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Club Car 1998 DS Maintenance Service Manual

Club car 1998-1999 ds golf cars gasoline/electric
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See also: Owner's Manual
1998-1999
MAINTENANCE
S E R V I C E
MANUAL
DS GOLF CARS
GASOLINE/ELECTRIC
MANUAL NUMBER 101968401
EDITION CODE
0199B0312A

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Summary of Contents for Club Car 1998 DS

  • Page 1 1998-1999 MAINTENANCE S E R V I C E MANUAL DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 101968401 EDITION CODE 0199B0312A...
  • Page 3 Golf Car service. However, unique situations do sometimes arise when servicing a golf car. If it appears that a service question is not answered in this manual or the supplement, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917; Attention: Technical Services, or contact a Club Car Technical Service representative at (706) 863-3000, extension 3580.
  • Page 4 SPECIFICATIONS OR MODIFICATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF, WILL VOID THE WARRANTY. • CLUB CAR, INC. RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER.

  • Page 5: Table Of Contents

    CONTENTS SAFETY SECTION General Warning ..........................VEHICLE SPECIFICATIONS SECTION General Information .......................... GENERAL INFORMATION SECTION Model Identification ........................... Safety Committee ..........................Pre-Operation Checklist ........................Controls ............................Driving Instructions ........................... Towing ............................... 3-11 Transporting on a Trailer ........................3-11 Storage - Gasoline Vehicle ....................... 3-12 Storage - Electric Vehicle ........................
  • Page 6 STEERING AND FRONT SUSPENSION SECTION General Information - Steering......................Steering Wheel ..........................Steering Column ..........................Steering Adjustment .......................... Rack and Pinion ..........................Tie Rod and Drag Link ........................7-10 Front Suspension ..........................7-12 Front Suspension Components ......................7-14 Front Wheel Bearings and Hubs ....................... 7-18 WHEELS AND TIRES SECTION...

  • Page 7: General Warning

    SECTION 1–SAFETY To insure the safety of those servicing Club Car DS Golf Cars, and to protect the vehicles from possible dam- age resulting from improper service or maintenance, the procedures in this manual must be followed. It is important to note that throughout this manual there are statements which are contained within boxes labeled DANGER, WARNING, or CAUTION.
  • Page 8 SAFETY General Warning General Warning, Continued: DANGER • GASOLINE - FLAMMABLE! EXPLOSIVE! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY FROM VEHICLE AND SERVICE AREA. SERVICE ONLY IN A WELL-VENTILATED AREA. • DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION.
  • Page 9 SAFETY General Warning WARNING GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE: - DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST (FIGURE 1-1) . - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG. • FRAME GROUND - DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING.

  • Page 11: Vehicle Specifications

    SECTION 2–VEHICLE SPECIFICATIONS GENERAL INFORMATION Club Car, Inc. reserves the right to change vehicle specifications and design of either gasoline or electric vehicles at any time without obligation to make these changes on units previously sold. POWERDRIVE POWERDRIVE SPECIFICATIONS SYSTEM 48...
  • Page 12 VEHICLE SPECIFICATIONS General Information POWERDRIVE POWERDRIVE SPECIFICATIONS SYSTEM 48 PLUS 36-VOLT GASOLINE ELECTRIC ELECTRIC ELECTRIC DIMENSIONS/WEIGHT 91-1/2" 91-1/2" 91-1/2" 91-1/2" Overall Length (232 cm) (232 cm) (232 cm) (232 cm) 47-1/4" 47-1/4" 47-1/4" 47-1/4" Overall Width (120 cm) (120 cm) (120 cm) (120 cm) 48"...

  • Page 13: General Information Section

    SAFETY COMMITTEE If the golf car is to be rented or is part of a fleet, Club Car, Inc. recommends a safety committee be appointed. One of the main concerns of this committee should be the safe operation of the golf cars.

  • Page 14: Pre-Operation Checklist

    PRE-OPERATION CHECKLIST Each Club Car vehicle is thoroughly inspected and adjusted at the factory and by a Club Car distributor/dealer. However, upon receipt of any new Club Car vehicle, become familiar with the controls and vehicle operation. Carefully inspect each vehicle to be satisfied it is in proper working condition before accepting delivery.

