1015439 0889A00000
Contents
1. Mild soap or detergent with a sponge or ir soft loth for normal cleaning is recommended For stubborn or imbedded dirt a soft bristle brush may be used Do not use any harsh detergents or cleaning solvents on the body cowl or seat Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately w prevent Dessins stains Subsequent Owner Registration In the event that this vehicle has been bought as a used car from another individual or from a distributor dealer re registration is necessary This will enable us to contact you if the need arises Please send your E name address and serial number s of the car s to CLUB CAR INC P O Box 19998 Augusta GA 30917 e 4658 ATEN Vehicle See Overall Length 91 25 Overall Width 47 25 Overall Height 46 Wheelbase 65 5 gt Ground Clearance 4 5 Front Wheel Tread 1 34 5 Rear Wheel Tread 38 5 Weight oise 622 Ibs dry Speed sie roi erapr ENT EETA 12 14 MPH governed Curb to Curb Clearance Circle 176 Braking Distance 14 at 12 MPH Engine asie eo his tes 4 cycle 341 cc 8 5 hp single cylinder air cooled Carburetor Float bowl with fixed jets and impulse fuel pump Governor ane Internally geared in transmission Ignition2. TT cesse al CDI electronic ignition Drive Unit TRPE Double reduction helical gear with 12 64 to 1 final ratio Transmission s soso uvre E Forward reverse and neutral fully py ekonized SLGGHAG shiek ook ore ete self adjusting rack and pinion SUSPENSION sive nee ceed Front and rear tapered mono leaf springs with dual hydraulic shock absorbers Torque Converter Automatic variable speed dry type Frame Chassis Twin l Beam welded aluminum Rear Body sisi sites esse Fiber reinforced plastic compression molded Front Body Reaction injection molded plastic Paint sister tereo es o a WO part epoxy synthetic enamel Seating Capacity oe ee ee 2 persons Electrical System 12 volt 325 cold cranking amp banery and 35 amp charging capacity starter generator Brakas cspern h aa ss Mechanical brake cable system to individual drum brakes on each rear wheel Park brake is automatically released MNCS societal D DL 18 00 x 8 50 8 00 tubeless 4 ply rated PUG TAK sides aera woes eka were 7 4 gal U S regular or unleaded Standard Equipment Rack and Pinion Steering Ball Holder Beverage Holders Dual Dash Compartments Scorecard and Pencil Holder Reverse Warning Buzzer Wear Resistant Floormats and Pedals Front and Rear Bumpers Side Rubber Rails Two Way Ignition Key Automatic Release Park Brake Quick Release Bag Strap Buc
3. cam out approximately of an inch and rotate it one half turn until it snaps back into place See Figure 5 Forward OPERATE Position Neutral Figure 5 With cam in SERVICE position car may move suddenly if forward and reverse lever is shifted or accidentally bumped while engine is running Block front and rear wheels to prevent vehicle movement NOTE If car will not run check to be sure neutral lock out cam is in OPERATE position Accelerator Pedal The accelerator pedal is the pedal on the right with the word GO molded in it See Figure 6 When the key switch is on and the shift lever is in either forward or reverse and the accelerator pedal is pushed the parking brake will be automatically released and the engine will start As the pedal is pushed further the engine speeds up and the car will begin to move in the preselected direction forward or reverse Push the accelerator pedal further to increase vehicle speed When the accelerator pedal is released the engine will stop running NOTE For safety the DS Gasoline car is equipped with a governor to control the maximum speed and is set for 12 14 MPH on a level surface The accelerator pedal differs from that of an automobile in the following way Depressing the accelerator will release the parking brake if engaged Depressing the accelerator automatically starts the vehicle moving Each time the accelerator pedal is released the en
4. car With your choice of the CLUB CAR Model DS Gasoline golf car as your personal or fleet vehicle you have joined a select group of discriminating owners who look for the very best and who have shown their concern for safety efficiency and long term lasting value This owner s manual is designed to instruct you or anyone you may rent or loan the golf car to in the safe operation of the CLUB CAR DS Gasoline golf car In addition this manual will acquaint you with the Nora Boe maintenance required in order to provide you safe optimum vehicle performance If any repairs or service need to be performed there are certain basic mechanical that should be known and understood Without such basic knowledge repairs or service to this golf car may render the golf car unsafe which could result in severe personal injury or death For this reason we advise that all repairs and service be performed by an authorized CLUB CAR Distributor Dealer or representative except as specified in the Periodic Service Schedule Should you require further information please contact your nearest CLUB CAR Distributor Dealer who can provide you with technical advice service parts or the CLUB CAR DS Gasoline Golf Car Maintenance and Service Manual For the name and address of your nearest CLUB CAR Distributor Dealer contact CLUB CAR INC P O Box 4658 Augusta Georgia 30917 4658 U S A Telephone 404 863 3000 The Club Car Limited Warranty appears on the insid
