Club Car DS Gasoline 1990 User manual

1990 DS Gasoline
Golf Car
Owner's Manual
Manual Number
1015439
Effective August 1, 1989
0889A00000

This instruction manual should be read completely and carefuHy before attempting to drive or service
this car. Failure tofollow the instructions inthis manualcould result insevere personal injury or death.
NOTE: If this vehicle is equipped as a Fairway Villager four-passenger vehicle, supplements to this manual
are required. If this information does not accompany this manual, contact CLUB CAR, INC., Customer
Serviceand request the FairwayVillager supplement.
Safety Details:
It is important to note that some statements throughout this manual are preceded by the words DANGER,
WARNING, CAUTION or
NOTE. We recommend that you take special notice of these safety procedures
for your protection. Safety procedures are essential and must be followed.
A danger indicatesan immediate hazardwhich will result in severe personal injuryor death.
A warning indicatesan immediate hazardwhichcould result insevere personal injurybr death.
A caution indicates hazards or unsafe practices which could result
in minor personal injury or product
or property damage.
NOTE:
A note provideskey information to make procedures easier or clearer.
The safety procedures listed below must be followed whenever the car is being repaired or serviced. Other
specific warnings appear throughout this manual.
Only trained people should repair or service this car. Everyone doing even simple repairs or service
shouldfollowthecorrectproceduresandobeythewarningslistedinthismanualaswellasthemaintenance
andservice manual.
Alwayswear safety glassesor eye protectionwhenservicingthe car.
Always useinsulated toolswhen working around batteriesor electrical connections.
Improper use of this vehicle or the failure to maintain it could result in decreased vehicle performance
or severe personalinjury.
Any modification or change to the vehicle which affects the stability or increases the speed beyond
the factory specifications couldresult
in severe personal injuryor death.
Gasoline/Battery Vapors - Flammable - Explosive - Do not smoke. Keep sparks and flames away
from thearea ofthe car. Onlyservice inwell-ventilated area.
Engines produce carbon monoxide which
is an odorless, deadly poison. DO NOT OPERATE IN AN
ENCLOSEDAREA WITHOUT PROPER VENTILATION.
If any of the warning labels become damaged, have been removed or cannot be easily read, they should
be replacedimmediately.Contact your CLUB CAR Distributor/Dealer.

TABLE OF CONTENTS
Page
..........................................................
Safety Details InsideFront Cover
Foreword
......................................................................... 1
......................................
Vehicle Feature Identification
.. .. 2-3
Modelldentification
................................................................. 4
SafetyCommittee ................................................................... 4
..............................................................
Pre-Operation Checklist 4
Fuelinglnstructions
................................................................. 5
Controls
.......................................................................... 6
.................................................................
Driving Instructions 8
TowingandTransporting .............................................................. 9
Storage .......................................................................... 10
Maintenance
................................................................... 11
Lubricationchart ................................................................... 13
EngineOilLevel .................................................................... 13
Capacities
........................................................................ 14
Battery
........................................................................ 14
Jumpstarting ..................................................................... 14
Cleaning
.......................................................................... 15
........................................................
Subsequent Owner Registration 15
Specifications
.................................................................... 16
Warranty, ............................................................. InsideBackCover
Foreword
Congratulationsfor havingchosenthefinest golf car onthe markettoday1Over 25years of the mostadvanced
development, engineering and field experience known to this industry has gone into the manufacture of
your golf car.
With your choice of the CLUB CAR Model DS Gasoline golf car as your personal or fleet
vehicle, you have joined a select group of discriminating owners who look for the very best and who have
shown their concern for safety, efficiency and long-term lasting value. This owner's manual
is designed
to instruct you, or anyone you may rent or loan the golf car to, in the safe operation of the CLUB CAR
DS Gasoline golf car. In addition, this manual will acquaint you with the normal preventive maintenance
requiredinorder to provide you safe, optimum vehicle performance.
If any repairs or service need to be performed, there are certain basic mechanical procedures that should
be known and understood. Without such basic knowledge, repairs or service to this golf car may render
the golf car unsafe which could result in severe personal injury or death. For this reason, we advise that
all repairs andservice be performed by an authorized CLUB CAR Distributor/Dealer or representative except
as specified
in the Periodic Service Schedule. Should you requirefurther information, please contact your
nearest CLUB CAR Distributor/Dealer who can provide you with technical advice, service, parts, or the
CLUB CAR DS Gasoline Golf Car Maintenance and Service Manual. For the name and address of your
nearest CLUB CAR Distributor/Dealer, contact CLUB CAR, INC., P.
0. Box 4658, Augusta, Georgia 30917-
4658, U.S.A., Telephone:[phone].
The Club Car LimitedWarranty appears onthe inside back cover of this manual. Noother warranties express
or implied are contained herein. Your Distributor/Dealer has checked your car(s) prior to delivery to you
andwill provideyou with a completedwarranty registration card.
CLUB CAR, INC., shall not be tiable for errors contained herein or for incidental or consequential damages
which resultfrom the use of the material
in this manual.
This manual should be considered a permanent part of this vehicle.
It should stay with the vehicle when
soldto provide the next owner with important operating, safety, and maintenance information.

