1998 Club Car Repair Manual Free Download UPDATED

1998 Club Car Repair Manual Free Download

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  Summary of Contents for Guild Motorcar 1998 DS

• Page 1 1998-1999 MAINTENANCE S E R V I C E Transmission DS GOLF CARS GASOLINE/ELECTRIC MANUAL NUMBER 101968401 EDITION CODE 0199B0312A...
• Page 3 Golf Automobile service. However, unique situations do sometimes arise when servicing a golf car. If it appears that a service question is non 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 Guild Car Technical Service representative at (706) 863-3000, extension 3580.
• Page four SPECIFICATIONS OR MODIFICATIONS WHICH Bear upon THE STABILITY OF THE VEHICLE OR THE Performance THEREOF, WILL VOID THE WARRANTY. • Social club Auto, INC. RESERVES THE Correct TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT Observe AND WITHOUT INCURRING Whatever 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 - Electrical Vehicle ........................
• Folio 6 STEERING AND FRONT SUSPENSION Department General Information - Steering......................Steering Bike ..........................Steering Cavalcade ..........................Steering Adjustment .......................... Rack and Pinion ..........................Necktie Rod and Drag Link ........................7-10 Front end Intermission ..........................7-12 Front Intermission Components ......................seven-14 Front Bike Bearings and Hubs ....................... 7-18 WHEELS AND TIRES Section...

• Folio 7: General Warning

  Department ane–Condom 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 of import to note that throughout this manual there are statements which are independent inside boxes labeled DANGER, WARNING, or Circumspection.
• Folio 8 SAFETY General Alarm General Alarm, Continued: DANGER • GASOLINE - Flammable! EXPLOSIVE! DO Non Smoke. Continue SPARKS AND FLAMES Away FROM VEHICLE AND SERVICE AREA. SERVICE ONLY IN A WELL-VENTILATED Surface area. • Exercise NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION.
• Page 9 Prophylactic General Alert WARNING GASOLINE VEHICLES ONLY: • TO Avoid UNINTENTIONALLY STARTING THE VEHICLE: - DISCONNECT BATTERY CABLES, NEGATIVE (-) Start (Effigy 1-1) . - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG. • FRAME GROUND - Practice NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING Bombardment CABLES OR OTHER Electrical WIRING.

• Folio xi: Vehicle Specifications

  SECTION 2–VEHICLE SPECIFICATIONS GENERAL INFORMATION Club Car, Inc. reserves the correct to change vehicle specifications and design of either gasoline or electrical vehicles at any time without obligation to brand these changes on units previously sold. POWERDRIVE POWERDRIVE SPECIFICATIONS SYSTEM 48...
• Folio 12 VEHICLE SPECIFICATIONS General Information POWERDRIVE POWERDRIVE SPECIFICATIONS System 48 PLUS 36-VOLT GASOLINE ELECTRIC Electric ELECTRIC DIMENSIONS/WEIGHT 91-ane/2" 91-i/two" 91-i/2" 91-one/ii" Overall Length (232 cm) (232 cm) (232 cm) (232 cm) 47-1/four" 47-one/iv" 47-ane/iv" 47-one/4" Overall Width (120 cm) (120 cm) (120 cm) (120 cm) 48"...

• Folio 13: General Information Section

  SAFETY Commission If the golf automobile is to be rented or is office of a fleet, Lodge Car, Inc. recommends a safety commission be appointed. One of the main concerns of this committee should be the safe performance of the golf cars.

• Page 14: Pre-Operation Checklist

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

• Folio xv: Controls

  (xix-24 kph) on a level surface. • Full general: Mind for any unusual noises such every bit squeaks or rattles. Check the vehicle ride and perfor- mance. Accept a CLUB Motorcar distributor/dealer or a trained mechanic investigate anything unusual. DS PowerDrive Plus Vehicles with Motor Braking: •...
• Page 16 Full general Data Controls Controls, Continued: Fundamental SWITCH The key switch is mounted on the dash to the right of the steering column (Figure 3-three, Folio 3-iv) . It has two positions, OFF and ON, which are clearly labeled. NOTE • THE KEY CAN BE REMOVED WHEN THE Primal SWITCH IS IN THE OFF POSITION ONLY. Figure iii-three Fundamental Switch Effigy 3-4 Forward and Contrary Handle Forwards/REVERSE CONTROL...
• Page 17 General INFORMATION Controls NOTE • THE Operation OF THE ACCELERATOR PEDAL DIFFERS FROM THAT OF AN Machine. WHEN THE Central 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 ( Frontward 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 Frontward/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 benefactor/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 wheel. Charger and batteries should be checked by your Order Car distributor/dealer. • The alarm light will repeatedly illuminate for 10 seconds, with 4 second intervals, during a charge cycle (DC plug is still continued) if Air conditioning power to the charger is interrupted.

