1988 Club Car DS Service Manual

The 1988 Club Car DS Service Manual provides comprehensive maintenance and repair information for the 1988 Club Car DS golf cart model. This manual covers gasoline and electric variants, including engine specifications, electrical systems, brake systems, steering, suspension, body components, and troubleshooting procedures. Below are key sections for specifications, maintenance schedules, repair procedures, and troubleshooting.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Electrical Systems 5. Brake Systems 6. Steering & Suspension 7. Body & Frame 8. Troubleshooting 9. Parts Catalog 10. Warranty Information

Vehicle Specifications

Key specifications for 1988 Club Car DS models including dimensions, weight capacity, and performance data.

Specification	Description
Model Year	1988
Model Series	DS (Drive System)
Engine Options	Gasoline: 341cc 4-cycle; Electric: 36V DC motor
Weight Capacity	800 lbs (including passengers and cargo)
Overall Length	91.5 inches
Overall Width	47.5 inches
Wheelbase	65.5 inches
Turning Radius	11.5 feet
Top Speed	12-14 mph (depending on model and conditions)
Battery System	Electric: Six 6-volt batteries (36V total)

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

Daily: Check tire pressure, brake operation, and overall condition
Weekly: Inspect battery water levels (electric models), check fluid levels (gas models)
Monthly: Lubricate steering components, check brake adjustment
Every 6 months: Change engine oil (gas models), inspect brake pads
Annually: Complete electrical system check, suspension inspection

WARNING! Always disconnect battery before performing electrical maintenance. Use proper lifting equipment when working under vehicle.

Engine Systems

Service procedures for gasoline engine maintenance and repair.

Oil Change: Drain old oil, replace filter, refill with SAE 30 weight oil
Spark Plug: Replace every 100 hours of operation with Champion RJ19LM
Air Filter: Clean or replace every 50 hours of operation
Fuel System: Inspect fuel lines, clean carburetor, check fuel pump
Cooling System: Check fan belt tension, clean cooling fins

CAUTION! Engine components may be hot during operation. Allow to cool before servicing.

Electrical Systems

Battery System: Six 6-volt deep cycle batteries, 36V total
Charging: Automatic charger with 15-amp output
Controller: Solid-state speed controller with thermal protection
Wiring: Color-coded 10-gauge primary circuits
Lights: 12V accessory circuit with headlights and taillights
Fuses: Main 30-amp fuse, accessory 10-amp fuse
Motor: 36V DC series wound, 2.5 HP continuous duty
Voltage Requirements: 36V DC for drive system, 12V DC for accessories

Brake Systems

Service procedures for mechanical drum brake system.

Front Brakes: Self-adjusting drum brakes, cable operated

Adjustment: Park on level surface, apply parking brake 3-4 clicks, adjust cable tension if needed. Inspection: Check brake shoes for wear, replace if lining is less than 1/8 inch thick. Lubrication: Lightly lubricate brake pedal pivot points and cable ends.

Steering & Suspension

Steering system uses rack and pinion design. Suspension features leaf spring rear, independent front.

Steering Wheel Removal: Remove center cap, remove nut, pull wheel straight off
Tie Rod Adjustment: Loosen lock nuts, adjust toe-in to 1/8 inch
Leaf Spring Inspection: Check for cracks or sagging
Shock Absorbers: Replace if leaking or poor damping

Tip: Check wheel alignment every 500 hours of operation or annually.

Body & Frame

Aluminum body panels on steel frame construction.

Body Panel Removal: Remove screws along edges, lift panel straight up
Seat Installation: Align mounting holes, secure with provided hardware
Windshield: Tempered glass, remove frame screws for replacement
Storage Box: Plastic construction, remove by detaching mounting brackets
Bumper: Steel construction, remove four mounting bolts for replacement

WARNING! Use proper lifting techniques when handling body panels. Wear gloves to prevent cuts from sharp edges.

Troubleshooting

Common issues and solutions for 1988 Club Car DS models.

Symptom	Possible Cause	Corrective Action
Cart won't start	Dead battery, loose connections	Check battery voltage, clean terminals, tighten connections
Poor acceleration	Worn brushes, controller issue	Inspect motor brushes, test controller output
Brakes grabbing	Contaminated linings, adjustment	Clean brake drums, adjust brake cables
Steering wheel play	Worn tie rod ends	Replace tie rod ends, check rack mounting
Electrical accessories not working	Blown fuse, bad switch	Check 10-amp accessory fuse, test switch continuity

Parts Catalog

Genuine Club Car replacement parts and recommended equivalents.

Common Replacement Parts: Battery part #1014954, Brake Shoes #1016217, Spark Plug #1016810, Air Filter #1019091, Tire 18x8.50-8

Warranty Information

Original 1988 warranty: 12 months on frame, 6 months on electrical components, 90 days on batteries. Current parts warranty may vary. Contact Club Car for current warranty policies and service locations.

Service Support: Contact Club Car Customer Service at 1-800-CLUBCAR or visit www.clubcar.com for technical assistance and parts ordering.