Club Car Gasoline User manual

DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 101905101
EDITION CODE 1196H0799C
MAINTENANCE
SERVICE
1995-1996

FOREWORD
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 of the vehicle. This Maintenance and Service Manual will provide the mechanic with proper detailed
procedures for the maintenance and repair of the Club Car DS Golf Car, including periodic maintenance,
troubleshooting, disassembly, repair, and reassembly of all vehicle components. This manual should be thor-
oughly studied prior to servicing the vehicle. The procedures provided must be properly implemented, and
the NOTE, CAUTION, WARNING, and DANGER statements must be heeded.
This manual was written for the vehicle mechanic who already posseses 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
mechanic.
It is the policy of Club Car, Incorporated to assist its distributors and dealers in continually updating their ser-
vice knowledge and facilities so that they can provide prompt and efficient service for the vehicle owner.
Regional technical representatives, golf car service seminars, periodic service bulletins, this manual, and
other service publications also represent Club Car’s continuing commitment to customer support.
This service manual covers all aspects of 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, you may
write to us or contact a Club Car technical service representative by phone at [phone], ext. 3580.
©1996 Club Car, Inc.
Club Car, Armorflex, PowerDrive, PowerDrive Plus,
and Tranquility are registered trademarks of Club Car, Inc.
This manual effective August 1, 1995
• THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF PUBLICA-
TION. 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 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

CONTENTS
SAFETY SECTION
Safety ................................................................................................................................................ 1-1
VEHICLE SPECIFICATIONS SECTION
Vehicle Specifications ....................................................................................................................... 2-1
GENERAL INFORMATION SECTION
Model Identification ........................................................................................................................... 3-1
Safety Committee ............................................................................................................................. 3-1
Pre-Operation Checklist .................................................................................................................... 3-2
Performance Inspection ................................................................................................................ 3-2
Controls ............................................................................................................................................. 3-3
Driving Instructions ........................................................................................................................... 3-8
Towing ............................................................................................................................................... 3-9
Transporting on a Trailer .................................................................................................................... 3-10
Storage - Gasoline Vehicle ................................................................................................................ 3-10
Storage - Electric Vehicle .................................................................................................................. 3-12
PERIODIC MAINTENANCE SECTION
Lubrication - Gasoline Vehicles ......................................................................................................... 4-2
Lubrication - Electric Vehicles ........................................................................................................... 4-3
Vehicle Capacities ............................................................................................................................. 4-4
Periodic Service - Gasoline Vehicles ................................................................................................ 4-5
Periodic Service - Electric Vehicles ................................................................................................... 4-7
BODY AND TRIM SECTION
General Information .......................................................................................................................... 5-1
Front and Rear Body Repair ............................................................................................................. 5-2
Seat ................................................................................................................................................... 5-4
Front Body ........................................................................................................................................ 5-4
Rear Body ......................................................................................................................................... 5-5
• 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
1
2
3
4
5

Floormat ............................................................................................................................................ 5-8
ACCELERATOR AND BRAKE PEDAL GROUP SECTION
General Information .......................................................................................................................... 6-1
Pedal Group Adjustment - Early 1995 Vehicles ................................................................................ 6-1
Pedal Group Disassembly and Assembly - Early 1995 Vehicles ...................................................... 6-9
Pedal Group Adjustment - Late 1995 and 1996 Vehicles ................................................................. 6-13
Pedal Group Disassembly and Assembly - Late 1995 and 1996 Vehicles ....................................... 6-23
6