  • Page 15: Controls

    (19-24 kph) on a level surface. • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle ride and perfor- mance. Have a CLUB CAR distributor/dealer or a trained mechanic investigate anything unusual. DS PowerDrive Plus Vehicles with Motor Braking: •...
  • Page 16 GENERAL INFORMATION Controls Controls, Continued: KEY SWITCH The key switch is mounted on the dash to the right of the steering column (Figure 3-3, Page 3-4) . It has two positions, OFF and ON, which are clearly labeled. NOTE • THE KEY CAN BE REMOVED WHEN THE KEY SWITCH IS IN THE OFF POSITION ONLY. Figure 3-3 Key Switch Figure 3-4 Forward and Reverse Handle FORWARD/REVERSE CONTROL...
  • Page 17 GENERAL INFORMATION Controls NOTE • THE OPERATION OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN AUTOMOBILE. WHEN THE KEY SWITCH IS ON , AND THE SHIFT HANDLE IS IN EITHER FORWARD OR REVERSE , DEPRESSING THE ACCELERATOR PEDAL WILL AUTOMATICALLY RELEASE THE PARK BRAKE AND START THE VEHICLE MOVING IN THE DIRECTION SELECTED ( FORWARD OR REVERSE ).
  • Page 18 GENERAL INFORMATION Controls Neutral Lock-out, Continued: This will allow the mechanic to run the engine in NEUTRAL for certain maintenance procedures. With the cam in this position, the vehicle will not operate if Forward/Reverse handle is placed in either FORWARD or REVERSE position.

  • Page 19: Battery Warning Light

    If the warning light comes on and the vehicle is unable to finish the round, have a Club Car distributor/dealer check the vehicle for a possible battery or electrical system problem.
  • Page 20 16 hours (see charger manual) and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. Charger and batteries should be checked by your Club Car distributor/dealer. • The warning light will repeatedly illuminate for 10 seconds, with 4 second intervals, during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted.

  • Page 21: Driving Instructions

    GENERAL INFORMATION Driving Instructions The Tow/Run switch should be placed in the TOW position under the following conditions: • Before Towing the Vehicle: Place the Tow/Run switch in the TOW position to disable all motor braking functions, thus preventing possible damage that could occur to the vehicle or electrical components if the vehicle is towed while the Zero-Speed Detect motor braking function is operating.
  • Page 22 GENERAL INFORMATION Driving Instructions Driving Instructions, Continued: No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle controls. An experienced operator should accompany each first-time driver on a test drive before allowing him(her) to operate the vehicle alone.

  • Page 23: Towing

    • DO NOT ALLOW PASSENGERS IN THE VEHICLES BEING TOWED. • AVOID SUDDEN STARTS, SUDDEN STOPS, AND TIGHT TURNS WHEN TOWING. • DO NOT TOW MORE THAN ONE CLUB CAR VEHICLE WITH ANOTHER CLUB CAR VEHICLE. IF MORE THAN ONE VEHICLE MUST BE TOWED, USE AN ADEQUATELY POWERED VEHICLE (TRACTOR OR FULL SIZED TRUCK) PROPERLY FITTED, WITH A TOW HITCH HEIGHT OF 11 INCHES.

  • Page 24: Storage - Gasoline Vehicle

    GENERAL INFORMATION Storage - Gasoline Vehicle STORAGE - GASOLINE VEHICLE To prepare your vehicle for extended off season storage: 1. Store vehicle in a cool place. This will prevent self-discharge of the battery. If the battery appears to be weak, have it charged using an automotive-type 12-volt battery charger rated 10 amps or less. DANGER •...

  • Page 25: Storage - Electric Vehicle

    (do not allow this solution to enter the batteries). Let the terminals dry and coat them with Battery Terminal Spray, Club Car Part No. 1014305. 3. Store in a cool, dry place. This will prevent self-discharge of the batteries.
  • Page 26 GENERAL INFORMATION Storage - Electric Vehicle Storage - Electric Vehicle, Continued: 4. Adjust tire pressure to 20 psi (.96 kPa). 5. Grease front suspension and do all quarterly periodic lubrication. See Periodic Lubrication Sched- ule, Section 10, Maintenance and Service Supplement. 6.

