1995-1997 Club Car DS Golf Cars (Gasoline/Electric) Service & Repair Manual
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DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 101905101
EDITION CODE 1196H0799C
MAINTENANCE
SERVICE
1995-1996
FOREWORD
Club Car golf cars are designed and built to provide maximum efficiency and performance. However, proper
maintenance and repair is essential for achieving maximum service life and continued safe and reliable oper-
ation of the vehicle. This Maintenance and Service Manual will provide the mechanic with proper detailed
procedures for the maintenance and repair of the Club Car DS Golf Car, including periodic maintenance,
troubleshooting, disassembly, repair, and reassembly of all vehicle components. This manual should be thor-
oughly studied prior to servicing the vehicle. The procedures provided must be properly implemented, and
the NOTE, CAUTION, WARNING, and DANGER statements must be heeded.
This manual was written for the vehicle mechanic who already posseses basic knowledge and skills in elec-
trical and mechanical repair. If the mechanic does not have such basic knowledge and skills, attempted ser-
vice or repairs to the vehicle may render it unsafe. For this reason, we advise that all repairs and/or service
be performed by an authorized Club Car distributor’s/dealer’s representative or by a Club Car factory trained
mechanic.
It is the policy of Club Car, Incorporated to assist its distributors and dealers in continually updating their ser-
vice knowledge and facilities so that they can provide prompt and efficient service for the vehicle owner.
Regional technical representatives, golf car service seminars, periodic service bulletins, this manual, and
other service publications also represent Club Car’s continuing commitment to customer support.
This service manual covers all aspects of DS Golf Car service. However, unique situations do sometimes
arise when servicing a golf car. If it appears that a service question is not answered in this manual, you may
write to us or contact a Club Car technical service representative by phone at (706) 863-3000, ext. 3580.
©1996 Club Car, Inc.
Club Car, Armorflex, PowerDrive, PowerDrive Plus,
and Tranquility are registered trademarks of Club Car, Inc.
This manual effective August 1, 1995
• THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF PUBLICA-
TION. CLUB CAR, INC. IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR 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.
• 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 MAINTE-
NANCE AS INSTRUCTED IN THE VEHICLE OWNER’S MANUAL), ACCIDENT OR ALTERATION,
INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFI-
CATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF,
WILL VOID THE WARRANTY.
• CLUB CAR, INC. RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT
ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY
WHATSOEVER.
• 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.
NOTE
CONTENTS
SAFETY SECTION
Safety ................................................................................................................................................ 1-1
VEHICLE SPECIFICATIONS SECTION
Vehicle Specifications ....................................................................................................................... 2-1
GENERAL INFORMATION SECTION
Model Identification ........................................................................................................................... 3-1
Safety Committee ............................................................................................................................. 3-1
Pre-Operation Checklist .................................................................................................................... 3-2
Performance Inspection ................................................................................................................ 3-2
Controls ............................................................................................................................................. 3-3
Driving Instructions ........................................................................................................................... 3-8
Towing ............................................................................................................................................... 3-9
Transporting on a Trailer .................................................................................................................... 3-10
Storage - Gasoline Vehicle ................................................................................................................ 3-10
Storage - Electric Vehicle .................................................................................................................. 3-12
PERIODIC MAINTENANCE SECTION
Lubrication - Gasoline Vehicles ......................................................................................................... 4-2
Lubrication - Electric Vehicles ........................................................................................................... 4-3
Vehicle Capacities ............................................................................................................................. 4-4
Periodic Service - Gasoline Vehicles ................................................................................................ 4-5
Periodic Service - Electric Vehicles ................................................................................................... 4-7
BODY AND TRIM SECTION
General Information .......................................................................................................................... 5-1
Front and Rear Body Repair ............................................................................................................. 5-2
Seat ................................................................................................................................................... 5-4
Front Body ........................................................................................................................................ 5-4
Rear Body ......................................................................................................................................... 5-5
• READ SECTION 1 - SAFETY - BEFORE ATTEMPTING ANY SERVICE ON THIS VEHICLE.
• BEFORE SERVICING VEHICLE, READ COMPLETE SECTION(S) AND ANY REFERENCED
INFORMATION RELEVANT TO SERVICE OR REPAIR TO BE PERFORMED.