5. light above the steering column See Figure 10 When the oil light is on it indicates low engine oil Oil should be added before further use The car should never be driven if the oil light comes on and stays on If the oil light goes on and off you may proceed but add oil at the first opportunity lf the oil level is correct and light stays on have a trained and experienced mechanic check the car Driving Instructions No one should drive the golf car without first being instructed in the proper operation and use of the golf car controls An experienced operator should accompany each first time driver on a short test drive before they operate the golf car alone Only licensed drivers should be allowed to drive this vehicle Do not drive under the influence of alcohol drugs or medications if renting or loaning this golf car make sure the driver is familiar with all controls and operating procedures before allowing the car to be driven This car is not specially equipped for handicapped persons Be sure all er ere persons can properly operate the car prior to allowing them to drive To insure safe operation of the DS Gasoline golf car follow all of the procedures listed below exactly and in order Read and understand all instructions prior to driving the car Starting the Car CO OO O U1 WD Enter the car Be sure everyone is seated Study and understand controls Read safety warnings located abov
6. to avoid unintentional starting of the vehicle 1 Store in a cool place This will prevent self discharge of the battery lf the battery appears to be weak have it charged by a trained mechanic Batteries in low state of charge will freeze at low temperatures Do not attempt to charge a battery if it is frozen or the case is bulged Discard battery Frozen batteries can explode 2 Using a siphon with a suction device See Figure 71 drain all of the gas out of the tank into an approved gasoline container Never attempt to siphon gasoline using a hose without a built in suction device Never attempt to siphon gasoline using your mouth 10 Gasoline Flammable Explosive Do Not Smoke Keep sparks and flames away from area of cars Do not attempt to drain gasoline while engine is running or hot Store gasoline only in an approved gasoline container in a well ventilated area Keep out of reach of children Keep sparks fire and flames away from area of gasoline Engines produce carbon monoxide which ts an odorless deadly poison DO NOT OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION 3 Be sure the tank has been drained and the stored gasoline has been removed from the area Place the forward and reverse lever in neutral Place neutral lock out cam in the SERVICE position Turn key on Run the engine until all of the gasoline has been drawn out of the fuel lines and carbure
7. your CLUB CAR Distributor Dealer However when receiving your new CLUB CAR s you should become familiar with its controls and operation and carefully inspect each car to be satisfied with its condition before accepting delivery Only trained people should repair or service this car Everyone doing even simple repairs or service should follow the correct procedures and obey the warnings listed in this manual as well as the maintenance and service manual Always wear safety glasses or eye protection when servicing the car Use this checklist as a guide to inspect your car Any problems must be corrected only by your CLUB CAR Distributor Dealer or a trained mechanic Visual Inspection Look for the following on your vehicle General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight All hose clamps should be tight Check the starter belt for tightness Warning Labels Check that all warning and operation labels are in place See Pages 2 amp 3 Tires Check tire pressure It should be 12 14 psi Engine Check for proper engine oil level See Page 12 Be sure spark plug wire is in clamp on top of engine Fuel Check fuel level See Fueling Instructions Page 5 Be sure the plastic has been removed from the bottom of the seat before operating vehicle Failure to do so may result in a fire or property damage Performance Inspection After you ha
8. Ce 1990 DS Gasoline Golf Car Owners Manual Manual Number 1015439 Effective August 1 1989 0889A00000 WARNING This instruction manual should be read completely and carefully before attempting to drive or service this car Failure to follow the instructions in this manual could result in severe personal injury or death NOTE If this vehicle is equipped as a Fairway Villager four passenger vehicle supplements to this manual are required If this information does not accompany this manual contact CLUB CAR INC Customer Service and request the Fairway Villager supplement Safety Details It is important to note that some statements throughout this manual are preceded by the words DANGER WARNING CAUTION or NOTE We recommend that you take special notice of these safety procedures for your protection Safety procedures are essential and must be followed SRSA 44474 4444 NE NS A danger indicates an immediate hazard which will result in severe personal injury or death WARNING A warning indicates an immediate hazard which could result in severe personal injury or death A caution indicates hazards or unsafe practices which could result in minor personal injury or product or property damage NOTE A note provides key information to make procedures easier or clearer The safety procedures listed below must be followed whenever the car is being repaired or senviced Other specific warnings appear OMON this m