Vehicle Feature
YRKBRAKEPEDAL
OPERATING INSTRUCTIONS
LABEL
\ BRAKE PEDAL
I
b f
OPERATING INSTRUCTIONS
Study hodUnd*nland Controls. Be SunEvevone IsSaaled.
BeforeDdrlng Cw. Read Safe$ Wamfngs bcrlcdAboroPcdals.
Mare SureWhe*lc Are hmedInDedrr6 DlrecUon.
.Be SuaNolhlng lr InYourPaL.
lam KeyTo ON Pollllon.
SelretDincllonB~Placln~Shift Lavat b DadredPoclthn;
F. fonard H. Neutral R. Revetce
slowly PushAccnleralor Pedal To IncreaseSpeed. Park Orah*
will R.I~~O When Accelerator Pedalis Pushed.
.
lo Slop Cr. UaIealeAc~elanlorPedal and Push Brahe Pedal.
e A111, stoppingEar, FIrmlrPurh Park BnhaUnUl I1Locks.
a RemoraHeyAnd Place ShlflLeverIn The Straight Up Neutral
Posltlon When Car IsNot In Uu.
w rot Further oelallr. Read OwnaflManual.
OILWARNING
1 I LIGHT'
ACCESS DOOR
MOVINGPARTS
I
SAFETY WARNING LABEL

, .
GASOLINETANK
DANGER
LABEL (ON BODY
ERY DANGER
/ / CHOKE
/ ./ ./---+,,\ *r"d
FORWARD-REVERSE /: +
LEVER
& \
:P, * P j
ii
NEUTRALLOCK-OUT CAM

Model Identification:
The serial number of your CLUB CAR is stamped on a data plate mounted on the frame directly under
the right dash (Example:AG9005-123456).
NOTE: Always mentionthis number-whenordering parts or making inquiries
(See Figure
1 ).
Safety Committee:
Ifthe golf car isgoing toberentedor ispartof afleet, westrongly 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 includes such
things as where the golf cars should be driven, who should and who should
not drive the golf cars, instructing all first time drivers
in the controls and
operation of the golf car, seeing that the golf cars are well maintained
in
safe driving condition and how the various rules are to be enforced. The
safety committee should include all these items at a minimum and such
-,
others as the committee feels necessary or appropriate. Figure
1
Pre-Operation Checklist:
Your CLUB CAR has beenthoroughly inspectedandadjustedbythefactory andbyyour CLUB CAR Distributor/
Dealer. However, when receiving your new CLUB CAR(s) you should become familiar with its controis and
operation and carefully inspect each car to be satisfied with its condition before accepting delivery.
Only trained people should repair or service
this car. Everyone doing even simple repairs or service
shouldfollowthecorrect proceduresandobeythewarningslistedinthismanual
as wellasthemaintenance
andservice manual.
Always wear safety glasses oreye protectionwhen servicingthe car.
Use this checklist as a guide to i'nspect your car. Any problems must be corrected only by your CLUB CAR
Distributor/Dealer or a trained mechanic.
Visual inspection - Look for the following onyour vehicle:
General:
All the parts should be in place and properly installed. Be sure that all nuts, bolts and screws
are tight. All hose clamps should be tight. Check the starter beltfor tightness.
Warning Labels:
Check that all warning and operation labels are inplace (See Pages
2 & 3).
Tires: Check tire pressure.
It should be 12-14 psi.
Engine:
Check for proper engine oil level (See Page
12). Be sure spark plug wire is in clamp on top of
engine.
Fuel: Check fuel level (See Fueling
instructions - Page 5).
Be sure the plastic
has been removed from the bottom of the seat before operating vehicle. Failure
todo
so may result in a fire or propertydamage.

Performance inspection - After you have familiarized yourself with the car's controls (See Page 5) and
have read and understood the driving instructions (See Page
7), take the car for a short test drive. Check
the following:
Brakes:
Be sure that the brakes work properly. Both rear wheels should brake properly and the pedal
should notgo more than halfwaytothe floor. if
it does, have brakes adjusted.
Park Brake:
The park brake should lock the wheels when latched and should release when the accelerator
or brake pedal is pushed.
Steering:
The car should be easy to steer and should not have free play inthe steering wheel.
Accelerator Pedal:
As the accelerator pedal
is pushed, the engine should start and the car should come smoothly
up to full speed. When the pedal is released
it should return to the original position and the
engine should stop gradually.
Governor:
Check the speed of the car.
It should run 12-14 MPH on a level surface.
General:
Listen for any unusual noises such as squeaks or rattles. Check the car's ride and performance.
Have a trained mechanic investigate anything unusual.
Any modification or change to the vehicle which affects the stability or increases the speed beyond
thefactory specifications couldresult insevere personal
injury ordeath.
Fueling Instructions:
GASOLINE - FLAMMABLE - EXPLOSIVE - NO SMOKING
Keepbsparks and flames from the area of the car. Only service or repair in well-ventilated area. Never
pour gasoline intotankwhile engine is hotor running.
To avoid electric arc caused by static electricity, the fuel storage/pumping device must be grounded.
If pump is not grounded, the vehicle must be grounded to the pump before and during the fueling
operation.
1. Lift and remove seat bottom.
2. Fuel tank is located on passenger side of car. Remove fuef cap and fill the fuel,tank with regular or
unleadedgasoline. Do not usegasohol or gasolines with methyl alcohol blends.
To allowfor expansion, do notfill higherthan one
(1 ) inchfromtopoftank.
Besure toclean up
any spilled gas before operating vehicle.
3. Replacefuel cap ontank, being sure cap is tightly sealed to tank.
4. Replaceseat bottom