WARNING
1
2
3
4
5
Floormat ............................................................................................................................................ 5-8
ACCELERATOR AND BRAKE PEDAL GROUP SECTION
General Information .......................................................................................................................... 6-1
Pedal Group Adjustment - Early 1995 Vehicles ................................................................................ 6-1
Pedal Group Disassembly and Assembly - Early 1995 Vehicles ...................................................... 6-9
Pedal Group Adjustment - Late 1995 and 1996 Vehicles ................................................................. 6-13
Pedal Group Disassembly and Assembly - Late 1995 and 1996 Vehicles ....................................... 6-23
6
WHEEL BRAKE ASSEMBLIES SECTION
Removal of Brake Shoes and Cleaning of Wheel Brake Assemblies ................................................ 7-3
Installing the Brake Shoes ................................................................................................................ 7-6
Brake Assembly ................................................................................................................................ 7-7
STEERING AND FRONT SUSPENSION SECTION
General Information - Steering .......................................................................................................... 8-1
Steering Wheel ................................................................................................................................. 8-2
Steering Column ............................................................................................................................... 8-2
Steering Adjustment ......................................................................................................................... 8-6
Rack and Pinion ................................................................................................................................ 8-6
Tie Rod and Drag Link ...................................................................................................................... 8-16
Front Suspension .............................................................................................................................. 8-18
Lubrication .................................................................................................................................... 8-18
Wheel Alignment ........................................................................................................................... 8-18
Front Suspension Components ........................................................................................................ 8-20
Front Wheel Bearings and Hubs ....................................................................................................... 8-24
TRANSAXLE SECTION
Lubrication ........................................................................................................................................ 9-1
Axle Shaft .......................................................................................................................................... 9-2
Axle Bearing .................................................................................................................................. 9-3
Removing the Transaxle .................................................................................................................... 9-5
Disassembly, Inspection, and Assembly of the Transaxle ................................................................. 9-10
Shimming the Transaxle .................................................................................................................... 9-14
Installation of the Transaxle ............................................................................................................... 9-15
WHEELS AND TIRES SECTION
General Information ........................................................................................................................... 10-1
Wheel Removal ................................................................................................................................. 10-2
Wheel Installation .............................................................................................................................. 10-2
Removing the Tire from the Rim ....................................................................................................... 10-3
Repairing a Tire ................................................................................................................................ 10-3
Installing the Tire on the Rim ............................................................................................................ 10-3
TROUBLESHOOTING THE GASOLINE VEHICLE SECTION
Troubleshooting Guide ...................................................................................................................... 11-1
ELECTRICAL SYSTEM - GASOLINE VEHICLE SECTION
General Information .......................................................................................................................... 12-2
FE 290 Gasoline Vehicle Electrical Circuit ........................................................................................ 12-2
Circuit Testing .................................................................................................................................... 12-7
Test Procedures ................................................................................................................................ 12-14
Electrical System Components ......................................................................................................... 12-27
7
8
9
10
11
12
Starter/Generator .......................................................................................................................... 12-27
Voltage Regulator ......................................................................................................................... 12-38
Key Switch .................................................................................................................................... 12-39
Solenoid ........................................................................................................................................ 12-40
Fuse .............................................................................................................................................. 12-41
Limit Switches ............................................................................................................................... 12-41
Neutral Lock-out Cam ................................................................................................................... 12-44
Reverse Warning Buzzer .............................................................................................................. 12-44
Oil Warning Light .......................................................................................................................... 12-46
Battery .......................................................................................................................................... 12-46
FE 290 ENGINE SECTION
General Information .......................................................................................................................... 13-1
Special Tools ..................................................................................................................................... 13-2
Mechanical Systems ......................................................................................................................... 13-2
Electrical System .............................................................................................................................. 13-4
Lubrication System ........................................................................................................................... 13-5
Spark Plug ........................................................................................................................................ 13-6
Engine Mounting and Inner Frame (See Rear Suspension - Section 18)
Rebuilding the Cylinder Head ........................................................................................................... 13-7
Rebuilding Crankcase Components ................................................................................................. 13-23
Engine Assembly .............................................................................................................................. 13-46
Service Specifications ...................................................................................................................... 13-47
Specifications for Resizing Cylinder Bore ......................................................................................... 13-49
Torque Specifications ........................................................................................................................ 13-49
Adjustments and Settings ................................................................................................................. 13-50
FUEL SYSTEM SECTION
General Information .......................................................................................................................... 14-1
How the Carburetor Works ............................................................................................................... 14-1
