102318601 0802D0203A
Contents
1.2. Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner element Crankcase Cylinder head Breather chamber and internal parts Intake pipe and tube WARNING After refueling make sure the tank cap is closed securely f gasoline is spilled on the fuel tank wipe it off immediately Cil Viscosity Choose the viscosity according to the tem perature as follows 20 C 10 C 0 C ES 40 lt SAE10W 30 SAE 10w 40 gt 10W 30 SAE 10W 40 ccc 14 F 32 F 50 F 68 F 86 F 104 F NOTE Engine Oil The following engine oils are recommended API Service Classification SC SD SE SF SG or SH 2003 DS Golf Car Gasoline Vehicle Owner s Manual e Using multi grade oils BW 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them Page 1 NOTICE The Club Car Limited Warranty for owners of individual golf cars appears on the pages following 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 representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form Club Car is not liable for errors in this manual or for incidental or conse
3. REGULAR INTERVAL SERVICE Monthly service by owner or trained technician Semiannual service by trained technician only every 50 hours of operation or every 100 rounds for golf cars Engine Check engine oil level change if necessary See Periodic Lubrication Schedule on page 25 Check engine cooling air intake clean if necessary Visually inspect the unshrouded area around engine exhaust for grass and debris and clean if necessary Tires Check air pressure and adjust as necessary See Vehicle Specifications on page 30 General vehicle Battery Wash engine compartment and underside of vehicle Do not wash engine when hot Clean terminals and wash dirt from casing check electrolyte level See Battery on page 28 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace if necessary Lubricate brake slides See Periodic Lubrication Schedule on page 25 Check brake cables for damage replace if necessary Annual service by trained technician only every 100 hours of operation or every 200 rounds for golf cars Engine Check for leaks around gaskets fill plugs etc Inspect clean and regap spark plug replace if necessary En
4. Lubricate front suspension and do all other semiannual periodic lubrication See Periodic Lubrication Schedule on page 25 Thoroughly clean front body rear body seats engine compartment and underside of vehicle Do not engage the park brake Chock the wheels to prevent the vehicle from rolling CLOSED OFF POSITION SELECTOR I ALIGNED FULL OPEN ON WITH OFF MARKINGS ON THE SIDES OF VALVE POSITION edi VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 12 Fuel Shut off Valve Closed Position Figure 13 Fuel Shut off Valve Open Position PARTIALLY CLOSED POSITION VIEWED FROM SELECTOR SIDE OF VALVE Figure 14 Fuel Shut off Valve Partially Closed Position 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 21 Maintenance RETURNING THE STORED VEHICLE TO SERVICE 1 Restore fuel system to operation Figure 17 Page 26 1 1 Remove plug from fuel tank vent 1 2 Connect vent tube to fuel tank vent 2 Connect battery cables positive cable first 3 Completely open the fuel shut off valve Figure 13 Make sure the valve is fully open A partially closed fuel shut off valve Figure 14 combined with the use of the choke can result in a fouled spark plug and engine failure 4 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the SER VICE position Crank the engine until fuel is pumped into the carburetor and fuel lines and th
5. LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential 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 SERVICES 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 beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death Page 4 2003 DS Golf Car Gasoline Vehicle Owner s Manual FOREWORD Thank you for choosing Club Car the golf car most widely recognized as the industry leader in vehicle effi ciency and long lasting value You have chosen the finest golf car on the market Please protect your invest ment and ensure that your Club Car provides years of reliable superior performance 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 oper ating instructions and safety precautions in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you
6. WARNING and CAUTION state ments and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA WARNING This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm Page 6 2003 DS Golf Car Gasoline Vehicle Owner s Manual TABLE OF CONTENTS Safety Details 7 ec ne TURCA ee mier a eA ad 8 General Warnings aco eri ERE wale kare pad etal re RE RR 9 Vehicle Feature Identification 9 10 General Information lh rr rrr ern 11 Model IdentifiCatlori xime en sense Rowe oe CU dub MERERI RM e eek a teta 11 Safety Committee io ee eee ee bee ee ee a A 11 Controls and Indicatots Bein eddie ea eee hie da 12 Pre Operation and Daily Safety Checklist scili eh 15 Driving Instructions insu ti eren ea a ace EUER TR MS RU E xu 17 TOWING cd usce ERI PREMO re rare Pd e pote rA RIEN weg Ro CR ep E Ee vid 19 Transporting Trailer l 19 St ra g ni na na to Meee EM ee a s Be ed eee 20 Mainitenance by pe aed dead ob ein Seed PL ee dhe e ee ee 22 Periodic Service Schedule 9
7. do not fill higher than one inch from the top of the fuel tank Avoid fuel spillage NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the Vehicle for Extended Storage on page 20 1 Turn the key switch to the OFF position 2 Lift and remove seat bottom 3 The fuel tank is located on passenger side of vehicle Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only See preceding CAUTION 4 Replace fuel cap on tank Make sure cap is tightened securely 5 Replace seat bottom 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 27 Battery BATTERY Read DANGER and WARNING on page 9 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 Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when working with batteries Charge battery in a well ventilated area only 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 wate