Controls:
If renting or loaning this car, make sure that the driver is familiar with
allcontrolsandoperating instructions beforeallowingthecartobedriven.
Key Switch
- The key switch is mounted on the dash to the right of the
steering column(SeeFigure
2). It hastwo (2) positions, "on" and "off" which
areclearly labeled. Remove key inthe "of" position only.
Turn key switch to
"off" and remove key when car is notinuse to avoid
unintentionalstarting of the car.
Forward-Reverse Control
- The forward-reverse shift lever is locatedbelow
and to the right of the driver's right knee on the seat support panel (See
Figure
3). The lever has three (3) distinct positions: F (forward), N (neutral),
and
R (reverse). Rotatethe levertoward the driver (F) to runthe car inforward
and toward the passenger
(R) to run the car in reverse. When the lever
is in the straight up or neutral
(N) position, the car will not run and the
engine wiilstop if shiftedtothis position while running.
Donot shift forward and reverse lever while car is in motion. Always
bring car
to a full stop before shifting lever to avoid injury to an
unsuspecting passenger anddamagetothecar.
Turn key switch "off" and place shift lever
in neutral when leaving
car
to avoid unintentional starting ofthe car,
Buzzer willsound as a warningwhen car
is in reverse.
NeutralLock-Out-Thegolf car
has aneutrallock-out circuitthatprevents
the driver from starting the car in neutral. If the car is started inforward
or reverse and shiftedto neutral the engine stops running.
For the convenience of the trained and experienced mechanic, there is
a neutral lock-out cam located on the back of the forward and reverse
lever. If the neutral lock-out cam
is pulledout approximately ?4 of an inch
and rotated one half turn until
it snaps. into place, the cam will be in
the SERVICE position (See Figure
4). This will allow the mechanic to run
the car in neutral for certain maintenance procedures. With the cam in
this position the car will not runif the forward and reverse lever is placed
inthe forward or reverse positions. To putthe car back into the
OPERATE
position, pull the cam out approximately % of an inch and rotate it one
half turn until it snaps back into place(See Figure
5).
Figure 2
Figure 3
Neutral Forward
SERVICE Position
Figure
4
Neutral Forward
OPERATE Position
s
Figure 5
With cam. in SERVICE position, car may move suddenly if forward and reverse lever is shifted or
accidentally bumpedwhile engine isrunning.
Block front and rear wheels toprevent vehicle movement,
NOTE: If car will not run, check to be sure neutral lock-out cam is inOPERATE position.

Accelerator Pedal - The accelerator pedal is the pedal on the right with the word "GO" molded in it (See
Figure
6). When the key switch is "on" and the shift lever is ineither forward or reverse and the accelerator
pedal is pushed, the parking brake will be automatically released and the engine wiu start.
As the pedal
is pushedfurther, the engine speeds up and the car will begin to move inthe preselected direction (forward
or reverse). Push the accelerator pedal further to increase vehicle speed. When the accelerator pedal
is
released, the engine will stop running.
NOTE: For safety, the DS Gasoline car is equipped with a governor to control the maximum speed and
is setfor 12-14 MPH ona level surface.
The accelerator pedal differs from that of an automobile
in the following way: Depressing the accelerator
will releasethe parkingbrake if engaged. Depressingthe accelerator automatically starts the vehicle moving.
Eachtime the accelerator pedal isreleased, the engine will quit running.
Do not tamper
with the car's governor. To do so wit[ void the limited warranty, result in damage to
engine and other components andcouid result in severe personal injury due to unsafe speeds.
Brake Pedal
- The brake pedal is the large pedal onthe le-ft with the word "STOP" molded in it (See Figure
7). To slow or stop the car, pushthe brake pedal withyour right foot.
Parking Brake Pedal
- The parking or park brake pedal is the small raised portion in the upper left corner
of the brake pedal with the word
"PARK" molded in it (See Figure 7). The words "Park Brake" are marked
above this pedal. To set the park brake, push the brake pedal firmly and
tilt the park brake portion of the
pedalforwardwithfoot (See Figure
8).
The park brake pedal will release when the accelerator or brake pedal is pushed. The parking brake has
many lockingteeth so that the brake can be locked inseveral positions.
Figure
6 Figure 7 Figure 8
Always set thepark brake firmly beforeleaving the golf car to preventthe car frorn rolling.

