Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 43 / 544

Page 5-5
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1. Remove screws (Item 3) and nylon lock hex nuts (Item 4) to remove front bumper from car frame.
Remove blind rivets (Item 5) (Figure 5-9, Page 5-6).
2. Remove carriage bolts (Item 10), lock nuts (Item 4), and washers (Item 11) from front body trim.
Remove screws (Item 3) from top of front body (Figure 5-9, Page 5-6).
3. Loosen (do not remove) T-nuts (Item 13) holding front body trim (Item 9) against front body (Figure 5-9,
Page 5-6).
4. Pull front body from under front body trim (Item 9) and lift it from the vehicle (Figure 5-9, Page 5-6).
FRONT BODY INSTALLATION
1. Reverse removal procedure.
REAR BODY
REAR BODY REMOVAL
1. Remove the seat from the rear body.
• 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
AND HEED ALL WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR A RESPIRATOR APPROVED FOR DUST AND MIST WHEN CUTTING, SANDING,
PAINTING, OR REPAIRING BODY PANELS.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY BEFORE SERVICING THE VEHICLE.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WITH THE ENGINE/MOTOR
RUNNING.
• HOT! - DO NOT ATTEMPT TO SERVICE HOT MOTOR, RESISTORS, ENGINE, OR EXHAUST
SYSTEM. FAILURE TO HEED THIS WARNING CAN RESULT IN SEVERE BURNS.
• GASOLINE VEHICLE: TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT
THE SPARK PLUG WIRE FROM THE PLUG.
• ELECTRIC VEHICLE: TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT
BATTERIES AS SHOWN IN FIGURES 22-5 AND 22-6, PAGE 22-5. THEN DISCHARGE THE CON-
TROLLER ON POWERDRIVE VEHICLES AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE
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.
• REAR BUMPER DOES NOT HAVE TO BE REMOVED TO REMOVE REAR BODY.
WARNING
NOTE