Club Car DS Golf Cars 2004 User manual

Club Car
MANUAL NUMBER 102397601 
EDITION CODE 1203B0312A
DS GOLF CARS 
GASOLINE/ELECTRIC
2004
MAINTENANCE
SERVICE
MANUAL

2004 DS Golf Car Maintenance and Service Manual Page i
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.
This manual provides detailed information for the maintenance and repair of DS Golf Cars, and should be
used in conjunction with the appropriate maintenance and service supplement.
If you do not have the appropriate maintenance and service supplement, you may order one from your local
Club Car representative. Maintenance and service supplements available include the following:
This manual and corresponding maintenance and service supplement should be thoroughly reviewed prior to
servicing the vehicle.The procedures provided must be properly implemented, and the DANGER, WARNING,
and CAUTION statements must be heeded.
This manual was written for the trained technician who already has knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to
the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be
performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained tech-
nician.
It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.
This manual, used in conjunction with the appropriate maintenance and service supplement, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc.; P.O.
Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech-
nical Service Representative at [phone], extension 3580.
2004 PowerDrive System 48 Vehicle Maintenance & Service Supplement Publication Part No. 102397605
2004 V-Glide 36-Volt Vehicle Maintenance & Service Supplement Publication Part No. 102397604
2004 FE290 Gasoline Vehicle Maintenance & Service Supplement Publication Part No. 102397607
2004 IQ System Vehicle Maintenance and Service Supplement Publication Part No. 102397606
Copyright © 2003, 2012 Club Car, Inc.
Club Car, ArmorFlex, PowerDrive, and Tranquility
are registered trademarks of Club Car Inc.
This manual effective July 28, 2003.

Page ii 2004 DS Golf Car Maintenance and Service Manual
∆
WARNING
• Read Section 1 – Safety before attempting any service on the vehicle.
•Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is
continually working to further improve its vehicles and other products. These improvements may
affect servicing procedures. Any modification and/or significant change in specifications or proce-
dures will be forwarded to all Club Car distributors and dealers and will, when applicable, appear in
future editions of this manual.
Club Car, Inc. reserves the right to change specifications and designs at any time without notice
and without the obligation of making changes to units previously sold.
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., P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.

2004 DS Golf Car Maintenance and Service Manual Page iii
CONTENTS
SECTION 1 – SAFETY
General Warning ................................................................................................................................ 1-1
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
Serial Number Identification ............................................................................................................... 3-1
Safety Committee .............................................................................................................................. 3-2
Storage – Gasoline Vehicle ............................................................................................................... 3-2
Preparing the Gasoline Vehicle for Extended Off-Season Storage ............................................... 3-3
Returning the Stored Gasoline Vehicle to Service ......................................................................... 3-4
Storage – Electric Vehicle ................................................................................................................. 3-5
Preparing the Electric Vehicle for Extended Off-Season Storage ................................................. 3-5
Returning the Stored Electric Vehicle to Service ........................................................................... 3-6
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle .......................................................................................................................... 4-1
Seat ............................................................................................................................................... 4-1
Front and Rear Body Repair .............................................................................................................. 4-2
Stress Lines or Streaks .................................................................................................................. 4-2
Minor Impact Damage/Deformations ............................................................................................. 4-2
Minor Scratches and Surface Blemishes ....................................................................................... 4-2
Small Scratches That Cannot Be Buffed Out ................................................................................ 4-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ........................................................ 4-3
Touch-up Paint Color Chart ........................................................................................................... 4-3
Canopy .............................................................................................................................................. 4-3
Canopy Removal ........................................................................................................................... 4-3
Canopy Installation ........................................................................................................................ 4-5
Front Body ......................................................................................................................................... 4-5
Front Body Removal ...................................................................................................................... 4-5
Front Body Installation ................................................................................................................... 4-5
Rear Body .......................................................................................................................................... 4-7
Rear Body Removal ....................................................................................................................... 4-7
Rear Body Installation .................................................................................................................... 4-9

