Club Car DS Gasoline Golf Cart Complete Workshop Service Repair Manual 1998 1999

DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 101968401 0199B0312A 1998-1999 MAINTENANCE SERVICE MANUAL EDITION CODE

1998/1999 DS Golf Car Maintenance and Service Manual Page i FORWARD 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. This maintenance and service manual provides detailed procedures for the maintenance and repair of those components that are common to all Club Car DS Golf Cars, and should be used in conjunction with the appropriate maintenance and service supplement. The supplement will provide maintenance and repair procedures for those components specific to a particular type of vehicle. If you do not have the appropriate supplement for your vehicle(s), you may obtain one of the following from your Club Car distributor: This manual and the supplement should be read prior to servicing the vehicle. The procedures provided must be properly implemented, and the CAUTION , WARNING , and DANGER statements must be heeded. This manual was written for the vehicle mechanic who already possesses basic knowledge and skills in elec- trical 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 technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical representatives, golf car service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support. This service manual, used in conjunction with the appropriate supplement, covers all aspects of typical 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 or the supplement, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917; Attention: Technical Services, or contact a Club Car Technical Service representative at (706) 863-3000, extension 3580. ©1999, 2012 Club Car, Inc. Club Car, Armorflex, PowerDrive, PowerDrive Plus, and Tranquility are registered trademarks of Club Car, Inc. This manual effective August 1, 1998 1998/1999 PowerDrive System 48 Vehicle Maintenance & Service Supplement Publication Part No. 101968404 1998/1999 PowerDrive Plus Vehicle Maintenance & Service Supplement Publication Part No. 101968405 1998/1999 V-Glide 36-Volt Vehicle Maintenance & Service Supplement Publication Part No. 101968406 1998/1999 FE 290 Gasoline Vehicle Maintenance & Service Supplement Publication Part No. 101968407

Page ii 1998/1999 DS Golf Car Maintenance and Service Manual • 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. • THIS MANUAL REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF PUBLICATION. 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 MAINTENANCE AS INSTRUCTED IN THE VEHICLE OWNER’S MANUAL), ACCIDENT OR ALTERATION, INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFICATIONS 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. WARNING NOTE

1998/1999 DS Golf Car Maintenance and Service Manual Page iii CONTENTS SAFETY SECTION General Warning ............................................................................................................................... 1-1 VEHICLE SPECIFICATIONS SECTION General Information .......................................................................................................................... 2-1 GENERAL INFORMATION SECTION Model Identification ........................................................................................................................... 3-1 Safety Committee ............................................................................................................................. 3-1 Pre-Operation Checklist .................................................................................................................... 3-2 Controls ............................................................................................................................................ 3-3 Driving Instructions ........................................................................................................................... 3-9 Towing ............................................................................................................................................... 3-11 Transporting on a Trailer ................................................................................................................... 3-11 Storage - Gasoline Vehicle ............................................................................................................... 3-12 Storage - Electric Vehicle .................................................................................................................. 3-13 BODY AND TRIM SECTION General Information .......................................................................................................................... 4-2 Front and Rear Body Repair ............................................................................................................. 4-2 Seat .................................................................................................................................................. 4-4 Front Body ........................................................................................................................................ 4-4 Rear Body ......................................................................................................................................... 4-6 Floormat ............................................................................................................................................ 4-8 ACCELERATOR AND BRAKE PEDAL GROUP SECTION General Information .......................................................................................................................... 5-1 Pedal Group Adjustment .................................................................................................................... 5-2 Pedal Group Disassembly and Assembly ......................................................................................... 5-8 WHEEL BRAKE ASSEMBLIES SECTION Removal and Cleaning of Wheel Brake Assemblies ......................................................................... 6-3 Installing the Brake Shoes ................................................................................................................ 6-5 Adjusting the Brakes ......................................................................................................................... 6-8 Removal and Installation of Brake Assembly .................................................................................... 6-8 1 2 3 4 5 6

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Club Car DS Gasoline Golf Cart Complete Workshop Service Repair Manual 1998 1999

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