Choke - The choke is located below and to the left of the driver's left knee
on the seat support panel (See Figure
9). If on a cool morning the car is
hardto start, simply push inthe choke cover with your left hand to activate
the choke. Releasethe choke after the engine starts and runs smoothly.
Oil tight - The DS Gasoline golf car is equipped with a dash mounted oil
light above the steering column {See Figure
10). When the oil light is on,
it indicates low engine
oil. Oil should be added before further use. The car
should never be driven
if the oil light comes on and stays on. If the oil
light goes on and off, you may proceed, but add oil at the first opportunity.
If the oil level
is correct and light stays on, have a trained and experienced
mechanic check the car.
Figure
9
Driving Instructions:
No one should drive the golf car without first being instructed inthe proper
operation and use of the golf car controls.
An experienced operator should
accompany each first time driver on a short test drive before they operate
thegolf car alone. Onlylicenseddrivers should
be allowedtodrivethisvehicle.
Do not drive under the influence of alcohol, drugs or medications.
If renting or loaning this golf car, make sure the driver is familiar with
ail controls and operating procedures before allowing the car to be driven.
This car is not specially equipped for handicapped persons. Be sure all
Figure 10
personscan properly operate the car prior to allowing them to drive.
To insure safe operation of the DS Gasoline golf car, follow all of the pro'cedures listed below exactly and
inorder. Readand understand all instructions prior to drivingthe
car.
Starting the Car:
1. Enter the car.
2. Be sure everyone isseated.
3. Study and understand controls.
4. Read safety warnings located above pedals.
5. Make sure wheels areturned indesired direction.
6. Be sure nothing is inyour path.
7. Turn key to "on" position.
8. Select direction by placing shift lever indesiredposition F = forwardor R = reverse.
9. Slowlypushaccelerator pedai.The parkbrake pedalwillreleaseandtheengine will start. Pushaccelerator
further andthecar will move andthe speed
will increase as the accelerator is depressed untilgoverned
speed is reached.
Nomorethan two people should be on thevehicle at one time.
Stop car beforeshifting forward and reverse lever. Failure
to do so couldresultininjuryto an unsuspecting
passengerand damage to
the golf car.
A buzzer will sound as a warning when the car is in reverse.

When DrivingThe Car:
e
Operate the car fromthe driver's seat only.
@
Remain seated inmoving car and hold on to prevent falis.
@ Keep arms, legs, feet and entire body inside car to prevent getting them caught between the golf
car and the ground or other objects.
e
Drive slowly in turns and drive slowly straight up and down slopes to prevent turning the vehicle
over.
a
Reduce speed for poor driving conditions such aswet grass or rough terrain to avoid losing control
ofthe car.
e
Do not use on public roads. This car is not designed or intended for street use and should not
be licensed for use onpublic roads.
e
Obey all local rulesconcerning golf cars.
0
Cars should be driven only inspecified areas bytrained people.
Stopping the,Car:
1. To stopthe car, releasethe accelerator pedal and pushthe brake pedalwith your right foot.
When stopped on a
hiil, use the brake pedal toholdyour position, notthe accelerator pedal.
Driving through deep water may affect the brakes. Check their effectiveness by pressing the brake
pedal gently.
If the car does not slow down at the normal rate, continue to apply the brakes gently
untilthey dry out and normal performance returns.
Parkingand Leaving the Car:
1. After stopping the car, firmly push park brake pedal until it locks. This will prevent the car from roiling.
2. Turn the key to "off" and place shift lever in the straight up "neutral" position when leaving the car.
This avoids unintentional starting of car. Removekeywhen car is not in use.
To avoid being struck byvehicle, do notstand in front ofor behind vehicle.
Towing and Transporting:
Towing - All CLUB CARS are equipped with tow bar attaching points both front and rear. For breakdown
towing and single-car towing,
a light-duty tow bar is available. For multi-car towing, a heavy-duty tow bar
is available. Observe all of the following warnings and precautionswhen towing.
Never tow
a golf car on publicstreets or highways.
Use only approved
CLUB CAR tow bars.
Extreme caution should be usedwhentowing any golf car.

Donotexceedfive (5) miles per hour towingspeed.
Donottowmorethan one
(4 ) car withanother CLUB CAR.
If morethan one car must betowed, a properly fitted vehicle withtow hitchheight of 11 inches should
be used. Only heavy-duty tow bars should be used for multi-car towing. Never tow more than five
(5) carsatonetime.
Donotallow peopleincars beingtowed.
Avoid sudden starts, stops andtight turns,
Turn keyswitch "off" and placeshift lever inneutral when car is intow.
Transporting On
A Trailer - If your golf car must betransported over long distances or on public highways,
it should be doneon an approved trailer observing allthefollowing warnings andprecautions.
For use on public roads the trailer must meet all federal, state and local requirements such as taillights,
brake tights, etc.
Always use an approved trailer that has a load rating of 1200 Ibs, per golf car. (Example: A 2-car
traiier should be ratedat 2 x 1200 = 2400 lbs.).
The golf car should be securely tied down to the trailer. The golf car's key switch should be "off",
theshift lever in
"neutra1"and the park brake firmly applied and locked.
When towinga trailer, normalspeeds should be reduced and care should be used when turning a corner
duetothe added lengthof the trailer.
Nevertow a golf car behind a passengervehicte or truck unless
it isonanapproved trailer.
Removethewindshield before transporting
a golf car ona trailer.
Storage:
To prepare your golf car for extendedoff season storage:
Turn key switch "off", remove key and place forward and reverse lever in neutral position to avoid
unintentionalstarting of thevehicle.
1. Store in a cool place. This will prevent self discharge of the battery. If the battery appears to be weak,
have
it charged by a trained mechanic.
Batteries inlowstate of charge willfreeze at lowtemperatures.
Do not attempt to charge a battery if
it is frozen or the case is bulged.
Discard battery. Frozenbatteries can explode.
2. Using a siphon with a suction device (See Figure 1 I), drain all of the
gas out of the tank into an approved gasoline container,
Never attempt tosiphon gasoline using a hose without a built-insuction
device.
Never attempttosiphon gasoline using your mouth.
Figure 11