WHEEL BRAKE ASSEMBLIES SECTION
Removal of Brake Shoes and Cleaning of Wheel Brake Assemblies ................................................ 7-3
Installing the Brake Shoes ................................................................................................................ 7-6
Brake Assembly ................................................................................................................................ 7-7
STEERING AND FRONT SUSPENSION SECTION
General Information - Steering .......................................................................................................... 8-1
Steering Wheel ................................................................................................................................. 8-2
Steering Column ............................................................................................................................... 8-2
Steering Adjustment ......................................................................................................................... 8-6
Rack and Pinion ................................................................................................................................ 8-6
Tie Rod and Drag Link ...................................................................................................................... 8-16
Front Suspension .............................................................................................................................. 8-18
Lubrication .................................................................................................................................... 8-18
Wheel Alignment ........................................................................................................................... 8-18
Front Suspension Components ........................................................................................................ 8-20
Front Wheel Bearings and Hubs ....................................................................................................... 8-24
TRANSAXLE SECTION
Lubrication ........................................................................................................................................ 9-1
Axle Shaft .......................................................................................................................................... 9-2
Axle Bearing .................................................................................................................................. 9-3
Removing the Transaxle .................................................................................................................... 9-5
Disassembly, Inspection, and Assembly of the Transaxle ................................................................. 9-10
Shimming the Transaxle .................................................................................................................... 9-14
Installation of the Transaxle ............................................................................................................... 9-15
WHEELS AND TIRES SECTION
General Information ........................................................................................................................... 10-1
Wheel Removal ................................................................................................................................. 10-2
Wheel Installation .............................................................................................................................. 10-2
Removing the Tire from the Rim ....................................................................................................... 10-3
Repairing a Tire ................................................................................................................................ 10-3
Installing the Tire on the Rim ............................................................................................................ 10-3
TROUBLESHOOTING THE GASOLINE VEHICLE SECTION
Troubleshooting Guide ...................................................................................................................... 11-1
ELECTRICAL SYSTEM - GASOLINE VEHICLE SECTION
General Information .......................................................................................................................... 12-2
FE 290 Gasoline Vehicle Electrical Circuit ........................................................................................ 12-2
Circuit Testing .................................................................................................................................... 12-7
Test Procedures ................................................................................................................................ 12-14
Electrical System Components ......................................................................................................... 12-27
7
8
9
10
11
12

Starter/Generator .......................................................................................................................... 12-27
Voltage Regulator ......................................................................................................................... 12-38
Key Switch .................................................................................................................................... 12-39
Solenoid ........................................................................................................................................ 12-40
Fuse .............................................................................................................................................. 12-41
Limit Switches ............................................................................................................................... 12-41
Neutral Lock-out Cam ................................................................................................................... 12-44
Reverse Warning Buzzer .............................................................................................................. 12-44
Oil Warning Light .......................................................................................................................... 12-46
Battery .......................................................................................................................................... 12-46
FE 290 ENGINE SECTION
General Information .......................................................................................................................... 13-1
Special Tools ..................................................................................................................................... 13-2
Mechanical Systems ......................................................................................................................... 13-2
Electrical System .............................................................................................................................. 13-4
Lubrication System ........................................................................................................................... 13-5
Spark Plug ........................................................................................................................................ 13-6
Engine Mounting and Inner Frame (See Rear Suspension - Section 18)
Rebuilding the Cylinder Head ........................................................................................................... 13-7
Rebuilding Crankcase Components ................................................................................................. 13-23
Engine Assembly .............................................................................................................................. 13-46
Service Specifications ...................................................................................................................... 13-47
Specifications for Resizing Cylinder Bore ......................................................................................... 13-49
Torque Specifications ........................................................................................................................ 13-49
Adjustments and Settings ................................................................................................................. 13-50
FUEL SYSTEM SECTION
General Information .......................................................................................................................... 14-1
How the Carburetor Works ............................................................................................................... 14-1
Carburetor ......................................................................................................................................... 14-4
Main Jet Elevation/Size Chart ....................................................................................................... 14-4
Engine Control Linkage .................................................................................................................... 14-8
Choke and Intake System ................................................................................................................. 14-14
Fuel Filters ........................................................................................................................................ 14-17
Fuel Pump ........................................................................................................................................ 14-19
Fuel Tank .......................................................................................................................................... 14-22
Fuel Lines ......................................................................................................................................... 14-24
Fuel Tank Vent .................................................................................................................................. 14-24
EXHAUST SYSTEM SECTION
General Information .......................................................................................................................... 15-1
Muffler ............................................................................................................................................... 15-1
TORQUE CONVERTER SECTION
General Information .......................................................................................................................... 16-1
13
14
15
16