• Page 21: Driving Instructions

  Full general Information Driving Instructions The Tow/Run switch should exist 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 Find motor braking function is operating.
• Folio 22 GENERAL INFORMATION Driving Instructions Driving Instructions, Continued: No i should bulldoze the vehicle without first being instructed in the proper performance 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

  • Practise Not ALLOW PASSENGERS IN THE VEHICLES Existence TOWED. • Avert SUDDEN STARTS, SUDDEN STOPS, AND TIGHT TURNS WHEN TOWING. • Exercise Non TOW MORE THAN ONE CLUB CAR VEHICLE WITH Some other CLUB Motorcar VEHICLE. IF More than THAN Ane VEHICLE MUST Be TOWED, Employ AN Adequately POWERED VEHICLE (TRACTOR OR FULL SIZED TRUCK) PROPERLY FITTED, WITH A TOW HITCH Peak OF xi 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 absurd place. This will prevent self-discharge of the bombardment. If the battery appears to exist weak, have it charged using an automotive-type 12-volt bombardment charger rated 10 amps or less. DANGER •...

• Folio 25: Storage - Electric Vehicle

  (do not allow this solution to enter the batteries). Let the terminals dry out and glaze them with Battery Last Spray, Lodge Car Office No. 1014305. 3. Store in a absurd, dry place. This will preclude self-belch of the batteries.
• Page 26 General Data Storage - Electrical Vehicle Storage - Electric Vehicle, Continued: 4. Adjust tire pressure level to 20 psi (.96 kPa). five. Grease front end suspension and do all quarterly periodic lubrication. See Periodic Lubrication Sched- ule, Department 10, Maintenance and Service Supplement. vi.

• Page 27: Torso And Trim

  SECTION 4–Body AND TRIM WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN Elementary REPAIRS OR SERVICE SHOULD Accept Knowledge AND Experience IN GENERAL Electric 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 Data CAUTION • Exercise Not USE DETERGENTS OR CLEANING SOLVENTS THAT Comprise AMMONIA, Effluvious SOLVENTS, OR Brine MATERIALS ON BODY PANELS OR SEATS. • DO Non ALLOW Bombardment ACID TO Baste ON Body PANELS. BATTERY Acid Volition CAUSE PERMANENT BLEMISHES.
• Page 29 101978901) to only the bare body cloth. vii. Fill up the scratch with trunk filler (Club Auto Part No. 1017295). Allow the filler to dry and then sand lightly. 8. Utilise primer to the filled and promoter covered surface area. Permit the primer to dry out, then perform steps 3 through 5 to a higher place.

• Page 30: Seat

  Torso AND TRIM Seat Front and Rear Body Repair, Connected: Club Car Bear on-Upwardly 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 Archetype Blue 1019972-11 Burgundy 1019972-12 GOUGES, PUNCTURES, TEARS, Large SCRATCHES, AND ABRASIONS Touch up is non recommended.

• Folio 31: Front Torso Installation

  Trunk AND TRIM Forepart Body 2. Remove carriage bolts (10), locknuts (17), and washers (11) from front end body trim. Remove screws (xvi) from top of front torso (Figure 4-1, Page 4-five) . 3. Loosen (do non remove) T-nut screws (12) securing front trunk trim (9) against forepart torso (Figure iv-1, Page 4-5) . iv.

• Page 32: Rear Trunk

  Trunk AND TRIM Rear Body REAR BODY Run across WARNING and CAUTION on pages four-1 and 4-2. REAR BODY REMOVAL Annotation
  
  
  
  
    yyyyy zzzzz ||||| • REAR BUMPER DOES NOT Take TO BE REMOVED TO REMOVE REAR BODY.
  
  
  
  
    yyyyy...
• Page 33 Body AND TRIM Rear Trunk • PowerDrive System 48 and PowerDrive Plus vehicles (Figure iv-four, Page 4-half-dozen): The charger receptacle must be disconnected, but does not have to exist removed from the body: five.ane. Remove wire necktie bounden 10 judge red wire (from charger receptacle to battery) to Forward/ Reverse switch wires.