Gasoline - Flammable - Explosive - DoNotSmoke. Keep sparks and flames awayfromarea of cars.
Donot
anempt todrain gasoline while engine is running or hot.
Store gasoline only in an approved gasoline container in a weli-ventilated area. Keep out of reach of
children. Keep sparks, fire andflames away from area of gasoline.
Engines produce carbon monoxide which is an odorless, deadly poison. DO NOT OPERATE
IN AN
ENCLOSEDAREA WITHOUT PROPER VENTILATION.
3. Be sure the tank has been drained and the stored gasoline has been removed from the area. Place
the forward and reverse lever in "neutral". Place neutral lock-out cam in the SERVICE position. Turn
key on. Run the engine until all of the gasoline has been drawn out of the fuel lines and carburetor
and engine stalls. Return neutral lock-out cam to the OPERATE position. Turn the key switch to the
"off" position and remove key.
4. To protect the engine, remove the spark plug and pour '/2 ounce of SAE 10 weight oil into the engine
through the spark plug hole. Rotatethe engine several times and then reinstall the spark plug.
NOTE: When restartingengine,
it may smoke excessively due to the oil added instep 4.
5. Increasethe tire pressure to 20 psi.
6. Grease front suspension and do all quarterly periodic lubrication shown in lubrication chart (See Page 12).
7. Thoroughly clean body, seats and underside of car.
8. Do not latch the park brake. Block the wheels toprevent the car from roliing.
To Return Stored Cars To Service:
1. Fill the gas tank with regular or unleaded gasoline (See Fueling Instructions - Page 5).
Gasoline - Flammable - Explosive - No Smoking. Keep sparks and flames from the area of the car.
Onlyservice or repair
in well-ventilated area. Neverpour gasoline intotank while engine is hotor running,
Donotoverfill. Besure toclean upany spilled gas beforeoperating vehicle.
- --
2. Readjusttire pressure to 12-14 psi.
3. Perform the pre-operationchecks (See Page 4) before returningthe car to service.
Maintenance:
General information - To be,sure you have a trouble-free car, it is very important to follow an established
preventive maintenance program. This isthe least expensive maintenance requirement. Preventive mainte-
nance means regularly scheduled services which includecertain maintenance procedures that are performed
onthe cars even though the cars are functional. A good preventive maintenance program can prevent more
expensive repairs from being required. Any car that is not functioning correctly should be removed from
use until
it is properly repaired.
Conta~tyour local CLUB CAR Distributor/Dealer to perform all repairs and the semi-annual and annual
periodic service.
Only trained people should repair or service this car. Everyone doing even simple repairs or service
shouldfollowthecorrectproceduresandobeythewarningslistedinthismanual
as wellasthemaintenance
andservice manual.
Turn key switch "off", remove key, and place forward and reverse lever in neutral position prior to
servicing.
Always wear safety glasses oreye protectionwhen servicing thiscar.

Movingparts - Do notattempt to service the car with engine running.
Hot
- Donotattempttoservice hotengine or exhaust system. Can cause extreme burns.
Remove spark
plug wireto avoid unintentionalstarting of enginewhen servicing car.
Do notwear loose clothing and remove jewelry, such as rings, watches, chains, etc,, before servicing
vehicle.
AIways use insulatedtools whenworking around batteriesor electrical connections.
Periodic Service Schedule:
Regular Interval Service
DailyService by Owner Check steering andlinkages
Check brake operation
Check to be sure all warning labels are inplace (see Pages
2 and 3)
Check tires for wear anddamage
Check engine for proper operation
Check accelerator/governor linkagefor free movement and return
Check reverse warning buzzerfor proper operation
Check engine air intakescreen to be sure
it is notclogged
Check to be sure park brake latches and releases properly
Weekly Service by Owner Check speed of vehicle
Clean batteryterminals andwash dirt off battery case
Wash engine and undersideof car
Check all electrical wires and grounds for tightness or damage
Inspect car for loose hardware andtighten as required
Check all daily items listed
above
-
Monthly Serviceby Owner Check exhaust system for leaks
Check brake pedal play
Check tire pressure and adjust to
12-14 psi
Check air intake expansion chamber for leaks
Check engine
oil level
Check fuel tank, lines, cap, pump and carburetor for fuel leakage
Check all daily andweekly items listed above
Quarterly Service by Owner Do quarterly lubricationas shown iniubrication chart on Page
12
or Trained Personnel Check
all daily, weekly and monthly items listed above
Semi-AnnualService by Check, clean and adjust brakes
Trained Personnel Only Check front wheel alignment
(Every
100 Rounds or Check air filter
every
50 hours of Check spark plugwire and boot for damage andproper routing
operation) Check head gasket and exhaust header/pipe flange connection gasket
Check starter/generator belt tension
Check condition of muffler
lnspect drive belt
Do semi-annual lubricationas shown inlubrication chart on Page
12
Check ail daily, weekly, monthly and quarterly items listed above
Annual Service by Trained Replace fuel filters
Personnel Only Inspect starter/generator brush length
(Every
200 Rounds or Inspect, clean and regap spark plug
every
100 hours of
Do annual lubricationas shown inlubrication chart on page 12
operation) Check all items listed above
If your periodic service inspection reveals any problems, do not operate until repairs are made. Failure
to make necessary repairs could resultinfire, severe personal injury or death.

