Club Car DS Golf Car Gasoline/Electric 1995 User manual

Practice Safety
Moving Parts
4 J
Safety signs like you see above may at first seem shocking, but their impact is mild
compared with the reality of severe personal injury.
Your safety and satisfaction are of the utmost importance to Club Car. That is why we
urgeyou tostudythis owner's manual, andto read, understand, and heedthewarnings
inthis manual, as well as the safety signs on your vehicle,
before operating the vehicle.
Take time to understandthe languageof safety. It isa languagethat can save your life.

Notice
The Club Car Limited Warranty appears on the pagesfollowing this notice, and the Limited Lifetime Fleet Warranty appears
on the last pages of this manual. No other warranties, express or implied, are contained herein. Your authorized repre-
sentative checkedthis vehicle before it was delivered to you and will provide you with a completed warranty registrationcard.
Club Car is not liablefor errors in this manual or for incidental or consequential damages that result from the use of the mate-
rial in this manual.
This vehicle conforms to the current American National Standards Institute's
21 30 Safety and Performance Requirements
for Golf Cars. This standard, which promotes safety in the design, application, and operation of golf cars, defines a golf car
as "avehicle used to convey a person or persons and equipment to play the game of golf in an area designated as a golf
course". Throughout this manual, the words "golf car" and "vehicle" are used interchangeably.
This manual contains proprietary informationthat is protected by copyright. All rights are reserved. No part of this manu-
al may be photocopied, reproduced, or translated to another language without the written consent of Club Car, Inc.
The information contained in this document is subject to change without notice.
Club Car reserves the right to make design changes to either gasoline or electric vehicles without obligation to make these
changes on units previously sold.
These vehicles are designed and manufactured for off-road use only. They do not conform to Federal Motor Vehicle Safe-
ty Standards or EPA regulations and are not equipped for operation on public streets, roads, or highways.
01 994 Club Car, Inc.
This manual effective August
1, 1994
Manual print code: 0894A00000

CLUB CAR LIMITED THREE (3) YEAR WARRANTY FOR 1995 INDIVIDUAL GOLF
CAR INTHE UNITED STATES AND CANADA
1. WARRANTY:
CLUB CAR, INC. ("CLUB CAR") hereby warrants to the original retail purchaser that its new 1995 Model DS golf car pur-
chased from CLUB CAR or an authorized distributor or dealer for use in the United States or Canada shall be free from
defects in materials and workmanship under normal use and service as a golf car for the periods stated below, subject to
the provisions, limitations, and exclusions contained inthis limited warranty.
LIMITED THREE YEAR WARRANTY:
The golf car frame (excluding the front and rear bumper mounts), rack and pinion steering gearbox unit, suspension sys-
tem (definedas the shock absorbers, shock mounts, A-plate, leaf springs, shackles, and associated hardware), gasoline
engine, transmission, torque converter (drive and driven), drive unit, starter generator, and electric motor are warranted
with respect to parts and labor against defects in materials and workmanship for a period of three years from the date of
purchase.
LIMITEDTWO YEAR WARRANTY:
All remaining components of the golf car not specified otherwise are warranted with respect to parts and labor against
defects in materials and workmanship for a period of two years from the date of purchase.
This limited warranty covers materials, workmanship, and repair labor cost as to those items specifically listed above for
the periods specified. Such repair labor shall be performed only by CLUB CAR, its authorized distributors or dealers, or
a service agency approved by CLUB CAR.
IFTHE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF
THE ORIGINAL RETAIL SALE, PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WAR-
RANTY CLAIM.

2. EXCLUSIONS:
Excluded from any CLUB CAR warranty are all optional equipment and accessories, fuses, filters, decals, spark plugs, lubri-
cants, the front body, rear body and trim pieces, seats, routine wear items such as the charger plug and receptacle, brake
shoes, belts, brushes, bushings, engine mounts, mats and pads, maintenance adjustments, cosmetic deterioration,
items which deteriorate or fail due to exposure or ordinary wear and tear. Batteries andthe battery charger are covered by
separate Club Car warranties. Tires are warranted by their manufacturer. Also excluded from any CLUB CAR warranty is
damage to a golf car or component resulting from a cause other than a defect including unreasonable or unintended strain
or use, improper installation of accessories, installation of parts or accessories that are not original equipment, overloading,
accident, alteration, abuse, or neglect.
Transportation expenses for warranty service are also excluded from this warranty.
3. VOIDING OF WARRANTY:
THIS AND ANY OTHER WARRANTY SHALL BE VOlD IFTHE GOLF CAR ISABUSED OR USED INAN UNINTENDED
MANNER OR SHOWS INDICATIONSTHAT IT HAS BEEN ALTERED INANY WAY, INCLUDING, BUT NOT LIMITEDTO,
MODIFICATION OF THE SPEED GOVERNOR, BRAKING SYSTEM, STEERING, DRIVE UNIT, OR OTHER OPERATING
SYSTEMS OF THE CAR TO CAUSE ITTO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS. THE WARRANTY IS
LIKEWISE VOlD IF THE CAR SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS
OUTLINED INTHE OWNER'S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE
TIME AND INTHE MANNER SPECIFIED IN SUCH MANUALS.
4. SOLE REMEDY:
CLUB CAR's only liability under this limited warranty, or in any action, whether based upon warranty, contract, negligence,
strict product liability, or otherwise, is limited to the repair or replacement, at CLUB CAR's option, of a golf car or component
thereof that CLUB CAR deems to be defective. Replacement shall mean furnishing, during the applicable limited warranty
period, a new golf car or factory reconditioned vehicle or component thereof which is identical or reasonably equivalent to
the warranted product or component at no cost to the purchaser. Repair shall mean remedyinga defect in the golf car or
component thereof at no cost to the purchaser during the applicable limited warranty period. If CLUB CAR elects to repair

