1995 1996 1997 Club Car Ds Gasoline And Electric Vehicle Repair Manual – PDF Download
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 thoroughly
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
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
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.
TABLE OF CONTENTS
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
Driving Instructions 3-8
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
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
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