2003 Club Car DS Golf Cars (Gasoline/Electric) Maintenance Service Manual (incl. FE290)

Club Car MANUAL NUMBER 102318801 EDITION CODE 1202C0312B DS GOLF CARS GASOLINE/ELECTRIC 2003 MAINTENANCE SERVICE MANUAL

2003 DS Golf Car Maintenance and Service Manual Page i FOREWORD Club Car vehicles are designed and built to provide the ultimate in performance efﬁciency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation. This manual provides detailed information for the maintenance and repair of DS Golf Cars, and should be used in conjunction with the appropriate maintenance and service supplement. If you do not have the appropriate maintenance and service supplement, you may order one from your local Club Car representative. Maintenance and service supplements available include: This manual and corresponding maintenance and service supplement should be thoroughly reviewed prior to servicing the vehicle. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded. This manual was written for the trained technician who already has knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efﬁcient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support. This manual, used in conjunction with the appropriate maintenance and service supplement, covers all aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car Tech- nical Service Representative at (706) 863-3000, extension 3580. 2003 PowerDrive System 48 Vehicle Maintenance & Service Supplement Publication Part No. 102318805 2003 V-Glide 36-Volt Vehicle Maintenance & Service Supplement Publication Part No. 102318804 2003 FE290 Gasoline Vehicle Maintenance & Service Supplement Publication Part No. 102318807 2003 IQ System Vehicle Maintenance and Service Supplement Publication Part No. 102318806 Copyright © 2002, 2012 Club Car, Inc. Club Car, ArmorFlex, PowerDrive, and Tranquility are registered trademarks of Club Car Inc. This manual effective July 24, 2002.

Page ii 2003 DS Golf Car Maintenance and Service Manual ∆ WARNING • Read Section 1 – Safety before attempting any service on the vehicle. • Before servicing vehicle, read complete section(s) and any referenced information that may be relevant to the service or repair to be performed. NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all Club Car distributors and dealers and will, when applicable, appear in future editions of this manual. Club Car, Inc. reserves the right to change specifications and designs at any time without notice and without the obligation of making changes to units previously sold. There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658, USA, Attention: Warranty Administration.

2003 DS Golf Car Maintenance and Service Manual Page iii CONTENTS SECTION 1 – SAFETY General Warning ................................................................................................................................ 1-1 SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification ............................................................................................................... 3-1 Safety Committee .............................................................................................................................. 3-2 Storage – Gasoline Vehicle ............................................................................................................... 3-2 Preparing the Gasoline Vehicle for Extended Off-Season Storage ............................................... 3-3 Returning the Stored Gasoline Vehicle to Service ......................................................................... 3-4 Storage – Electric Vehicle .................................................................................................................. 3-5 Preparing the Electric Vehicle for Extended Off-Season Storage ................................................. 3-5 Returning the Stored Electric Vehicle to Service ........................................................................... 3-6 SECTION 4 – BODY AND TRIM Cleaning the Vehicle .......................................................................................................................... 4-1 Seat ............................................................................................................................................... 4-1 Front and Rear Body Repair .............................................................................................................. 4-2 Stress Lines or Streaks .................................................................................................................. 4-2 Minor Impact Damage/Deformations ............................................................................................. 4-2 Minor Scratches and Surface Blemishes ....................................................................................... 4-2 Small Scratches That Cannot Be Buffed Out ................................................................................ 4-2 Gouges, Punctures, Tears, Large Scratches, and Abrasions ........................................................ 4-3 Touch-up Paint Color Chart ........................................................................................................... 4-3 Canopy .............................................................................................................................................. 4-3 Canopy removal ............................................................................................................................. 4-3 canopy installation ......................................................................................................................... 4-5 Front Body ......................................................................................................................................... 4-5 Front Body Removal ...................................................................................................................... 4-5 Front Body Installation ................................................................................................................... 4-5 Rear Body .......................................................................................................................................... 4-7 Rear Body Removal ....................................................................................................................... 4-7 Rear Body Installation .................................................................................................................... 4-9

Page iv 2003 DS Golf Car Maintenance and Service Manual Floor Mat ............................................................................................................................................ 4-10 Floor Mat Removal ......................................................................................................................... 4-10 Floor Mat Installation ...................................................................................................................... 4-10 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP Throttle Input device identification ...................................................................................................... 5-1 Brake Pedal and Park Brake .............................................................................................................. 5-1 Brake Pedal Removal .................................................................................................................... 5-1 Brake Pedal Installation ................................................................................................................. 5-2 Park Brake Removal ...................................................................................................................... 5-4 Park Brake Installation ................................................................................................................... 5-5 Accelerator Pedal – Gasoline and Electric V-Glide Vehicles .............................................................. 5-6 Accelerator Pedal Removal ............................................................................................................ 5-6 Accelerator Pedal Installation ......................................................................................................... 5-8 Accelerator Pedal – Electric MCOR Vehicles .................................................................................... 5-9 Accelerator Pedal Removal ............................................................................................................ 5-9 Accelerator Pedal Installation ......................................................................................................... 5-11 Pedal Group Adjustment – Gasoline Vehicle ...................................................................................... 5-12 Pedal Group Adjustment – Electric MCOR Vehicles .......................................................................... 5-17 Pedal Group Adjustment – Electric V-Glide Vehicles.......................................................................... 5-21 SECTION 6 – WHEEL BRAKE ASSEMBLIES General Information ........................................................................................................................... 6-1 Brake Shoe Removal ......................................................................................................................... 6-1 Brake Assembly Cleaning ................................................................................................................... 6-5 Brake Shoe Installation ...................................................................................................................... 6-6 Brake Adjustment ............................................................................................................................... 6-8 Brake Cluster Removal and Installation ............................................................................................. 6-8 Brake Cluster Installation ............................................................................................................... 6-9 Brake Cable Removal and Installation ............................................................................................... 6-9 SECTION 7 – STEERING AND FRONT SUSPENSION General Information ........................................................................................................................... 7-1 Steering Wheel ................................................................................................................................... 7-1 Steering Wheel Removal ............................................................................................................... 7-1 Steering Wheel Installation ............................................................................................................ 7-2 Steering Column ................................................................................................................................ 7-2 Steering Column Removal ............................................................................................................. 7-2 Steering Column Disassembly ....................................................................................................... 7-5 Steering Column Assembly ............................................................................................................ 7-5 Steering Column Installation .......................................................................................................... 7-6