the golf car, it may provide factory reconditioned parts or components. All parts and components replaced under warranty
shall become the property of CLUB CAR.
5. HOW TO MAKE A WARRANTY CLAIM:
To make a warranty claim under this limited warranty, you must present the golf car or defective component to an
authorized CLUB CAR distributor or dealer or send the defective component, freight prepaid, to WARRANTY ADMINIS-
TRATION, CLUB CAR, INC., 4152 Washington Road, P.O. Box 204658, Augusta, Georgia 30917-4658.
6. DISCLAIMER:
THlS LIMITED WARRANTY ISEXCLUSIVE. CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSOR
IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
WHICH EXCEEDTHE OBLIGATIONS OR TIME LIMITS STATED INTHlS WARRANTY ARE HEREBY DISCLAIMED BY
CLUBCARANDEXCLUDEDFROMTHlSWARRANTY.THEPURCHASERANDCLUBCAREXPRESSLYAGREE
THAT THE REMEDY OF REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF
ISTHE EXCLUSIVE AND SOLE REMEDY OF THE PURCHASER. CLUB CAR MAKES NO OTHER REPRESENTATION
OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE,EMPLOYEE, DISTRIBUTOROR DEALER OF CLUB CAR
HASTHE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT WHICH INANY
WAY VARIES THE TERMS OF THlS WARRANTY.
7. NO CONSEQUENTIAL DAMAGES:
IN NO EVENT SHALL CLUB CAR BE LIABLEFOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING,
BUT NOT LIMITED TO, LOSS RELATEDTO PROPERTY OTHER THAN THE GOLF CAR, LOSS OF USE, LOSS OF
TIME, INCONVENIENCE, OR ANY OTHER ECONOMIC LOSS.
Some states allow neither limitation on the duration of an impliedwarranty nor exclusions or limitation of incidental or con-
sequential damages. Therefore, the above limitations or exclusions may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

8. INFORMATION:
For further information contact WARRANTY ADMINISTRATION, CLUB CAR, INC., P.O. Box 204658, Augusta, Georgia
30917-4658, U.S.A., 706-863-3000.
9. WARNING:
Any modification or alteration of any golf car beyondfactory specifications, including those that affect the weight distrib-
ution, stability, or speed of the golf car, can cause serious personal injury
or death.

Foreword
Thank you for choosing Club Car. Whether you have chosen the DS Gasoline or DS Electric, you have chosen the finest
golf car on the market--the golf car most widely recognizedas the industry leader invehicle efficiency and long-lastingvalue.
Please protect your investment and ensure that your Club Car provides years of reliable, superior performance by
returning your Warranty Registration (providedby your distributorldealer), and by reading and following the maintenance
instructions in this manual.
Your comfort and safety are important to us as well, so we urge you to read and follow the step-by-step operating instruc-
tions and safety procedures in this manual. These instructions must be followed in order to avoid the risk of severe per-
sonal injury. If you rent or loan your vehicle to others, we recommend that you ask them to read this manual beforethey
operate the vehicle.
Club Car products are backed by a customer support system designed to offer you fast, courteous service. Inthe event that
your golf car needs repairs or services, we recommend that your local authorized Club Car representative perform
them. Forthe name and address of the Club Car representative nearest you, call 706-863-3000, Ext. 261. If you would pre-
fer to write to us, direct your letter to: Club Car, Attention: Product Development Department, P.O. Box 204658, Augus-
ta, Ga.
30917-4658 USA.Your local authorized Club Car representative can also provide technical advice, parts, and ser-
vice manuals.
We hope you will consider this owner's manual a permanent part of your golf car. If you sell the vehicle, please include the
manual so that the next owner will have the important operating, safety, and maintenance information it contains.