  • Page 27: Body And Trim

    SECTION 4–BODY AND TRIM WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY. • HEED DANGER, WARNING, AND CAUTION STATEMENTS IN THIS MANUAL, AS WELL AS MANUFACTURERS’...

  • Page 28: General Information

    BODY AND TRIM General Information CAUTION • DO NOT USE DETERGENTS OR CLEANING SOLVENTS THAT CONTAIN AMMONIA, AROMATIC SOLVENTS, OR ALKALI MATERIALS ON BODY PANELS OR SEATS. • DO NOT ALLOW BATTERY ACID TO DRIP ON BODY PANELS. BATTERY ACID WILL CAUSE PERMANENT BLEMISHES.
  • Page 29 101978901) to only the bare body material. 7. Fill the scratch with body filler (Club Car Part No. 1017295). Allow the filler to dry and then sand lightly. 8. Apply primer to the filled and promoter covered area. Allow the primer to dry, then perform steps 3 through 5 above.

  • Page 30: Seat

    BODY AND TRIM Seat Front and Rear Body Repair, Continued: Club Car Touch-Up Paint Part Numbers Beige 1019972-01 White 1019972-02 Gray 1019972-04 1019972-06 Dark Blue 1019972-08 Dark Green 1019972-09 Black 1019972-10 Classic Blue 1019972-11 Burgundy 1019972-12 GOUGES, PUNCTURES, TEARS, LARGE SCRATCHES, AND ABRASIONS Touch up is not recommended.

  • Page 31: Front Body Installation

    BODY AND TRIM Front Body 2. Remove carriage bolts (10), locknuts (17), and washers (11) from front body trim. Remove screws (16) from top of front body (Figure 4-1, Page 4-5) . 3. Loosen (do not remove) T-nut screws (12) securing front body trim (9) against front body (Figure 4-1, Page 4-5) . 4.

  • Page 32: Rear Body

    BODY AND TRIM Rear Body REAR BODY See WARNING and CAUTION on pages 4-1 and 4-2. REAR BODY REMOVAL NOTE    yyyyy zzzzz ||||| • REAR BUMPER DOES NOT HAVE TO BE REMOVED TO REMOVE REAR BODY.    yyyyy...
  • Page 33 BODY AND TRIM Rear Body • PowerDrive System 48 and PowerDrive Plus vehicles (Figure 4-4, Page 4-6): The charger receptacle must be disconnected, but does not have to be removed from the body: 5.1. Remove wire tie binding 10 gauge red wire (from charger receptacle to battery) to Forward/ Reverse switch wires.

  • Page 34: Floormat

    BODY AND TRIM Floormat REAR BODY INSTALLATION 1. Install two screws in kick-plate. Tighten to 20 in.lb (2.3 N-m) (Figure 4-3, Page 4-6) . 2. Tighten two screws (1) and locknuts located under bagwell protector in bagwell floor to 20 in.lb (2.3 N-m) (Figure 4-2, Page 4-6) .

  • Page 35: Accelerator And Brake Pedal Group

    SECTION 5–ACCELERATOR AND BRAKE PEDAL GROUP GENERAL INFORMATION WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR. • FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND HEED DANGER, WARNING, AND CAUTION STATEMENTS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE.