8. 1012151 Front suspension 5 fittings Qv Chassis Lube EP NLGI Grade 2 Brake slides Qv Dry Moly Lube CCI P N 1012151 Checkfiluntized transaxle to every 100 hours of plug Gear Lube operation for golf cars Repack tapered front wheel bearings Sealed bearings 7 d Chassis Lube EP NLGI Grade 2 require no lubrication First change 100 hours additional change every 200 hours of 32 oz 95 liter without filter 38 oz operation or every 400 Change engine oil and oil filter Qv 1 12 liters with filter Figure 15 Lubrication Points 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 25 Engine Oil ENGINE OIL Even though the low oil warning light on the dash should warn you if your oil is getting low engine oil level should be checked monthly Vehicle should be on a level surface when checking oil Figure 16 Do not overfill with oil ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from stick See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube and immediately remove it again 3 If the oil level is at or below to the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 4 Rein
9. DECAL LIGHT ON VEHICLE FRAME NEAR BATTERY Excessive speed Can cause severe injury or death Do not tamper with engine governor adjustment CCI 1019152 01 Negative frame ground Gan cause severe injury Do not contact positive battery post or cable to frame Disconnect negative battery lead first PARK BRAKE PEDAL WARNING Z WARNING ROTATING PARTS AND HOT MANIFOLD DECAL GASOLINE WARNING DECAL ON STARTER GENERATOR AND ENGINE ON VEHICLE FRAME NEAR FUEL TANK A WARNING WARNING GASOLINE EXPLOSION FIRE CAN CAUSE SEVERE INJURY CAN CAUSE SEVERE INJURY OR DEATH Rotating parts NO SMOKING SPARKS OR OPEN FLAME STOP ENGINE ALLOW TO COOL BEFORE REFUELING TURN FUEL VALVE ON DURING OPERATION a OFF DURING STORAGE OR TRANSPORT CCI 1015476 01 HOT OIL FILL manifold amp muffler KEEP CLEAR cci 1019605 01 FUEL SHUT OFF FORWARD REVERSE HANDLE NEUTRAL CHOKE LOCKOUT CAM Page 10 2003 DS Golf Car Gasoline Vehicle Owner s Manual General Information GENERAL INFORMATION We urge the owner operator to read and understand this manual and to pay special attention to the features specific to his her vehicle s MODEL IDENTIFICATION The serial number of your Club Car is printed on a bar code decal mounted on the frame directly above the accelerator pedal Example AGO301 123456 Figure 2 There is also a second serial number decal mounted o
10. Slowly depress accelerator pedal The park brake will release automatically and the vehicle will start to move As the accelerator pedal is depressed speed will increase until full speed is reached See fol lowing WARNING and NOTE WARNING Operator must control speed when going downhill Do not shift the vehicle out of forward while going downhill If you do you will not be able to shift into reverse or back into forward until stopped Depress the brake pedal as necessary and partially depress the accelerator when descending a hill With the accelerator pedal partially depressed the governor will cause the engine to assist the brakes in controlling downhill speed NOTE If the Forward Reverse handle is shifted into NEUTRAL power will be cut off and the engine will stop running STOPPING THE VEHICLE To stop the vehicle release the accelerator pedal and depress the brake pedal with your right foot until the vehicle comes to a complete stop WARNING Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently depressing the brake pedal If the vehicle does not slow down at the normal rate continue to depress the brake pedal until the brakes dry out and normal performance returns CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal PARKING AND LEAVING THE VEHICLE 1 After stopping th
11. consequential 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 9 INFORMATION For further information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 10 WARNING Any modification or alteration of any golf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 33 Your Comments Are Appreciated Please select your category Distributor Dealer Technician Individual Owner Golf Course Superintendent Other In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 1 Ease of Understanding 2 Ease of Finding Information 3 Clarity of Illustrations L LJ L Comments Suggestions Please fax a copy of this page to 706 228 2662 Thank You Club Car Technical Publications Department 2003 DS Golf Car Gasoline Vehicle Owner s Manual Manual No 102318601 Edition Code 0802D0203A Golf Cars Gasoline Club Car Inc P O Box 204658 Augusta GA 30917 4658 am
12. material and workmanship for a period of one year from the date of purchase This limited warranty covers material 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 IF THE 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 WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals spark plugs light bulbs lubricants 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 and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties 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 servi
13. rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your golf car needs repairs or service we recommend that your local authorized Club Car rep resentative perform them For the name and address of the Club Car representative nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 USA Your local authorized Club Car representative can also provide technical advice parts and service 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 informa tion it contains 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 5 Practice Safety WARNING Rotating Parts 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 before operating the vehicle we urge you to review the information in this manual Understand and become familiar with the DANGER
14. 22 2002 Page 2 2003 DS Golf Car Gasoline Vehicle Owner s Manual CLUB CAR LIMITED THREE YEAR WARRANTY FOR 2003 INDIVIDUAL GOLF CARS 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the Original Retail Purchaser that its new 2003 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer shall be free from defects in material and workmanship under normal use and service as a golf car for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED THREE YEAR WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit suspension system defined as the shock absorbers shock mounts A plate leaf springs shackles and associated hardware gasoline engine unitized transaxle torque converters drive and driven starter generator transaxle electric vehicle and electric motor are warranted with respect to parts and labor for a period of three years from the date of purchase LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are warranted with respect to parts and labor against defects in material and workmanship for a period of two years from the date of purchase LIMITED ONE YEAR WARRANTY All original equipment options and accessories supplied by CLUB CAR are warranted with respect to parts and labor against defects in
