Club Car Gold Standard Gasoline 2005 Owner'S Manual Download

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Vehicle Specifications – DS Golf, Four-Passenger, and DS

Box Bed Vehicles

Page 30

2005 Gold Standard Gasoline Vehicle Owner’s Manual

VEHICLE SPECIFICATIONS – DS GOLF, FOUR-PASSENGER, AND DS
BOX BED VEHICLES

SPECIFICATIONS

GASOLINE

POWER SOURCE

Engine: 4-cycle OHV, 286 cc, 9.0 hp rated, single-cylinder, air-cooled, with pressure lubrication system

•

Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump

•

Governor: Automatic ground-speed sensing, internally geared in unitized transaxle

•

Ignition: Transistor electronic ignition with electronic RPM limiter

•

Unitized transaxle: Fully synchronized forward and reverse with neutral and reduced speed reverse (11.8:1 forward,
17.1:1 reverse)

•

Torque converter: Automatic, variable-speed, dry type

•

Electrical system: 12 volt, 500 cca at 0 °F (-17.8 °C), 650 at 32 °F (0 °C). 105-minute reserve capacity and 35-amp
charging capacity

•

STEERING/SUSPENSION/BRAKES

Steering: Self-adjusting rack and pinion

•

Suspension: Front and rear tapered mono-leaf springs with dual hydraulic shocks

•

Brakes: Dual rear wheel self-adjusting brakes with cast iron drums and single brake pedal with automatic-release park
brake

•

BODY/CHASSIS

Frame/Chassis: Twin I-Beam welded aluminum

•

Front and rear body: ArmorFlex

•

Body finish: Matched paint finish over molded-in color

•

Tires: 18 x 8.50 – 8 tubeless, 4 ply rated

•

DIMENSIONS/WEIGHT

Overall length

91.5 in. (232 cm)

Overall width

47.25 in. (120 cm)

Overall height (with canopy)

68.5 in. (174 cm)

Overall height (at steering wheel)

48 in. (122 cm)

Wheelbase

65.5 in. (166 cm)

Ground clearance

4.5 in. (11 cm)

Front wheel tread

34.5 in (88 cm)

Rear wheel tread

38.5 in. (98 cm)

Weight (dry, without battery)

619 lb. (281 kg)

Forward speed

12-15 mph (19-24 km/h)

Curb clearance circle (diameter)

17 ft.-6 in. (533 cm)

Standard seating capacity (DS and DS box bed vehicle)

Standard seating capacity (Four-passenger vehicle)

LIQUID CAPACITIES

Engine crankcase (without filter)

32 oz. (.95 liter)

Engine crankcase (with filter)

38 oz.

(1.12 liters)

Unitized transaxle

27 oz. (.8 liter)

Vehicle specifications continued on next page...

Summary of Contents for Gold Standard Gasoline 2005

Page 1: ...2005 Owner s Manual Gold Standard Gasoline Vehicles F F A A A C C T T O R R Y EM NU U R E D C E R T I I F ED GOLD STA A N D D R CLUB CAR Club Car Club Car Club Car ...

Page 2: ......

Page 3: ...e used to convey a person or persons and equip ment to play the game of golf in an area designated as a golf course Throughout this manual the words golf car are used in reference to golf cars only The word vehicle is used in reference to any other vehicles cov ered in this manual or may be used when referring to all vehicles including golf cars categorically This manual contains proprietary infor...

Page 4: ...his manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event that your Club Car vehicle needs repairs or service we recommend that your local authorized Club Car representative perform them For the name and address of the Club Car representative nearest you logon to our web site at www clubcar com or ...

Page 5: ...nx Vehicles 17 Towing with the Vehicle DS Golf DS Box Bed and Lynx Vehicles 18 Towing the Vehicle 19 Transporting on a Trailer 19 Storage 20 Maintenance 22 Periodic Service Schedule 23 Periodic Lubrication Schedule 25 Battery 26 Engine Oil 27 Fueling Instructions 28 Cleaning the Vehicle 29 Accessories 29 Subsequent Owner Registration 29 Vehicle Specifications DS Golf Four Passenger and DS Box Bed ...

Page 6: ... pedal to increase speed Park brake will release when accelerator pedal is depressed To stop release accelerator pedal and depress brake pedal After stopping the vehicle Firmly depress park brake until it locks Place Forward Reverse switch in NEUTRAL position Turn key OFF and remove key when not in use CCI 101621601 VEHICLE LOADING Read Owner s Manual and warnings on dash Vehicle rated capacity 55...