  • Page 36: Pedal Group Adjustment

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment WARNING ELECTRIC VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES AS SHOWN (SECTION 1, FIGURE 1-2 OR 1-3, PAGE 1-3) . • ON POWERDRIVE PLUS VEHICLES, PLACE TOW/RUN SWITCH IN THE TOW POSITION BEFORE DISCONNECTING BATTERIES.
  • Page 37 3.1. Loosen the nut and bolt (Figure 5-8, Page 5-5) securing the accelerator pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (Club Car Part No. 101871001) to the accelerator pedal, with the end marked accelerator pedal height toward the floorboard, then depress the accelerator pedal until the end of the tool rests against the floorboard (pedal...
  • Page 38 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment CAUTION • AFTER ACCELERATOR ROD ADJUSTMENT, MAKE SURE THAT APPROXIMATELY THE SAME AMOUNT OF THREAD IS EXPOSED AT EACH END OF THE ROD. • IF THE LEVER ON THE LIMIT SWITCH IN THE ELECTRICAL BOX IS BENT, REPLACE THE LIMIT SWITCH.
  • Page 39    yyyyy zzzzz ||||| ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment    yyyyy zzzzz ||||| RATCHET (B) TOOTH LENGTH LOCKED POSITION    yyyyy zzzzz ||||| WITH PARK BRAKE UNLOCKED MEASURE FROM FLOOR BOARD TO BACK   |||||...
  • Page 40 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Adjust the Accelerator Rod, Continued: 15° TO 17° TOP VIEW OF THE ELECTRICAL COMPONENT Figure 5-10 Accelerator Cable Cam Position • Adjust the Accelerator Rod - V-Glide 36-volt vehicles, PowerDrive System 48 and PowerDrive Plus vehicles.
  • Page 41 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment 4.4. While holding accelerator rod (17) with pliers, loosen the jam nut (18) and adjust the ball joint (19) sleeve to fit on the wiper switch ball stud, with approximately the same number of threads show- ing at each end of the rod.

  • Page 42: Pedal Group Disassembly And Assembly

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly PEDAL GROUP DISASSEMBLY AND ASSEMBLY Removing the Brake Pedal Assembly 1. Make sure key switch is OFF and that the Forward/Reverse handle is in NEUTRAL, then disconnect battery or batteries as instructed in WARNING on pages 5-1 and 5-2. See following CAUTION. CAUTION •...
  • Page 43 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly 1.4. Install the brake cables (6) on the equalizer rod using new cotter pins (8) and the clevis pins (9) that were removed when the brake pedal assembly was disassembled (Figure 5-12, Page 5-9). Tighten the nut (5) on the equalizer rod so that brake pedal free-play is 1/4 in.
  • Page 44 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Removing the Park Brake Assembly 1. Make sure the key switch is off and that the Forward/Reverse handle is in NEUTRAL, then disconnect the battery or batteries as instructed in WARNING on pages 5-1 and 5-2. See following CAUTION. CAUTION •...
  • Page 45 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Figure 5-13 Brake Pedal Weldment Through Floor Figure 5-14 Park Brake Assembly HOOK ONE TURN HEX NUTS UNTIL END OF THERE IS A 1/4" TO 1/2" (6.3 TO SPRING (20) 12.7 MM) FREE PLAY OF ON PARK THE BRAKE PEDAL...
  • Page 46 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Removing the Accelerator Pedal Assembly, Continued: 3. Remove the nut (23), two washers (25), and bolt (4) securing the accelerator pedal (1) to the pivot rod (6) (Figure 5-11, Page 5-7). 4.
  • Page 47 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly 7. Move the pivot rod back toward the driver side of the vehicle and line up the scribed match marks on the pivot rod and ratchet. Rotate the pivot rod back and forth slightly to align the splines and slide the ratchet onto the splines.

  • Page 49: Wheel Brake Assemblies

    REVERSE POSITION. - SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS SOUNDING, THE CONTROLLER IS DISCHARGED. 1998 DS Golf Car Maintenance and Service Manual Page 6-1...
  • Page 50 TYPICAL 4 PLACES yy yy TYPICAL 2 PLACES TYPICAL 2 PLACES ELECTRIC VEHICLE ONLY GASOLINE VEHICLE ONLY SEE REAR SUSPENSION - SECTION 9 FOR MOUNTING Figure 6-1 Self-adjusting Wheel Brake Assembly Page 6-2 1998 DS Golf Car Maintenance and Service Manual...