• Folio 34: Floormat

  BODY AND TRIM Floormat REAR BODY INSTALLATION 1. Install two screws in kick-plate. Tighten to xx in.lb (2.iii N-m) (Figure 4-three, Page iv-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-two, Page iv-six) .

• Page 35: Accelerator And Brake Pedal Group

  Department 5–ACCELERATOR AND BRAKE PEDAL Group Full general INFORMATION WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD Accept Knowledge AND Feel IN ELECTRICAL AND MECHANICAL REPAIR. • FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND Heed DANGER, Alert, AND CAUTION STATEMENTS LISTED IN THIS Manual AS WELL As THOSE AFFIXED TO THE VEHICLE.

• Page 36: Pedal Grouping Adjustment

  ACCELERATOR AND BRAKE PEDAL Group Pedal Group Adjustment WARNING ELECTRIC VEHICLES Merely: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES As SHOWN (Department 1, FIGURE 1-2 OR 1-3, Page i-3) . • ON POWERDRIVE PLUS VEHICLES, PLACE TOW/RUN SWITCH IN THE TOW POSITION Earlier DISCONNECTING BATTERIES.
• Page 37 3.1. Loosen the nut and bolt (Effigy 5-8, Page 5-5) securing the accelerator pedal to the pivot plate. Clamp the accelerator pedal adjustment tool (Order Automobile Office No. 101871001) to the accelerator pedal, with the stop marked accelerator pedal height toward the floorboard, so depress the accelerator pedal until the end of the tool rests against the floorboard (pedal...
• Page 38 ACCELERATOR AND BRAKE PEDAL Grouping Pedal Group Adjustment Circumspection • Later on ACCELERATOR ROD Aligning, 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 Electric BOX IS BENT, REPLACE THE LIMIT SWITCH.
• Page 39
  
  
  
  
    yyyyy zzzzz ||||| ACCELERATOR AND BRAKE PEDAL GROUP Pedal Grouping Adjustment
  
  
  
  
    yyyyy zzzzz ||||| RATCHET (B) Tooth LENGTH LOCKED POSITION
  
  
  
  
    yyyyy zzzzz ||||| WITH PARK Restriction UNLOCKED Measure out FROM Flooring Board TO BACK   |||||...
• Page 40 ACCELERATOR AND Brake PEDAL Group Pedal Group Adjustment Adjust the Accelerator Rod, Connected: 15° TO 17° Peak 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 Aligning four.four. While property accelerator rod (17) with pliers, loosen the jam nut (18) and adjust the ball joint (19) sleeve to fit on the wiper switch brawl stud, with approximately the aforementioned number of threads testify- ing at each finish of the rod.

• Page 42: Pedal Grouping Disassembly And Assembly

  ACCELERATOR AND Brake PEDAL Group Pedal Group Disassembly and Assembly PEDAL Group DISASSEMBLY AND ASSEMBLY Removing the Brake Pedal Associates 1. Make certain key switch is OFF and that the Forward/Opposite handle is in NEUTRAL, then disconnect battery or batteries as instructed in Warning on pages 5-one and v-2. Run into following Caution. CAUTION •...
• Page 43 ACCELERATOR AND Restriction PEDAL GROUP Pedal Group Disassembly and Assembly 1.4. Install the restriction cables (6) on the equalizer rod using new cotter pins (viii) and the clevis pins (9) that were removed when the brake pedal assembly was disassembled (Effigy 5-12, Folio v-9). Tighten the nut (v) on the equalizer rod so that restriction pedal costless-play is 1/four in.
• Page 44 ACCELERATOR AND Brake PEDAL GROUP Pedal Group Disassembly and Associates Removing the Park Restriction Assembly 1. Make sure the key switch is off and that the Frontward/Reverse handle is in NEUTRAL, and so disconnect the battery or batteries as instructed in WARNING on pages five-1 and five-2. Come across following CAUTION. Caution •...
• Page 45 ACCELERATOR AND Brake PEDAL GROUP Pedal Group Disassembly and Assembly Figure five-13 Restriction Pedal Weldment Through Floor Effigy v-xiv Park Restriction Assembly Claw I TURN HEX NUTS UNTIL Stop OF THERE IS A 1/4" TO 1/2" (6.3 TO SPRING (20) 12.7 MM) Gratuitous PLAY OF ON PARK THE BRAKE PEDAL...
• Page 46 ACCELERATOR AND BRAKE PEDAL Group Pedal Grouping Disassembly and Assembly Removing the Accelerator Pedal Assembly, Continued: 3. Remove the nut (23), ii washers (25), and commodities (4) securing the accelerator pedal (1) to the pivot rod (6) (Effigy v-11, Page 5-7). four.
• Page 47 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Grouping Disassembly and Assembly 7. Move the pin rod dorsum toward the driver side of the vehicle and line upwards the scribed lucifer marks on the pivot rod and ratchet. Rotate the pivot rod back and along slightly to align the splines and slide the ratchet onto the splines.