Page iv 2004 DS Golf Car Maintenance and Service Manual
Floor Mat ............................................................................................................................................ 4-10
Floor Mat Removal ......................................................................................................................... 4-10
Floor Mat Installation ...................................................................................................................... 4-10
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP
Throttle Input Device Identification ..................................................................................................... 5-1
Brake Pedal and Park Brake .............................................................................................................. 5-1
Brake Pedal Removal .................................................................................................................... 5-1
Brake Pedal Installation ................................................................................................................. 5-2
Park Brake Removal ...................................................................................................................... 5-4
Park Brake Installation ................................................................................................................... 5-5
Accelerator Pedal – Gasoline and Electric V-Glide Vehicles ............................................................. 5-6
Accelerator Pedal Removal ............................................................................................................ 5-6
Accelerator Pedal Installation ......................................................................................................... 5-8
Accelerator Pedal – Electric MCOR Vehicles .................................................................................... 5-9
Accelerator Pedal Removal ............................................................................................................ 5-9
Accelerator Pedal Installation ......................................................................................................... 5-11
Pedal Group Adjustment – Gasoline Vehicle ..................................................................................... 5-12
Pedal Group Adjustment – Electric MCOR Vehicles .......................................................................... 5-17
Pedal Group Adjustment – Electric V-Glide Vehicles ......................................................................... 5-21
SECTION 6 – WHEEL BRAKE ASSEMBLIES
General Information ........................................................................................................................... 6-1
Brake Shoe Removal ......................................................................................................................... 6-1
Brake Assembly Cleaning .................................................................................................................. 6-5
Brake Shoe Installation ...................................................................................................................... 6-6
Brake Adjustment ............................................................................................................................... 6-8
Brake Cluster Removal and Installation ............................................................................................. 6-8
Brake Cluster Installation ............................................................................................................... 6-9
Brake Cable Removal and Installation ............................................................................................... 6-9
SECTION 7 – STEERING AND FRONT SUSPENSION
General Information ........................................................................................................................... 7-1
Steering Wheel ................................................................................................................................... 7-1
Steering Wheel Removal ............................................................................................................... 7-1
Steering Wheel Installation ............................................................................................................ 7-2
Steering Column ................................................................................................................................ 7-2
Steering Column Removal ............................................................................................................. 7-2
Steering Column Disassembly ....................................................................................................... 7-5
Steering Column Assembly ............................................................................................................ 7-5
Steering Column Installation .......................................................................................................... 7-6

2004 DS Golf Car Maintenance and Service Manual Page v
Steering Adjustment .......................................................................................................................... 7-6
Rack and Pinion ................................................................................................................................ 7-8
Rack and Pinion Removal ............................................................................................................. 7-8
Rack and Pinion Disassembly ....................................................................................................... 7-8
Rack and Pinion Assembly ............................................................................................................ 7-11
Rack and Pinion Installation .......................................................................................................... 7-13
Tie Rod and Drag Link ....................................................................................................................... 7-13
Tie Rod and Drag Link Removal .................................................................................................... 7-13
Tie Rod and Drag Link Installation ................................................................................................. 7-13
Front Suspension .............................................................................................................................. 7-14
Lubrication ..................................................................................................................................... 7-14
Wheel Alignment ............................................................................................................................ 7-14
Front Suspension Components ......................................................................................................... 7-16
Tapered Leaf Spring Removal ....................................................................................................... 7-16
Tapered Leaf Spring Installation .................................................................................................... 7-16
Kingpin and Steering Spindle Removal ......................................................................................... 7-17
Kingpin and Steering Spindle Installation ...................................................................................... 7-17
Delta A-Plate Removal .................................................................................................................. 7-17
Delta A-Plate Installation ............................................................................................................... 7-20
Shock Absorber Removal .............................................................................................................. 7-20
Shock Absorber Installation ........................................................................................................... 7-20
Front Wheel Bearings and Hubs ....................................................................................................... 7-20
Front Wheel Free Play Inspection ................................................................................................. 7-20
Front Hub Removal ........................................................................................................................ 7-20
Front Hub Installation ..................................................................................................................... 7-21
SECTION 8 – WHEELS AND TIRES
General Information ........................................................................................................................... 8-1
Wheels ............................................................................................................................................... 8-1
Wheel Removal ............................................................................................................................. 8-1
Wheel Installation .......................................................................................................................... 8-1
Tires ................................................................................................................................................... 8-1
Tire Removal ................................................................................................................................. 8-1
Tire Repair ..................................................................................................................................... 8-2
Tire Installation .............................................................................................................................. 8-3
SECTION 9 – REAR SUSPENSION
General Information ........................................................................................................................... 9-1
Shock Absorbers ............................................................................................................................... 9-1
Shock Absorber Removal and Inspection ...................................................................................... 9-1
Shock Absorber Installation ........................................................................................................... 9-1