Table of Contents:
Safety Details ......................................................................................................................................................... 1
Vehicle Feature Identification ................................................................................................................................. 4
Model Identification
................................................................................................................................................ 8
Safety Committee
................................................................................................................................................... 9
Pre-Operation Checklist
......................................................................................................................................... 9
Controls ................................................................................................................................................................. 11
Driving Instructions
................................................................................................................................................. 18
Towing
................................................................................................................................................................... 21
Transporting on a Trailer
........................................................................................................................................ 22
.....................................................................................................................................
Storage . Gasoline Vehicle 23
.......................................................................................................................................
Storage . Electric Vehicle 26
Maintenance
.......................................................................................................................................................... 27
Periodic Service Schedule
...................................................................................................................................... 30
Periodic Lubrication Schedule
. Gasoline Vehicles .................................................................................................. 32
Periodic Lubrication Schedule
. Electric Vehicles .................................................................................................... 34
Capacities
.............................................................................................................................................................. 36
Engine Oil
. Gasoline Vehicle ................................................................................................................................. 37
Fueling Instructions
................................................................................................................................................ 38
Battery
. Gasoline Vehicle ...................................................................................................................................... 39
Battery
. Electric Vehicle ........................................................................................................................................ 41
vii

Table of Contents
...........................................................................................................................
Battery Charger . Electric Vehicle 43
Cleaning
................................................................................................................................................................ 49
Vehicle Controllers
................................................................................................................................................. 49
Accessories and Options
........................................................................................................................................ 50
.............................................................................................................................
Subsequent Owner Registration 51
Fairway Villager
..................................................................................................................................................... 51
Vehicle Specifications
............................................................................................................................................ 54

Safety Details:
THIS OWNER'S MANUAL SHOULD BE READ COMPLETELY BEFORE ATTEMPTING 88 DRIVEOR SERVICE
THE VEHICLE. Failureto follow the insbuctions in this rnanuai could result in severe personal injury, property darn-
/ age or death.
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It is importantto note that some vital statements throughout this manual and on the labels afiixedto the vehicle are pre-
ceded by the words DANGER, WARNING, CAUTION, or NOTE. For your protection, we recommendthat you take special
notice sf these safety procedures. Safety procedures are essential and must be foiiowed.
Throughout this manual and on the labels affixed to the vehicle, the words "golf car" and "'vehicle" are used interchange-
ably. "Golf car" is defined in
the Notice of this manual and no other representation is stated or implied.
IF any of the labels on the vehicle become damaged, have been removed or cannot be easily read they should be
replaced immediately to avoid possible personal injury, properly damage, or death. Contact your CLUB CAR distribu-
torldealer.
I
A DANGER INDICATESAN IMMEDIATE HAZARD WHICH WILL RESULT lN SEVERE PERSONAL INJURY OR
1 DEATH. I
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1
A WARNING INDiCATESAN IMFdEDlATEHAZARDWHICH COULD RESULT IN SEVERE PERSONAL INJURY OR /
I DEATH.
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A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHiCH COULD RESULT 1N PRODUCT OR
i
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PROPERTY DAMAGE OR MINOR PERSONAL INJURY.
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NOTE E
A note provides key informationto make procedures more easily understood.
The safely procedures listed must be followed whenever the vehicle is
being repaired or serviced. Other specific warnings
appear throughout this manual and on the vehicle.
GASOLINE VAPORS - FLAMMABLE - EXPLOSIVE - DO NOT SMOKE. Keep sparks and flames away from the area
of the vehicie. Service
only in well-ventilated areas.
BATTERY VAPORS - FLAMMABLE - EXPLOSIVE - DO NOSSMOKE. Keep sparks and flames away from the area
of the vehicle. Service only in wetl-ventilated areas.
DO NOT OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION. Engine produces carbon
monoxidewhich
is an odorless, deadly poison.
A GOLF CAR WILL PROVIDE PROTECTION FROM LIGHTNING, FLYING OBJECTS, OR OTHER STORM
RELATED HAZARDS.
If caught in a storm while driving a golf car, exit the vehicle and seek shelter in accordance
with safety guidelines applicabie to your location.
A WARNING
, .. - - .- .. -. .- -- .- .... -- .. - ---- --- -.
/
ONLY TRAINED TECHNIC1ANS SHOULD REPAlR OR SERVICE THE VEHICLE. Anyone doing even simple
I

