DS Golf Cars M Gasoline and Electric - Club Car

1 Club CarDS Golf Cars Gasoline and Electric2004 owner s manual FUEL AND OIL RECOMMENDATIONSFuelUse only clean, fresh, unleaded regular RatingThe octane rating of a Gasoline is a measureof its resistance to knocking . Use of a mini-mum of 87 octane of the anti-knock index isrecommended. The anti-knock index is posted onservice station pumps in the FuelIf you use oxygenated fuel (either ethanol orMTBE added to Gasoline ), be sure it is unleadedand meets the minimum octane rating following are the EPA approved percent-ages of fuel : (Ethyl or Grain Alcohol) You mayuse Gasoline containing up to 10% ethanol : (Methyl Tertiary Butyl Ether) You mayuse Gasoline containing up to 15% MTBE : (Methanol or Wood Alcohol) 5% may use Gasoline containing up to 5%methanol by volume, as long as it also containscosolvents and corrosion inhibitors to protectthe fuel system. Gasoline containing more than5% methanol by volume may cause startingand/or performance problems.

2 It may also dam-age metal, rubber, and plastic parts of your OilThe following engine oils are Service Classification: SC, SD, SE, SF,SG, or ViscosityChoose the viscosity according to the tem-perature as follows:Fuel InformationTHIS vehicle IS CERTIFIED TO OPER-ATE ON UNLEADED REGULAR GRADEGASOLINE ONLY. A minimum of 87 octane ofthe anti-knock index is recommended. The anti-knock index is posted on service station pumpsin the Control InformationTo protect the environment in which we alllive, Club Car has incorporated crankcase emis-sion (1) and exhaust emission (2) control sys-tems (EM) in compliance with applicable regu-lations of the Environmental ProtectionAgency and California Air Resources Crankcase Emission Control SystemA sealed-type crankcase emission controlsystem is used to eliminate blow-by gases. Theblow-by gases are led to the breather chamberthrough the crankcase. Then, it is led to the is separated from the gases while passingthrough the inside of the breather chamberfrom the crankcase, and then returned back tothe bottom of the Exhaust Emission Control SystemThe exhaust emission control system appliedto this engine consists of a carburetor and anignition system having optimum ignition carburetors have been calibrated toprovide lean air/fuel mixture characteristicsand optimum fuel economy with a suitable aircleaner and exhaust and WarrantyProper maintenance is necessary to ensurethat your engine will continue to have low emis-sion levels.

3 Those items identified by the PeriodicMaintenance Chart are necessary to ensurecompliance with the applicable Club Car Limited Emission ControlSystem Warranty requires that you return yourengine to an authorized Club Car Dealer forremedy under warranty. Please read the warrantycarefully, and keep it valid by complying withthe owner s obligations it with Emission ControlSystem ProhibitedCalifornia State law prohibits the followingacts or the causing thereof: (1) the removal orrendering inoperative by any person other thanfor purposes of maintenance, repair, or replace-ment, of any device or element of design incor-porated into any new engine for the purposes ofemission control prior to its sale or delivery to theultimate purchaser or while it is in use, or (2) theuse of the engine after such device or element ofdesign has been removed or rendered inopera-tive by any those acts presumed to constitutetampering are the acts listed below:Do not tamper with the original emission relat-ed parts.

4 Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner element Crankcase Cylinder head Breather chamber and internal parts Intake pipe and tubeEMISSION CONTROL INFORMATION-20 C-10 C0 C10 C20 C30 C40 C-4 F14 F32 F50 F68 F86 F104 FSAE 5W-20 SAE 10W-30/SAE 10W-40 SAE 30 SAE 40 NOTE If knocking or pinging occurs, use adifferent brand of Gasoline or higheroctane rating. Do not mix oil with Gasoline . Gasoline is extremely flammable andcan be explosive under certain con-ditions. Turn the engine switch not smoke. Make sure the area iswell ventilated and free from anysource of flame or sparks; thisincludes any appliance with a pilotlight. Never fill the tank so the fuellevel rises into the filler neck. If thetank is overfilled, heat may causethe fuel to expand and overflowthrough the vent in the fuel tank. After refueling, make sure the tankcap is closed securely.

5 If Gasoline is spilled on the fuel tankwipe it off Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oilconsumption. Check oil level morefrequently when using them. 2004 DS Golf Car owner s ManualPage 1 P. O. Box 204658 Augusta, Georgia 30917-4658 USAT elephone 706-863-3000 Service Parts Fax Page 22004 DS Golf Car owner s manual NOTICE The Club Car Limited Warranty for owners of individual golf cars and the Limited Lifetime Fleet Warrantyappear at the end of this manual , along with limited warranty information for 2004 T-105 6-Volt Batteries, 2004 PowerDrive 8-Volt Batteries, 2004 36-Volt Battery Chargers, 2004 PowerDrive Battery Chargers, and 2004 Onboard Computers and Solid State Speed Controllers. No other warranties, expressed or implied, are con-tained herein. Your authorized representative checked the vehicle before it was delivered to you and will pro-vide you a copy of the completed vehicle warranty registration Car is not liable for errors in this manual or for incidental or consequential damages that result from theuse of the material in this vehicle conforms to the current American National Standards Institute s Z130 Safety and PerformanceRequirements for Golf Cars.

