Club Car 2004 DS Gasoline, Owner'S Manual

Page 1: ...Club Car DS Golf Cars Gasoline and Electric 2 0 0 4 O w n e r s M a n u a l...

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Page 3: ...ics 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 mainte...

Page 4: ...dards Institute s Z130 Safety 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 t...

Page 5: ...k them 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 vehicl...

Page 6: ...Page 4 2004 DS Golf Car Owner s Manual...

Page 7: ...on a Trailer 26 Storage Electric Vehicle 27 Storage Gasoline Vehicle 28 Maintenance 30 Periodic Service Schedules 30 Periodic Lubrication Schedules 33 Vehicle Controller Electric Vehicle 35 Batteries...

Page 8: ...ht up and down 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 beh...

Page 9: ...ICE CCI 1016109 01 DO NOT OPERATE VEHICLE WITHOUT COVER IN PLACE DO NOT DIRECT WATER STREAM AT THIS SWITCH TOW RUN CCI 101908601 FAILURE TO HEED THIS WARNING COULD RESULT IN A BATTERY EXPLOSION OR SEV...

Page 10: ...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 11: ...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 GOVER...

Page 12: ...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 13: ...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 14: ...eases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure...

Page 15: ...cle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Figure 1 Gasoline Vehicle Figure 2 V Glid...

Page 16: ...e 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 available when ordering parts or making...

Page 17: ...y to an unsuspecting passenger or damage to the vehicle always bring the vehicle to a full stop before shifting the Forward Reverse handle or switch Release the accelerator pedal and then press the br...

Page 18: ...the seat support panel below and to the right of the driver s right knee The F FORWARD and R REVERSE positions are clearly marked Push down the FORWARD side of the switch to operate the vehi cle in t...

Page 19: ...e FORWARD or REVERSE position pressing 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 pe...

Page 20: ...ur Club Car distributor dealer 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 po...

Page 21: ...nds 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 placed...

Page 22: ...it snaps into place Figure 14 See following WARNING and NOTE WARNING With the cam in the SERVICE position and the engine running the vehicle may move suddenly if the Forward Reverse handle is shifted...

Page 23: ...nction with the Periodic Service Schedules on page 30 Any problems should be corrected by a Club Car distributor dealer or a trained technician General All the parts should be in place and properly in...

Page 24: ...14 feet 4 3 m If the pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop within 14 feet 4 3 m have the brake system checked and adjusted as required Brake adjustment m...

Page 25: ...Car vehicles operate at reduced speed in reverse Governor Check maximum speed of the vehicle The vehicle should operate at 12 15 mph 19 24 km h on a level surface DRIVING INSTRUCTIONS WARNING Only li...

Page 26: ...seated and holding onto seat hand holds or handrails 3 Read safety warnings located on dash and or above pedals 4 Make sure wheels are turned in desired direction 5 Turn key to the ON position and ma...

Page 27: ...with the Forward Reverse switch or key switch in any position the zero speed detect function will prevent the vehicle from roll ing at more than 1 to 3 mph 1 5 to 4 8 km h unless the accelerator is pr...

Page 28: ...etc Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer The vehicle to be towed should be tied securely to the trailer with the Forwa...

Page 29: ...en coat them with Battery Terminal Protector Spray CCI P N 1014305 3 Store vehicle in a cool dry place This will minimize battery self discharge 4 Adjust tires to recommended tire pressure See Vehicle...

Page 30: ...an automotive type 12 volt battery charger rated at 10 amps or less 2 Drain carburetor and seal the fuel tank 2 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam i...

Page 31: ...underside of vehicle 9 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1 Restore fuel system to operation Figure 31...

Page 32: ...eriodic Lubrication Schedules to keep the vehicle in proper working condition Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further d...

Page 33: ...to frame Check moveable contact for correct operation General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 50 hours of operation or 10...

Page 34: ...or every 100 rounds for golf cars Battery Clean terminals and wash dirt from casing check electrolyte level See Battery Gasoline Vehicle on page 41 Front wheel alignment and camber Check and adjust if...

Page 35: ...ts V Glide only Accelerator pivot rod supports PowerDrive and IQ System Dry Moly Lube CCI P N 1012151 Charger receptacle all vehicles Forward Reverse switch contacts V Glide and PowerDrive only WD 40...

Page 36: ...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 every...

Page 37: ...th water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes...

Page 38: ...cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life add only distilled water See following NOTE NOTE A ba...

Page 39: ...e 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 damaged in any...

Page 40: ...with an AC electric cord having an equipment grounding conductor and a grounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accord...

Page 41: ...ceptacle and push straight in slowly The PowerDrive Charger interacts with an onboard computer on PowerDrive System 48 and IQ System vehi cles The computer records the amount of energy consumed during...

Page 42: ...rand spray lubricant The plug should then be inserted and removed several times to ensure ease of inser tion ease of removal and good electrical contact See following NOTE NOTE If the warning tag has...

Page 43: ...minutes Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables The battery in the Club Car gasoline vehicle is a 12 volt low maintenance battery...

Page 44: ...oil from dipstick Figure 29 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube and immediately remove it...

Page 45: ...1 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 fuel s...

Page 46: ...sed 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 water properly ACCESSORIES The...

Page 47: ...ry type Electrical system 48 volts DC reduced speed reverse Electrical system 36 volts DC reduced speed reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capac...

Page 48: ...ut battery 619 lb 281 kg Forward speed 12 15 mph 19 24 km h Curb clearance circle diameter 17 ft 6 in 533 cm Braking distance at 12 mph 19 km h 14 ft 427 cm Standard seating capacity 2 2 2 2 LIQUID CA...

Page 49: ...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 50: ...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 51: ...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 52: ...nd conditions contained herein This limited warranty only covers defects in material and workmanship for a period of three years or 600 golf car rounds from date of purchase The terms of this three ye...

Page 53: ...information contact WARRANTY SERVICES CLUB CAR INC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CAR LIMITED FOUR YEAR WARRANTY FOR 2004 POWERDRIVE 8 VOLT BATTERIES CLUB CAR INC CL...

Page 54: ...ers the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL D...

Page 55: ...IED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRA...

Page 56: ...shall mean remedying a defect in the charger or component thereof at no cost to the purchaser during the applicable limited warranty period If CLUB CAR elects to repair the charger it may provide fact...

Page 57: ...IMITATIONS CLUB CAR s liability under this limited warranty shall be to replace a defective Computer or Controller Replacement shall be furnishing a new or reconditioned Computer or Controller which i...

Page 58: ...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...

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Page 60: ...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 102397401 Edition Code 0803B12...