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Old 02-07-2014, 01:21 PM   #1
SickPup404
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Default My 1998 Club Car DS project

Good afternoon!

I just wanted to get a thread going to be able to document my planning and problems in this project.

I have a 1998 CC DS (s/n AG9832-xxxxxx) that hasn't been very well cared for, mostly since it hasn't been used very often because of the issue it has. It's been sitting in our barn getting dusty for a few years, but I recently took up the hobby of shooting sporting clays and this might come in handy.

I've attached some pics for reference.

I bought it from my sister about 8 years ago, and she got it from a local place in it's current configuration. It's currently painted blue metal flake (the Haley stickers are gone), has a chrome diamond plate cargo box, and snap in chrome hub caps. Everything else equipment-wise appears to be stock to me.

The issue it has is that it only has two speeds: stop or WFO, and it's very fast. From the searches I've done, it appears it probably needs to have the governor cable reinstalled/adjusted, and checked out for possible changes to bump up that top end (not that I mind it, but my wife would like to use it too). Having low speed would be ideal to allow me to spray Round Up along our property (15g sprayer, 7.5 acres).

I have downloaded a collection of PDFs that include: 1998 Owners Manual, 1998 Illustrated Parts List, 1998-1999 Maintenance Service Manual, Service specs for the 1998-1999 FE290 (torque, clearances, etc.), and a 1997 Service Manual Supplement that may or may not help.

So my list begins like this:
  • Tune-up and general maintenance on neglected items. I have spark plug, air filter, oil filter, two fuel filters, starter/generator belt, and drive belt all on the way.
  • Remove/reinstall/adjust the governor cable.

*** Stop here ***
If the above doesn't resolve speed issues and smooth running operation, I will likely think about replacing the carb, fuel pump, and fuel lines (another $120-$150 or so). If that still doesn't resolve it, I'll likely trade in for a newer electric cart. If the issues ARE solved, continue on.)
*** Stop here ***

The rest of these items are in no certain order.
  • Apply a vinyl skin. Found typical camo skins (Realtree, Mossy Oak, etc.) on Amazon for $90 for 4'x5' (20 sq. ft.). Looking at golf cart kits, nearly all of them are two rolls of 2'x10' (40 sq. ft. total) for anywhere from $220-$300. I also found a 4'x5' roll of Realtree snow camo on Amazon for $70. I've not seen any snow camo, so that might make it appealing enough with the unique factor & cheap factor to be the one I use. I would plan on removing the front and rear body panels to make it easier to apply the film.
  • Depending on how I think it will look, I might spray all of the roof (top and inside), roof struts, shiny aluminum body trim, rims, etc. with something like bedliner or grill paint. I'm thinking the snow camo will look better with stock hardware, but a dark camo like a flavor of Realtree or Mossy oak would look better with black.
  • Add a mesh sporting clays basket to the front. I have a fold down windshield, but I think it will still work.
  • Add a headlight/taillight kit. Found one of these cheap on Amazon as well - about $68.
  • Add a front brush guard/bumper.
  • New tires, maybe rims. The stock tires and rims look junky. If I go this far, may as well add some better rubber.
  • Add rear heavy leaf spring kit to prevent rear end "sag".
  • Add a few vertical gun racks to the dump body or next to the windshield.
  • Probably no lift kit.

Any thoughts, suggestions, pointers, etc. are most welcome!

Thanks!
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File Type: jpg IMG_1279.JPG (108.6 KB, 0 views)
File Type: jpg IMG_1282.JPG (118.9 KB, 0 views)

Last edited by SickPup404; 02-07-2014 at 01:38 PM.. Reason: Leaf spring/gun rack reference
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Old 02-07-2014, 03:25 PM   #2
PAPABEAR1
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Default Re: My 1998 Club Car DS project

Good look'n ride , esp. for sittin in the barn so long. I mounted my gun rack on the dash right behind the window. Its nice like that just not for long guns.

oh and welcome to the site , keep the pics coming. A lot of good folks on here .
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Old 02-07-2014, 10:14 PM   #3
KillerCC
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Default Re: My 1998 Club Car DS project

How old is the gas in the tank? May want to completely drain the tank and refill with fresh fuel.
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Old 02-09-2014, 04:51 PM   #4
SickPup404
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Default Re: My 1998 Club Car DS project

Oh yeah, forgot to actually put that down in the list. Thanks for the reminder!
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Old 02-09-2014, 10:23 PM   #5
nobuckbuild
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Default Re: My 1998 Club Car DS project

ACTUALLY LETS go first to check the carb butterfly to see if it is still in there or broken off that is the main issue with these club cars and wot problem its a quick check and could be running just fine on the cheap get it running right first , it may require a carb replacement if you cannot fab something up but check around here its a common problem
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Old 02-11-2014, 12:52 AM   #6
F239141
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Default Re: My 1998 Club Car DS project

Quote:
Originally Posted by nobuckbuild View Post
ACTUALLY LETS go first to check the carb butterfly to see if it is still in there or broken off that is the main issue with these club cars and wot problem its a quick check and could be running just fine on the cheap get it running right first , it may require a carb replacement if you cannot fab something up but check around here its a common problem
Yeah that's what I was thinking
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Old 02-11-2014, 07:16 AM   #7
SickPup404
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Default Re: My 1998 Club Car DS project

I'll check that carb out. Great info and support here! Thanks!
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Old 02-11-2014, 07:17 AM   #8
SickPup404
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Default Re: My 1998 Club Car DS project

BTW: It might be a bit of time getting to work on it - too freakin' cold outside!
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Old 02-11-2014, 09:18 AM   #9
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Default Re: My 1998 Club Car DS project

no excuses its colder here, pull the hose off and get a finger in there that way you know wether or not to order that carb so by the time it arrives it should be warmer
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Old 02-11-2014, 10:30 AM   #10
SickPup404
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Default Re: My 1998 Club Car DS project

Well, since I don't know what I'm feeling for (my wife would probably agree!), here's a pic down the intake pipe. For orientation, the top of the pipe is at the 6 o'clock position in the shot.
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Last edited by SickPup404; 02-11-2014 at 10:32 AM.. Reason: Orientation
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