• Folio 49: Wheel Brake Assemblies

  REVERSE POSITION. - SLOWLY DEPRESS THE ACCELERATOR PEDAL AND Go on Information technology DEPRESSED UNTIL THE REVERSE Warning Cablegram Tin can NO LONGER BE HEARD. WHEN THE BUZZER STOPS SOUNDING, THE CONTROLLER IS DISCHARGED. 1998 DS Golf Car Maintenance and Service Transmission Page vi-1...
• Page 50 TYPICAL iv PLACES yy yy TYPICAL 2 PLACES TYPICAL 2 PLACES ELECTRIC VEHICLE Merely GASOLINE VEHICLE Simply SEE REAR SUSPENSION - SECTION 9 FOR MOUNTING Figure half dozen-ane Self-adjusting Bike Restriction 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 Pace 4 TO MINIMIZE Damage TO THE BRAKE CLUSTER AND BRAKE COMPONENTS. 1998 DS Golf Machine Maintenance and Service Transmission Page 6-3...
• Page 52 ROTATE CLIP RETAINER (1) 90° TO RELEASE CLIP (ii) Hold SHOES FIRMLY AND REMOVE WITH SPRINGS As A UNIT Figure half dozen-5 Remove Shoe Servant Clip Figure 6-6 Remove Brake Shoes Page half-dozen-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 (ane) and slide plate (2) with dry out moly lubricant (Lodge Automobile Office No. 1012151). After lubri- cating, piece of work the slide back and forth to ensure that it slides smoothly and easily (Figure 6-viii, Page 6-6).
• Page 54 WHEEL Then THAT THE AMOUNTS OF WHITE LITHIUM NLGI #2 SHOE SLOT IS VERTICAL GREASE TO THE AREAS INDICATED. Figure 6-11 Employ Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe Page 6-6 1998 DS Golf Automobile Maintenance and Service Manual...
• Folio 55 flush at the top with the top surfaces of the wedge shapes on the shoe mounting blocks as shown (Figure vi-16, Folio half-dozen-7) . 1998 DS Golf Machine Maintenance and Service Transmission Folio six-7...

• Folio 56: Adjusting The Brakes

  floor jack. Place jackstands nether the axle tubes to back up the vehicle. Read WARNING on page vi-one . 2. Loosen the blaster retaining nuts (i) on the equalizer rod (2) to slightly loosen the brake cable (Fig- ure half dozen-2, Folio half dozen-3) . Page 6-8 1998 DS Golf Auto Maintenance and Service Transmission...
• Folio 57 Installing Brake Assembly Onto Axle Tube 1. Install in contrary order of disassembly. 2. Be sure bolts (11) (Lodge Motorcar Function No. 1014153) and lock nuts (10) (Gild Car Part No. 1013924) are used to mount the brake associates (Figure 6-one, Page half-dozen-2).

• Page 59: Steering And Front Suspension

  SECTION 7–STEERING AND FRONT Suspension Full general INFORMATION - STEERING Steering is controlled through a rack and pinion steering associates that is connected by a steering cavalcade to a steering bicycle. 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 bike nut (26) and dorsum information technology off approximately one/4 in. (half dozen mm). Do not remove nut (Effigy 7-ii, Page seven-3) . 4. Pull the steering wheel until information technology breaks free from the shaft splines (Club Car recommends using a steer- ing bicycle puller) (Effigy 7-1, Page 7-two) .
• Page 61 STEERING AND Front SUSPENSION Steering Column yy yy yy yy TYPICAL ii PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL iii PLACES Figure vii-2 Steering Column Associates and Installation three.1. Remove the plastic cap roofing the screw on each side of the center dash. 3.two.
• Folio 62 STEERING AND FRONT SUSPENSION Steering Column Steering Column Removal, Continued: 3.4. Pull center dash out approximately i in. from the frame and so bend the top right corner in while pulling the superlative of the panel out and down. NOTE •...