Page vi 2004 DS Golf Car Maintenance and Service Manual
Leaf Springs ....................................................................................................................................... 9-1
Leaf Spring Removal ...................................................................................................................... 9-1
Leaf Spring Installation ................................................................................................................... 9-4
SECTION i – INDEX

2004 DS Golf Car Maintenance and Service Manual Page 1-1
1
SECTION 1 – SAFETY
To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage
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 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 statements labeled NOTE, which provide other essen-
tial service or maintenance information.
∆
DANGER
•ADANGER indicates an immediate hazard that will result in severe personal injury or death.
∆
WARNING
•AWARNING indicates an immediate hazard that could result in severe personal injury or
death.
∆
CAUTION
•ACAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result
in minor personal injury or product or property damage.
CAUTION
•ACAUTION without the safety alert symbol indicates a potentially hazardous situation that
could result in property damage.
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements. Also, other specific
safety statements appear throughout this manual and on the vehicle.
∆
DANGER
•Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area.Ventilate when charging or operating vehicle in an enclosed area.Wear a full face
shield and rubber gloves 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 magnesia or vegetable
oil. Call a physician immediately.
-Eyes: Flush with water for 15 minutes. Call a physician immediately.
•Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the
vehicle and service area. Service only in a well-ventilated area.
•Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine
produces carbon monoxide, which is an odorless, deadly poison.

SAFETY General Warning
Page 1-2 2004 DS Golf Car Maintenance and Service Manual
1
∆
WARNING
•Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle.
•Only trained technicians should service or repair the vehicle. Anyone doing even simple
repairs or service should have knowledge and experience in electrical and mechanical repair.
The appropriate instructions must be used when performing maintenance, service, or
accessory installation.
•Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF,
remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
Gasoline vehicles only:
•To avoid unintentionally starting the vehicle:
- Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3).
- Disconnect the spark plug wire from the spark plug.
•Frame ground – Do not allow tools or other metal objects to contact frame when
disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch
the vehicle frame, engine, or any other metal component.
Electric vehicles only:
• IQ System Vehicles:
Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries.
• All Electric Vehicles:
To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-2,
1-3, or 1-4 on page 1-3).
• IQ System Vehicles:
After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
•PowerDrive System 48 Vehicles:
After disconnecting the batteries, discharge the controller capacitors as follows:
-Turn the key switch to ON and place the Forward/Reverse handle in the REVERSE position.
-Slowly press the accelerator pedal and keep it pressed until the reverse warning buzzer can
no longer be heard. When the buzzer stops sounding, the controller capacitors are
discharged.
All vehicles:
•Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face
shield and rubber gloves when working on or near batteries.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle.
•Moving parts! Do not attempt to service the vehicle while it is running.
•Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning
could result in severe burns.
•Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
•Check the vehicle owner’s manual for proper location of all vehicle safety and operation
decals and make sure they are in place and are easy to read.
•Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
WARNING CONTINUED ON NEXT PAGE...