Periodic Lubrication Schedule and Lubrication Chart:
Regular interval Service Recommended Lubricant
Quarterly by
1. Brake shaft bearing DryGraphite Lube
Owner or CLUB
CAR part kt1012151
Trained Personnel 2. Brake linkage and pivots DryGraphite Lube
CLUB CAR part
#1012151
3. Accelerator push rodpivots DryGraphite Lube
CLUB
CAR part #1012151
4. Throttle and governor pivots DryGraphite Lube
CLUB CAR part
#I012151
5. Front suspension (9 fittings) Chassis Lube
Semi-Annually by
6. Check/fill drive unit to plug
Trained Personnel level
Only
7. Check/fiil transmission to plug
level
Annually byTrained
8. Inspectfront wheel bearings
Personnel Only and repack as necessary
9. Change engine oil
80-90 VVT. API Class GL-3 or 80-90 VVT.
AGMA Class 5 EP Gear Lube
80-90 VVT. API Class GL-3 or 80-90 WT.
AGMA Class 5 EP Gear Lube
Chassis Lube
SAE 10-40,20-45,10-55,20-50, API
Classification SF or SE
Engine Oil:
Engine oil level should be checked at least monthly. The oil light on
the dash should warn you
if your oil is getting low(See Figure 33).
Engine must be in level position. Remove oil level gauge by
unscrewing from crankcase. Check
oil by inserting gauge into oil
filler hole. Do not screw
oil gauge in when checking. If oil does
not reach the upper line (mark) of the gauge, add oil until
it does.
Do
not overfillwith oil. When oil is at proper level, screw oil gauge
inand hand tighten securely.
Figure
12
Figure 13

Capacities:
Engine Crankcase 40oz.
Transmission
20 oz.
Drive Unit
22 oz.
Gasoline Tank
7.4 U.S. Gal.
Tire Pressure
12-14 psi
Battery:
Always wear safetyglasses or eye protectionwhen servicing the car.
Always use insulated tools whenworkingaround batteries or electrical connections.
Battery
- Explosive Gases. Keepsparks, flames, cigarettes away. Ventilate when charging inan enclosed
space.
Poison - Contains acid - Causes severe burns - Avoid contactwith skin, eyes orclothing.
Antidotes:
External
- Flushwithwater. Call physicianimmediately.
internal
- Drink large quantities of milk or water, follow with milk of magnesia or vegetable oil.
Call physician immediately.
Eyes
-
Flushwithwater for 15 minutes. Call physicianimmediately.
The battery in the DS Gasoline is a 12 volt, maintenance free battery that
does not require periodic watering of the battery (See Figure 14).
Any corrosion around the positive
(+) or negative (-) terrninais should be
washedoff withasolutionof bakingsoda andwater. Rinse.
Be sureterminals
are tight. Let the terminals dry and then spray them with
CLUB CAR battery
protector spray, part #1014305.
Be sure battery holddowns are properly tightened. Torque to 9-14 in.-lbs.
A loose holddown may allow the battery to become damaged from vibration
or jarring. A holddownthat is tootight may buckle or crack the battery case.
If battery appearsweak, have it charged by a trained mechanic.
Jump Starting The Engine:
Figure 14
To start
a car with a dead battery, use another battery of the same voltage, and proper jumper cables.
Alwayswear safety glasses oreye protection when servicing
the car.
Procedures other than those which follow could cause severe injury or death from battery acid spray,
explosion,
or charging system overload.
Never connect tothe negative postofthe "Dead" battery, connecttoframe (See Figure
15).
Never allowthetwocarstotouch each other.
Never allowthejumper cable clamps totoucheach other.
Neverlean over the batterywhen making connections.