15. 23 Periodic Lubrication Schedule 00 00 25 Engine Oils at oad geod Dat qu E eed ae et ebbe ns wee tt ne da dale 26 Fueling Instructions a ae 27 a wate deter RD Ex xa dead ug ede uev sd ate decane ete 28 Cleaning the Vehicle lh herr eher 29 ACCOSSOLIGS2 roo E LLL dre qr cs Au ipM n a AE oe 29 Subsequent Owner Registration heres 30 Vehicle Specifications here 30 Club Car Limited Lifetime Warranty for 2003 Fleet Golf 32 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 7 Safety Details SAFETY DETAILS WARNING This owner s manual should be read completely before attempting to drive or service the vehicle Failure to follow the instructions in this manual could result in property damage severe personal injury or death It is important to note that some vital statements throughout this manual and on the decals affixed to the vehi cle are preceded by the words DANGER WARNING or CAUTION For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed Throughout this manual and on the operation and safety decals affixed to the vehicle the words golf and vehicle are used interchangeably Golf is defined in the Notice of this manual and no other repre
16. DSGolfCar Gasoline Vehicles 2003 Owners Manual cubcar play to win EMISSION CONTROL INFORMATION Fuel Information THIS VEHICLE IS CERTIFIED TO OPER ATE ON UNLEADED REGULAR GRADE GASOLINE ONLY A minimum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A Emission Control Information To protect the environment in which we all live Club Car has incorporated crankcase emis sion 1 and exhaust emission 2 control sys tems EM in compliance with applicable regu lations of the U S Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control System is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of the crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper maintenance is necessary t
17. ICATIONS DS GAS BODY CHASSIS Frame Chassis Twin welded aluminum Front and rear body ArmorFlex Front body finish Matched paint finish over molded in color Tires 8 tubeless 4 ply rated 18 x 8 50 DIMENSIONS WEIGHT Overall length 91 5 in 232 cm Overall width 47 25 in 120 cm Overall height at steering wheel 48 in 122 cm Wheelbase 65 5 in 166 cm Ground clearance 4 5 in 11 cm Front wheel tread 34 5 in 88 cm Rear wheel tread 38 5 in 98 cm Weight dry without battery 619 Ib 281 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Braking distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase without filter 32 oz 95 liter Engine crankcase with filter 38 oz 1 12 liters Unitized transaxle 27 02 8 liter Fuel tank 7 gallons 26 5 liters TIRE PRESSURE Front and rear 12 14 psi 83 96 Bars 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 31 CLUB CAR LIMITED LIFETIME WARRANTY FOR 2003 FLEET GOLF CARS 1 WARRANTY CLUB CAR INC CLUB CAR hereby warrants to the Original Retail Fleet Purchaser or Original Retail Fleet Lessee as those terms are defined herein and subject to the provisions limit
18. ake pedal firmly and tilt the park brake portion of the pedal forward with your foot Figure 7 See following WARNING WARNING The park brake will release automatically when either the accelerator or brake pedal is depressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling NEUTRAL LOCKOUT For the convenience of the trained technician there is a neutral lockout cam located on the back of the For ward Reverse shifter If the neutral lockout cam is pulled out approximately 3 8 inch 10 mm and then rotated one half turn until it snaps into place the cam will be in the SERVICE position Figure 8 This will allow the technician to operate the engine in neutral for certain maintenance procedures With the cam in this position the vehicle will not operate if the Forward Reverse handle is placed in either the FORWARD or REVERSE position To put the cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate it one half turn until it snaps into place Figure 9 See following WARNING and NOTE WARNING With the cam in the SERVICE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted or accidentally bumped To prevent this chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle NOTE Be sure to return the cam to the OPERATE po
19. als and make sure they are in place and are easy to read 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 To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 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 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 Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 9 Vehicle Feature Identification DS GASOLINE VEHICLE DRIVER PASSENGER WARNING DECAL A WARNING Read Owner s Manual and safety warnings located on dash panel prior to driving ROLLOVER OR FALLING OFF MAY CAUSE DEATH Study and understand controls Before u
20. atched the park brake should lock the wheels and hold the vehicle stationary on an incline of 2096 or less It should release when either the accelerator or brake pedal is depressed Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse handle is in REVERSE Steering The vehicle should be easy to steer and should not have any play in the steering wheel Accelerator With the key switch ON and the Forward Reverse handle in the FORWARD position as the accelerator pedal is depressed the engine should start and the vehicle should come up smoothly to full speed When the pedal is released it should return to the original position and the engine should stop All Club Car vehicles operate at reduced speed in reverse Governor Check maximum speed of the vehicle The vehicle should operate at 12 15 mph 19 24 km h on a level surface General Listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and perfor mance Have a Club Car distributor dealer or a trained technician investigate anything unusual Page 16 2003 DS Golf Car Gasoline Vehicle Owner s Manual Driving Instructions DRIVING INSTRUCTIONS WARNING Only licensed drivers should be allowed to drive the vehicle If renting or loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven No more than two people should be on the vehicle a
