Description
1991 Club Car DS 4-Passenger Electric Utility Transit Vehicle
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Condition: Pre-Owned / Classic Fleet Core Platform
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Year: 1991 Model Year
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Make/Brand: Club Car
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Model Line: DS Series (Configured with an Outboard 4-Passenger Rear-Facing Conversion)
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Power System: 36-Volt Direct Current (DC) Electric System
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Motor / Drive Layout: 36V Shunt/Series Wound DC Electric Motor // Multi-Step Resistor Coils with Solenoid Activation
The 1991 Club Car DS 4-Passenger Electric is a multi-passenger utility and course transport vehicle built on Club Car’s legacy first-generation DS architecture (initially conceptualized by designer Dom Saporito). This specific model year features the highly mechanical, pre-solid-state electrical design that relies on individual resistor coils to regulate speed thresholds. It is configured with a rear-facing flip seat layout to handle 4-passenger logistics across retirement estates, sports complexes, and private facilities.
The core structural framework consists of a proprietary 6061-T6 aircraft-grade extruded aluminum I-beam chassis. The body panels feature a hybrid composite layout typical of the pre-1993 era, utilizing a molded fiberglass-reinforced plastic (FRP) rear body structure paired with a thermoplastic front cowl.
36V Mechanical Powertrain & Velocity Regulation
Multi-Step Resistor Block Configuration: The 1991 electrical architecture manages motor velocity through a mechanical wiper switch and a series of heavy-duty wire resistor coils mounted to an insulated board behind the battery compartment. At partial throttle, excess amperage is dissipated across the coils as thermal energy; full pedal depression bypasses the resistors to route 120 amperes of continuous current directly to the 36V DC motor shaft.
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Mechanical Speed Switching: Employs a 5-solenoid system or a slide-wiper V-glide switch housing that stages the power drop across three independent nichrome alloy resistor coils.
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Direct-Drive Differential Transaxle: Power transfers directly from the splined motor armature into a fully sealed, oil-bath helical gear transaxle housing with a standard 12.44:1 final drive gear ratio.
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Directional Control Mechanical Lever: Directional changes (Forward, Neutral, Reverse) are mechanical, operating via a high-amperage shifting lever linkage mounted on the lower seat support panel.
Key Specifications & Technical Profile
| Feature Category | Factory Technical Specification Profile |
| Seating Allocation | 4-Passenger (Dual Forward Bench + Dual Rear-Facing Folding Bench) |
| Chassis Assembly | Extruded Structural Aluminum I-Beam with Steel Suspension Mounts |
| Powertrain Setup | 36-Volt Continuous-Duty DC Electric Traction Motor |
| Speed Regulation | Multi-Point Mechanical Resistor Board Assembly |
| Electrical Architecture | Six 6-Volt Heavy-Duty Deep Cycle Lead-Acid Battery Storage Cells |
| Charging Interface | Side-Body Mounted 3-Pin Molded Receptacle |
| Braking Mechanism | Dual Rear-Wheel Mechanical Expansion Drum Brakes |
| Steering Layout | Self-Compensating Double-Reduction Helical Rack and Pinion |
| Suspension Geometry | Front Mono-Leaf Spring // Rear Dual-Leaf Springs with Hydraulic Shocks |
Dimensions & Functional Cabin Equipment
1. Physical Footprint & Weight Profiles
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Total Longitudinal Length: 272 cm (107.0 inches) including the secondary passenger footrest step
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Total Transverse Width: 118.1 cm (46.5 inches)
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Total Height (No Canopy): 114.3 cm (45.0 inches) to the upper edge of the steering wheel rim
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Total Height (With Extended Roof): 176.5 cm (69.5 inches) down to ground plane
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Wheelbase Distance: 166.4 cm (65.5 inches)
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Ground Clearance (Minimum): 11.4 cm (4.5 inches) at the rear differential midpoint
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Total Vehicle Curb Weight: 395 kg (870 lbs) with standard 6V lead-acid cells installed
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Rated Carrying Capacity: 363 kg (800 lbs) maximum distributed passenger mass limit
2. Structural Materials & Secondary Equipment
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Rear Conversional Bench: Outfitted with an aftermarket structural steel rear-facing flip seat frame. The marine-grade vinyl seating section converts via dual hinges to reveal a flat, painted steel or poly deck area for material cargo haulage.
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Body Panels & Trim: Features a high-gloss gel-coat fiberglass rear section with an impact-modified thermoplastic front cowl assembly bordered by heavy-gauge extruded aluminum side perimeter rub-rails.
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Operator Dashboard Utilities: Dual open-face storage compartments embedded into the left and right dash sections, a central flat console panel, and an inline key-switch starter.
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Windshield & Roof Canopy: Equipped with an aftermarket extended-length thermoformed plastic sun roof assembly designed to deflect precipitation over both seating rows, paired with a clear, split-folding acrylic front windshield windshield.
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Lighting Components: Retrofitted with standard front bumper-mounted quartz-halogen headlights and red single-stage rear marker lights.
Maintenance Profile & Operational Longevity
The 1991 Club Car DS 4-Passenger Electric represents a purely mechanical, low-complexity platform. The lack of sensitive integrated circuitry, microcontrollers, or solid-state transistors allows for direct component isolation during diagnostics. The structural integrity of the rust-free aluminum frame ensures basic operational utility across industrial environments and estate applications.
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