Club Car
MANUAL NUMBER 103209103
EDITION CODE 0407C0312B
DS GOLF CARS
GASOLINE/ELECTRIC
2007
MAINTENANCE
SERVICE
MANUAL
2007 DS Golf Car Maintenance and Service Manual Page 1
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 the Club Car DS Golf Cars and
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 possesses 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 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 repre-
sentatives, 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 covers all aspects of typical vehicle service; however, unique situations 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, GA 30917-4658 USA, Attention: Technical Services, or contact a
Club Car Technical Service Representative at (706) 863-3000, ext. 3580.
Copyright © 2007, 2012 Club Car, Inc.
Club Car is a registered
trademark of Club Car, Inc
This manual effective August 1, 2006.
Page 2 2007 DS Golf Car Maintenance and Service Manual
ý 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 is contin-
ually 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 dealers and will, when applicable, appear in future editions of this
manual.
Club Car 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.
2007 DS Golf Car Maintenance and Service Manual Page 3
CONTENTS
SECTION i – INDEX
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 .......................................................................... 3-5
SECTION 4 – PERIODIC MAINTENANCE
General Information .......................................................................................................................... 4-1
Periodic Service Schedules .............................................................................................................. 4-1
Periodic Lubrication Schedules ...................................................................................................... 4-4
Engine Oil – Gasoline Vehicles ........................................................................................................ 4-6
Engine Oil Level Check ................................................................................................................ 4-6
Engine Oil And Filter Change ....................................................................................................... 4-6
Oil Viscosity .................................................................................................................................. 4-8
SECTION 5 – BODY AND TRIM
Cleaning the Vehicle ......................................................................................................................... 5-1
Seat Cleaning ............................................................................................................................... 5-1
Page 4 2007 DS Golf Car Maintenance and Service Manual
Front and Rear Body Repair ............................................................................................................ 5-2
Stress Lines or Streaks ................................................................................................................ 5-2
Minor Impact Damage/Deformations ............................................................................................ 5-2
Minor Scratches and Surface Blemishes ..................................................................................... 5-2
Small Scratches That Cannot Be Buffed Out ............................................................................... 5-2
Gouges, Punctures, Tears, Large Scratches, and Abrasions ...................................................... 5-3
Touch-up Paint Color Chart ......................................................................................................... 5-3
Canopy ............................................................................................................................................. 5-3
Canopy Removal .......................................................................................................................... 5-3
Canopy Installation ....................................................................................................................... 5-5
Front Body ........................................................................................................................................ 5-5
Front Body Removal ..................................................................................................................... 5-5
Front Body Installation .................................................................................................................. 5-5
Rear Body ........................................................................................................................................ 5-7
Rear Body Removal ..................................................................................................................... 5-7
Rear Body Installation .................................................................................................................. 5-9
Floor Mat .......................................................................................................................................... 5-10
Floor Mat Removal ....................................................................................................................... 5-10
Floor Mat Installation .................................................................................................................... 5-10
SECTION 6 – WHEEL BRAKE ASSEMBLIES
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
Steering Adjustment ......................................................................................................................... 7-6
2007 DS Golf Car Maintenance and Service Manual Page 5
Rack and Pinion ................................................................................................................................ 7-8
Rack and Pinion Removal ............................................................................................................ 7-8
Rack and Pinion Disassembly ...................................................................................................... 7-8
Rack and Pinion Assembly ........................................................................................................... 7-11
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 Hub Removal ....................................................................................................................... 7-20
Front 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 6 2007 DS Golf Car Maintenance and Service Manual
Leaf Springs ..................................................................................................................................... 9-1
Leaf Spring Removal .................................................................................................................... 9-1
Leaf Spring Installation ................................................................................................................. 9-4
SECTION 10 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHI-
CLES
General Information ......................................................................................................................... 10-1
Troubleshooting Guide ..................................................................................................................... 10-1
Electrical System .............................................................................................................................. 10-8
Test Procedures ............................................................................................................................... 10-8
Index of Test Procedures ............................................................................................................. 10-8
SECTION 11 – ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter/Generator (MODEL G425419) ............................................................................................. 11-1
Starter/Generator (MODEL 114-01-4005) ........................................................................................ 11-12
Voltage Regulator ............................................................................................................................ 11-22
Key Switch ....................................................................................................................................... 11-23
Solenoid ........................................................................................................................................... 11-24
Fuse ................................................................................................................................................. 11-25
Accelerator Pedal Limit Switch ......................................................................................................... 11-25
Kill Limit Switch ................................................................................................................................ 11-26
Neutral Lockout Limit Switch ............................................................................................................ 11-27
Neutral Lockout Cam ....................................................................................................................... 11-28
Reverse Warning Buzzer ................................................................................................................. 11-29
Reverse Buzzer Limit Switch ........................................................................................................... 11-30
Low Oil Warning Light ...................................................................................................................... 11-31
Fuel Gauge/Hour Meter ................................................................................................................... 11-32
Fuel Level Sending Unit ................................................................................................................... 11-33
RPM Limiter ..................................................................................................................................... 11-33
Ignition Coil ...................................................................................................................................... 11-34
Oil Level Sensor ............................................................................................................................... 11-37
Battery .............................................................................................................................................. 11-38
Ground Cables ................................................................................................................................. 11-42
SECTION 12 – FE290 ENGINE
General Information ......................................................................................................................... 12-1
Before Servicing ........................................................................................................................... 12-1