Carburetor ......................................................................................................................................... 14-4
Main Jet Elevation/Size Chart ....................................................................................................... 14-4
Engine Control Linkage .................................................................................................................... 14-8
Choke and Intake System ................................................................................................................. 14-14
Fuel Filters ........................................................................................................................................ 14-17
Fuel Pump ........................................................................................................................................ 14-19
Fuel Tank .......................................................................................................................................... 14-22
Fuel Lines ......................................................................................................................................... 14-24
Fuel Tank Vent .................................................................................................................................. 14-24
EXHAUST SYSTEM SECTION
General Information .......................................................................................................................... 15-1
Muffler ............................................................................................................................................... 15-1
TORQUE CONVERTER SECTION
General Information .......................................................................................................................... 16-1
13
14
15
16
Torque Converter, Continued:
Troubleshooting ................................................................................................................................. 16-3
Drive Belt .......................................................................................................................................... 16-3
Drive Clutch ...................................................................................................................................... 16-4
Driven Clutch .................................................................................................................................... 16-12
Clutch Alignment ............................................................................................................................... 16-17
TRANSMISSION AND GOVERNOR SECTION
General Information .......................................................................................................................... 17-2
Lubrication ........................................................................................................................................ 17-2
Transmission ..................................................................................................................................... 17-3
Forward and Reverse Shifter Cable .................................................................................................. 17-22
REAR SUSPENSION - GASOLINE VEHICLE SECTION
General Information .......................................................................................................................... 18-1
Shock Absorbers ............................................................................................................................... 18-1
Mono-Leaf Springs ........................................................................................................................... 18-3
The Snubber ..................................................................................................................................... 18-4
ELECTRICAL SYSTEM - V-GLIDE 36 VOLT VEHICLE SECTION
General Information .......................................................................................................................... 19-1
V-Glide Electrical Circuits .................................................................................................................. 19-2
Troubleshooting ................................................................................................................................. 19-5
Circuit Testing .................................................................................................................................... 19-8
ELECTRICAL COMPONENTS - V-GLIDE 36 VOLT VEHICLE SECTION
Key Switch ........................................................................................................................................ 19-18
Forward and Reverse Anti-arcing Limit Switch ................................................................................. 19-19
Accelerator Pedal Limit Switch .......................................................................................................... 19-20
The Reverse Buzzer ......................................................................................................................... 19-21
The Solenoid ..................................................................................................................................... 19-22
Resistors ........................................................................................................................................... 19-23
V-Glide Wiper Switch ........................................................................................................................ 19-25
Forward and Reverse Switch ............................................................................................................ 19-32
ELECTRICAL SYSTEM - POWERDRIVE SYSTEM 48 SECTION
General Information .......................................................................................................................... 20-1
The On-Board Computer .................................................................................................................. 20-2
PowerDrive Vehicle Electrical Circuits ............................................................................................... 20-2
Troubleshooting Guide ...................................................................................................................... 20-6
Circuit Testing .................................................................................................................................... 20-9
The Communication Display Module (CDM) ..................................................................................... 20-22
Communication Display Module Troubleshooting Guide ................................................................... 20-24
ELECTRICAL COMPONENTS - POWERDRIVE SYSTEM 48 VEHICLE SECTION
The Key Switch ................................................................................................................................. 20-25
17
18
19A
19B
20A
20B
Forward and Reverse Switch ............................................................................................................ 20-27
Forward and Reverse Limit Switches ............................................................................................ 20-28
The Reverse Buzzer ......................................................................................................................... 20-29
The Solenoid .................................................................................................................................... 20-31
On-Board Computer ......................................................................................................................... 20-33
Solid State Speed Controller ............................................................................................................ 20-34
Charger Receptacle .......................................................................................................................... 20-34
Receptacle Fuse Link ................................................................................................................... 20-36
Continuously Variable Potentiometer ................................................................................................ 20-37
Multi-Step Potentiometer .................................................................................................................. 20-40
Battery Warning Light ....................................................................................................................... 20-41
ELECTRICAL SYSTEM - POWERDRIVE PLUS SECTION
General Information .......................................................................................................................... 21-1
Z Plug Connections Chart ................................................................................................................ 21-4
The Control Circuit ............................................................................................................................ 21-5
The Power Circuit ............................................................................................................................. 21-16
The Charge Circuit ............................................................................................................................ 21-19
Troubleshooting Guide ...................................................................................................................... 21-20
Test Procedures ................................................................................................................................ 21-25