9. E ee TT CA Club Car Inc P O Box 4658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR INC 1989
10. EL PRACTICE GOLF ETIQUETTE e Observe club rules e Drive on golf car paths when possible e Keep proper distance from greens e Replace divots e Repair ball marks on greens Rake sand traps e Allow faster players to play through e Help speed up play e Dispose of litter properly Club Car oid USA ON OFF LABEL UNDER KEY SWITCH SERIAL NUMBER MOVING PARTS WARNING LABEL UNDER DOOR A N WARNING ACCELERATOR PEDAL ACCESS DOOR SAFETY WARNING LABEL or Read Operating instructions Before e Do Not Use On Public Roads R WANING MC ETC y AS Settee Bat que ony toe Ar ee me n r ehicle Opera cie From rs Side Vehicle Should Be Driven Only in Specified Do Not Start Vehicle Until AR People Ate j Stop Vanica Sores Chs mgng Direction Seated Drive Slowly in Turns Instructions Can Cause ean Areas By Trained Persons DO NOT screwoil gauge in when IN checking oil a GOVERNOR WARNING Ee i a Ne FILL LABEL UNDER FUEL CAP _ Low Oil Mark SS Governoris Factory Adjusted for 14 mph Max Do Not Tamper With Adjustment to increase speed above 1 mph To do 50 1 will void the warranty 2 may result in damage to the engine or com ponents 3 could resultin severe personal injury Ol L LEVE DECAL BATTERY DANGER LABEL ON FRAME GASOLINE TANK Gasoline Extremely Flammable a Keep Heat Sparks A
11. Lube Annually by Trained 8 Inspect front wheel bearings Chassis Lube Personnel Only and repack as necessary 9 Change engine oil SAE 10 40 20 40 10 50 20 50 API Classification SF or SE Engine Oil Engine oil level should be checked at least monthly The oil light on DO NOT i gauge in when checking the dash should warn you if your oil is getting low See Figure 13 9 amp Se n CS recite te Se IEE MERI BA OSS ST Engine must be in level position Remove oil level gauge by unscrewing from crankcase Check oil by inserting gauge into oil filler hole Do not screw oil gauge in when checking If otl does not reach the upper line mark of the gauge add oil until it does Do not overfill with oil When oil is at proper level screw oil gauge in and hand tighten securely Figure 13 13 Capacities Engine Crankcase 40 oz Transmission 20 oz Drive Unit 22 oz Gasoline Tank 7 4 U S Gal Tire Pressure 12 14 psi Battery Always wear safety glasses or eye protection when servicing the car Always use insulated tools when working around batteries or electrical connections oy ws N ARRAN ANAS SAAS Battery Explosive Gases Keep sparks flames cigarettes away Ventilate when charging in an enclosed space Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call physician i
12. anual WARNING Only trained people should repair or service this car Everyone doing even simple repairs or service should follow the correct procedures and obey the warnings listed in this manual as well as the maintenance and service manual Always wear safety glasses or eye protection when servicing the car Always use insulated tools when working around batteries or electrical connections Improper use of this vehicle or the failure to maintain it could result in eee vehicle performance or severe personal i injury Any modification or change to the vehicle which affects the stability or increases the speed beyond the factory specifications could result in severe personal i injury or death A N N N N NAAN NAN SN NS 44447 Gasoline Battery Vapors Flammable Explosive Do not smoke Keep sparks and flames away from the area of the car Only service in well ventilated area Engines produce carbon monoxide which is an odorless deadly poison DO NOT OPERATE Li AN ENCLOSED AREA WITHOUT PROPER VENTILATION lf any of the warning labels become damaged have been removed or cannot be easily read they should be replaced immediately Contact your CLUB CAR Distributor Dealer TABLE OF CONTENTS Page Safety Details SNS Cibo a Woe TT Rd Inside Front Cover Foreword sis sis dre ns dede ele ide de Toute ee nr due EEEE E ou CT Vehicle Feature Identification ee rare eer E eee sn Na ou
13. contained herein This limited warranty covers materials and workmanship for a period of two 2 years from the date of purchase and repair labor costs for a period of one 1 year from the date of purchase Such labor shall be performed only by Manufacturer its authorized distributors or dealers or a service agency approved by Manufacturer IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PROOF OF DATE OF PURCHASE MUST BE PROVIDED WITH ANY WARRANTY CLAIM For further information or to present a warranty claim contact Warranty Administrator CLUB CAR INC P O Box 4658 Augusta Georgia 30917 4658 USA 404 863 3000 ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED SUBSEQUENT TO TWO 2 YEARS FROM THE DATE OF PURCHASE THE REPLACEMENT OR REPAIR OF THE GOLF CAR OR DEFECTIVE COMPONENT THEREOF IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY MANUFACTURER MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF MANUFACTURER HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS LIMITED WARRANTY LIMITED WARRANTY EXCLUSIONS Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusions Manufacturer does not warrant that its golf car is suitable for us