• Folio 63: Steering Column Assembly

  2. Press the bearing (eighteen) all the way into the bearing seat (nineteen) using a steering column bearing printing tool (Club Car Part No. 1014264) or a metal tube approximately 6 in. (15 cm) long with a maximum outer diameter of 1-iii/sixteen in. (3.3 cm) and a minimum within diameter of seven/8 in. (ii.2 cm). Be sure the bearing is installed in the bearing seat as shown (Effigy vii-3, Page 7-5) so that the wedge (17) will ride against the inner race of the begetting.

• Page 64: Steering Adjustment

  STEERING AND Forepart SUSPENSION Steering Adjustment STEERING Column INSTALLATION 1. Reinstall mount (four and 5) onto end of steering column. Tighten bolts (six) to 22 ft.lb (thirty N-m) (Figure seven-2, Page vii-three). 2. For ease of associates and to forestall corrosion, employ 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 Pause Rack and Pinion RACK AND PINION Read Warning on folio vii-i. Effigy vii-5 Adjust Steering Alignment Figure seven-6 Remove Ball Joint Figure 7-7 Remove Dust Seal Figure vii-8 Remove Snap Band RACK AND PINION REMOVAL i. Remove the front torso every bit instructed in Section four, Body and Trim. 2.
• Page 66 STEERING AND FRONT Break Rack and Pinion Rack and Pinion Disassembly, Continued: PRY OR Crash-land PINION GEAR Printing RAM OUT WITH UNIVERSAL Joint REINSTALLED PINION GEAR BEARING Figure 7-9 Remove Pinion from Housing Effigy 7-x Remove Bearing from Pinion ii. Remove the drag link (28) (Figure 7-13, Folio vii-11). iii.
• Page 67 STEERING AND FRONT Pause Rack and Pinion fifteen/sixteen DEEP WELL INNER SOCKET Brawl TAB WASHER JOINT Grit SEAL SECURE RACK USING Forest BLOCKS AND A VISE Figure 7-11 Secure Rack In Vise Effigy 7-12 Press In Grit Seal iii. Employ a liberal amount of grease to teeth of rack (17), and then slide rack through the bushing (5) and housing (six).

• Page 68: Necktie Rod And Drag Link

  STEERING AND FRONT Interruption Necktie Rod and Drag Link Rack and Pinion Associates, Continued: 17. Install the ball joint (23) (Figure vii-13). Encounter previous CAUTION and following Annotation. NOTE • TO Exist Sure THAT RACK AND PINION IS WORKING PROPERLY, Turn UNIVERSAL Articulation Assembly BY HAND.
• Folio 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 artillery (23) (Effigy 7-18, Page 7-15). 3. Thread the elevate link rod (28) all the way onto the threaded stud of the inner ball articulation assembly (3) (right-hand threads) (Figure 7-xiii, Page 7-11).

• Page 70: Front Suspension

  Notation • WHENEVER THE VEHICLE MUST BE MOVED DURING THE ALIGNMENT Procedure, Always Curl THE VEHICLE FORWARD. Practise NOT ROLL IT Astern. PROPER LOOSEN 4 BOLTS (30) Camber Club Motorcar ADJUSTMENT LOOSEN HEX NUT (8) ON ECCENTRIC ECCENTRIC EQUAL SPACES...

• Page 71: Toe-In Aligning

  • THE TIE ROD HAS Right-HAND THREADS ON One Cease AND LEFT-HAND THREADS ON THE OTHER END. RIGHT-HAND THREADS ARE IDENTIFIED By A GROOVE IN THE Tie ROD. LOOSEN LOCKING NUT WITH iii/4" WRENCH, THEN ROTATE Lodge Car Necktie ROD WITH LOCKING PLIERS TO Increase OR DECREASE TOE-IN...

• Folio 72: Tapered Leaf Spring Removal/Installation

  STEERING AND Front end Suspension Front end Intermission Components vii. Check toe-in over again to confirm proper aligning. 7.1. Scroll vehicle forrad one and one one-half tire revolutions and again measure rear-facing marks. vii.1. Roll the vehicle forward and once again measure forward-facing marks. Decrease the front measure- ment from the rear measurement to confirm adjustment.
• Page 73 STEERING AND Forepart Intermission Front Break Components TYPICAL ii PLACES REFERENCE STEERING GEAR TYPICAL iv PLACES TYPICAL 3 PLACES TYPICAL two PLACES TYPICAL iv PLACES TYPICAL 3 PLACES Figure 7-18 Upper Front Intermission Assembly 4. Raise the A-Plate clevis (16) from the kingpin (Figure seven-nineteen, Page 7-17). 5.
• Page 74 STEERING AND FRONT SUSPENSION Front end 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 exist replaced. eleven. Inspect the bushings (iii and four) (Effigy 7-19, Page 7-17). If the bushings are worn or damaged, remove them and press in new ones.
• Page 75 STEERING AND Front Break Front Intermission Components REFERENCE STEERING GEAR Assembly Passenger'S SIDE Simply TYPICAL 4 PLACES Commuter'Southward SIDE Just TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-19 Lower Front Interruption Assembly 1998/1999 DS Golf Machine Maintenance and Service Transmission Page 7-17...

