Club Car 1996 DS Golf Car Gasoline Manuals

Manuals and User Guides for Club Car 1996 DS Golf Car Gasoline. We have 1 Club Car 1996 DS Golf Car Gasoline manual available for free PDF download: Service Manual

Club Car 1996 DS Golf Car Gasoline Service Manual (544 pages)

1995-1996 DS GOLF CARS

Brand: Club Car | Category: Golf Cars | Size: 18.71 MB

Table of Contents
4
Safety

11
Vehicle Speciﬁcations

13
Vehicle Specifications

13
General Information Section

15
- Model Identification
  15
- Safety Committee
  15
- Pre-Operation Checklist
  16
  - Performance Inspection
    16
- Controls
  17
- Driving Instructions
  22
- Towing
  23
- Transporting on a Trailer
  24
- Storage - Gasoline Vehicle
  24
- Storage - Electric Vehicle
  26
Periodic Maintenance

29
Body and Trim

39
- General Information
  39
- Front and Rear Body Repair
  40
- Seat
  42
- Front Body
  42
- Rear Body
  43
- Floormat
  46
Accelerator and Brake Pedal Group

47
Wheel Brake Assemblies

77
Steering and Front Suspension

85
- General Information - Steering
  85
- Steering Wheel
  86
- Steering Column
  86
- Steering Adjustment
  90
- Rack and Pinion
  90
- Tie Rod and Drag Link
  100
- Front Suspension
  102
  - Lubrication
    102
  - Wheel Alignment
    102
- Front Suspension Components
  104
- Front Wheel Bearings and Hubs
  108
Transaxle

111
- Lubrication
  111
- Axle Shaft
  112
  - Axle Bearing
    113
- Removing the Transaxle
  115
- Disassembly, Inspection, and Assembly of the Transaxle
  120
- Shimming the Transaxle
  124
- Installation of the Transaxle
  125
Wheels and Tires

127
- General Information
  127
- Wheel Removal
  128
- Wheel Installation
  128
- Removing the Tire from the Rim
  129
- Repairing a Tire
  129
- Installing the Tire on the Rim
  129
Troubleshooting the Gasoline Vehicle

131
- Troubleshooting Guide
  131
Electrical System - Gasoline Vehicle

138
- General Information
  138
- FE 290 Gasoline Vehicle Electrical Circuit
  138
- Circuit Testing
  143
- Test Procedures
  150
- Electrical System Components
  163
  - Starter/Generator
    163
  - Voltage Regulator
    174
  - Key Switch
    175
  - Solenoid
    176
  - Fuse
    177
  - Neutral Lock-Out Cam
    180
  - Reverse Warning Buzzer
    180
  - Reverse Buzzer Limit Switch
    181
  - Oil Warning Light
    182
  - Battery
    182
Fe 290 Engine

191
- General Information
  191
- Special Tools
  192
- Before Servicing
  192
- Mechanical Systems
  192
- Electrical System
  194
- Lubrication System
  195
- Spark Plug
  196
  - Cylinder Head
    197
  - Oil Pump
    221
- Engine Assembly
  236
- Service Specifications
  237
- Specifications for Resizing Cylinder Bore
  239
- Torque Specifications
  239
- Adjustments and Settings
  240
Fuel System

241
- General Information
  241
- How the Carburetor Works
  241
- Carburetor
  244
  - Main Jet Elevation/Size Chart
    244
- Engine Control Linkage
  248
- Choke and Intake System
  254
- Fuel Filters
  257
- Fuel Pump
  259
- Fuel Tank
  262
- Fuel Lines
  264
- Fuel Tank Vent
  264
Exhaust System

265
- General Information
  265
- Mufﬂer
  265
Torque Converter

269
- General Information
  269
- Troubleshooting
  271
- Drive Belt
  271
- Drive Clutch
  272
- Driven Clutch
  280
- Clutch Alignment
  285
Transmission and Governor

287
- General Information
  288
- Lubrication
  288
- Transmission
  289
- Forward and Reverse Shifter Cable
  308
Rear Suspension - Gasoline Vehicle

311
- General Information
  311
- Shock Absorbers
  311
- Mono-Leaf Springs
  313
- Installing the Mono-Leaf Springs
  314
- The Snubber
  314
Electrical System - V-Glide 36 Volt Vehicle

317
- General Information
  317
- V-Glide Electrical Circuits
  317
- Troubleshooting
  321
- Circuit Testing
  324
  - 19B
    334
Electrical Components - V-Glide 36 Volt Vehicle