14. e back cover of this manual No other warranties express or implied are contained herein Your Distributor Dealer has checked your carg prior to SENTE to yeu and will provide you with a completed warranty registration card CLUB CAR INC shall not be tiable for errors contained herein or for incidental or aneda damages which result from the use of the material in this manual This manual should be considered a permanent part of this vehicle It should stay with the de when sold to provide the next owner with important operating safety and maintenance information 1 _ Vehicle Feature OPERATING INSTRUCTIONS LABEL BRAKE PEDAL OPERATING INSTRUCTIONS a Study And Understand Controls Be Sure Everyone ls Seated Before Driving Car Read Safety Warnings Located Above Pedals Make Sure Wheels Are Turned In Desired Direction e Be Sure Nothing Is in Yaur Path Tarn Key To ON Position Select Direction By Placing Shift Lever In Oesired Position F Forward N Neutral AR Reverse Slowly Push Accelerator Pedal Yo increase Speed Park Brake Will Release When Accelerator Pedal is Pushed e To Stop Car Release Accelerator Pedal and Push Brake Pedal After Stopping Car Firmly Push Park Brake Until It Locks Remove Key And Place Shift Lever In The Straight Up Neutral Position When Car Is Not In Use e For Further Detalis Read Owner s Manual OIL WARNING LIGHT GOLF ETIQUETTE LAB
15. e on any particular golf course or terrain As in the operation of any vehicle a prudent driver will read and study the Owner s Manual learn the proper operation of the controls and exercise care and safe driving habits THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO a Normal maintenance services such as brake adjustments steering and suspension adjustments linkage adjustments recommended lubrication oil changes and filter replacements b All accessory options bag straps battery wires and connectors body panels and trim pieces charger plugs and receptacles decals drive and generator belts filters floormats oils and lubricants pedal pads seats spark plugs fuses tubes and hoses and c Tires batteries and battery chargers Warranted solely through their respective manufacturers Any warranty service which includes labor must be performed by Manufacturer its authorized distributors or dealers or a service agency approved by manufacturer THIS GOLF CARIS INTENDED TO BE USED BY PERSONS PLAYING GOLF WITHIN THE CONFINES OF A GOLF COURSE AND ANY OTHER USE RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME ARE HEREBY EXCLUDED ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE LOSS OF REVENUE LOSS OF TIME OR INCONVENIENCE Some states do not allow limitations on how long an impl
16. e pedals Make sure wheels are turned in desired direction Be sure nothing is in your path Turn key to on position Select direction by placing shift lever in desired position F forward or R reverse Slowly push accelerator pedal The park brake peda will release and the engine will start Push accelerator further and the car will move and the speed will increase as the accelerator is depressed until governed speed is reached No more than two people should be on the vehicle at one time Stop car before shifting forward and reverse lever Failure to do so could result in injury to an unsuspecting passenger and damage to the golf car A buzzer will sound as a warning when the car is In reverse When Driving The Car Operate the car from the driver s seat only Remain seated in moving car and hold on to prevent falls e Keep arms legs feet and entire body inside car to prevent getting them caught between the golf car and the ground or other objects e Drive slowly in turns and drive slowly straight up and down slopes to prevent turning the vehicle over e Reduce speed for poor driving conditions such as wet grass or rough terrain to avoid losing control of the car e Do not use on public roads This car is not designed or intended for street use and should not be licensed for use on public roads Obey all local rules concerning golf cars Cars should be driven only in specified areas b
17. eee ses tree 20 Model Identification err ee ree eee ee ee ee ee ee 4 Safety Committee une ee ce Ac ea Dire ee ss A Pre Operation Checklist Rd T de eee oc 5 a ss FUCTING Instructions sine lauederdestrcertenreneshad reset dires horse sorssssessssse D COMO Si il ne Marine tr eae KORA coneveresssesesssrsesssrerses 6 Drivingiinstructions nie ennemi xcunsambaes cae on a do ed Nue 8 Towing and Transporting oe EE EEE eres E EEEN EEEE 9 Storage io nn ne ce ce 10 Maintenance a erck RTS athe ican Se eee E T A E ensrsssesses 11 Lubrication Chart To berit ie ee ee a RP ee er E Engine Oil Level eo ee tata Ni id d dia one di ee ne ee era Capacities cceeseeeee co OEE SEPELE E EAE AE EP EAE A EEE EES 14 Battery oc cece cece cece eee eee renee eee acer ssessessee sensor Mises 14 Jump Starting sceccceeeeece pegs ie A Satta are A od ard See CT CO ree re Cleaning ore Ne Setar or oi eo set aa iota ats OT Te ee eT ay e Subsequent Owner Registration i ee jossustessse 10 Specifications eee e ere oe rss Re E de trot 10 Warranty e 0 4 0 eae EE E e e 00e 0e te 0 0e 8 denesesereses e Inside Back Cover Foreword Congratulations for having chosen the finest golf car on the market today Over 25 years of the most advanced development engineering and field experience known to this industry has gone into the manufacture of your golf
