Club Car 2005 DS, Owner'S Manual

Page 1: ...Club Car DS Golf Cars Gasoline and Electric 2 0 0 5 O w n e r s M a n u a l...

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Page 3: ...and Performance Requirements for Golf Cars This standard which promotes safety in the design application and operation of golf cars defines a golf car as a vehicle used to convey a person or persons a...

Page 4: ...hem to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehicle n...

Page 5: ...ist 18 Driving Instructions 20 Towing 22 Transporting on a Trailer 23 Storage Electric Vehicles 24 Storage Gasoline Vehicles 25 Maintenance 27 Periodic Service Schedules 28 Periodic Lubrication Schedu...

Page 6: ...wn slopes Do not leave children unattended on vehicle Never operate under the influence of alcohol or drugs Use brakes to reduce speed when coasting downhill Never stand in front of or behind vehicle...

Page 7: ...out this cover properly installed Do not direct water stream in this area will cause damage to components See vehicle maintenance and service manual before servicing CCI 101931501 TOW RUN CCI 10190860...

Page 8: ...Owner s Manual and safety warnings located on dash panel prior to driving Study and understand controls Make sure wheels are turned in desired direction Turn key to ON position and be sure nothing is...

Page 9: ...ENGINE ALLOW TO COOL BEFORE REFUELING TURN FUEL VALVE ON DURING OPERATION OFF DURING STORAGE OR TRANSPORT CCI 1015476 01 WARNING GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK FRAME GROUND AND...

Page 10: ...le we urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION state ments and procedures it contains along with the safety decals that are...

Page 11: ...d they should be replaced immediately to avoid possible property damage personal injury or death Contact your Club Car distributor dealer DANGER A DANGER indicates an immediate hazard that will result...

Page 12: ...ions could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read Only trained...

Page 13: ...second serial number decal mounted on the front body frame behind the center dash panel The center dash panel must be removed to view this decal See following NOTE NOTE Have the vehicle serial number...

Page 14: ...operating procedures before allowing the vehicle to be driven Do not shift the Forward Reverse handle or switch while the vehicle is moving To avoid injury to an unsuspecting passenger or damage to t...

Page 15: ...andle has three distinct positions F FORWARD R REVERSE and N NEUTRAL Rotate the handle towards the driver FORWARD to operate the vehicle in the forward direction or towards the passenger REVERSE to op...

Page 16: ...g the acceler ator pedal will automatically release the park brake and start the vehicle moving in the direction selected for ward or reverse As the accelerator pedal is pressed speed will increase un...

Page 17: ...ler check the vehicle for a possible battery or electrical system problem When the batteries receive an incomplete charge because 1 the DC power cord is disconnected 2 AC power to the charger is inter...

Page 18: ...seconds to elapse before switching back to the RUN position After placing the Tow Run switch in the RUN position allow 10 seconds to elapse before operating the vehicle The Tow Run switch should be p...

Page 19: ...ither the FORWARD or REVERSE position To put the cam back into the OPERATE position pull the cam out approximately 3 8 inch 10 mm and rotate it one half turn until it snaps into place Figure 12 See fo...

Page 20: ...thoroughly inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensu...

Page 21: ...cted by a Club Car distributor dealer or a trained technician All Vehicles Forward Reverse control Check for proper operation See Controls and Indicators on page 12 Brakes Be sure the brakes function...

Page 22: ...y slightly exceed its maximum designed speed requiring use of the brake pedal Gasoline Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD positio...

Page 23: ...ld drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before all...

Page 24: ...brake pedal to hold your position Do not use the accelerator pedal To stop the vehicle release the accelerator pedal and press the brake pedal with your right foot until the vehi cle comes to a comple...

Page 25: ...uipped with both front and rear tow bar attaching points A light duty tow bar is available for break down towing and single vehicle towing A heavy duty tow bar and an onboard tow bar are available for...

Page 26: ...ries on page 35 2 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rin...

Page 27: ...N Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Store vehicle in a cool dry place This will minimize battery self discharge I...

Page 28: ...crankshaft by hand several times and then install the spark plug 6 Adjust tires to recommended tire pressure See Vehicle Specifications on page 42 7 Perform semiannual periodic lubrication See Period...

Page 29: ...ance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 18 and the fol lowing Periodic Service Schedules and Perio...

Page 30: ...ust if necessary See Vehicle Specifications on page 42 General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 50 hours of operation or 10...

Page 31: ...or every 100 rounds for golf cars Battery Clean terminals and wash dirt from casing check electrolyte level See Battery Gasoline Vehicles on page 37 Front wheel alignment and camber Check and adjust i...

Page 32: ...I P N 1012151 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 Accelerator pivot rod supports Dry Moly Lube CCI P N 1012151 Charger receptacle WD 40 Brake slides Dry Moly Lube CCI P N 1012151 Fr...

Page 33: ...s Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only every 100 hours of operation or...

Page 34: ...ntities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately WARNING Wear safety glasses or a...

Page 35: ...el For best battery life add only distilled water See following NOTE NOTE A battery watering gun or bottle is available at many auto parts dealers 3 The hold down straps should be tight enough so that...

Page 36: ...ire Gauge and be as short as possible The use of improper extension cord could result in fire or an electrical shock Do not operate the charger if it has received a sharp blow was dropped or otherwise...

Page 37: ...short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to dam age or stress Ensure that the charger ventilation slots are unobstr...

Page 38: ...rive chargers Other Club Car models or vehicles made by other manufacturers are not compatible As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging...

Page 39: ...before replacing the fuse Contact your nearest Club Car distributor dealer BATTERY GASOLINE VEHICLES See General Warnings on page 9 DANGER Battery Explosive gases Do not smoke Keep sparks and flames a...

Page 40: ...to enter battery Be sure terminals are tight battery terminals should be tightened to 20 ft lb 27 1 N m Let the terminals dry and then spray them with Battery Terminal Protector Spray CCI P N 1014305...

Page 41: ...ller tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 4 Reinsert dipstick i...

Page 42: ...re 28 To avoid the possibility of fire clean up any spilled gasoline before operating the vehicle CAUTION To allow for expansion do not fill higher than one inch from the top of the fuel tank Avoid fu...

Page 43: ...oft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the appropriate maintenance and ser vice manual NOTE Dispose of waste wate...

Page 44: ...35 amp charging capacity Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Charger Automatic 48 volt UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting ra...

Page 45: ...saxle 22 oz 0 67 L Engine crankcase without filter 32 oz 0 95 L Engine crankcase with filter 38 oz 1 12 L Unitized transaxle 27 oz 0 8 L Fuel tank 7 gallons 26 5 L TIRE PRESSURE Front and rear 18 20 p...

Page 46: ...ats routine wear items such as the charger plug and receptacle brake shoes belts brushes bushings engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate...

Page 47: ...olf car beyond factory specifications including those that affect the weight distribution stability or speed of the golf car can cause serious personal injury or death CLUB CAR LIMITED LIFETIME WARRAN...

Page 48: ...AS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS 4 SOLE REMEDY CLUB CAR s liability under this limited warranty or in any action whether based upon warranty contract negligence...

Page 49: ...This limited warranty only covers defects in material and workmanship for a period of four years or 800 golf car rounds from date of purchase The terms of this four year or 800 round limited warranty...

Page 50: ...ranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may...

Page 51: ...ALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE BATTERY CHARGER LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OT...

Page 52: ...AR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE O...

Page 53: ...trations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following...

Page 54: ...cs The carburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper mainten...

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Page 56: ...b Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 Publication Part Number 102680202 Edition Code 0704A00...