21. ations and exclusions contained in this limited warranty that its new 2003 Model DS golf car purchased from CLUB CAR or an authorized distributor or dealer shall be free from defects in material and workmanship under normal use and service as a golf car for the periods stated below subject to the provisions limitations and exclusions contained in this limited warranty LIMITED LIFETIME WARRANTY The golf car frame excluding the front and rear bumper mounts rack and pinion steering gearbox unit and suspension system defined as the shock absorbers shock mounts A plates leaf springs shackles and associated hardware are warranted for the lifetime of the vehicle with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED THREE YEAR WARRANTY The gasoline engine torque converter drive and driven unitized transaxle starter generator transaxle electric vehicle and electric motor are warranted for a period of three years with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED TWO YEAR WARRANTY All remaining components of the golf car not specified otherwise except options and accessories are warranted for a period of two year
22. ayers for use on such golf courses In the event the golf car is purchased or leased by any entity for the purpose of leasing it to an Original Retail Fleet Lessee then this limited warranty shall extend only to the first Original Retail Fleet Lessee and not to such entity or to any subsequent lessee of the golf car 7 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 8 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO 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 implied warranty nor exclusions or limitation of incidental or
23. ces are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE GOLF CAR IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CARS liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB option of the 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 remedying a 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
24. driving conditions such as wet grass or rough terrain Do not use the vehicle on public roads It is not designed or intended for street use and should not be licensed for use on public roads Obey all local rules concerning golf cars The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medications Use brakes to reduce speed when coasting downhill No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to operate the vehicle alone To ensure safe operation of the vehicle follow exactly and in order all of the following precautions Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Study and understand controls 2 Make sure everyone is seated and holding onto seat handles or handrails 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 17 Driving Instructions Read safety warnings located on dash and or above pedals Make sure wheels are turned in desired direction Turn key to the ON position and make sure nothing is in your path oc A o Select direction by placing Forward Reverse handle in desired position F forward or R reverse A buzzer will sound as a warning when the Forward Reverse handle is in REVERSE 7
25. e should be taken that these accessories are properly installed by trained technicians and that they are used in the manner for which they were designed See following WARNING WARNING Tinted windshields and weather proof enclosures will not protect occupants from flying objects golf balls etc 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 29 Subsequent Owner Registration ACCESSORY EQUIPMENT Accent striping Rear view mirror Differential guard Custom club decals Glove box Hour meter Number decals Performance grade tires Information holder Rear rain curtain Standard tread tires Beverage cooler Weather proof enclosure Extra traction tires Extra two bag attachment Tinted split hinged windshield Ashtray Sand bunker rake kit Tinted snap on windshield Chrome hub wheel covers Golf club and ball cleaner Club protector Chrome sport wheel covers Fuel gauge Sand bottle divot repair kit Uncommon key switch Spark arrestor kit Sand bucket divot repair kit Box bed kit Trailer hitch Lighting package headlights taillights Temporary tow bar for single brake lights and horn vehicle towing Permanent tow bar for multiple Turn signals for vehicles with lights vehicle towing factory installed SUBSEQUENT OWNER REGISTRATION Onboard tow bar Heavy duty front bumper In the event a vehicle is bought as a used vehicle from another individual or from a distributor dealer we strongly urge the new owner to register the ve
26. e engine starts Turn the engine off and return neutral lockout cam to the OPERATE position See following NOTE NOTE Due to the oil added to the engine in preparation for storage engine may smoke excessively for a short while when running if for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specifications on page 30 6 Perform the Pre Operation and Daily Safety Checklist on page 15 MAINTENANCE Read DANGER and WARNING on page 9 To ensure trouble free vehicle performance it is very important to follow an established preventive mainte nance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 15 and the fol lowing Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual periodic ser vice WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal i
27. e fully charged Engine Check for proper engine oil level See Engine Oil on page 26 Fuel Check fuel level See Fueling Instructions on page 27 Check fuel tank lines cap pump fuel filters and carburetor for fuel leakage Exhaust system Check for leaks WARNING Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so may result in a fire property damage personal injury or death PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive Use the following checklist as a guide to inspect the vehicle and check daily for proper operation Any prob lems should be corrected by a Club Car distributor dealer or a trained technician Forward Reverse shifter Check for proper operation See Controls and Indicators on page 12 Brakes Be sure the brakes function properly When brake pedal is fully depressed under moderate pressure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop within 14 feet 427 cm If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet have the brake system checked and adjusted as required Brake adjust ment must be maintained so that the brake pedal cannot be depressed to the floor under any circum stance Park brake When l