Numerical Listing of Test Procedures ........................................................................................... 21-25
ELECTRICAL COMPONENTS - POWERDRIVE PLUS SECTION
Key Switch ........................................................................................................................................ 21-53
Forward and Reverse Switch ............................................................................................................ 21-54
Reverse Buzzer ................................................................................................................................ 21-54
Main Solenoid ................................................................................................................................... 21-55
Dynamic Braking Solenoid ................................................................................................................ 21-56
On-Board Computer ......................................................................................................................... 21-56
Controller .......................................................................................................................................... 21-57
Charger Receptacle .......................................................................................................................... 21-58
Continuously Variable Potentiometer ................................................................................................ 21-58
Battery Warning Light ....................................................................................................................... 21-58
Energy Displacement Module ........................................................................................................... 21-59
BATTERIES SECTION
General Information .......................................................................................................................... 22-1
Common Misconceptions about Batteries ........................................................................................ 22-3
Replacing Batteries .......................................................................................................................... 22-4
Battery Care ..................................................................................................................................... 22-5
Battery Charging ............................................................................................................................... 22-7
Battery Testing .................................................................................................................................. 22-8
Battery Troubleshooting Chart - 36 and 48 Volt ................................................................................ 22-10
Battery Storage ................................................................................................................................. 22-17
Charging Battery Pack with Low Voltage .......................................................................................... 22-18
21A
21B
22
x
ACCU-POWER BATTERY CHARGER SECTION
General Information .......................................................................................................................... 23-1
The Charge Circuit ............................................................................................................................ 23-3
Charger Installation and Use ............................................................................................................ 23-3
Troubleshooting ................................................................................................................................. 23-6
Test Procedures ................................................................................................................................ 23-7
Plug and Receptacle Replacement ................................................................................................... 23-18
On-Board Receptacle Fuse Link ................................................................................................... 23-21
Charger Repairs ................................................................................................................................ 23-22
Capacitor ....................................................................................................................................... 23-23
Heat Sink Assembly ...................................................................................................................... 23-24
Transformer ................................................................................................................................... 23-24
Ammeter ....................................................................................................................................... 23-25
Charger Fuse Link Assembly ........................................................................................................ 23-26
POWERDRIVE BATTERY CHARGER SECTION
General Information .......................................................................................................................... 23-27
Battery Warning Light ....................................................................................................................... 23-28
The Charge Circuit ............................................................................................................................ 23-28
Charger Installation and Use ............................................................................................................ 23-30
Checking Battery Condition after a Charge Cycle ............................................................................ 23-33
Troubleshooting ................................................................................................................................. 23-34
Test Procedures ................................................................................................................................ 23-37
Plug and Receptacle Replacement ................................................................................................... 23-46
Charger Cord Replacement .......................................................................................................... 23-46
Charger Repairs ................................................................................................................................ 23-47
Rectifier .......................................................................................................................................... 23-48
Transformer ................................................................................................................................... 23-48
Ammeter ....................................................................................................................................... 23-48
Fuse Link ...................................................................................................................................... 23-49
Charger Relay ............................................................................................................................... 23-49
Charger AC Circuit Breaker .......................................................................................................... 23-50
Charger AC Cord .......................................................................................................................... 23-50
MOTOR SECTION
General Information .......................................................................................................................... 24-1
External Motor Testing ...................................................................................................................... 24-1
REAR SUSPENSION - ELECTRIC VEHICLE SECTION
General Information .......................................................................................................................... 25-1
Shock Absorbers ............................................................................................................................... 25-2
Mono-Leaf Springs ........................................................................................................................... 25-2
23A
23B
24
25
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1995-1997 Club Car DS Golf Cars (Gasoline/Electric) Service & Repair Manual
This service and repair manual for the 1995-1997 Club Car DS Golf Cars (Gasoline/Electric) provides complete technical details to maintain and repair these models. Covering all systems, the manual includes detailed troubleshooting procedures, maintenance schedules, wiring diagrams, and step-by-step repair instructions for both gasoline and electric variants.
Designed to meet the needs of DIY enthusiasts and professional technicians, this manual covers components like the engine, electrical systems, drivetrain, suspension, and brakes. It also provides factory specifications and diagnostic procedures specific to the Club Car DS models from 1995 to 1997, ensuring precise and efficient repairs.
Available in a user-friendly digital format, the manual is accessible on computers and mobile devices, making it a practical resource for on-the-go repairs. Whether you’re handling routine maintenance or more complex system repairs, this manual ensures you have the right information to keep your Club Car DS Golf Car in optimal condition.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
