
cycle (DC plug is still connected) if AC power to the charger is interrupted.The light will go out when AC
power is restored.
POWERDRIVE PLUS ELECTRIC VEHICLES ONLY
Tow/Run Switch
All 1998/1999 DS PowerDrive Plus vehicles (with motor braking) are equipped with a Tow/Run switch,
located under the seat just above the Forward/Reverse rocker switch (Figure 3-13, Page 3-8).The Tow/Run
switch must be in the RUN position in order to operate the vehicle. When the switch is in the TOW position,
power to the vehicle electrical components is turned off and the vehicle will not operate.
•TO AVOID POSSIBLE BATTERY EXPLOSION, THE TOW/RUN SWITCH MUST BE IN THE TOW
POSITION BEFORE DISCONNECTING OR CONNECTING BATTERY WIRES.
•WHEN THE TOW/RUN SWITCH IS IN THE TOW POSITION, ALL MOTOR BRAKING FUNCTIONS,
INCLUDING ZERO-SPEED DETECT, ARE DISABLED.
Figure 3-13 Tow/Run Switch Figure 3-14 Fuel Tank,Vent, and Lines
•AFTER PLACING THE SWITCH IN TOW POSITION, ALLOW 10 SECONDS BEFORE SWITCHING
BACK TO RUN.
•AFTER PLACING THE SWITCH IN THE RUN POSITION, ALLOW 10 SECONDS BEFORE
OPERATING THE VEHICLE.
WARNING
F
TOW RUN
WARNING
VENT TUBES
TO CARBURETOR
SHUT-OFF
VALVE
VENT
NOTE