18. et and exhaust header pipe flange connection gasket Check starter generator belt tension Check condition of muffler inspect drive belt Do semi annual lubrication as shown in lubrication chart on Page 12 Check all daily weekly monthly and quarterly items listed above Annual Service by Trained Replace fuel filters Personnel Only Inspect starter generator brush length Every 200 Rounds or Inspect clean and regap spark plug every 100 hours of Do annual lubrication as shown in lubrication chart on page 12 operation Check all items listed above If your periodic service inspection reveals any problems do not operate until repairs are made Failure to make necessary repairs could resuit in fire severe Eee injury or death Periodic Lubrication Schedule and Lubrication Chart Regular Interval Service Recommended Lubricant Quarterly by 1 Brake shaft bearing Dry Graphite Lube Owner or CLUB CAR part 1012151 Trained Personnel 2 Brake linkage and pivots Dry Graphite Lube CLUB CAR part 1012151 3 Accelerator push rod pivots Dry Graphite Lube CLUB CAR part 1012151 4 Throttle and governor pivots Dry Graphite Lube CLUB CAR part 1012151 5 Front suspension 9 fittings Chassis Lube Semi Annually by 6 Check fill drive unit to plug 80 90 WT API Class GL 3 or 80 90 WT Trained Personnel level AGMA Class 5 EP Gear Lube Only 7 Check fill transmission to plug 80 90 WT API Class GL 3 or 80 90 WT level AGMA Class 5 EP Gear
19. ever lean over the battery when making connections 14 Place forward and reverse lever in neutral position place neutral lock out cam in the peer position To connect the jumper cables follow these steps exactly and in order See Figure 16 1 Connect one end of red jumper cable to positive terminal of the stalled battery 2 Connect other end of red jumper cable to positive terminal of booster battery 3 Connect one end of black jumper cable to negative terminal of booster battery 4 Connect other end of black jumper cable to stalled car rame away from gasoline and battery as in Figure 15 To remove the cables reverse the above procedures ekari Figure 15 RED JUMPER CABLE TO STARTER SWITCH TO STARTER SWITCH POSITIVE TO POSITIVE ae BOOSTER STALLED STARTER CAR BATTERY BATTERY TO GROUND 7 nn BLACKJUMPER Se TO GROUND CABLE CAR FRAME oa NEGATIVE POST ON fk BOOSTER BATTERYTO STEP4 CAR FRAME Figure 16 Cleaning The CLUB CAR is equipped with a reaction injection molded plastic cow and a compression molded fiber reinforced plastic body Use only mild dishwashing liquid soap with a sponge or soft cloth for nara cleaning Minor scratches or blemishes in the body can be buffed out using most commercially available polishing ge T compounds and polishes Your golf car seat will last longer with proper cleaning
20. gine will quit running Do not tamper with the car s governor To do so will void the limited warranty result in damage to engine and other components and could result in severe personal injury due to unsafe speeds Brake Pedal The brake pedal is the large pedal on the left with the word STOP molded in it See Figure 7 To slow or stop the car push the brake l pegal with your right foot Parking Brake Pedal The parking or park brake pedal is the small raised portion in the upper left corner of the brake peda with the word PARK molded in it See Figure 7 The words Park Brake are marked above this pedal To set the park brake push the brake pedal firmly and tilt the park brake portion of the peda forward with foot See Figure 8 The park brake pedal will release when the accelerator or brake pedal is pushed The parking brake has many locking teeth so that the brake can be locked in several positions Figure 6 Figure 7 Figure 8 Always set the park brake firmly before leaving the golf car to prevent the car from rolling Choke The choke is located below and to the left of the driver s left knee on the seat support panel See Figure 9 If on a cool morning the car is hard to start simply push in the choke cover with your left hand to activate the choke Release the choke after the engine starts and runs smoothly Oil Light The DS Gasoline golf car is equipped with a dash mounted oil
21. ied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you WARRANTY LIMITATIONS Manufacturer s liability shall be at tts sole option to either replace or repair a defective golf car or component thereof Replacement shall mean furnishing a new golf car or component thereof which ts identical or reasonably equivalent to the warranted product at no cost to purchaser during the two 2 year limited warranty period except for repair labor costs after the first year Repair shall mean remedying a defect in the golf car or component thereof at no cost to purchaser during the two 2 year limited warranty period except for repair labor costs after the first year If Manufacturer elects to repair your golf car it may use factory reconditioned parts or components Damage to a vehicle or component thereof not resulting from a defect or which occurs due to unreasonable or unintended use overloading abuse or neglect including failure to provide reasonable or necessary maintenance as outlined in the Owner s Manual accident or alteration including increasing the speed beyond factory specifications or modifications which affect the stability of the vehicle or the operation thereof is excluded from the limited warranty This warranty gives you specific legal rights and you may also have other rights which vary from state to state Sa E a SN Ee BE ON ee Oe RE Re Ne Ny Ee Oe
