1997 Club Car DS (Gas) Service & Repair Manual

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 operation 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 electrical and mechanical repair. If the mechanic does not have such basic knowledge and skills, attempted service 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 service 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

1997 Club Car DS (Gas) Service & Repair Manual

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