6 This standard, which promotes safety in the design, application, and operation ofgolf cars, defines a golf car as a vehicle used to convey a person or persons and equipment to play the gameof golf in an area designated as a golf course. Throughout this manual , the words golf car and vehicle areused manual contains proprietary information that is protected by copyright. All rights are reserved. No part ofthis manual may be photocopied, reproduced, or translated to another language without the written consentof Club Car, information contained in this document is subject to change without Car reserves the right to make design changes to vehicles without obligation to make these changes onunits previously vehicles do not conform to Federal Motor vehicle Safety Standards for automobiles or to FMVSS 500for low-speed vehicles, and are not equipped for operation on public streets, roads, or 2003 Club Car, Inc. Club Car , ArmorFlex , and PowerDrive are registered trademarks of Club Car, manual effective July 28, 2003.

7 2004 DS Golf Car owner s ManualPage 3 FOREWORD Thank you for choosing Club Car, the vehicle most widely recognized as the industry leader in vehicle effi-ciency and long-lasting value. You have chosen the finest golf car on the market. Please protect your invest-ment and ensure that your Club Car vehicle (s) provides years of reliable, superior performance by readingand following the maintenance instructions in this comfort and safety are important to us, so we urge you to read and follow the step-by-step operatinginstructions and safety procedures in this manual . These instructions must be followed in order to avoid therisk of severe personal injury. If you rent or loan your vehicle to others, we recommend that you ask them toread this manual before they operate the Car products are backed by a customer support system designed to offer you fast, courteous service. Inthe event that your Club Car vehicle needs repairs or service, we recommend that your local authorized ClubCar representative perform them.

8 For the name and address of the Club Car representative nearest you,logon to our web site at or call 1-800-ClubCar (258-2227). If you would prefer to write to us,direct your letter to: Club Car, Attention: Marketing Services, Box 204658, Augusta, Georgia 30917-4658 USA. Your local authorized Club Car representative can also provide technical advice, parts, and hope you will consider this owner s manual a permanent part of your Club Car vehicle . If you sell the vehi-cle, please include the manual so that the next owner will have the important operating, safety, and mainte-nance information it contains. Page 42004 DS Golf Car owner s manual 2004 DS Golf Car owner s ManualPage 5 TABLE OF CONTENTS vehicle Feature Identification DS Electric vehicle .. 6 vehicle Feature Identification DS Gasoline vehicle .. 8 Safety Details .. 11 General Warnings .. 11 General Information .. 14 Model Identification.

9 14 Safety Committee .. 14 Controls and Indicators .. 15 Pre-Operation and Daily Safety Checklist .. 21 Driving Instructions .. 23 Towing .. 25 Transporting 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 Electric vehicle .. 35 Battery Charger Electric vehicle .. 37 Battery Gasoline vehicle .. 41 Engine Oil Gasoline vehicle .. 42 Fueling Instructions Gasoline vehicle .. 43 Cleaning the vehicle .. 44 Accessories .. 44 Subsequent owner Registration .. 44 vehicle Specifications .. 45 Club Car Limited Three Year Warranty for 2004 Individual Golf Cars .. 47 Club Car Limited Lifetime Warranty for 2004 Fleet Golf Cars .. 48 vehicle Feature Identification Page 62004 DS Golf Car owner s manual DS Electric vehicle Maximum vehicle speed is limited by motor braking during downhill operationwith accelerator pedal depressed.

10 If motor brake enabled, vehicle motor will brake when accelerator pedal is released. Beeping alarm indicates reduction in motor braking. Apply brakes to reduce speed. System is activated only when tow switch is in the "RUN" position. When towing vehicle , tow switch must be in the "TOW" NUMBERBRAKE PEDALPARK BRAKE PEDALMOTOR BRAKING DECAL(IQ SYSTEM VEHICLES ONLY)ACCELERATORPEDALOPERATING INSTRUCTIONSDECALDRIVER / PASSENGERWARNING DECALKEY SWITCHPRIVATE SPEED DECAL (IQ VEHICLES WITH PRIVATE SPEED OPTION) Before using vehicle , read operating instructions. Remain seated and hold on to seat handle while moving. Do not start vehicle until all occupants are seated. Two (2) persons per seat maximum. Operate from driver side only and not on public roads. Keep entire body inside vehicle while moving. Drive slowly in turns and straight up and down slopes. Do not leave children unattended on vehicle . Never operate under the influence of alcohol or drugs.