  • Page 51: Removal And Cleaning Of Wheel Brake Assemblies

    • WHEN SERVICING VEHICLES WITH SEVERELY WORN BRAKE SHOES AND WHEN THE DRUMS CANNOT BE REMOVED BY NORMAL METHODS, PROCEED TO STEP 4 TO MINIMIZE DAMAGE TO THE BRAKE CLUSTER AND BRAKE COMPONENTS. 1998 DS Golf Car Maintenance and Service Manual Page 6-3...
  • Page 52 ROTATE CLIP RETAINER (1) 90° TO RELEASE CLIP (2) HOLD SHOES FIRMLY AND REMOVE WITH SPRINGS AS A UNIT Figure 6-5 Remove Shoe Retainer Clip Figure 6-6 Remove Brake Shoes Page 6-4 1998 DS Golf Car Maintenance and Service Manual...

  • Page 53: Installing The Brake Shoes

    TEM OR LOW PRESSURE/WET CLEANING METHOD PER OSHA/29 CFR - 1910.1001. 10. Lubricate slide (1) and slide plate (2) with dry moly lubricant (Club Car Part No. 1012151). After lubri- cating, work the slide back and forth to ensure that it slides smoothly and easily (Figure 6-8, Page 6-6).
  • Page 54 WHEEL SO THAT THE AMOUNTS OF WHITE LITHIUM NLGI #2 SHOE SLOT IS VERTICAL GREASE TO THE AREAS INDICATED. Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe Page 6-6 1998 DS Golf Car Maintenance and Service Manual...
  • Page 55 flush at the top with the top surfaces of the wedge shapes on the shoe mounting blocks as shown (Figure 6-16, Page 6-7) . 1998 DS Golf Car Maintenance and Service Manual Page 6-7...

  • Page 56: Adjusting The Brakes

    floor jack. Place jackstands under the axle tubes to support the vehicle. Read WARNING on page 6-1 . 2. Loosen the equalizer retaining nuts (1) on the equalizer rod (2) to slightly loosen the brake cable (Fig- ure 6-2, Page 6-3) . Page 6-8 1998 DS Golf Car Maintenance and Service Manual...
  • Page 57 Installing Brake Assembly Onto Axle Tube 1. Install in reverse order of disassembly. 2. Be sure bolts (11) (Club Car Part No. 1014153) and lock nuts (10) (Club Car Part No. 1013924) are used to mount the brake assembly (Figure 6-1, Page 6-2).

  • Page 59: Steering And Front Suspension

    SECTION 7–STEERING AND FRONT SUSPENSION GENERAL INFORMATION - STEERING Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel. No manual adjustment to the rack and pinion gear assembly is required. A spring loaded self-adjusting mechanism is incorporated into the assembly.

  • Page 60: Steering Wheel

    3. Loosen steering wheel nut (26) and back it off approximately 1/4 in. (6 mm). Do not remove nut (Figure 7-2, Page 7-3) . 4. Pull the steering wheel until it breaks free from the shaft splines (Club Car recommends using a steer- ing wheel puller) (Figure 7-1, Page 7-2) .
  • Page 61 STEERING AND FRONT SUSPENSION Steering Column yy yy yy yy TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 3 PLACES Figure 7-2 Steering Column Assembly and Installation 3.1. Remove the plastic cap covering the screw on each side of the center dash. 3.2.
  • Page 62 STEERING AND FRONT SUSPENSION Steering Column Steering Column Removal, Continued: 3.4. Pull center dash out approximately 1 in. from the frame and then bend the top right corner inward while pulling the top of the panel out and down. NOTE •...

  • Page 63: Steering Column Assembly

    2. Press the bearing (18) all the way into the bearing seat (19) using a steering column bearing press tool (Club Car Part No. 1014264) or a metal tube approximately 6 in. (15 cm) long with a maximum outer diameter of 1-3/16 in. (3.3 cm) and a minimum inside diameter of 7/8 in. (2.2 cm). Be sure the bearing is installed in the bearing seat as shown (Figure 7-3, Page 7-5) so that the wedge (17) will ride against the inner race of the bearing.