WARNING CONTINUED:
repairs or service should follow the correct procedures and obey the warnings listed in this manual as well as those
inthe maintenance and service manual.
l ALWAYS WEAR SAFETY GLASSES OR EYE PROTECTION WHEN SERVICING THE VEHICLE.
TURNKEY SWITCH TO "OFF, REMOVE KEY, BLOCK TIRES, PLACE FORWARDIREVERSE LEVER IN"NEUTRAL"
AND DISCONNECT BATTERY(IES) PRIOR TO SERVICING. (Figures
1 and 2)
ALWAYS USE INSULATEDTOOLS WHEN WORKING AROUND BATTERIES OR ELECTRICAL CONNECTIONS.
l IMPROPER USE OFTHE VEHICLE, OR FAILURE TO PROPERLY MAINTAIN IT, COULD RESULT IN DECREASED
VEHICLE PERFORMANCE OR SEVERE PERSONAL INJURY.
l ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR INCREASES THE
SPEED BEYOND THE FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR
DEATH.
Figure 1 --
I 4 I
, I FRONTOF CAR A
1 Disconnectbattery cables at these
locations beforeworking on
36 volt electricvehicle
Figure 2
4
FRONTOF CAR
Disconnect battery cables at these locations
beforeworking on PowerDriveSystem
48 electricvehicle

DS Gaso ine Vehic e Feature
GOLF
ETIQUEmE
LABEL
WARNING
LlGHT

dentif ication
HOT MANIFOLD AND PERlODlC SERVICE
FORWARD - REVERSE
DANGER
LABEL
ON BODY ON FRAME

ectric Vehic e feature
GOLF
ETlQUErrE
LABEL

dentif ication
- . ~- ~
- - -
~
RESISTOR WARNlNG --
LABEL DANGER LABEL
ON BODY
-.
/2*#*$
, '- 8
FORWA~D - REVERSE
LEVER
i, {
\. 1
\
CHARGER RECEPTACLE
SPEED SWITCH
CAUTION LABEL
ON SPEED SWlTCH CASE

Model Identification:
The serial number of your CLUB CAR is stamped on the data plate mounted on the frame directly above the accelerator
pedai (Example:A9501-123456 for Electric or A69501 -1 23456 for Gasoline) (See Figure 3).
1 NOTE i
Always mention this number when ordering parts or making inquiries. If this vehicle is equipped as a Fairway Villager
four-passenger vehicle, readthe special instructions on Pages 51-52.
Figure 3

Safety Committee:
- m9 B-wm~-~-
If the golf car isto be rented or is part of a fleet, we strongly recommendthat 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.
Who should and who should not drive golf cars.
Instructingfirst time drivers.
Maintaining golf cars in a safe driving condition.
How various rules are to be enforced.
The safety committee should include all these items and such others as the committee feels necessary or appropriate.
Pre-Operation Checklist:
Pv--P---
Your CLUB CAR has been thoroughly inspected and adjusted at the factory, and also by your CLUB CAR distributor1deal-
er. However, upon arrival of your new CLUB CAR(s), you should become familiar with its controls and operation, and care-
fully 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 distributorldealer or a trained mechanic.
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 Pages 4-7)
Tires: Check for proper tire pressure. (See Capacities, Page 36)
DS Electric Batteries (all models): Check electrolyte to ensure that it is at its proper level. (See Figure 20, Page 40)

Check battery posts. Wires should be tight and tree of corrosion. Charge batteries fully before first use of vehi-
.i
cfe.
DS Etectric Speed Switch: Be sure speed switch cover is properly secured prior to operating the vehicle.
DS Gasoline Engine: Check for proper engine oil level. (See Engine Oil, Page 37)
DS Gasoline Fuel: Check fuel levei, (See Fueling Instructions, Page 38)
/
BE SURE THE PLASTiC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERATiNG VEHICLE. Fail-
'
ure to do so may result in a fire, property damage, personal injury, or death.
PERFORMANCE INSPECTION:
After you have familiarized yourself with the vehicle's controls, and have read and understoodthe driving instructions, take
the vehicle for a test drive, Check the foliowing:
Brakes: Be sure that the brakes function properly. Both rear wheels shouid brake simuitaneously. The pedal should
not go more than halfwayto the floor.
If it does, have the brakes adjnsted.
Park Brake: The park brake shouid lackthe wheels when latched, and shoutd 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 acceierator pedaI isdepressed, the engine or motor should start and the vehicle shouid come up
smoothly to full speed. When the pedal is released it should return
to the original position and the engine or motor
should stop. The DS Electric vehicle runs at reduced speed in reverse.
DS GasolineGovernor: Check the speed of the vehicle. The vehicle should run at 19-24 KPH (12-1 5 MPH) on a [eve!
surface.
General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle's ride and performance. Have
a CLUB CAR distributorldealer or
a trained mechanic investigate anything unusual.