28. e is in the straight up position NEUTRAL the vehicle will not operate The engine will stop if it is shifted to this position during operation Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse handle is in REVERSE ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 5 The operation of the accelerator pedal differs from that of an automobile When the key switch is ON and the Forward Reverse handle is in either FORWARD or REVERSE depressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected FORWARD or REVERSE As the acceler ator pedal is depressed speed will increase until full speed is reached When the accelerator is released power will be cut off and the engine will stop running Figure 6 Brake Pedal Figure 7 Park Brake Pedal 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 13 Controls and Indicators BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 5 To slow or stop the vehicle depress the brake pedal with your foot Figure 6 PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it and the words PARK BRAKE marked on top of it Figure 6 To set the park brake depress the br
29. e vehicle firmly depress the park brake pedal until it locks This will prevent the vehicle from rolling 2 Turn key switch to OFF and place the Forward Reverse handle in the NEUTRAL position Remove the key and turn fuel shut off valve to closed OFF position when the vehicle is not in use Figure 12 Page 21 Page 18 2003 DS Golf Car Gasoline Vehicle Owner s Manual Towing TOWING All vehicles are equipped with both front and rear tow bar attaching points A light duty tow bar is available for breakdown towing and single vehicle towing A heavy duty tow bar and an onboard tow bar are available for multi vehicle towing See following WARNING WARNING Do not tow the vehicle on public streets or highways Use only approved Club Car tow bars Turn the key switch to OFF and place the Forward Reverse handle in NEUTRAL before towing the vehicle Extreme caution should be used when towing any vehicle Do not tow more than one Club Car vehicle with another Club Car vehicle If more than one vehicle must be towed an adequately powered vehicle tractor or full sized truck properly fitted with a tow hitch height of 11 inches should be used Only heavy duty tow bars should be used for multi vehicle towing Never tow more than five vehicles at one time Turn fuel shut off valve to closed OFF position Figure 12 Page 21 Do not exceed 5 mph 8 km h towing speed Do not allow people in the vehicles being towed Avoid sudden s
30. en working on or near batteries 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 A Club Car vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving a Club Car vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location 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 Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle 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 Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death 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 Check the vehicle for proper location of all vehicle safety and operation dec
31. g Light PRE OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper working condition an in conjunction with the Periodic Service Schedule on page 23 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight Check all hose clamps for tight fit as well as the starter belt for tightness Safety and information decals Check to ensure that all safety and information decals are in place See Vehicle Feature Identification on page 10 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 15 Pre Operation and Daily Safety Checklist Tires Check for proper tire pressure See Vehicle Specifications on page 30 Visually inspect for wear damage and proper inflation Battery Before using vehicle for the first time check electrolyte to ensure it is at the proper level Figure 20 Page 28 Check battery posts Wires should be tight and free of corrosion and battery should b
32. ger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties 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 services are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE GOLF CAR IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CARS liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB CAR s option of the golf car or component thereof that CLUB CAR deems to be defective Replacement s
33. gine air intake system Check air filter element clean or replace if necessary Check clamps for tightness check hose for cracks General vehicle Check for loose hardware and tighten if necessary Two year service by trained technician only every 200 hours of operation or every 400 rounds for golf cars Fuel filters Replace Dispose of used filters properly WARNING If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Page 24 2003 DS Golf Car Gasoline Vehicle Owner s Manual PERIODIC LUBRICATION SCHEDULE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE rounds for golf cars or annually whichever comes first T Tapered front wheel bearings are provided with a chrome metal bearing cap Sealed ball bearing front wheel bearings are provided with a black plastic bearing cap REGULAR INTERVAL SERVICE LUBRICATION RECOMMENDED LUBRICANT Semiannually by owner Brake pedal shaft bearings Oo Dry Moly Lube CCI P N 1012151 or trained technician every 50 hours of j operation or every 100 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 rounds for golf cars PUE acd oto ccelerator push rod pivots mounts and shifter cable pivots 9 Dry Moly Lube P N
34. hall mean furnishing during the applicable limited warranty period Page 32 2003 DS Golf Car Gasoline Vehicle Owner s Manual 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 remedying a 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 SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 30809 U S A 706 863 3000 6 DEFINITIONS For the purpose of this warranty an Original Retail Fleet Purchaser is the original purchaser of the golf car who is in the business of owning or operating golf courses and who purchases such golf car for the purpose of renting it to golf players for use on such courses An Original Retail Fleet Lessee is the first end user of the golf car who is in the business of owning and operating golf courses and who leases such golf car for the purpose of renting it to golf pl