  • Page 64: Steering Adjustment

    STEERING AND FRONT SUSPENSION Steering Adjustment STEERING COLUMN INSTALLATION 1. Reinstall mount (4 and 5) onto end of steering column. Tighten bolts (6) to 22 ft.lb (30 N-m) (Figure 7-2, Page 7-3). 2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating com- pound to both splined ends of the steering shaft.

  • Page 65: Rack And Pinion

    STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION Read WARNING on page 7-1. Figure 7-5 Adjust Steering Alignment Figure 7-6 Remove Ball Joint Figure 7-7 Remove Dust Seal Figure 7-8 Remove Snap Ring RACK AND PINION REMOVAL 1. Remove the front body as instructed in Section 4, Body and Trim. 2.
  • Page 66 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: PRY OR BUMP PINION GEAR PRESS RAM OUT WITH UNIVERSAL JOINT REINSTALLED PINION GEAR BEARING Figure 7-9 Remove Pinion from Housing Figure 7-10 Remove Bearing from Pinion 2. Remove the drag link (28) (Figure 7-13, Page 7-11). 3.
  • Page 67 STEERING AND FRONT SUSPENSION Rack and Pinion 15/16 DEEP WELL INNER SOCKET BALL TAB WASHER JOINT DUST SEAL SECURE RACK USING WOOD BLOCKS AND A VISE Figure 7-11 Secure Rack In Vise Figure 7-12 Press In Dust Seal 3. Apply a liberal amount of grease to teeth of rack (17), then slide rack through the bushing (5) and housing (6).

  • Page 68: Tie Rod And Drag Link

    STEERING AND FRONT SUSPENSION Tie Rod and Drag Link Rack and Pinion Assembly, Continued: 17. Install the ball joint (23) (Figure 7-13). See previous CAUTION and following NOTE. NOTE • TO BE SURE THAT RACK AND PINION IS WORKING PROPERLY, TURN UNIVERSAL JOINT ASSEMBLY BY HAND.
  • Page 69 STEERING AND FRONT SUSPENSION Tie Rod and Drag Link TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 7-13 Steering Gear Assembly 2. Install the ball joint ends (6 and 13) into the spindle arms (23) (Figure 7-18, Page 7-15). 3. Thread the drag link rod (28) all the way onto the threaded stud of the inner ball joint assembly (3) (right-hand threads) (Figure 7-13, Page 7-11).

  • Page 70: Front Suspension

    NOTE • WHENEVER THE VEHICLE MUST BE MOVED DURING THE ALIGNMENT PROCESS, ALWAYS ROLL THE VEHICLE FORWARD. DO NOT ROLL IT BACKWARD. PROPER LOOSEN 4 BOLTS (30) CAMBER Club Car ADJUSTMENT LOOSEN HEX NUT (8) ON ECCENTRIC ECCENTRIC EQUAL SPACES...

  • Page 71: Toe-In Adjustment

    • THE TIE ROD HAS RIGHT-HAND THREADS ON ONE END AND LEFT-HAND THREADS ON THE OTHER END. RIGHT-HAND THREADS ARE IDENTIFIED BY A GROOVE IN THE TIE ROD. LOOSEN LOCKING NUT WITH 3/4" WRENCH, THEN ROTATE Club Car TIE ROD WITH LOCKING PLIERS TO INCREASE OR DECREASE TOE-IN...

  • Page 72: Tapered Leaf Spring Removal/Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components 7. Check toe-in again to confirm proper adjustment. 7.1. Roll vehicle forward one and one half tire revolutions and again measure rear-facing marks. 7.1. Roll the vehicle forward and again measure forward-facing marks. Subtract the front measure- ment from the rear measurement to confirm adjustment.
  • Page 73 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 2 PLACES REFERENCE STEERING GEAR TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-18 Upper Front Suspension Assembly 4. Raise the A-Plate clevis (16) from the kingpin (Figure 7-19, Page 7-17). 5.
  • Page 74 STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Removal, Continued: 9. Remove the kingpin. 10. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced. 11. Inspect the bushings (3 and 4) (Figure 7-19, Page 7-17). If the bushings are worn or damaged, remove them and press in new ones.
  • Page 75 STEERING AND FRONT SUSPENSION Front Suspension Components REFERENCE STEERING GEAR ASSEMBLY PASSENGER'S SIDE ONLY TYPICAL 4 PLACES DRIVER'S SIDE ONLY TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-19 Lower Front Suspension Assembly 1998/1999 DS Golf Car Maintenance and Service Manual Page 7-17...