Engine Rotation ............................................................................................................................ 12-1
Spark Plug .................................................................................................................................... 12-1
2007 DS Golf Car Maintenance and Service Manual Page 7
Cylinder Head ................................................................................................................................... 12-3
General Information ...................................................................................................................... 12-3
Breather Valve (Reed Valve) ........................................................................................................ 12-3
Crankcase ......................................................................................................................................... 12-3
Engine Removal ........................................................................................................................... 12-3
Crankcase Cover Removal ........................................................................................................... 12-3
Oil Level Sensor ........................................................................................................................... 12-5
Crankcase Cover Installation ........................................................................................................ 12-5
Ignition Coil and Flywheel ................................................................................................................. 12-6
Flywheel Installation ......................................................................................................................... 12-8
Engine Installation ............................................................................................................................ 12-9
Torque Specifications ................................................................................................................... 12-10
Adjustments and Settings ............................................................................................................ 12-10
SECTION 13 – FUEL SYSTEM: GASOLINE VEHICLE
General Information .......................................................................................................................... 13-1
Carburetor ......................................................................................................................................... 13-1
Main Jet Elevation/Size Chart ....................................................................................................... 13-2
Changing the Main Jet .................................................................................................................. 13-2
Engine Control Linkage .................................................................................................................... 13-5
General Information ...................................................................................................................... 13-5
Accelerator Rod ............................................................................................................................ 13-6
Governor Cable ............................................................................................................................ 13-8
Accelerator Cable ......................................................................................................................... 13-9
Closed Throttle or Idle Adjustment ............................................................................................... 13-11
Engine RPM Adjustment ............................................................................................................... 13-11
Choke and Air Intake System ........................................................................................................... 13-12
Choke Button Removal ................................................................................................................. 13-12
Choke Button Installation .............................................................................................................. 13-12
Air Box Removal ........................................................................................................................... 13-12
Air Box Installation ........................................................................................................................ 13-12
Intake Duct Removal .................................................................................................................... 13-13
Intake Duct Installation ................................................................................................................. 13-13
Air Filter ........................................................................................................................................ 13-15
Fuel Filters ........................................................................................................................................ 13-15
Fuel Filter Removal ....................................................................................................................... 13-15
Fuel Filter Installation .................................................................................................................... 13-17
Page 8 2007 DS Golf Car Maintenance and Service Manual
Fuel Pump ........................................................................................................................................ 13-18
General Information ...................................................................................................................... 13-18
Fuel Pump Removal ..................................................................................................................... 13-18
Fuel Pump Disassembly ............................................................................................................... 13-18
Fuel Pump Cleaning and Inspection ............................................................................................ 13-19
Fuel Pump Assembly ................................................................................................................... 13-19
Fuel Pump Installation .................................................................................................................. 13-20
Fuel Tank ......................................................................................................................................... 13-20
General Information ...................................................................................................................... 13-20
Fuel Tank Removal ...................................................................................................................... 13-21
Fuel Tank Disposal ....................................................................................................................... 13-22
Fuel Tank Storage ........................................................................................................................ 13-22
Fuel Tank Installation ................................................................................................................... 13-22
Fuel Lines ......................................................................................................................................... 13-24
Fuel Shut-Off Valve .......................................................................................................................... 13-25
SECTION 14 – EXHAUST SYSTEM: GASOLINE VEHICLES
Muffler .............................................................................................................................................. 14-1
Muffler Removal ........................................................................................................................... 14-1
Muffler Installation ........................................................................................................................ 14-1
SECTION 15 – UNITIZED TRANSAXLE: GASOLINE VEHICLE
General Information ......................................................................................................................... 15-1
Lubrication .................................................................................................................................... 15-2
Axle Shaft ......................................................................................................................................... 15-3
Axle Shaft and Oil Seal Removal ................................................................................................. 15-3
Axle Bearing ................................................................................................................................. 15-4
Axle Shaft Installation ................................................................................................................... 15-6
Unitized Transaxle Removal ............................................................................................................ 15-7
Unitized Transaxle Installation ......................................................................................................... 15-14
Forward/Reverse Shifter Cable ........................................................................................................ 15-19
Forward/Reverse Shifter Cable Removal ..................................................................................... 15-19
Forward/Reverse Shifter Cable Installation .................................................................................. 15-20
Forward/Reverse Shifter Cable Adjustment ................................................................................. 15-21
SECTION 16 – TORQUE CONVERTER: GASOLINE VEHICLE
General Information ......................................................................................................................... 16-1
Troubleshooting ............................................................................................................................... 16-1
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2007 Club Car OS Gas Factory Service & Work Shop Manual
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Description
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2007 Club Car OS Gas.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every maintenance and repair procedure. With hundreds of pages, it offers clear instructions for tasks ranging from simple oil changes to complex transmission swaps. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual is designed to walk you through the fundamentals of maintenance and repair, empowering you with the knowledge that factory-trained technicians possess. By following the instructions in this manual, any owner can confidently make informed decisions about maintaining and repairing their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction.
