Club Car Gasoline User Manual

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DS GOLF CARS

GASOLINE/ELECTRIC

MANUAL NUMBER 101905101

EDITION CODE 1196H0799C

MAINTENANCE

SERVICE

1995-1996

Table of Contents

Default Chapter4
- Table of Contents4
Safety11
Vehicle Speciﬁcations13
Vehicle Specifications13
General Information Section15
- Model Identification15
- Safety Committee15
- Pre-Operation Checklist16
  - Performance Inspection16
- Controls17
- Driving Instructions22
- Towing23
- Transporting on a Trailer24
- Storage - Gasoline Vehicle24
- Storage - Electric Vehicle26
Periodic Maintenance29
- Lubrication - Gasoline Vehicles30
- Lubrication - Electric Vehicles31
- Vehicle Capacities32
- Periodic Service - Gasoline Vehicles33
- Periodic Service - Electric Vehicles35
Body and Trim39
- General Information39
- Front and Rear Body Repair40
- Seat42
- Front Body42
- Rear Body43
- Floormat46
Accelerator and Brake Pedal Group47
- General Information47
- Pedal Group Adjustment - Early 1995 Vehicles47
- Pedal Group Disassembly and Assembly - Early 1995 Vehicles55
- Pedal Group Adjustment - Late 1995 and 1996 Vehicles59
- Pedal Group Disassembly and Assembly - Late 1995 and 1996 Vehicles69
Wheel Brake Assemblies77
- Removal of Brake Shoes and Cleaning of Wheel Brake Assemblies79
- Installing the Brake Shoes82
- Brake Assembly83
Steering and Front Suspension85
- General Information - Steering85
- Steering Wheel86
- Steering Column86
- Steering Adjustment90
- Rack and Pinion90
- Tie Rod and Drag Link100
- Front Suspension102
  - Lubrication102
  - Wheel Alignment102
- Front Suspension Components104
- Front Wheel Bearings and Hubs108
Transaxle111
- Lubrication111
- Axle Shaft112
  - Axle Bearing113
- Removing the Transaxle115
- Disassembly, Inspection, and Assembly of the Transaxle120
- Shimming the Transaxle124
- Installation of the Transaxle125
Wheels and Tires127
- General Information127
- Wheel Removal128
- Wheel Installation128
- Removing the Tire from the Rim129
- Repairing a Tire129
- Installing the Tire on the Rim129
Troubleshooting the Gasoline Vehicle131
- Troubleshooting Guide131
Electrical System - Gasoline Vehicle138
- General Information138
- FE 290 Gasoline Vehicle Electrical Circuit138
- Circuit Testing143
- Test Procedures150
- Electrical System Components163
Fe 290 Engine191
- General Information191
- Special Tools192
- Before Servicing192
- Mechanical Systems192
- Electrical System194
- Lubrication System195
- Spark Plug196
  - Cylinder Head197
  - Oil Pump221
- Engine Assembly236
- Service Specifications237
- Specifications for Resizing Cylinder Bore239
- Torque Specifications239
- Adjustments and Settings240
Fuel System241
- General Information241
- How the Carburetor Works241
- Carburetor244
  - Main Jet Elevation/Size Chart244
- Engine Control Linkage248
- Choke and Intake System254
- Fuel Filters257
- Fuel Pump259
- Fuel Tank262
- Fuel Lines264
- Fuel Tank Vent264
Exhaust System265
- General Information265
- Mufﬂer265
Torque Converter269
- General Information269
- Troubleshooting271
- Drive Belt271
- Drive Clutch272
- Driven Clutch280
- Clutch Alignment285
Transmission and Governor287
- General Information288
- Lubrication288
- Transmission289
- Forward and Reverse Shifter Cable308
Rear Suspension - Gasoline Vehicle311
- General Information311
- Shock Absorbers311
- Mono-Leaf Springs313
- Installing the Mono-Leaf Springs314
- The Snubber314
Electrical System - V-Glide 36 Volt Vehicle317
- General Information317
- V-Glide Electrical Circuits317
- Troubleshooting321
- Circuit Testing324
  - 19B334
Electrical Components - V-Glide 36 Volt Vehicle334
- Key Switch334
- Forward and Reverse Anti-Arcing Limit Switch335
- Accelerator Pedal Limit Switch336
- The Reverse Buzzer337
- The Solenoid338
- Resistors339
- V-Glide Wiper Switch341
- Forward and Reverse Switch348
Electrical System - Powerdrive System351
- General Information351
- The On-Board Computer352
- Powerdrive Vehicle Electrical Circuits352
- Troubleshooting Guide356
- Circuit Testing359
- The Communication Display Module (CDM)372
- Communication Display Module Troubleshooting Guide374
- The Key Switch375
- Forward and Reverse Switch377
  - Forward and Reverse Limit Switches378
- The Reverse Buzzer379
- The Solenoid381
- On-Board Computer383
- Solid State Speed Controller384
- Charger Receptacle384
  - Receptacle Fuse Link386
- Continuously Variable Potentiometer387
- Multi-Step Potentiometer390
- Battery Warning Light391
Electrical System - Powerdrive Plus393
- General Information393
- The Control Circuit397
- The Power Circuit408
- The Charge Circuit411
- Troubleshooting Guide412
- Test Procedures417
  - Numerical Listing of Test Procedures417
Electrical Components - Powerdrive Plus445
- Key Switch445
- Forward and Reverse Switch446
- Reverse Buzzer446
- Main Solenoid447
- Dynamic Braking Solenoid448
- On-Board Computer448
- Controller449
- Charger Receptacle450
- Continuously Variable Potentiometer450
- Battery Warning Light450
- Energy Displacement Module450
Batteries453
- General Information453
- Common Misconceptions about Batteries455
- Replacing Batteries456
- Battery Care457
- Battery Charging459
- Battery Testing460
- Battery Troubleshooting Chart - 36 and 48 Volt462
- Battery Troubleshooting Examples467
- Battery Storage469
- Charging Battery Pack with Low Voltage470
Accu-Power Battery Charger473
- General Information473
- The Charge Circuit475
- Charger Installation and Use475
- Troubleshooting478
- Test Procedures479
- Plug and Receptacle Replacement490
  - On-Board Receptacle Fuse Link493
- Charger Repairs494
Powerdrive Battery Charger499
- General Information499
- Battery Warning Light500
- The Charge Circuit500
- Charger Installation and Use502
- Checking Battery Condition after a Charge Cycle505
- Troubleshooting506
- Test Procedures511
- Plug and Receptacle Replacement518
  - Charger Cord Replacement518
- Charger Repairs519
Motor525
- General Information525
- External Motor Testing525
Rear Suspension - Electric Vehicle539
- General Information539
- Shock Absorbers540

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Club Car Gasoline Specifications

General

Brand	Club Car
Model	Gasoline
Category	Golf Cars
Language	English

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