Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 265 / 544

Page 15-1
G
15
SECTION 15 - EXHAUST SYSTEM
GENERAL INFORMATION
The exhaust system on the DS gasoline vehicle is designed to provide quiet vehicle operation. If the muffler
should ever need to be removed for repairs or replacement, follow the instructions below.
MUFFLER
Removing The Muffler
1. Remove the service access panel from the rear body. It is located between the seat and bag well.
2. Remove the seat from the vehicle.
3. Disconnect the spark plug wire from the spark plug and disconnect the battery cables, negative (-)
cable first.
4. Remove the retaining bolts (5), lock washers (4), and flat washers (3) from the muffler bracket (2) (Fig-
ure 15-1, Page 15-2).
5. Remove the hex nuts (10) and lock washers (11) (Figure 15-1, Page 15-2).
6. Remove the hex head cap screw (7), lock washer (8), and flat washer (9) (Figure 15-1, Page 15-2).
7. Remove the muffler and bracket assembly from the vehicle.
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• HOT! - DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST SYSTEM. FAILURE TO
HEED THIS WARNING COULD RESULT IN SEVERE BURNS.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERY OR ELECTRICAL CON-
NECTIONS.
• FRAME GROUND - DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT
FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING. NEVER
ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, INNER FRAME, OR
OTHER METAL COMPONENT.
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING:
- DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
- DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
WARNING