334
- Key Switch
  334
- Forward and Reverse Anti-Arcing Limit Switch
  335
- Accelerator Pedal Limit Switch
  336
- The Reverse Buzzer
  337
- The Solenoid
  338
- Resistors
  339
- V-Glide Wiper Switch
  341
- Forward and Reverse Switch
  348
Electrical System - Powerdrive System

351
- General Information
  351
- The On-Board Computer
  352
- Powerdrive Vehicle Electrical Circuits
  352
- Troubleshooting Guide
  356
- Circuit Testing
  359
- The Communication Display Module (CDM)
  372
- Communication Display Module Troubleshooting Guide
  374
- The Key Switch
  375
- Forward and Reverse Switch
  377
  - Forward and Reverse Limit Switches
    378
- The Reverse Buzzer
  379
- The Solenoid
  381
- On-Board Computer
  383
- Solid State Speed Controller
  384
- Charger Receptacle
  384
  - Receptacle Fuse Link
    386
- Continuously Variable Potentiometer
  387
- Multi-Step Potentiometer
  390
- Battery Warning Light
  391
Electrical System - Powerdrive Plus

393
- General Information
  393
- The Control Circuit
  397
- The Power Circuit
  408
- The Charge Circuit
  411
- Troubleshooting Guide
  412
- Test Procedures
  417
  - Numerical Listing of Test Procedures
    417
Electrical Components - Powerdrive Plus

445
- Key Switch
  445
- Forward and Reverse Switch
  446
- Reverse Buzzer
  446
- Main Solenoid
  447
- Dynamic Braking Solenoid
  448
- On-Board Computer
  448
- Controller
  449
- Charger Receptacle
  450
- Continuously Variable Potentiometer
  450
- Battery Warning Light
  450
- Energy Displacement Module
  450
Batteries

453
- General Information
  453
- Common Misconceptions about Batteries
  455
- Replacing Batteries
  456
- Battery Care
  457
- Battery Charging
  459
- Battery Testing
  460
- Battery Troubleshooting Chart - 36 and 48 Volt
  462
- Battery Troubleshooting Examples
  467
- Battery Storage
  469
- Charging Battery Pack with Low Voltage
  470
Accu-Power Battery Charger

473
- General Information
  473
- The Charge Circuit
  475
- Charger Installation and Use
  475
- Troubleshooting
  478
- Test Procedures
  479
- Plug and Receptacle Replacement
  490
  - On-Board Receptacle Fuse Link
    493
- Charger Repairs
  494
  - Capacitor
    495
  - Heat Sink Assembly
    496
  - Transformer
    496
  - Ammeter
    497
  - Charger Fuse Link Assembly
    498
Powerdrive Battery Charger

499
- General Information
  499
- Battery Warning Light
  500
- The Charge Circuit
  500
- Charger Installation and Use
  502
- Checking Battery Condition after a Charge Cycle
  505
- Troubleshooting
  506
- Test Procedures
  511
- Plug and Receptacle Replacement
  518
  - Charger Cord Replacement
    518
- Charger Repairs
  519
  - Transformer
    520
  - Ammeter
    520
  - Fuse Link
    521
  - Charger Relay
    521
  - Charger AC Circuit Breaker
    522
  - Charger AC Cord
    522
Motor

525
- General Information
  525
- External Motor Testing
  525
  - Motor Removal
    527
  - Motor Disassembly
    528
  - Testing and Inspecting Individual Components
    529
  - Reconditioning the Motor
    534
  - Motor Assembly
    535
  - Motor Installation
    537
Rear Suspension - Electric Vehicle

539
- General Information
  539
- Shock Absorbers
  540

Club Car Categories

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Club Car 1996 DS Golf Car Gasoline Manuals

Club Car 1996 DS Golf Car Gasoline Service Manual (544 pages)

Table of Contents

Safety

Vehicle Speciﬁcations

Vehicle Specifications

General Information Section

Periodic Maintenance

Body and Trim

Accelerator and Brake Pedal Group

Wheel Brake Assemblies

Steering and Front Suspension

Transaxle

Wheels and Tires

Troubleshooting the Gasoline Vehicle

Electrical System - Gasoline Vehicle

Fe 290 Engine

Fuel System

Exhaust System

Torque Converter

Transmission and Governor

Rear Suspension - Gasoline Vehicle

Electrical System - V-Glide 36 Volt Vehicle

Electrical Components - V-Glide 36 Volt Vehicle

Electrical System - Powerdrive System

Electrical System - Powerdrive Plus

Electrical Components - Powerdrive Plus

Batteries

Accu-Power Battery Charger

Powerdrive Battery Charger

Motor

Rear Suspension - Electric Vehicle

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