Torque Converter, Continued:
Troubleshooting ................................................................................................................................. 16-3
Drive Belt .......................................................................................................................................... 16-3
Drive Clutch ...................................................................................................................................... 16-4
Driven Clutch .................................................................................................................................... 16-12
Clutch Alignment ............................................................................................................................... 16-17
TRANSMISSION AND GOVERNOR SECTION
General Information .......................................................................................................................... 17-2
Lubrication ........................................................................................................................................ 17-2
Transmission ..................................................................................................................................... 17-3
Forward and Reverse Shifter Cable .................................................................................................. 17-22
REAR SUSPENSION - GASOLINE VEHICLE SECTION
General Information .......................................................................................................................... 18-1
Shock Absorbers ............................................................................................................................... 18-1
Mono-Leaf Springs ........................................................................................................................... 18-3
The Snubber ..................................................................................................................................... 18-4
ELECTRICAL SYSTEM - V-GLIDE 36 VOLT VEHICLE SECTION
General Information .......................................................................................................................... 19-1
V-Glide Electrical Circuits .................................................................................................................. 19-2
Troubleshooting ................................................................................................................................. 19-5
Circuit Testing .................................................................................................................................... 19-8
ELECTRICAL COMPONENTS - V-GLIDE 36 VOLT VEHICLE SECTION
Key Switch ........................................................................................................................................ 19-18
Forward and Reverse Anti-arcing Limit Switch ................................................................................. 19-19
Accelerator Pedal Limit Switch .......................................................................................................... 19-20
The Reverse Buzzer ......................................................................................................................... 19-21
The Solenoid ..................................................................................................................................... 19-22
Resistors ........................................................................................................................................... 19-23
V-Glide Wiper Switch ........................................................................................................................ 19-25
Forward and Reverse Switch ............................................................................................................ 19-32
ELECTRICAL SYSTEM - POWERDRIVE SYSTEM 48 SECTION
General Information .......................................................................................................................... 20-1
The On-Board Computer .................................................................................................................. 20-2
PowerDrive Vehicle Electrical Circuits ............................................................................................... 20-2
Troubleshooting Guide ...................................................................................................................... 20-6
Circuit Testing .................................................................................................................................... 20-9
The Communication Display Module (CDM) ..................................................................................... 20-22
Communication Display Module Troubleshooting Guide ................................................................... 20-24
ELECTRICAL COMPONENTS - POWERDRIVE SYSTEM 48 VEHICLE SECTION
The Key Switch ................................................................................................................................. 20-25
17
18
19A
19B
20A
20B

Forward and Reverse Switch ............................................................................................................ 20-27
Forward and Reverse Limit Switches ............................................................................................ 20-28
The Reverse Buzzer ......................................................................................................................... 20-29
The Solenoid .................................................................................................................................... 20-31
On-Board Computer ......................................................................................................................... 20-33
Solid State Speed Controller ............................................................................................................ 20-34
Charger Receptacle .......................................................................................................................... 20-34
Receptacle Fuse Link ................................................................................................................... 20-36
Continuously Variable Potentiometer ................................................................................................ 20-37
Multi-Step Potentiometer .................................................................................................................. 20-40
Battery Warning Light ....................................................................................................................... 20-41
ELECTRICAL SYSTEM - POWERDRIVE PLUS SECTION
General Information .......................................................................................................................... 21-1
Z Plug Connections Chart ................................................................................................................ 21-4
The Control Circuit ............................................................................................................................ 21-5
The Power Circuit ............................................................................................................................. 21-16
The Charge Circuit ............................................................................................................................ 21-19
Troubleshooting Guide ...................................................................................................................... 21-20
Test Procedures ................................................................................................................................ 21-25
Numerical Listing of Test Procedures ........................................................................................... 21-25
ELECTRICAL COMPONENTS - POWERDRIVE PLUS SECTION
Key Switch ........................................................................................................................................ 21-53
Forward and Reverse Switch ............................................................................................................ 21-54
Reverse Buzzer ................................................................................................................................ 21-54
Main Solenoid ................................................................................................................................... 21-55
Dynamic Braking Solenoid ................................................................................................................ 21-56
On-Board Computer ......................................................................................................................... 21-56
Controller .......................................................................................................................................... 21-57
Charger Receptacle .......................................................................................................................... 21-58
Continuously Variable Potentiometer ................................................................................................ 21-58
Battery Warning Light ....................................................................................................................... 21-58
Energy Displacement Module ........................................................................................................... 21-59
BATTERIES SECTION
General Information .......................................................................................................................... 22-1
Common Misconceptions about Batteries ........................................................................................ 22-3
Replacing Batteries .......................................................................................................................... 22-4
Battery Care ..................................................................................................................................... 22-5
Battery Charging ............................................................................................................................... 22-7
Battery Testing .................................................................................................................................. 22-8
Battery Troubleshooting Chart - 36 and 48 Volt ................................................................................ 22-10
Battery Storage ................................................................................................................................. 22-17
Charging Battery Pack with Low Voltage .......................................................................................... 22-18
21A
21B
22