SAFETY General Warning
2004 DS Golf Car Maintenance and Service Manual Page 1-3
1
∆
WARNING
•Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic
floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold
vehicle in raised position. Use approved jack stands of proper weight capacity to support the
vehicle and chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
•If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage, personal injury, or death.
•Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Do not leave children unattended on vehicle.
Figure 1-1 Gasoline Vehicle Figure 1-2 IQ System Vehicle
Figure 1-3 PowerDrive System 48 Vehicle Figure 1-4 V-Glide 36-Volt Vehicle
AS SEEN FROM
PASSENGER SIDE
OF VEHICLE
FRONT
OF VEHICLE
Remove
negative
cable first.
DISCONNECT BATTERY CABLES
BEFORE WORKING ON VEHICLE
TOW RUN
WARNING
1
2
3
4
6
5
FRONT
OF VEHICLE
Place Tow/Run
Switch in TOW.
Remove negative
cable first.
PLACE TOW/RUN SWITCH
IN THE TOW POSITION BEFORE
DISCONNECTING OR
CONNECTING BATTERY CABLES
1
2
3
4
6
5
DISCONNECT BATTERY
CABLES HERE
FRONT
OF VEHICLE
Remove
negative
cable first.
1
2
3
4
6
5
DISCONNECT BATTERY
CABLES HERE
FRONT
OF VEHICLE
Remove
negative
cable first.

1

2004 DS Golf Car Maintenance and Service Manual Page 2-1
2
SECTION 2 – VEHICLE SPECIFICATIONS
SPECIFICATIONS
DS
GASOLINE
POWERDRIVE
SYSTEM 48
ELECTRIC
IQ SYSTEM
ELECTRIC
DS
36-VOLT
ELECTRIC
POWER SOURCE
Engine : 4 cycle, OHV, 286 cc, 9.0 hp rated, single
cylinder, air cooled, with pressure lubrication system •
Drive motor: Direct drive, 48 volts DC, series wound,
3.1 hp •
Drive motor: Direct drive, 48 volts DC, shunt wound,
3.2 hp •
Drive motor: Direct drive, 36 volts DC, series wound,
2.97 hp •
Fuel system: Side draft carburetor with float bowl,
fixed jets, fuel filter, and impulse fuel pump •
Governor: Automatic ground speed sensing, internally
geared in unitized transaxle •
Ignition: Transistor electronic ignition with electronic
RPM limiter •
Unitized transaxle: Fully synchronized forward and
reverse with neutral and reduced speed reverse
(11.8:1 forward, 17.1:1 reverse) •
Transaxle: Double reduction helical gear with 12.28:1
direct drive axle •••
Electrical system: Battery - 12 volt, 500 cold cranking
amps at 0°, 650 cranking amps at 32°, 105 minute reserve
and 35 amp charging capacity •
Electrical system: 48 volts DC, reduced speed reverse • •
Electrical system: 36 volts DC, reduced speed reverse •
Batteries: High capacity, deep cycle, Trojan PowerDrive
8 volt, 117 min. capacity ••
Batteries: High capacity, deep cycle, Trojan 6 volt,
115 min. capacity •
Charger: Automatic, 48 volt UL and CSA listed • •
Charger: Automatic, 36 volt 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 hydraulic shocks ••••
Brakes: Dual rear wheel self-adjusting brakes with cast
iron drums and single brake pedal with automatic-release
park brake ••••
BODY/CHASSIS
Frame/Chassis: Twin I-Beam welded aluminum ••••
Front and rear body: ArmorFlex
®
••••
Body finish: Matched paint finish over molded-in color ••••
Tires: 18 x 8.5 - 8 tubeless, 4 ply rated ••••
DIMENSIONS/WEIGHT
Overall length
91-1/2 in.
(232 cm) 91-1/2 in. (232 cm) 91-1/2 in. (232 cm) 91-1/2 in. (232 cm)
Specifications continued on next page...