Page 7: ...Remain seated with entire body inside vehicle and hold on to seat handle or handrail at all times Two 2 persons per bench seat maximum One 1 person per bucket seat maximum Do not leave children unattended on vehicle at anytime Never stand in front of or behind vehicle CCI 101705701 WARNING GASOLINE WARNING DECAL ON VEHICLE FRAME NEAR FUEL TANK FRAME GROUND AND GOVERNOR WARNING DECAL ON VEHICLE FRA...

Page 8: ... the vehicle we urge you to review the information in this manual Understand and become familiar with the DANGER WARNING and CAUTION state ments and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA WARNING This product contains or emits chem...

Page 9: ...nal injury or death WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death CAUTION A CAUTION with a safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a situation that could potentially result in property damage GENERAL WARNINGS The following s...

Page 10: ...rvice should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 Disconnect the spark plug wire from the spark plug Frame ground Do not allow tools or other metal objects to contac...

Page 11: ... center dash panel must be removed to view this decal See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries The model year designation of a Gold Standard vehicle is the year that the vehicle was remanufac tured rather than the year that it was originally manufactured Figure 1 Gasoline Vehicle Figure 2 Serial Number Decal FRONT OF VEHICLE AS SEEN F...

Page 12: ...gure 3 It has two positions OFF and ON which are clearly labeled See following NOTE NOTE The key can be removed only when the key switch is in the OFF position FORWARD REVERSE CONTROL The Forward Reverse handle is located on the seat support panel below and to the right of the driver s right knee Figure 4 The Forward Reverse handle has three distinct positions F FORWARD R REVERSE and N NEUTRAL Rot...

Page 13: ...ward Reverse handle is in either the FORWARD or REVERSE position pressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected forward or reverse As the accelerator pedal is pressed speed will increase until full speed is reached When the accel erator is released power will be cut off and the motor will stop running BRAKE PEDAL The ...

Page 14: ...uld be firmly pressed and locked to prevent the vehicle from rolling NEUTRAL LOCKOUT For the convenience of the trained technician there is a neutral lockout cam located on the back of the For ward Reverse shifter If the neutral lockout cam is pulled out approximately 3 8 inch 10 mm and then rotated one half turn until it snaps into place the cam will be in the SERVICE position Figure 8 This will ...

Page 15: ...nel below and to the left of the driver s left knee Figure 10 If the vehicle is hard to start in cool or cold temperatures simply push in the choke cover to activate it Hold it during start up and release the choke cover after the engine starts and runs smoothly LOW OIL WARNING LIGHT The gasoline vehicle is equipped with a low oil warning light located on the dash panel just above the steering col...

Page 16: ...proper inflation on a daily basis Battery Check electrolyte to ensure that it is at its proper level Figure 17 Page 26 Check battery posts Wires should be tight and free of corrosion See Vehicle Specifications DS Golf Four Pas senger and DS Box Bed Vehicles on page 30 or Vehicle Specifications Lynx Vehicle on page 31 Engine Check for proper engine oil level See Engine Oil on page 27 Fuel Check fue...

Page 17: ...ch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the engine should start and the vehicle should accelerate smoothly to full speed When the pedal is released it should return to the original position and the engine should stop All Club Car vehicles operate at reduced speed in reverse Governor Check maximum speed of the vehicle The vehi...

Page 18: ... drive while under the influence of alcohol drugs or medications To prevent overturning the vehicle drive slowly in turns Use brakes to reduce speed when coasting downhill No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing him her to ...

Page 19: ...l If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal To stop the vehicle release the accelerator pedal and press the brake pedal with your right foot until the vehi cle comes to a complete stop PARKING ...

Page 20: ...owly in turns Avoid top heavy loads the center of gravity of a load should never exceed 15 inches 38 cm above the bottom of the cargo bed Unload cargo bed before raising vehicle with a lift hoist or jack When loading the vehicle center and secure cargo as far forward as possible in the cargo bed Do not over load the vehicle See the following chart for vehicle capacities TOWING WITH THE VEHICLE DS ...

Page 21: ...o overturn possibly resulting in severe personal injury Do not tow more than one Club Car vehicle with another Club Car vehicle If more than one vehicle must be towed an adequately powered vehicle tractor or full sized truck properly fitted with a tow hitch height of 11 inches 28 cm should be used Only heavy duty tow bars should be used for multi vehicle towing Never tow more than five vehicles at...

