🏷️ Basic Information Identification Make: Club Car Model: DS Year: 2004 Vehicle Type: Golf Cart Powertrain Type: Gasoline 👋 Introduction Market Position Target Audience: Owners, technicians, and enthusiasts of the 2004 Club Car DS gasoline golf cart seeking comprehensive repair and maintenance information. Key Features Instant Access: Instant download post-payment provides immediate access to critical repair data. Digital Convenience: Eliminates the need for physical manuals, reducing the risk of damage from grease and dirt, and allowing for on-the-go access via smart devices. Value Proposition Comprehensive Coverage: Offers a wide range of topics from basic maintenance to advanced troubleshooting, covering all major systems of the vehicle. 📋 Manual Details Identification Product Name: 2004 Club Car DS Gasoline Golf Cart Repair Manual Format: Downloadable PDF Language: English Coverage Applicable Models: 2004 Club Car DS Gasoline Golf Cart Manual Type: Repair Manual / Service Manual / Shop Manual Product Attributes Provider: GearHead Manuals 📖 Manual Coverage Systems Engine Management: Comprehensive coverage of engine operation, troubleshooting, and repair. Fuel System: Detailed information on fuel pump, carburetor, fuel lines, and filters. Lubrication And Cooling: Includes oil specifications, change intervals, cooling system components, and troubleshooting. Engine Mechanical: Engine removal and installation procedures, internal component specifications, and rebuild guides. Transmission And Drive: Coverage of transmission, drive chain, sprockets, and related maintenance. Steering: Procedures for steering system inspection, adjustment, and repair. Suspension: Detailed information on shocks, springs, and suspension component maintenance. Electrical System: Wiring diagrams, component testing, battery maintenance, and troubleshooting of electrical issues. Bodywork: Information pertaining to body panel removal, installation, and minor repairs. Intake And Exhaust: Details on air intake system and exhaust components. Wheels And Tires: Information on tire pressures, rotation, and wheel specifications. Procedures Routine Maintenance: Step-by-step guides for regular servicing and preventative care. Troubleshooting: Advanced diagnostic procedures and common issue resolutions. Component Replacement: Instructions for replacing various parts and components. Adjustment And Calibration: Procedures for calibrating and adjusting critical systems. General Information: Includes general overview, safety precautions, and vehicle identification. Engine Specifications: Detailed technical data for engine components, tolerances, and tuning. Technical Depth Repair Level: Covers everything from routine checks and fluid changes to major component overhauls and engine rebuilds. Diagnostic Capability: Advanced troubleshooting sections with symptom-based diagnostics and step-by-step repair instructions. 📊 Manual Specifications File Attributes File Format: PDF Searchability: Likely searchable text within the PDF for efficient navigation. Printability: Designed to be printable for on-site use. Ease Of Use: Plain, simple, easy-to-use PDF format, no compression required. Support Lifetime Policy: Lifetime Protection Policy against loss or damage. ⚙️ Engine Specifications Primary Engine Engine Type: Club Car's proprietary gasoline engine (specific model not detailed in product info, but typically a 4-stroke overhead valve). Performance Displacement: Typically around 240-300cc for gasoline models of this era. (Specific value requires manual lookup). Fuel System Fuel Delivery: Carburetor-based fuel delivery system. Cooling System Cooling Method: Air-cooled, with potential for fan assist. 🔧 Transmission Type Drive System: Continuously Variable Transmission (CVT) or similar automatic clutch system. Features Drive Mechanism: Belt-driven by the engine to the differential. Maintenance Fluid Type: Specific lubricant for the differential and drive system (details in manual). 📐 Dimensions Exterior Overall Length: Approx. 92-94 inches (exact specification varies by configuration and requires manual verification). Overall Width: Approx. 47-48 inches (exact specification varies). Overall Height: Approx. 45-47 inches to the top of the seat (without roof or windshield, requires manual verification). Weights Curb Weight: Approx. 550-600 lbs (dry, without passengers or accessories, requires manual verification). Payload Capacity: Typically around 700-800 lbs (including passengers, requires manual verification). 🛡️ Safety Features Features Braking System: Hydraulic drum brakes (rear) and potentially mechanical parking brake. (Specifics in manual). Lighting: Headlights and taillights (standard on many models, optional on some configurations). Seatbelts: Optional, often not standard equipment on golf course models. 💡 Technology Features Infotainment Features: Basic functionality; typically no advanced infotainment systems. Focus on mechanical and electrical operation. Driver Assistance Features: Limited to basic controls like accelerator, brake, and steering. Diagnostics Onboard Diagnostics: Manual provides diagnostic codes and procedures for identifying faults in various systems. 🔧 Maintenance Service Intervals Oil Change: Typically recommended every 50-100 operating hours or annually. (Specifics in manual). Air Filter Cleaning Replacement: Check and clean/replace every 100-150 operating hours. (Specifics in manual). Spark Plug Replacement: Recommended replacement every 200-300 operating hours. (Specifics in manual). Fluid Specifications Engine Oil Type: SAE 30W or 10W-30 (API Service SG or higher recommended). (Exact specification from manual is critical). Engine Oil Capacity: Approximately 1 quart (0.95 liters). (Exact capacity from manual is critical). Gear Lube Type: Specific gear oil for differential, e.g., SAE 80W-90. (Exact specification from manual is critical). Known Issues Carburetor Clogging: Can occur due to stale fuel or debris; requires cleaning or rebuilding. Drive Belt Wear: The CVT belt can wear over time and requires periodic inspection and replacement. Battery Maintenance: Regular checks of water levels...