Club Car 1995 Golf Car, Maintenance Service Supplement

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4
RAISE THE VEHICLE AND SECURE IT ON JACK STANDS.
4.1. Chock rear wheels, then raise the front end of the vehicle and rest it on
jackstands positioned at each end of the round frame cross-member locat-
ed beneath the junction of the flat and inclined portions of the floorboard
(Figure 2).
4.2. Release the hill brake.
5
ADJUST BRAKE PEDAL HEIGHT (FIGURE 2).
5.1. Using a 7/16” socket, loosen brake stop jam nut (Item 1) and adjust brake
stop bumper (Item 2) up or down. Adjusting the bumper upwards decreases
distance between pedal and floorboard. Adjusting bumper downwards
increases distance between pedal and floorboard. Proper brake pedal
height is 5-3/4” plus or minus 1/4”. Tighten jam nut to 7 - 9 ft.lbs.
6
ADJUST HILL BRAKE RATCHET (ITEM 3) / PAWL (ITEM 4)
GAP AND PAWL ENGAGEMENT. (FIGURE 2)
6.1. Using a 1/2” wrench, adjust retaining nut (Item 5) on spring support rod
until there is a .030 to .090 inch gap between the pawl and the tips of the
ratchet teeth. Use a feeler gauge to verify gap ( See Figure 2, Detail A).
6.2. Measure distance from the top of the accelerator pedal to the floorboard,
and then lock the park brake.
6.3. With the park brake locked, make sure that at least 75% of ratchet tooth
length engages the pawl ( See Figure 2, Detail B).
6.4. Then, with the park brake still locked, measure the distance from the top of
the accelerator pedal to the floorboard again. If the measurement has
changed, ratchet tooth engagement is too deep.
6.5. If ratchet/pawl engagement must be adjusted, separate ball joint at the top
of the hill brake rod and thread the ball joint sleeve clockwise to increase
engagement or counter-clockwise to decrease engagement. Reconnect
ball joint.
6.6. If it was disconnected, reconnect accelerator push rod to accelerator pedal.
Page 4
WARNING
• LIFT ONLY ONE END OF THE VEHICLE AT A TIME. CHOCK THE WHEELS AND LOCK HILL
BRAKE BEFORE LIFTING. USE A SUITABLE LIFTING DEVICE (CHAIN HOIST OR HYDRAULIC
FLOOR JACK) WITH 1000 LBS. (454 KILOGRAMS) MINIMUM LIFTING CAPACITY. DO NOT
USE LIFTING DEVICE TO HOLD VEHICLE IN ELEVATED POSITION. ALWAYS USE
APPROVED JACK STAND OF PROPER WEIGHT CAPACITY TO SUPPORT VEHICLE.
NOTE
• On all DS Electric vehicles with electronic controllers, the actuator lever must also be adjusted
(step 8) if the ratchet/pawl gap is adjusted.
• On DS V-Glide Electric and Gasoline powered vehicles, the accelerator rod adjustment must also
be checked if the ratchet/pawl gap is adjusted. See DS Maintenance and Service Manual.
• On DS V-Glide Electric and Gasoline powered vehicles, the accelerator push rod must be dis-
connected from the accelerator pedal before proceding to step 6.2.