x
ACCU-POWER BATTERY CHARGER SECTION
General Information .......................................................................................................................... 23-1
The Charge Circuit ............................................................................................................................ 23-3
Charger Installation and Use ............................................................................................................ 23-3
Troubleshooting ................................................................................................................................. 23-6
Test Procedures ................................................................................................................................ 23-7
Plug and Receptacle Replacement ................................................................................................... 23-18
On-Board Receptacle Fuse Link ................................................................................................... 23-21
Charger Repairs ................................................................................................................................ 23-22
Capacitor ....................................................................................................................................... 23-23
Heat Sink Assembly ...................................................................................................................... 23-24
Transformer ................................................................................................................................... 23-24
Ammeter ....................................................................................................................................... 23-25
Charger Fuse Link Assembly ........................................................................................................ 23-26
POWERDRIVE BATTERY CHARGER SECTION
General Information .......................................................................................................................... 23-27
Battery Warning Light ....................................................................................................................... 23-28
The Charge Circuit ............................................................................................................................ 23-28
Charger Installation and Use ............................................................................................................ 23-30
Checking Battery Condition after a Charge Cycle ............................................................................ 23-33
Troubleshooting ................................................................................................................................. 23-34
Test Procedures ................................................................................................................................ 23-37
Plug and Receptacle Replacement ................................................................................................... 23-46
Charger Cord Replacement .......................................................................................................... 23-46
Charger Repairs ................................................................................................................................ 23-47
Rectifier.......................................................................................................................................... 23-48
Transformer ................................................................................................................................... 23-48
Ammeter ....................................................................................................................................... 23-48
Fuse Link ...................................................................................................................................... 23-49
Charger Relay ............................................................................................................................... 23-49
Charger AC Circuit Breaker .......................................................................................................... 23-50
Charger AC Cord .......................................................................................................................... 23-50
MOTOR SECTION
General Information .......................................................................................................................... 24-1
External Motor Testing ...................................................................................................................... 24-1
REAR SUSPENSION - ELECTRIC VEHICLE SECTION
General Information .......................................................................................................................... 25-1
Shock Absorbers ............................................................................................................................... 25-2
Mono-Leaf Springs ........................................................................................................................... 25-2
23A
23B
24
25

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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, INNER FRAME, 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. THEN DISCHARGE THE CONTROLLER ON POW-
ERDRIVE 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
transmission. •
Ignition: Transistor electronic ignition with electronic RPM limiter. •
Transmission: Fully synchronized forward and reverse with neutral (97:1
forward, 1.03:1 reverse). •
Drive Unit: 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
There are four DS Golf Car models: the DS gasoline powered vehicle, the DS V-Glide 36 volt electric vehicle,
the DS PowerDrive System 48 (48 volt) electric vehicle, and the DS PowerDrive Plus (48 volt) electric vehicle
with regenerative 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.
MODEL IDENTIFICATION
The serial number of your CLUB CAR is on a stamped data plate (1995 and early 1996) or bar coded decal
(most of 1996) mounted on the frame directly above the accelerator pedal (Example: A9601-123456 for Elec-
tric or AG9601-123456 for Gasoline) (See Figure 3-1). Vehicles with bar code decals have a second serial
number decal located on the vehicle frame behind the center dash (Figure 3-2).
SAFETY COMMITTEE
If the golf car is to be rented or is part of a fleet, we strongly recommend that 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.
•Instructing first time drivers.
•ALWAYS MENTION THIS NUMBER WHEN ORDERING PARTS OR MAKING INQUIRIES. IF THIS
VEHICLE IS EQUIPPED AS A FAIRWAY VILLAGER FOUR PASSENGER VEHICLE, READ THE
SPECIAL INSTRUCTIONS IN THE DS OWNER’S MANUAL.
FIGURE 3-1 FIGURE 3-2
•SIGNS SUCH AS STEEP HILL AND SHARP TURN ARE AVAILABLE FROM THE GOLF CAR MAN-
UFACTURERS ASSOCIATION MEMBERS.
NOTE
• Dispose of litter properly.
• Help speed up play.
• Allow faster players to play through.
• Rake sand traps.
• Repair ball marks on greens.
• Replace divots.
• Keep proper distance from greens.
• Drive on golf car paths when possible.
• Observe club rules.
PRACTICE GOLF ETIQUETTE
Club Car, Inc.
e
rating instructions before
v
ehicle.
a
nd in front or behind vehicle.
s
hould be driven only in specified
b
y trained persons.
• Do not use on public roads.
• Only two persons per seat.
• Operate vehicle from driver’s side only.
• Do not start vehicle until all people
are seated.
• Remain seated and hold on in moving vehicle.
• Keep arms, legs, feet and body inside vehicle.
• Stop vehicle before changing direction.
Buzzer will sound in reverse.
• Drive slowly in turns.
• Drive slowly straight up and down slopes.
• Set park brake before leaving vehicle.
• Remove key when vehicle is not in use.
• Place shift lever in neutral when vehicle
is not in use.
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.
ClubCar
P.O Box 204658
Augusta, Georgia 30917-4658 USA
CAN’T
READ
A9631340276
GO
GO
SERIAL NUMBER
A9612-583947
P O BOX 204658
AUGUSTA GA 30917
Club Car R
SERIAL NUMBER DECAL
ON MOST 1996
VEHICLES
SERIAL NUMBER
A9612-583947
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