35. hicle with Club Car This will enable us to contact you if the need arises Please send your name address and serial number s of the vehicle s to Club Car Inc P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration VEHICLE SPECIFICATIONS SPECIFICATIONS DS GAS POWER SOURCE Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication system Fuel system Side draft carburetor with float bowl fixed jets fuel filters 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 Torque converter Automatic variable speed dry type Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 105 minute reserve capacity and 35 amp charging capacity 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 Specifications continued on next page Page 30 2003 DS Golf Car Gasoline Vehicle Owner s Manual Vehicle Specifications SPECIF
36. n the front body frame behind the center dash panel The center dash panel must be removed to view this decal See following NOTE NOTE Always have the vehicle serial number at hand when ordering parts or making inquiries SERIAL NUMBER a DECAL AG0301 123456 Clu Figure 2 Serial Number Decal SAFETY COMMITTEE If the golf car is to be rented or is part of a fleet we strongly recommend that a safety committee be appointed One of the main concerns of this committee should be the safe operation of the golf cars This should include at a minimum Where golf cars should be driven Ensuring that proper warnings of driving hazards are displayed and visible Who should and who should not drive golf cars Instructing first time drivers Maintaining golf cars in a safe driving condition How various rules are to be enforced 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 11 Controls and Indicators The safety committee should include all these items and such others as the committee feels necessary or appropriate WARNING SIGN CCI Sharp Left 9911211 Sharp Right 9921211 Steep Hill 9931211 CONTROLS AND INDICATORS Read DANGER and WARNING on page 9 A WARNING f renting or loaning the vehicle make sure the driver is familiar with all controls and operating procedures before allowing the vehicle to be driven Do not tamper with the governor D
37. njury or death Moving parts Do not attempt to service gasoline vehicle while the engine is running Hot Do not attempt to service hot engine or exhaust system Failure to heed this warning could result in severe burns Turn fuel shut off valve to the closed OFF position Figure 12 To avoid unintentionally starting the vehicle before servicing always disconnect the battery negative cable first Figure 1 and disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component Page 22 2003 DS Golf Car Gasoline Vehicle Owner s Manual Periodic Service Schedule PERIODIC SERVICE SCHEDULE Read DANGER and WARNING on page 9 WARNING Service repairs and adjustments must be made per instructions in the maintenance and service manual NOTE If the vehicle is constantly subjected to heavy use or severe operating conditions the preventive maintenance procedures should be performed more often than recommended in the periodic ser vice and lubrication schedules Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 23 Periodic Service Schedule PERIODIC SERVICE SCHEDULE
38. o ensure that your engine will continue to have low emis Sion levels Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards The Club Car Limited Emission Control System Warranty requires that you return your engine to an authorized Club Car Dealer for remedy under warranty Please read the warranty carefully and keep it valid by complying with the owner s obligations it contains Tampering with Emission Control System Prohibited California State law prohibits the following FUEL AND OIL RECOMMENDATIONS Fuel Use only clean fresh unleaded regular grade gasoline Octane Rating The octane rating of a gasoline is a measure of its resistance to knocking Use of a mini mum of 87 octane of the anti knock index is recommended The anti knock index is posted on service station pumps in the U S A NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane rating CAUTION Do not mix oil with gasoline Oxygenated Fuel If you use oxygenated fuel either ethanol or MTBE added to gasoline be sure it is unleaded and meets the minimum octane rating require ment The following are the EPA approved percent ages of fuel oxygenates ETHANOL Ethyl or Grain Alcohol You may use gasoline containing up to 10 ethanol by volume MTBE Methyl Tertiary Butyl Ether You may use gasoline containing
39. oing so will void the warranty as well as damage the engine and other components and could result in property damage personal injury or death due to accident at unsafe speed Do not shift the Forward Reverse handle while the vehicle is moving To avoid injury to an unsuspecting passenger or damage to the vehicle always bring the vehicle to a full stop before shifting the Forward Reverse handle Release the accelerator pedal and then depress the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake turn the key switch to OFF and remove the key when leaving the vehicle KEY SWITCH The key switch is mounted on the dash to the right of the steering column Figure 3 It has two positions OFF and ON which are clearly labeled See following NOTE NOTE The key can be removed only when the key switch is in the OFF position Figure 3 Key Switch Figure 4 Forward Reverse Handle Page 12 2003 DS Golf Car Gasoline Vehicle Owner s Manual Controls and Indicators FORWARD REVERSE CONTROL The Forward Reverse handle is located on the seat support panel below and to the right of the driver s right knee Figure 4 The handle has three distinct positions F FORWARD N NEUTRAL and R REVERSE Rotate the handle towards the driver FORWARD to operate the vehicle in the forward direction or towards the passenger REVERSE to operate the vehicle in reverse When the handl
40. ome damaged from vibration or jarring If battery appears weak have it charged by a trained technician The battery should never be left discharged any longer than absolutely necessary do not leave discharged overnight CLEANING THE VEHICLE Club Car vehicles are equipped with an ArmorFlex front body and rear body Use only commercially avail able automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal operating residential water pressure is adequate Club Car does not recommend any type of pressure washing or steam cleaning Such a process especially if the vehicle has an ArmorFlex rear body that is removed will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid dish soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the DS Maintenance and Service Manual NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors Car