Placeforward and,reverse lever inneutral position, place neutral lock-out cam inthe SERVICE position.
To connect the ium~ercables, follow these stem exactlv and in order (See
*.
Figure 16):
1, Connectone endof redjumper cable to positive (+)terminalof the stalled
battery.
2. Connect other end of redjumper cable to positive (+)terminalof booster
battery.
3, Connect one endof blackjumper cable to negative(-)terminal of . booster .
battery.
4. Connect other end of black jumper cabie to stalled car frame away from
gasoline andbattery as inFigure
15.
To remove the cables, reversethe above procedures exactly. Figure
15
REDJUMPER CABLE
POSITIVE (+J TO POSITIVE (+)
TO GROUND
BLACK JUMPER
TO GROUND NEGATIVE
(-) POST ON
BOOSTER BATTERY TO
Figure
16
The CLUB CAR is eq&ipped with a reaction injection molded plastic cowl and a compression molded fiber
reinforcedpiastic body.
I
Useonly milddishwashing liquidsoap with a sponge or soft cloth for normalcleaning.
Minor scratches or blemishes in the body can
be buffed out using most commercially available polishing
com~oundsand~olishes.
Your golf car seat'will last longer with proper cleaning. Mild soap or detergent with a sponge or soft cloth
for normal cleaning is recommended. For stubborn or imbeddeddirt, a soft bristle brush maybe used,
I
Donot use any harshdetergents or cleaning solvents onthe body, cowl or seat.
Battery acid, fertilizers, tars, asphalt, creosote, paint or chewing gum should be removed immediately to
prevent possible stains.
Subsequent owner Registration:
Inthe event that this vehicle has been bought as a used car from another individual or from a distributor/
dealer, re-registration is necessary. This will enable us to contact you
if the need arises. Please send your
name, address and serial number(s) of the car(s) to CLUB CAR, INC.,
P.O. Box 4658, Augusta, GA 30917-
4658, ATTN: Vehicle Registration.

DS Gaso ine Specifications
Overall Length ............... .91.25"
Overall Width ................47.25"
............... Overall Weight .46"
Wheelbase ................. .65.5'"
GroundClearance ............ .4.5"
FrontWheel Tread ............ .34.5"
............ Rear Wheel Tread .38.5"
Weight .................... .622 ibs., dry
Speed
........... , ......... .12-14 MPH, governed
....
Curbto Curb ClearanceCircle .17'6"
Braking Distance ............. .14' at 12 MPH
Engine ..................... .4-cycle, 341 cc, 8.5 hpsingle cylinder, air cooled
Carburetor
.................. .Float bowlwith fixedjets and impulse fuel pump
Governor
.................... Internally geared intransmission
Ignition
..................... CDI electronic ignition
Drive Unit
.................. .Double reduction helical gear with 12.64 to 1final ratio
Transmission
..........,...... Forward, reverse, and neutral, fully synchronized
Steering
.................... Self-adjusting rack and pinion
Suspension
.................. Frontand rear tapered mono-leaf springs withdual hydraulic shock
absorbers
Torque Converter
............. .Automatic, variable speed, dry type
Frame-Chassis
.............. .Twin I-Beamwelded aluminum
Rear Body
.................. .Fiber reinforced plastic(compressionmolded)
FrontBody
................... Reactioninjection moldedplastic
Paint
...................... .Two part epoxy synthetic enamel
SeatingCapacity
..,.......... .2 persons
ElectricalSystem
............. .12 volt, 325 cold cranking amp battery and 35 amp charging capacity
starter/generator
Brakes ..................... .Mechanical brake cable system to individual drum brakes on each rear
wheel. Park brake isautomatically released.
Tires
...................... ,18.00 x 8.50-8.00 tubeless, 4-ply rated
FuelTank
................... .7.4 gal. U.S., regular or unleaded
Standard Equipment
.......... .Rack and Pinion Steering, Ball Hotder, Beverage I-folders, Dual Dash
Compartments, Scorecard and Pencil Holder, Reverse Warning Buzzer,
Wear Resistant Floormats and Pedals, Front and Rear Bumpers, Side
Rubber Rails, Two-Way IgnitionKey, Automatic Release Park Brake, Quick
ReleaseBagStrap Buckles, CDI Electronic IgnitionSystem, Synchromesh
Transmission with Forward, Reverse and Neutral;
12 volt 325 Cold
Cranking Amp Battery, Neutral Lock-Out, Low Oil Level Warning Light,
FreshAir IntakeSystem.
Optional Equipment
........... .Canopy Top, Snap-On Tinted Windshield, Weatherproof Enclosure, Extra
Two-Bag Attachment, Sweater Basket, Rake Holder and Rake, Bagwell
Protector, Adjustable Seat Back, Wheei Covers, Power Rib Tires, Extra
Traction Tires, White Wall Tires, Club Insignia, I.D. Numbers, Accent
Stripe, Custom Colors, Stereo Radio, Ashtray, Lighting Package (High/
Low Headlights, Taillights, Brakelights and Horn), Lighting Package with
Turn Signals,
Fuei Gauge, Hour Meter, Sand Bottle Kit, Woodgrain Trim,
IceCooler, InfoHolder,Tee Holder, Extra Beverage Holders(2or 4),Trailer
Hitch, Rear View Mirror, Permanent Tow Bar for 'multiple car towing
(factoryinstallation), TemporaryTow Bar for single car towing.
CLUB CAR,
INC., reserves the right to change specifications and designs at any time without notice
and without incurringany obligation or liability whatsoever.
1