VEHICLE SPECIFICATIONS
Page 2-2 2004 DS Golf Car Maintenance and Service Manual
2
DIMENSIONS/WEIGHT, Continued:
Overall width
47-1/4 in.
(120 cm) 47-1/4 in. (120 cm) 47-1/4 in. (120 cm) 47-1/4 in. (120 cm)
Overall height (at steering wheel)
48 in.
(122 cm) 48 in. (122 cm) 48 in. (122 cm) 48 in. (122 cm)
Wheelbase
65-1/2 in.
(166 cm) 65-1/2 in. (166 cm) 65-1/2 in. (166 cm) 65-1/2 in. (166 cm)
Ground clearance
4-1/2 ft.
(11 cm) 4-1/2 ft. (11 cm) 4-1/2 ft. (11 cm) 4-1/2 ft. (11 cm)
Front wheel tread
34-1/2 in.
(88 cm) 34-1/2 in. (88 cm) 34-1/2 in. (88 cm 34-1/2 in. (88 cm
Rear wheel tread
38-1/2 in.
(98 cm) 38-1/2 in. (98 cm) 38-1/2 in. (98 cm) 38-1/2 in. (98 cm)
Weight (without batteries)
455 lb.
(206 kg) 494 lb. (224 kg) 448 lb. (203 kg)
Weight (dry, without battery)
598 lb.
(271 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)
Curb clearance circle (diameter)
17 ft.-6 in.
(533 cm) 17 ft.-6 in. (533 cm) 17 ft.-6 in. (533 cm) 17 ft.-6 in. (533 cm)
Braking distance (at 12 mph (19 km/h)
14 ft.
(427 cm) 14 ft. (427 cm) 14 ft. (427 cm) 14 ft. (427 cm)
Standard seating capacity (persons) 2222
Liquid Capacities
Engine crankcase without filter
32 oz.
(0.98 liters)
Engine crankcase with filter
38 oz.
(1.16 liters)
Unitized transaxle
27 oz.
(0.8 liters)
Transaxle
22 oz.
(0.67 liters) 22 oz. (0.67 liters) 22 oz. (0.67 liters)
Fuel (unleaded gasoline only)
7 gallons
(26.5 liters)
Tire Pressure
Front and rear
12-14 psi
(0.83-0.96 Bars) 18-20 psi (1.24-1.38 Bars) 18-20 psi (1.24-1.38 Bars) 18-20 psi (1.24-1.38 Bars)
SPECIFICATIONS
DS
GASOLINE
POWERDRIVE
SYSTEM 48
ELECTRIC
IQ SYSTEM
ELECTRIC
DS
36-VOLT
ELECTRIC

2004 DS Golf Car Maintenance and Service Manual Page 3-1
3
SECTION 3 – GENERAL INFORMATION
∆
DANGER
• See General Warning, Section 1, Page 1-1.
∆
WARNING
• See General Warning, Section 1, Page 1-1.
Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. rec-
ommends the owner/operator read and understand this manual and pay special attention to features specific
to their vehicle(s).
Refer to the owner’s manual provided with the vehicle for information on the following topics:
• Controls and Indicators
• Pre-Operation and Daily Safety Checklist
• Driving Instructions
• Towing
• Transporting on a Trailer
• Subsequent Owner Registration
• Warranties
SERIAL NUMBER IDENTIFICATION
The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accel-
erator pedal (Example: AQ0401-123456 for Electric or AG0401-123456 for Gasoline) (Figure 3-1, Page 3-1) .
There is also a second serial number decal mounted on the front body frame behind the center dash panel.
The center dash panel must be removed to view this decal.
NOTE: Have the vehicle serial number available when ordering parts or making inquiries.
Figure 3-1 Serial Number Decal
Club
GO
GO
SERIAL NUMBER
AQ0401-123456
P O BOX 204658
AUGUSTA GA 30917
Club Car R
SERIAL NUMBER
DECAL
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.