41. or components All parts and components replaced under warranty shall become the property of CLUB CAR 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 3 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 SERVICES CLUB CAR INC 4125 Washington Road Evans Georgia 308089 U S A 706 863 3000 6 DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE GOLF CAR OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY 7 NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE GOLF CAR LOSS OF USE
42. ould be transported on an approved trailer that has an approved load rating of 1200 Ib 544 kg per vehicle being transported NOTE A two car trailer should be rated at 2 x 1200 Ib 2400 Ib 2 x 544 kg 1088 kg STORAGE Read DANGER and WARNING on page 9 DANGER Do not attempt to 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 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 the fuel shut off valve to the closed OFF position Figure 12 Page 21 CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE VEHICLE FOR EXTENDED STORAGE 1 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 2 Drain carburetor and seal the fuel tank 2 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in
43. quential damages that result from the use of the material in this manual This vehicle conforms to the current American National Standards Institute s Z130 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 vehicle 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 information that is protected by copyright All rights are reserved No part of this manual 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 vehicles without obligation to make these changes on units previously sold These vehicles do not conform to Federal Motor Vehicle Safety Standards for automobiles or to FMVSS 500 for low speed vehicles and are not equipped for operation on public streets roads or highways Club Car i P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2002 Club Car Inc Club Car ArmorFlex and Tranquility are registered trademarks of Club Car Inc This manual effective July
44. r followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables The battery in the Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 19 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 637 mL per gallon 3 8 L of water Rinse solution off the battery Do not allow this solution to enter battery Be sure terminals are tight battery terminals should be tightened to 20 ft lb 27 1 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305 See preceding WARNING and following CAUTION CAUTION If battery wire terminals are damaged or corroded they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation BATTERY LEVEL INDICATOR PLATES E i ELECTROLYTE LEVEL AT LEAST 1 2 INCH 13 MM ABOVE PLATES OR TO LEVEL INDICATOR Figure 19 Battery Figure 20 Electrolyte Level for Battery Page 28 2003 DS Golf Car Gasoline Vehicle Owner s Manual Cleaning the Vehicle Be sure battery clamp is properly tightened Tighten to 12 ft Ib 16 3 N m A loose battery clamp may allow the battery to bec
45. s with respect to parts and labor against defects in material and workmanship from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee LIMITED ONE YEAR WARRANTY All original equipment options and accessories supplied by CLUB CAR are warranted with respect to parts and labor against defects in material and workmanship for a period of one year from the date of purchase while owned by the Original Retail Fleet Purchaser or in the possession of the Original Retail Fleet Lessee This limited warranty covers material 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 IF THE 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 WARRANTY CLAIM 2 EXCLUSIONS Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals spark plugs light bulbs lubricants 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 and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery char
46. senta tion is stated or implied If any of the operation or safety decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible personal injury property damage or death Contact your Club Car distributor dealer DANGER DANGER indicates an immediate hazard that will result in severe personal injury or death WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION indicates a hazard or unsafe practice that could result in minor personal injury or product or property damage AS SEEN FROM PASSENGER SIDE OF VEHICLE FRONT a VEHICY E ove J R rj lt 3 negative Mere eam 81 2 nace cable first BEFORE WORKING ON VEHICLE MI Figure 1 Battery Cable Removal Page 8 2003 DS Golf Car Gasoline Vehicle Owner s Manual General Warnings GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Vehicle feature identification information is also included on page 11 Other specific safety statements appear throughout this manual and on the vehicle A 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 wh
47. sert dipstick into the oil filler tube NOTE Properly recycle or dispose of used oil in accordance with local state and federal regulations VENT EZS Eee SHUT OFF aA Figure 16 Engine Oil Level Check Figure 17 Fuel Tank OIL VISCOSITY Choose the viscosity according to the temperature as indicated by the oil viscosity chart Figure 18 See fol lowing NOTE NOTE Using multi grade oils BW 20 10W 30 and 10W 40 will increase oil consumption Check oil level more frequently when using them Page 26 2003 DS Golf Car Gasoline Vehicle Owner s Manual 20 C 10 C 0 C 10 20 30 40 qm SAE 10W 30 SAE 10W 40 ee 4 F 14 F 3252 50 F 68 F 86 F 104 Figure 18 Oil Viscosity FUELING INSTRUCTIONS Read DANGER and WARNING on page 9 DANGER Turn key switch to the OFF position before fueling Fueling Instructions Do not pour gasoline into the fuel tank when the engine is hot or while it is running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation If the vehicle has an all weather enclosure installed be sure the fuel tank is properly vented as shown Figure 17 To avoid the possibility of fire clean up any spilled gasoline before operating the vehicle CAUTION To allow for expansion