22. is the least expensive maintenance requirement Preventive mainte nance means regularly scheduled services which include certain maintenance procedures that are performed on the cars even though the cars are functional A good preventive maintenance program can prevent more expensive repairs from being required Any car that is not Hnssenns correctly should be removed from use until it is properly repaired Contact your local CLUB CAR Distributor Dealer to perform all repairs and the semi annual and annual periodic service WARNING Only trained people should repair or service this car Everyone doing even simple repairs or service should follow the correct procedures and obey the warnings listed in this manual as well as the maintenance and service manual Turn key switch off remove key and place forward and reverse lever in neutral position prior to servicing Always wear safety glasses or eye protection when servicing this car 11 Moving parts Do not attempt to service the car with engine running Hot Do not attempt to service hot engine or exhaust system Can cause extreme burns Remove spark plug wire to avoid unintentional starting of engine when servicing car Do not wear loose clothing and remove jewelry such as rings watches chains etc before servicing vehicle Always use insulated tools when working around batteries or electrical connections Periodic Service Schedule Regular Interval Se
23. kles CDI Electronic Ignition System Synchromesh Transmission with Forward Reverse and Neutral 12 volt 325 Cold Cranking Amp Battery Neutral Lock Out Low Oi Level Warning Light Fresh Air Intake System Optional Equipment Canopy Top Snap On Tinted Windshield Weatherproof Enclosure Extra Two Bag Attachment Sweater Basket Rake Holder and Rake Bagwell Protector Adjustable Seat Back Wheel Covers Power Rib Tires Extra Traction Tires White Wall Tires Club Insignia I D Numbers Accent Stripe Custom Colors Stereo Radio Ashtray Lighting Package High Low Headlights Taillights Brakelights and Horn Lighting Package with Turn Signals Fuel Gauge Hour Meter Sand Bottle Kit Woodgrain Trim ice Cooler Info Holder Tee Holder Extra Beverage Holders 2 or 4 Trailer Hitch Rear View Mirror Permanent Tow Bar for multiple car towing ES installation Temporary Tow Bar iu single car towing CLUB CAR INC reserves the right to change specifications and designs at any time without notice and without incurring any obligation or liability whatsoever 16 A EE OTE AE CLUB CAR LIMITED TWO 2 YEAR WARRANTY CLUB CAR INC Manufacturer warrants to the original retail purchaser that its new DS Golf Car purchased from Manufacturer or an authorized distributor or dealer is free from defects in materials and workmanship for a period of two 2 years from the date of purchase subject to the terms and provisions
24. le engine is hot or running To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded lf pump is not grounded the vehicle must be grounded to the pump before and during the fueling operation 1 Lift and remove seat bottom 2 Fuel tank is located on passenger side of car Remove fuel cap and fill the fuel tank with regular or unleaded gasoline Do not use gasohol or gasolines with methyl alcohol blends NAAN SANNA Be sure to clean up any spilled gas before operating vehicle 3 Replace fuel cap on tank being sure cap is tightly sealed to tank 4 Replace seat bottom Controls lf renting or loaning this car make sure that the driver is familiar with all controls and operating instructions before aliowing the car to be driven Key Switch The key switch is mounted on the dash to the right of the steering column See Figure 2 It has two 2 positions on and off which are clearly labeled Remove key in the off position only Turn key switch to off and remove key when car is not in use to avoid unintentional starting of the car Forward Reverse Control The forward reverse shift lever is located below and to the right of the driver s right knee on the seat support panel See Figure 3 The lever has three 3 distinct positions F forward N neutral and R reverse Rotate the lever toward the driver F to r