- -
CLUB CAR LlMlTED TWO (2) YEAR WARRANTY
CLUB CAR, INC, "Manufacturer," warrants to the orrginal retail purchaser that its new DS Golf Car
purchased from Manufacturer or an
authorized distrrbutor or dealer IS free from defects in materials and
workmanship for a perlod of two
(2) years from the date of purchase, subject to the terms and provisions
contained herein
This limrted warranty covers materials and workmanshlp for a period of two
(2) years from the date
of purchase and repair labor costs for a period of one
(1) year from the date of purchase Such labor shall
be performed only by Manufacturer, its authorized distr~butorsor dealers, or a service agency approved
by Manufacturer IFTHE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB
CAR AT THE TIME OF THE ORIGINAL RETAIL SALE, PROOF
OF DATE OF PURCHASE MUST BE PROVIDED
WITH ANY WARRANTY CLAIM For further rnformatron or to present a warranty claim, contact Warranty
Administrator, CLUB CAR, INC
, P 0 Box 4658, Augusta, Georgia 30917-4658 U SA, [phone]
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
SHALLBEVOID AND EXCLUDED SUBSEQUENTTOTWO
(2) YEARS FROMTHE DATEOF PURCHASE
THE REPLACEMENT OR REPAIR OF THE GOLF CAR OR DEFECTIVE COMPONENT THEREOF IS
THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY
MANUFACTURER MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO
REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF MANUFACTURER HAS THE
AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT WHICH IN
ANY WAY VARIES THE TERMS OFTHlS LlMlTEDWARRANTY.
LlMlTEDWARRANTY EXCLUSIONS
Without limitingthegenerality of the foregoing inany way, and as partof itslimitedwarranty exclus~ons,
Manufacturer does not warrant that its golf car is suitable for use on any particular golf course or terrain
As in the operation of any vehicle, a prudent driver will read and study the Owner's Manual, learn the
properoperation of thecontrols, and exercise care andsafe drlving habits
THE PROVISIONS OF THlS LIMITEDWARRANTY SHALL NOT APPLY TO
(a) Normal maintenance services such as brake adjustments, steering and suspensron adjustments,
linkageadjustments, recommendedlubrication, oil changes, andfilter replacements,
(b)All accessory options, bag straps, battery wires andconnectors, body panels and trim pieces, charger
plugs and receptacles, decals, drive and generator belts, filters, floormats, oils and lubricants, pedal pads,
seats, spark plugs, fuses, tubes and hoses, and
(c)Tires, batterresand battery chargers (Warrantedsolely through their respectivemanufacturers)
Any warrantyservicewhlch rncludeslabor must be performedby Manufacturer, itsauthorized distributors
or dealers, or a serviceagency approvedby manufacturer.
THIS GOLFCAR ISINTENDEDTO BE USEDBYPERSONSPLAYINGGOLFWITHINTHE CONFINES
OF A GOLF COURSE AND ANY OTHER USE RENDERS THE LlMlTED WARRANTIES EXPRESSED
HEREINANDALL IMPLIED WARRANTiES NULLAND VOID AND SAMEARE HEREBY EXCLUDED.
ALSO EXCLUDED FROM THlS LlMlTED WARRANTY ARE ANY AND ALL INCIDENTAL OR
CONSEQUENTIALDAMAGESINCLUDING, BUTNOTLIMITEDTO, LOSSOF USE, LOSSOFREVENUE,
LOSS OF TIME, OR INCONVENIENCE.
Some states do not allow limitations on how long an ~mplred
warranty lasts or the exclusronor lrmitatronof ~ncrdentalor consequential damages so the above lim~tations
or exclusions may not apply to you
WARRANTY LIMITATIONS
Manufacturer's liability shall be at ~tssole option to either replace or repair a defectrve golf car or
componentthereof Replacementshall meanfurnishing anew
golf car or componentthereof which IS identrcal
or reasonably equrvalent to the warranted product at no cost to purchaser during the two (2) year lrmrted
warranty period except for repair labor costs after the frrst year Repair shall mean remedyrng a defect
inthe golf car or componentthereof at no cost to purchaser during the two
(2) year Irm~tedwarranty period
except for repair labor costs after the first year
If Manufacturer elects to repair your golf car, it may use
factory reconditioned parts or components.
Damagetoavehlcleor componentthereof notresultingfrom adefector whichoccurs duetounreasonable
or unintended use, overload~ng,abuse or neglect (including farlure to provide reasonable or necessary
maintenance as outlrned in the Owner's Manual), accident or alteration, includrng
increasing the speed
beyondfactory specificationsor modifications wh~chaffectthestability of thevehicleor the operation thereof,
IS excludedfromthe lrmitedwarranty
Thrs warranty gives you speclfic legal rights, andyou may also have other rights which vary from state
to state

Club Car, Inc. 1 P.O. Box 4658
Augusta, Georgia
3091 7-4658 U.S.A. 1706-863-3000
O CLUB CAR, INC., 1989