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Safety Committee, Continued:
•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
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 the Vehicle
Identification pages at the beginning of the vehicle Owner’s Manual).
• Tires: Check for proper tire pressure (See Capacities, Section 4, Page 4-4).
•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). Check battery posts. Wires should be tight and free of corrosion.
Charge batteries fully before first use of vehicle.
•DS V-Glide Speed Switch: Be sure speed switch cover is properly secured prior to operating the vehi-
cle.
• DS Gasoline Engine: Check for proper engine oil level (See Section 13, Page 47).
• DS Gasoline Fuel: Check fuel level.
PERFORMANCE INSPECTION:
After you have familiarized yourself with the vehicle’s controls and have read and understood the driving
instructions, take the vehicle for a test drive. Check the following:
All Vehicles:
• Brakes: Be sure that the brakes function properly. Both rear wheels should brake simultaneously. The
pedal should not go more than halfway to the floor. If it does, have the brake system checked.
•Park Brake: The park brake should lock the wheels when latched, and should release when either the
accelerator or brake pedal is depressed.
• Steering: The vehicle should be easy to steer and should not have any play in the steering wheel.
• Accelerator: As the accelerator pedal is depressed, the engine or motor should start and the vehicle
should come up smoothly to full speed. When the pedal is released it should return to the original posi-
tion and the engine or motor should stop. The DS Electric vehicle runs at reduced speed in reverse.
•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.
WARNING

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•DS Gasoline Governor: Check the 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’s ride and perfor-
mance. Have a CLUB CAR distributor/dealer or a trained mechanic investigate anything unusual.
DS PowerDrive Plus Vehicles with Regenerative Braking:
•Zero Speed Detect: With the vehicle parked on level ground and the park brake disengaged, turn the
ignition key to the ON position and attempt to push the vehicle. It should resist rolling with the forward
and reverse switch in any position.
•“Pedal Up” Motor Braking: Accelerate the vehicle to full speed and then release the accelerator
pedal. The vehicle should quickly and smoothly slow to approximately 9 mph using motor braking.
•“Pedal Down” Motor Braking: Accelerate down an incline with the accelerator pedal depressed.
When the vehicle reaches approximately 15 mph, the regenerative braking should engage and moder-
ate vehicle speed between 15 and 16 mph, depending upon the grade of the hill.
CONTROLS
KEY SWITCH -
The key switch is mounted on the dash to the right of the steering column (See Figure 3-3, Page 3-4). It has
two positions, OFF and ON, which are clearly labeled.
•DO NOT OPERATE THE 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 THE 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 UNSAFE SPEEDS.
•DO NOT MODIFY OR CHANGE THE VEHICLE IN ANY WAY THAT MAY AFFECT VEHICLE STA-
BILITY OR INCREASE SPEED BEYOND FACTORY SPECIFICATIONS. PROPERTY DAMAGE,
PERSONAL INJURY, OR DEATH COULD RESULT.
•DO NOT SHIFT THE FORWARD/REVERSE LEVER WHILE THE VEHICLE IS IN MOTION. TO
AVOID INJURY TO AN UNSUSPECTING PASSENGER OR DAMAGE TO THE VEHICLE, ALWAYS
BRING THE VEHICLE TO A FULL STOP BEFORE SHIFTING THE LEVER. A BUZZER WILL
SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE.
•DEPRESS THE BRAKE PEDAL FIRMLY UNTIL THE VEHICLE IS STOPPED. SET THE PARK
BRAKE, AND TURN THE KEY SWITCH TO OFF. TO AVOID UNINTENTIONAL STARTING OR
ROLLING OF THE VEHICLE, REMOVE THE KEY WHEN LEAVING.
•THE KEY CAN BE REMOVED ONLY WHEN THE KEY SWITCH IS IN THE OFF POSITION.
DANGER
WARNING
NOTE