25. le with tow hitch height of 11 inches should be used Only heavy duty tow bars should be used for multi car towing Never tow more than five 5 cars at one time Do not allow people in cars being towed Avoid sudden starts stops and tight turns Turn key switch off and place shift lever in neutral when car is in tow Transporting On A Trailer If your golf car must be transported over long distances or on public highways it houle be done on an approved trailer observing all the following warnings and precautions Fort use on te roads the trailer must meet all federal state and local requirements such as taillights brake lights etc Always use an approved trailer that has a load rating of 1200 Ibs per golf car Example A 2 car trailer should be rated at 2 x 1200 2400 Ibs The golf car should be securely tied down to the trailer The golf car s key switch should be off the shift lever in neutral and the park brake firmly applied and locked When towing a trailer normal speeds should be reduced and care should be used when turning a corner due to the added length of the trailer Never tow a golf car behind a passenger vehicle or truck unless it is on an approved trailer Remove the windshield before transporting a golf car on a trailer Storage To prepare your golf car for extended off season storage Turn key switch off remove key and place forward and reverse lever in neutral position
26. mmediately Internal Drink large quantities of milk or water follow with milk of magnesia or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes Call physician immediately The battery in the DS Gasoline is a 12 volt maintenance free battery that does not require periodic watering of the battery See Figure 14 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water Rinse Be sure terminals are tight Let the terminals dry and then spray them with CLUB CAR battery protector spray part 1014305 Be sure battery holddowns are properly tightened Torque to 9 14 in lbs A loose holddown may allow the battery to become damaged from vibration or jarring A holddown that is too tight may buckle or crack the battery case If battery appears weak have it charged by a trained mechanic Jump Starting The Engine Figure 14 To start a car with a dead battery use another battery of the same voltage and proper jumper cables Always wear safety glasses or eye protection when servicing the car Procedures other than those which follow could cause severe injury or death from battery acid spray explosion or charging system overload Never connect to the negative post of the Dead battery connect to frame See Figure 15 Never allow the two cars to touch each other Never allow the jumper cable clamps to touch each other N
27. nd Open Flames Away From Fuel Tank And Fuel Lines DoNot Add Fuel While Engine s Running Or Hot a Service By Trained Personnel FRAME GROUND WARNING LABEL ON FRAME Negative Frame Ground Do Not Contact Positive Battery Post Or Cable To Frame As This Con Cause Battery Explosion Electrical Shocks And Burns FORWARD REVERSE je LEVER i NEUTRAL LOCK OUT CAM Model identification The serial number of your CLUB CAR is stamped on a data plate mounted on the frame directly under the right dash Example AG9005 123456 NOTE Always mention this number when ordering parts or making inquiries See Figure 1 Safety Committee lf the golf car is going 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 includes such things as where the golf cars should be driven who should and who should not drive the golf cars instructing all first time drivers in the controls and operation of the golf car seeing that the golf cars are well maintained in safe driving condition and how the various rules are to be enforced The safety committee should include all these items at a minimum and such 4 B others as the committee feels necessary or appropriate Figure 1 Pre Operation Checklist Your CLUB CAR has been thoroughly inspected and adjusted by the factory and by
28. rvice Daily Service by Owner Check steering and linkages Check brake operation Check to be sure all warning labels are in place see Pages 2 and 3 Check tires for wear and damage Check engine for proper operation Check accelerator governor linkage for free movement and return Check reverse warning buzzer for proper operation Check engine air intake screen to be sure it is not clogged Check to be sure park brake latches and releases properly Weekly Service by Owner Check speed of vehicle Clean battery terminals and wash dirt off battery case Wash engine and underside of car Check all electrical wires and grounds for tightness or damage Inspect car for loose hardware and tighten as required Check all daily items listed above Monthly Service by Owner Check exhaust system for leaks Check brake pedal play Check tire pressure and adjust to 12 14 psi Check air intake expansion chamber for leaks Check engine oil level Check fuel tank lines cap pump and carburetor for fuel leakage Check all daily and weekly items listed above Quarterly Service by Owner Do quarterly lubrication as shown in lubrication chart on Page 12 or Trained Personnel Check all daily weekly and monthly items listed above Semi Annual Service by Check clean and adjust brakes Trained Personnel Only Check front wheel alignment Every 100 Rounds or Check air filter every 50 hours of Check spark plug wire and boot for damage and proper routing operation Check head gask