GENERAL INFORMATION Safety Committee
Page 3-2 2004 DS Golf Car Maintenance and Service Manual
3
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. See below for list of signs
available from Club Car Service Parts Department.
•Who should and who should not drive golf cars.
•Instructing first time drivers.
•Maintaining golf cars in a safe driving condition
•How various rules are to be enforced.
The safety committee should include all these items and such others as the committee feels necessary or
appropriate.
STORAGE – GASOLINE VEHICLE
See General Warning, Section 1, Page 1-1.
∆ DANGER
• Do not drain gasoline when the engine is hot or while it is running.
• Be sure to clean up any spilled gasoline before operating the vehicle.
•Store gasoline in an approved gasoline container only. Store in a well-ventilated area away
from sparks, open flames, heaters, or heat sources.
•Keep gasoline out of the reach of children.
• Do not siphon gasoline from the vehicle.
∆ WARNING
•Turn the key switch OFF, remove the key, and leave the Forward/Reverse handle in the
NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a
fire hazard.
•Turn fuel shut-off valve to closed (OFF) position (Figure 3-3, Page 3-3).
•Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery.
Frozen batteries can explode.
WARNING SIGN CCI P/N
Sharp Left S9911211
Sharp Right S9921211
Steep Hill S9931211

GENERAL INFORMATION Storage – Gasoline Vehicle
2004 DS Golf Car Maintenance and Service Manual Page 3-3
3
∆ CAUTION
• Batteries in a low state of charge will freeze at low temperatures.
PREPARING THE GASOLINE VEHICLE FOR EXTENDED OFF-SEASON STORAGE
1. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of
baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat-
teries. Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry
and then coat them with Battery Terminal Protector Spray (CCI P/N 1014305).
2. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be
weak, have it charged by a trained technician. Use an automotive-type 12-volt battery charger rated at
10 amps or less.
3. Drain carburetor and seal the fuel tank.
3.1. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the
SERVICE (MAINTENANCE) position. Turn the fuel shut-off valve to the closed (OFF) position
(Figure 3-3, Page 3-3) and run the engine until fuel remaining in the carburetor and fuel lines is
depleted and the engine stalls. Return the neutral lockout cam to the OPERATE position.
3.2. Loosen, but do not remove, the carburetor drain screw and drain fuel remaining in bowl into a small
container, then pour the fuel from the container into vehicle fuel tank. Tighten the carburetor drain
screw.
3.3. Disconnect fuel vent line from fuel tank vent nipple.
3.4. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap.
4. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning, Section 1, Page 1-2.
5. To protect the engine, remove the spark plug and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil into the
engine through the spark plug hole. Rotate the engine crankshaft by hand several times and then install
the spark plug.
6. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
Figure 3-2 Fuel Tank, Vent, and Lines Figure 3-3 Fuel Shut-Off Valve – Closed Position
VENT TUBES
TO CARBURETOR
SHUT-OFF
VALVE
VENT
CLOSED (OFF) POSITION
(SELECTOR IS ALIGNED
WITH OFF MARKINGS ON THE SIDES OF VALVE)
OFFOFF
VIEWED FROM SELECTOR
SIDE OF VALVE