• Page 76: Front Wheel Bearings And Hubs

  STEERING AND FRONT Intermission Front end Wheel Bearings and Hubs Front WHEEL BEARINGS AND HUBS Read Alert on page vii-ane. Cheque FRONT WHEEL Free PLAY one. Raise the front of the vehicle and try to stone the cycle back and forth on the hub. If there is any observable rocking on the hub, tighten the axle nut (3) and examination again for rocking.
• Page 77 STEERING AND FRONT Interruption Front Wheel Bearings and Hubs 4. Install the hub assembly (4) and flat washer (8) on the axle and start the beam nut (iii). five. Tighten the axle nut until the hub is difficult to turn, then back the nut off until the hub turns freely. Install the cotter pin (two) (Figure 7-20, Folio 7-18).

• Page 79: Wheels And Tires

  SECTION eight–WHEELS AND TIRES WARNING • ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING Even Elementary REPAIRS OR SERVICE SHOULD Have KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR. • FOLLOW ALL PROCEDURES EXACTLY Every bit STATED IN THIS Manual, AND Heed ALL DANGER, WARNING, AND Circumspection STATEMENTS LISTED IN THIS Transmission Besides Equally THOSE AFFIXED TO THE VEHICLE.

• Page fourscore: Wheel Removal, Repair And Installation

  WHEELS AND TIRES Bike Removal, Repair and Installation General Information, Continued: • Continue axle nuts and lug nuts properly torqued. • Keep the forepart end aligned and adjusted. Bicycle REMOVAL, REPAIR AND INSTALLATION Read Warning on folio eight-1. WHEEL REMOVAL i.

• Page 81: Repairing A Tire

  WHEELS AND TIRES Cycle 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 level AGAINST TIRE TOOL TIRE Chaplet POSITIONED USING TIRE TOOL, IN RIM WELL Advisedly Elevator 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, make clean the bicycle rim with a wire brush. NOTE • BECAUSE TUBELESS TIRES Crave A PERFECT SEAL IN ORDER TO SEAT, CLEANING OF THE TIRE AND RIM IS VERY IMPORTANT.

• Page 83: Rear Suspension

  Department nine–REAR Suspension GENERAL Data The rear suspension of the DS vehicle is completely independent. It consists of ii foliage springs controlled by two daze absorbers mounted betwixt the springs and the vehicle frame. WARNING • Just TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD Have KNOWLEDGE AND EXPERIENCE IN General Electric AND MECHANICAL REPAIR.
• Folio 84 REAR SUSPENSION General Data Brake CABLE HANGER MOUNTING GASOLINE VEHICLE Just TYPICAL ON TYPICAL ON EACH SIDE EACH SIDE OF VEHICLE OF VEHICLE BRAKE CABLE HANGER MOUNTING Electrical VEHICLE ONLY TYPICAL 2 PLACES Effigy 9-one Rear Suspension Associates and Mounting Page nine-2 1998/1999 DS Golf game Automobile Maintenance and Service Manual...

• Folio 85: Shock Absorbers

  REAR Intermission Shock Absorbers Stupor ABSORBERS INSPECTING AND REMOVING SHOCK ABSORBERS 1. Check shock absorbers (7) for fluid leakage at the indicate where the shaft enters the shock cushion torso. Replace leaking stupor absorbers (Effigy 9-one, Page nine-2) . ii. To remove a shock absorber, remove the nut (five), loving cup washer (ix) and safe bushing (10) from the stem at the top of the stupor absorber (Figure nine-1, Page 9-2) .
• Page 86 REAR SUSPENSION Leaf Springs Removing the Leaf Springs, Continued: 2. Identify a floorjack under the transaxle differential casing to back up (but not lift) the drivetrain. Raise information technology simply enough to salve tension on the shock absorbers without compressing them. 3. Remove the tire and bicycle associates on the side from which the jump is to be removed. 4.
• Page 88 Golf Cars Order Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...

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