29. tor and engine stalls Return neutral lock out cam to the OPERATE position Turn the key switch to the off position and remove key 4 To protect the engine remove the spark plug and pour ounce of SAE 10 weight oil into the engine through the spark plug hole Rotate the engine several times and then reinstall the spark plug NOTE When restarting engine it may smoke excessively due to the oi added in step 4 Increase the tire pressure to 20 psi Grease front suspension and do all quarterly periodic lubrication shown in lubrication chart See Page 12 Thoroughly clean body seats and underside of car ON OG Do not latch the park brake Block the wheels to prevent the car from rolling To Return Stored Cars To Service 1 Fill the gas tank with regular or unleaded gasoline See Fueling Instructions Page 5 NN NSSS N DANGER AAN NS AANA SAAN Gasoline ae Flammable Explosive No Smoking Keep sparks and flames from the area of the car Only service or repair in well ventilated area Never pour gasoline into tank while engine is hot or running Do not overfill Be sure to clean up any spilled gas before operating vehicle JILE 2 Readjust tire pressure to 12 14 psi 3 Perform the pre operation checks See Page 4 before returning the car to service Maintenance General Information To be sure you have a trouble free car it is very important to follow an established preventive maintenance program This
30. un the car in forward and toward the passenger R to run the car in reverse When the lever is in the straight up or neutral N position the car will not run and the engine will stop if shifted to this position while running Do not shift forward and reverse lever while car is in motion Always bring car to a full stop before shifting lever to avoid injury to an unsuspecting passenger and damage to the car Turn key switch off and place shift lever in neutral when leaving car to avoid unintentional starting of the car Buzzer will sound as a warning when car is in reverse Neutral Forward SERVICE Position Neutral Lock Out The golf car has a neutral lock out circuit that prevents the driver from starting the car in neutral If the car is started in forward or reverse and shifted to neutral the engine stops running Figure 4 For the convenience of the trained and experienced mechanic there is a neutral fock out cam located on the back of the forward and reverse lever lf the neutral lock out cam is pulled out approximately of an inch and rotated one half turn until it snaps into place the cam will be in the SERVICE position See Figure 4 This will allow the mechanic to run the car in neutral for certain maintenance procedures With the cam in this position the car will not run if the forward and reverse lever is placed in the forward or reverse positions To put the car back into the OPERATE position pull the
31. ve familiarized yourself with the car s controls See Page 5 and have read and understood the driving instructions See Page 7 take the car for a short test drive Check the following Brakes Be sure that the brakes work properly Both rear wheels should brake properly and the pedal should not go more than halfway to the floor If it does have brakes adjusted Park Brake The park brake should fock the wheels when latched and should release when the accelerator or brake pedal is pushed Steering The car should be easy to steer and should not have free play in the steering wheel Accelerator Pedal As the accelerator pedal is pushed the engine should start and the car should come smoothly up to full speed When the pedal is released it should return to the original position and the engine should stop gradually Governor Check the speed of the car It should run 12 14 MPH on a level surface General Listen for any unusual noises such as squeaks or rattles Check the car s ride and performance Have a trained mechanic investigate anything unusual Any modification or change to the vehicle which affects the stability or increases the speed beyond the factory specifications could result in severe personal injury or death Fueling Instructions PRS GASOLINE FLAMMABLE EXPLOSIVE NO SMOKING Keep sparks and flames from the area of the car Only service or repair in well ventilated area Never pour gasoline into tank whi
32. y trained people Stopping the Car 1 To stop the car release the accelerator pedal and push the brake pedal with your right foot Driving through deep water may affect the brakes Check their effectiveness by pressing the brake pedal gently If the car does not slow down at the normal rate continue to apply the brakes gently until they dry out and normal performance returns Parking and Leaving the Car 1 After stopping the car firmly push park brake pedal until it locks This will prevent the car from rolling 2 Turn the key to off and place shift lever in the straight up neutral position when leaving the car This avoids unintentional starting of car Remove key when car is not in use To avoid being struck by vehicle do not stand in front of or behind vehicle Towing and Transporting Towing All CLUB CARS are equipped with tow bar attaching points both front and rear For breakdown towing and single car towing a light duty tow bar is available For multi car towing a heavy duty tow bar is available Observe all of the following warnings and precautions when towing Never tow a golf car on public streets or highways Use only approved CLUB CAR tow bars Extreme caution should be used when towing any golf car Do not exceed five 5 miles per hour towing speed Do not tow more than one 1 car with another CLUB CAR if more than one car must be towed a properly fitted vehic
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