GENERAL INFORMATION Storage – Gasoline Vehicle
Page 3-4 2004 DS Golf Car Maintenance and Service Manual
3
Preparing the Gasoline Vehicle for Extended Off-Season Storage, Continued:
7. Perform semiannual periodic lubrication. See Periodic Lubrication Schedule, Section 10 – Periodic
Maintenance, in the appropriate maintenance and service supplement.
8. Thoroughly clean front body, rear body, seats, engine compartment, and underside of vehicle.
9. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling.
RETURNING THE STORED GASOLINE VEHICLE TO SERVICE
1. Connect battery cables, positive (+) cable first.
2. Restore fuel system to operation.
2.1. Remove plug from the fuel tank vent nipple and reconnect fuel vent line to nipple. Open the fuel
shut-off valve (Figure 3-4, Page 3-4). Make sure the valve is fully open. A partially closed fuel shut-
off valve (Figure 3-5, Page 3-4) combined with the use of the choke, can result in a fouled spark
plug and engine failure.
2.2. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam to the
SERVICE (MAINTENANCE) position. Crank the engine until fuel is pumped into the carburetor and
fuel lines and the engine starts.Turn the engine off and return the neutral lockout cam to the OPER-
ATE position. See following NOTE.
NOTE: Due to the oil added to the engine in preparation for storage, the engine may smoke excessively for
a short while when running it for the first time after storage.
3. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
4. Perform the Pre-Operation and Daily Safety Checklist. See the vehicle owner’s manual.
Figure 3-4 Fuel Shut-Off Valve – Open Position Figure 3-5 Incorrect Fuel Shut-off Valve Setting
VIEWED FROM SELECTOR
SIDE OF VALVE
FULL OPEN (ON)
POSITION
VIEWED FROM SELECTOR
SIDE OF VALVE
PARTIALLY CLOSED POSITION

GENERAL INFORMATION Storage – Electric Vehicle
2004 DS Golf Car Maintenance and Service Manual Page 3-5
3
STORAGE – ELECTRIC VEHICLE
See General Warning, Section 1, Page 1-1.
∆ WARNING
•Turn the key switch OFF, remove the key, and leave the Forward/Reverse handle in the
NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a
fire hazard.
•Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery.
Frozen batteries can explode.
∆ CAUTION
• Batteries in low state of charge will freeze at low temperatures.
•To avoid exposing electrical components to moisture and subsequent damage, do not use
any type of pressure washing or steam cleaning equipment to wash the vehicle.
• IQ System vehicles only: Place Tow/Run switch in the TOW position.
PREPARING THE ELECTRIC VEHICLE FOR EXTENDED OFF-SEASON STORAGE
1. Fully charge batteries. See Section 13 – Batteries, in the appropriate maintenance and service sup-
plement.
2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of
baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off bat-
teries. Do not allow this solution to enter the batteries. Be sure terminals are tight. Let the terminals dry
and then coat them with Battery Terminal Protector Spray (CCI P/N 1014305).
3. Store vehicle in a cool, dry place. This will minimize battery self-discharge.
4. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
5. Lubricate front suspension and do all other semiannual periodic lubrication. See Periodic Lubrication
Schedule, Section 10 – Periodic Maintenance, in the appropriate maintenance and service sup-
plement.
6. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle.
7. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling.
8. Keep batteries fully charged during storage.
NOTE: PowerDrive Battery Chargers: Leave PowerDrive battery chargers plugged in during storage.
The onboard computer will automatically activate the charger when necessary. If charger cannot
remain plugged in, or AC power will not be available during extended storage, disconnect the bat-
teries for storage. See WARNING “To avoid unintentionally starting...” in General Warning,
Section 1, Page 1-2.
Accu-Power Battery Chargers only: Charge batteries every six to eight weeks. If it is not possible
to charge the batteries every six to eight weeks, disconnect the batteries for storage. See WARN-
ING “To avoid unintentionally starting...” in General Warning, Section 1, Page 1-2.
CAUTION
• Check the vehicle monthly to ensure the charger is operating correctly during storage.

GENERAL INFORMATION Storage – Electric Vehicle
Page 3-6 2004 DS Golf Car Maintenance and Service Manual
3
RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE
1. If necessary, connect batteries.
2. Fully charge batteries.
3. Adjust tire to recommended pressure. See Section 2 – Vehicle Specifications.
4. Perform the Pre-Operation and Daily Safety Checklist. See the vehicle owner’s manual.