Club car ds service manual download

Fully charge batteries. Adjust tire to recommended pressure. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process especially if the vehicle has an ArmorFlex rear body that is removed will expose electrical components to moisture. Using the brush provided with the touch-up paint available from Club Car Service Parts — see following color chart , apply paint to the scratch.

Place the pads 12 on the front body and under the windshield frame mounting brackets Figure , Page Align the slots on the pads with the slots in the mounting brackets. Remove the seat from the rear body. However, adjustment of the choke positioner may be necessary after the rear body is reinstalled. Gasoline vehicles only: Check the choke positioner for proper adjustment and adjust if necessary.

Install fuel pump. All gasoline DS golf cars use the same type of pedal group; Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands. Secure the equalizer rod 13 to the brake pedal assembly 8 with the clevis pin 14 and bow-tie pin 15 as shown Figure , Page Tighten the jam nut 3 while holding the adjustment nut 2 in the correct position Figure , Page Adjust the pedal group. Remove the park brake assembly. To remove the park brake rod and pawl assembly 16 through 19 and 35 , remove the push nut 18 and disconnect the ball joint sleeve 20 from the park brake pedal 24 Figure , Page See following NOTE.

Finger-tighten nuts at this time Figure , Page This sections pertains to electric MCOR vehicles only. Finger-tighten hardware at this time. Disconnect the battery cables as instructed. Adjust brake pedal free play. NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm at the brake cluster moves.

Adjust accelerator pedal height. Loosen the nut and bolt Figure , Page securing the accelerator pedal to the pivot plate. Loosen the jam nuts 18 and disconnect the accelerator rod 17 at the accelerator pedal. See step 6 of Pedal Group Adjustment — Adjust the accelerator rod. See also Warning on Page Carefully clean the brake backing plate and all of its mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth. While maintaining spring attachment on both shoes, position tips of leading shoe in the mounting slots and then push shoe into place.

Hold shoe in position and install retaining clip Figure , Page Install the brake drum, and make sure that it is properly seated. Remove the axle. Pull the axle shaft 2 from the axle tube Figure , Page Rotate the brake cable upward and pull cable end through hole in top of equalizer 4. Remove E-clip from cable at vehicle frame 5 Figure , Page Remove cable from frame. Remove the steering wheel nut 27 and the steering wheel 25 from the steering column 20 Figure , Page Remove the center dash panel Figure , Page Remove the plastic cap 1 covering the mounting screw 2 on each side of the center dash panel 3 Figure , Page Remove screws 6 and mount 4 and 5 from steering column.

Remove boot 12 Figure , Page While supporting steering column 21 on a workbench, remove snap ring 13 from shaft. Install the wedge 16 , spring 15 , washer 14 , and snap ring 13 onto the bottom end of the steering shaft 19 Figure , Page Insert the shaft 19 from the bottom of the steering tube 20 Figure , Page Loosen the nuts 27 and 29 and turn the drag link 28 Figure , Page to adjust the drag link rod. Adjust the link rod with the steering wheel turned all the way to the right, so the passenger-side spindle stop lightly touches the passenger-side A-Plate.

Remove the front body as instructed in Section 4 — Body and Trim. Remove the cotter pin 22 and ball joint retaining nut 25 Figure , Page If the ball bearing 9 has been damaged, remove the external snap ring 10 Figure , Page and press the bearing off Figure , Page Install a new tab washer 4 and an inner ball joint 3 Figure , Page Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.

Install the rack guide 13 , pressure spring 14 , and screw The screw should be threaded in until a rotational torque of 10 in-lb 1. Position the steering gear box assembly on the shock and gear support and install the bolts 30 , wash- ers 31 , and nuts Do not tighten the mounting bolts Figure , Page Thread the drag link rod 28 all the way onto the threaded stud of the inner ball joint assembly 3 right- hand threads Figure , Page If adjustment is necessary, loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase or decrease toe-in Figure , Page Remove the front hub.

See Front Wheel Bearings and Hubs on page A Club Car service manual is a great source of information for operating, servicing and fixing your golf cart. There are several different types of manuals for your Club Car. Unlike a car manual that sits in your glove compartment, this golf cart manual just seems to get lost. Just download it to your computer for an easy reference. I saved and downloaded the manual for my year cart and I am happy to have it as a handy reference.

A Club Car repair manual has to be purchased. Copyright laws prohibit anyone from making or distributing copies of this manual. They will have to order one — so you might as well do it yourself and have it shipped to you. It is well worth the investment if you plan to do some of your own basic troubleshooting and repairs. For carts that are or newer you will find the serial number on the passenger side under the glove compartment.

The first letter identifies the model and then the next two numbers represent the year the cart was made. The serial number of each vehicle is printed on a bar code decal mounted either below the passenger side cup holder or above the accelerator or brake pedal Example: PH, as shown, or F The letters or letter at the beginning of the serial number 1 indicate the vehicle model, could be one or two letters. The following four digits 2 indicate the model year and production week during which the vehicle was built.

The six digits following the hyphen 3 represent the unique sequential number assigned to each vehicle built within a given model year. Club Car Service Manuals. Search for:. Previous Next. View Larger Image. Club Car Service Manual A Club Car service manual is a great source of information for operating, servicing and fixing your golf cart.