Page 22: ...g distances or on public highways it should be transported on an approved trailer that has the approved load rating of 1200 lb 544 kg per vehicle being transported NOTE A two car trailer should be rated at 2 x 1200 2400 lb 2 x 544 1088 kg STORAGE See General Warnings on page 7 DANGER Do not attempt to drain gasoline when the engine is hot or while it is running Be sure to clean up any spilled gaso...

Page 23: ... fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 4 Disconnect the battery cables negative cable first 5 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off bat teries Do not allow this solution to enter the batteries ...

Page 24: ... the oil added to the engine in preparation for storage engine may smoke excessively for a short time when it is run for the first time after storage 5 Adjust tires to recommended tire pressure See Vehicle Specifications DS Golf Four Passenger and DS Box Bed Vehicles on page 30 6 Perform the Pre Operation and Daily Safety Checklist on page 14 MAINTENANCE See General Warnings on page 7 To ensure tr...

Page 25: ...vere burns Do not work on the vehicle powertrain or under the cargo bed when it is loaded Moving parts Do not attempt to service gasoline vehicle while the engine is running Turn fuel shut off valve to the closed OFF position Figure 12 Page 21 To avoid unintentionally starting the vehicle before servicing always disconnect the battery negative cable first Figure 1 Page 9 and disconnect the spark p...

Page 26: ...100 rounds for golf cars Battery Clean terminals and wash dirt from casing check electrolyte level See Battery on page 26 Front wheel alignment and camber Check and adjust if necessary See Section 7 Steering and Front Suspension in the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Brake system Check brake shoes replace if necessary Lubr...

Page 27: ...pivots mounts and shifter cable pivots Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Brake slides Dry Moly Lube CCI P N 1012151 Annually by trained technician only every 100 hours of operation or every 200 rounds of golf Check fill unitized transaxle to plug level 27 oz 8 liter 80 90 WT API Class GL 3 or 80 90 WT AGMA Class EP Gear Lube Repack tapered front...

Page 28: ...s Call a physician immediately WARNING Do not jump start a dead battery using another battery and jumper cables The battery in the Club Car gasoline vehicle is a 12 volt low maintenance battery that requires infrequent watering Figure 16 Any corrosion around the positive or negative terminals should be washed off with a solution of baking soda and water 1 cup 237 mL per gallon 3 8 L of water Rinse...

Page 29: ...from dipstick Figure 18 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it 3 If the oil level is at or below the low level mark on the dipstick gauge add oil until the level is between low and full levels safe level 4 Reinsert dipstick into the oil filler tube NOTE Properly re...

Page 30: ...avoid the possibility of fire clean up any spilled gasoline before operating the vehicle CAUTION To allow for expansion do not fill higher than one inch from the top of the fuel tank Avoid spilling fuel NOTE Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Vehicles to be stored for extended periods should be prepared for storage as instructed See Preparing the...

Page 31: ...d dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see Section 4 of the appropriate maintenance and ser vice manual NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors You can obtain the name and phone number of your closest Club Car ...

Page 32: ...Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin I Beam welded aluminum Front and rear body ArmorFlex Body finish Matched paint finish over molded in color Tires 18 x 8 50 8 tubeless 4...

Page 33: ...olt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Front Suspension Tapered mono leaf springs with dual hydraulic shocks Rear Suspension Heavy duty multi leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal wi...

Page 34: ... km h Curb clearance circle diameter 12 15 mph 19 24 km h Standard seating capacity 2 LIQUID CAPACITIES Engine crankcase without filter 32 oz 95 liter Engine crankcase with filter 38 oz 1 12 liters Unitized transaxle 27 oz 8 liter Fuel tank 7 gallons 26 5 liters TIRE PRESSURE Front and rear Off road tread 14 18 psi 96 1 24 Bars SPECIFICATIONS GASOLINE ...

Page 35: ...tion abuse or neglect Transportation expenses for warranty services are also excluded from this warranty 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING ...

Page 36: ...TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have othe...

Page 37: ...y of Illustrations 4 Periodic Service and Periodic Lubrication Schedules Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in the following catgories Your Comments Are Appreciated Please select your category Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other ________...

Page 38: ...arburetors have been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system Maintenance and Warranty Proper maintenance is necessary to ensure that your engine will continue to have low emis sion levels Those items identified by the Periodic Maintenance Chart are necessary to ensure compliance with the applicable standard...

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Page 40: ...lication Part Number RMRM1011202 Edition Code 0704A00000 Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...

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