48. sing vehicle read operating instructions Make sure wheels are turned in desired direction Remain seated and hold on to seat handle while moving e Turn key to ON position and be sure nothing is in your path Do not start vehicle until all occupants are seated Pus nd Two 2 persons per seat maximum While vehicle is stopped select direction by placing Operate from driver side only and not on public roads shift lever or switch in desired position Keep entire body Inside vehicle while moving r F Forward N Neutral Reverse Buzzer will sound Drive slowly in turns and straight up and down slopes moie d 3 Do ot leave chlidred unattendad on vahiole Vehicle will start moving when accelerator pedal is depressed Never operate under the influence of alcohol or drugs e Slowly depress accelerator pedal to increase speed Park brake will Use brakes to reduce speed when coasting downhill release when accelerator pedal is depressed Never stand in front of or behind vehicle CCI 101960601 N To stop release accelerator pedal and depress brake pedal After stopping firmly depress park brake until it locks Place forward and reverse switch in neutral position Turn key OFF and remove key when not in use CCI 1016216 01 OPERATING INSTRUCTIONS DECAL KEY SWITCH OPERATING INSTRUCTIONS SERIAL NUMBER ACCELERATOR PEDAL BRAKE PEDAL LOW OIL FRAME GROUND AND WARNING GOVERNOR WARNING
49. sition after servicing the vehicle or it will not operate with the Forward Reverse handle in either the FORWARD or REVERSE position NEUTRAL NEUTRAL SERVICE POSITION OPERATE POSITION Figure 8 Neutral Lockout Service Figure 9 Neutral Lockout Operate Page 14 2003 DS Golf Car Gasoline Vehicle Owner s Manual Pre Operation and Daily Safety Checklist CHOKE The choke is located on the seat support panel below and to the left of the driver s left knee Figure 10 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover to activate it Hold it during start up and release the choke cover after the engine starts and runs smoothly LOW OIL WARNING LIGHT The gasoline golf car is equipped with a low oil warning light located on the dash panel just above the steer ing column Figure 11 If the warning light comes on oil should be checked and added to the engine as nec essary before continuing to use the vehicle The vehicle should never be driven with the low oil warning light remaining on If the warning light goes on and off you may proceed but oil should be added at the first oppor tunity If the oil level is correct and the warning light stays on have a trained technician check the vehicle See following CAUTION CAUTION Failure to add oil immediately when the low oil warning light stays on may result in permanent engine damage Figure 10 Choke Figure 11 Low Oil Warnin
50. t one time The vehicle is not specially equipped for handicapped persons Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one For night use the vehicle must be equipped with headlights taillights and reflectors Stop the vehicle before shifting the Forward Reverse handle Failure to do so may result in injury to an unsuspecting passenger and or damage to the vehicle Do not leave children unattended on vehicle To help avoid being struck do not stand in front of or behind the vehicle Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated in a moving vehicle and hold on to seat handles or handrails at all times Driver should keep both hands on the steering wheel when the vehicle is in motion To help prevent the possibility of serious injury keep your entire body inside the vehicle To help prevent overturning the vehicle drive slowly in turns To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 incline To help avoid possible injury to an inattentive passenger and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns To help avoid the possibility of losing control of or overturning the vehicle reduce speed for adverse
51. tarts sudden stops and tight turns when towing Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury TRANSPORTING ON A TRAILER A WARNING For use on public roads the trailer must meet all federal state and local requirements such as taillights brake lights etc Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle to be towed should be tied securely to the trailer with the Forward Reverse handle in NEUTRAL the key switch OFF and the park brake firmly depressed and locked When towing on a trailer normal road speed of the tow vehicle must be reduced Because of the added length of the trailer caution should be used when turning a corner Remove the vehicle windshield before transporting on a trailer Turn fuel shut off valve to the closed OFF position Figure 12 Page 21 Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury 2003 DS Golf Car Gasoline Vehicle Owner s Manual Page 19 Storage If the vehicle must be transported over long distances or on public highways it sh
52. the SERVICE position Turn the fuel shut off valve to the closed OFF position Figure 12 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 2 2 Loosen but do not remove the carburetor drain screw and drain fuel remaining in bowl into a small clean container then pour the fuel from the container into vehicle fuel tank Tighten the carburetor drain screw 2 3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 Disconnect the battery cables negative cable first Page 20 2003 DS Golf Car Gasoline Vehicle Owner s Manual Storage 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 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into the engine through the spark plug hole Rotate engine crankshaft by hand several times and then install the spark plug Adjust tires to recommended tire pressure See Vehicle Specifications on page 30
53. up to 15 MTBE by volume METHANOL Methanol or Wood Alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also dam age metal rubber and plastic parts of your fuel system WARNING Gasoline is extremely flammable and can be explosive under certain con ditions Turn the engine switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and overflow through the vent in the fuel tank acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incor porated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inopera tive by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission relat ed parts
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