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FORWARD AND REVERSE CONTROL -
DS Gasoline, DS V-Glide Electric, and DS PowerDrive System 48:
The Forward and Reverse Shift Lever is located on the seat support panel, below and to the right of the
driver’s right knee (See Figure 3-4). The lever has three distinct positions: F(forward), N(neutral), and R
(reverse). Rotate the lever 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 lever is in the straight up, or N
(neutral) position, the vehicle will not run. The engine on the DS Gasoline will stop if it is shifted to neutral
while it is running. The DS Electric vehicle operates at reduced speed in reverse.
DS PowerDrive Plus With Regenerative Braking:
The Forward and Reverse Shift Switch is located in the same place on the PowerDrive Plus as the Forward
and Reverse Shift Lever is 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 is depressed (See Figure 3-5).
ACCELERATOR PEDAL -
The accelerator pedal is the pedal on the right, with the word GO molded into it (See Figure 3-6).
FIGURE 3-3 FIGURE 3-4
•THE REVERSE BUZZER WILL SOUND AS A WARNING WHEN THE VEHICLE IS IN REVERSE.
•OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMOBILE.
WHEN THE KEY SWITCH IS ON, AND THE SHIFT LEVER 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 WITH REGENERATIVE BRAKING ONLY: SEE “PEDAL UP” AND
“PEDAL DOWN” MOTOR BRAKING ON PAGE 3-3.
PRACTICE GOLF ETIQUETTE
●
Observe club rules.
●
Drive on golf car paths when possible.
●
Keep proper distance from greens.
●
Replace divots.
●
Repair ball marks on greens.
●
Rake sand traps.
●
Allow faster players to play through.
●
Help speed up play.
●
Dispose of litter properly.
Club Car
OFF
ON
NOTE
NOTE

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BRAKE PEDAL -
The brake pedal is the large pedal on the left with the word STOP molded into it (See Figure 3-6). To slow or
stop the vehicle, depress the brake pedal with your right foot (See Figure 3-7).
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 (See Figure 3-7). To set the park
brake, depress the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot (See
Figure 3-8).
GASOLINE VEHICLES 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. However, for
the convenience of the trained mechanic, there is a neutral lock-out cam located on the back of the forward
and reverse lever.
FIGURE 3-5 FIGURE 3-6
•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 TO PREVENT THE VEHICLE FROM ROLLING.
FIGURE 3-7 FIGURE 3-8
R
F
SHOWN IN
NEUTRAL
POSITION
WARNING

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Neutral Lock-out Continued:
If the neutral lock-out cam is pulled out approximately 3/8 inch (10 millimeters) and then rotated one-half turn
until it snaps into place, the vehicle will be in the SERVICE position (See Figure 3-9). 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 the forward/reverse lever is placed in either the forward or reverse position. To
put the vehicle back into the OPERATE position, pull the cam out approximately 3/8 inch (10 millimeters) and
rotate it one-half turn until it snaps into place (See Figure 3-10).
CHOKE -
The choke is located on the seat support panel below and to the left of the driver’s left knee (See Figure 3-
11). If the vehicle is hard to start in cool or cold temperatures, simply push in the choke cover with your left
hand to activate it. Hold it in during start up and release it 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 (See Figure 3-12). 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 the 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 the oil level is correct and the light stays on, have a trained mechanic check the
vehicle.
POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES:
BATTERY WARNING LIGHT -
The PowerDrive System 48 vehicle features a dash mounted warning light (in the same location as the oil
warning light on the gasoline vehicle) (See Figure 3-12) that, when the vehicle is in operation, indicates low
battery voltage, or, when the vehicle is being charged, indicates a charging problem. The battery warning
light is controlled by the PowerDrive System 48 on-board 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 rated capacity.
•WITH THE CAM IN THE SERVICE POSITION AND THE ENGINE RUNNING, THE VEHICLE MAY
MOVE SUDDENLY IF THE FORWARD AND REVERSE LEVER IS SHIFTED OR ACCIDENTALLY
BUMPED. TO PREVENT THIS, BLOCK 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 VEHI-
CLE. OTHERWISE, THE VEHICLE WILL NOT RUN WITH THE FORWARD AND REVERSE LEVER
IN EITHER THE FORWARD OR REVERSE POSITION.
•FAILURE TO ADD OIL IMMEDIATELY WHEN THE OIL LIGHT STAYS ON MAY RESULT IN PER-
MANENT ENGINE DAMAGE.
WARNING
NOTE
WARNING