2003 DS Golf Car Maintenance and Service Manual Page v Steering Adjustment .......................................................................................................................... 7-6 Rack and Pinion ................................................................................................................................. 7-8 Rack and Pinion Removal ............................................................................................................. 7-8 Rack and Pinion Disassembly ....................................................................................................... 7-8 Rack and Pinion Assembly ............................................................................................................ 7-10 Rack and Pinion Installation .......................................................................................................... 7-13 Tie Rod and Drag Link ....................................................................................................................... 7-13 Tie Rod and Drag Link Removal .................................................................................................... 7-13 Tie Rod and Drag Link Installation ................................................................................................. 7-13 Front Suspension .............................................................................................................................. 7-14 Lubrication ..................................................................................................................................... 7-14 Wheel Alignment ............................................................................................................................ 7-14 Front Suspension Components ......................................................................................................... 7-16 Tapered Leaf Spring Removal ....................................................................................................... 7-16 Tapered Leaf Spring Installation .................................................................................................... 7-16 Kingpin and Steering Spindle Removal ......................................................................................... 7-17 Kingpin and Steering Spindle Installation ...................................................................................... 7-17 Delta A-Plate Removal .................................................................................................................. 7-17 Delta A-Plate Installation ............................................................................................................... 7-20 Shock Absorber Removal .............................................................................................................. 7-20 Shock Absorber Installation ........................................................................................................... 7-20 Front Wheel Bearings and Hubs ....................................................................................................... 7-20 Front Wheel Free Play Inspection ................................................................................................. 7-20 Front Wheel Bearings and Hub Removal ...................................................................................... 7-20 Front Wheel Bearings and Hub Installation ................................................................................... 7-21 SECTION 8 – WHEELS AND TIRES General Information ........................................................................................................................... 8-1 Wheels ............................................................................................................................................... 8-1 Wheel Removal ............................................................................................................................. 8-1 Wheel Installation .......................................................................................................................... 8-1 Tires ................................................................................................................................................... 8-1 Tire Removal ................................................................................................................................. 8-1 Tire Repair ..................................................................................................................................... 8-2 Tire Installation .............................................................................................................................. 8-3 SECTION 9 – REAR SUSPENSION General Information ........................................................................................................................... 9-1 Shock Absorbers ............................................................................................................................... 9-1 Shock Absorber Removal and Inspection ...................................................................................... 9-1 Shock Absorber Installation ........................................................................................................... 9-1

Page vi 2003 DS Golf Car Maintenance and Service Manual Leaf Springs ....................................................................................................................................... 9-1 Leaf Spring Removal ...................................................................................................................... 9-1 Leaf Spring Installation ................................................................................................................... 9-4 SECTION i – INDEX

2003 DS Golf Car Maintenance and Service Manual Page 1-1 1 SECTION 1 – SAFETY To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements labeled DANGER, WARNING, or CAUTION. These special statements relate to specific safety issues, and must be read, understood, and heeded before proceeding with procedures. There are statements labeled NOTE, which provide other essential service or maintenance information. ∆ DANGER • A 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. GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser- viced. Service technicians should become familiar with these general safety statements. Also, other specific safety statements appear throughout this manual and on the vehicle. ∆ DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. • Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing. Antidotes: - External: Flush with water. Call a physician immediately. - Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a physician immediately. - Eyes: Flush with water for 15 minutes. Call a physician immediately. • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. WARNING CONTINUED ON NEXT PAGE...

SAFETY General Warning Page 1-2 2003 DS Golf Car Maintenance and Service Manual 1 ∆ WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation. • Prior to servicing the vehicle or leaving the vehicle unattended, turn the key switch OFF, remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels when servicing the vehicle. Gasoline vehicles only: • To avoid unintentionally starting the vehicle: - Disconnect battery cables, negative (–) cable first (Figure 1-1, Page 1-3). - Disconnect the spark plug wire from the spark plug. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or any other metal component. Electric vehicles only: • IQ System Vehicles: Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. • All Electric Vehicles: To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 1-2, 1-3, or 1-4 on page 1-3). • IQ System Vehicles: After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge. • PowerDrive System 48 Vehicles: After disconnecting the batteries, discharge the controller capacitors as follows: - Turn the key switch to ON and place the Forward/Reverse handle in the REVERSE position. - Slowly depress the accelerator pedal and keep it depressed until the reverse warning buzzer can no longer be heard. When the buzzer stops sounding, the controller capacitors are discharged. All vehicles: • Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries. • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle. • Moving parts! Do not attempt to service the vehicle while it is running. • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could result in severe burns. • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. • Check the vehicle owner’s manual for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read. • Any modification or change to the vehicle that affects the stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, could result in severe personal injury or death. WARNING CONTINUED ON NEXT PAGE...

2003 Club Car DS Golf Cars (Gasoline/Electric) Maintenance Service Manual (incl. FE290)

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