  • Page 76: Front Wheel Bearings And Hubs

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS Read WARNING on page 7-1. CHECK FRONT WHEEL FREE PLAY 1. Raise the front of the vehicle and attempt to rock the wheel back and forth on the hub. If there is any observable rocking on the hub, tighten the axle nut (3) and test again for rocking.
  • Page 77 STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs 4. Install the hub assembly (4) and flat washer (8) on the axle and start the axle nut (3). 5. Tighten the axle nut until the hub is hard to turn, then back the nut off until the hub turns freely. Install the cotter pin (2) (Figure 7-20, Page 7-18).

  • Page 79: Wheels And Tires

    SECTION 8–WHEELS AND TIRES WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR. • FOLLOW ALL PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND HEED ALL DANGER, WARNING, AND CAUTION STATEMENTS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE.

  • Page 80: Wheel Removal, Repair And Installation

    WHEELS AND TIRES Wheel Removal, Repair and Installation General Information, Continued: • Keep axle nuts and lug nuts properly torqued. • Keep the front end aligned and adjusted. WHEEL REMOVAL, REPAIR AND INSTALLATION Read WARNING on page 8-1. WHEEL REMOVAL 1.

  • Page 81: Repairing A Tire

    WHEELS AND TIRES Wheel Removal, Repair and Installation TIRE BEADS WITH TIRE DEFLATED, LOOSEN TIRE BEADS FROM RIM BY APPLYING PRESSURE TO TIRE SIDE WALLS TIRE FLANGE BEADS PRESSURE AGAINST TIRE TOOL TIRE BEADS POSITIONED USING TIRE TOOL, IN RIM WELL CAREFULLY LIFT TIRE BEAD OVER RIM FLANGE...
  • Page 82 WHEELS AND TIRES Wheel Removal, Repair and Installation Installing the Tire on the Rim, Continued: 2. Where the tire beads seat, clean the wheel rim with a wire brush. NOTE • BECAUSE TUBELESS TIRES REQUIRE A PERFECT SEAL IN ORDER TO SEAT, CLEANING OF THE TIRE AND RIM IS VERY IMPORTANT.

  • Page 83: Rear Suspension

    SECTION 9–REAR SUSPENSION GENERAL INFORMATION The rear suspension of the DS vehicle is completely independent. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame. WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR.
  • Page 84 REAR SUSPENSION General Information BRAKE CABLE HANGER MOUNTING GASOLINE VEHICLE ONLY TYPICAL ON TYPICAL ON EACH SIDE EACH SIDE OF VEHICLE OF VEHICLE BRAKE CABLE HANGER MOUNTING ELECTRIC VEHICLE ONLY TYPICAL 2 PLACES Figure 9-1 Rear Suspension Assembly and Mounting Page 9-2 1998/1999 DS Golf Car Maintenance and Service Manual...

  • Page 85: Shock Absorbers

    REAR SUSPENSION Shock Absorbers SHOCK ABSORBERS INSPECTING AND REMOVING SHOCK ABSORBERS 1. Check shock absorbers (7) for fluid leakage at the point where the shaft enters the shock absorber body. Replace leaking shock absorbers (Figure 9-1, Page 9-2) . 2. To remove a shock absorber, remove the nut (5), cup washer (9) and rubber bushing (10) from the stem at the top of the shock absorber (Figure 9-1, Page 9-2) .
  • Page 86 REAR SUSPENSION Leaf Springs Removing the Leaf Springs, Continued: 2. Place a floorjack under the transaxle differential casing to support (but not lift) the drivetrain. Raise it just enough to relieve tension on the shock absorbers without compressing them. 3. Remove the tire and wheel assembly on the side from which the spring is to be removed. 4.
  • Page 88 Golf Cars Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...

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1999 ds

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