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.