Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 176 / 544

Page 12-40
12
G
Removing the Key Switch, Continued:
8. Remove the key switch:
• On vehicles prior to Serial No. 9522-436452, remove the key switch from the dash by holding the key
switch and turning the nut on the outside of the dash with the key switch tool (Club Car Part No.
1012801)
• On Vehicles Serial No. 9522-436452 and later, remove the cover over the key switch with a small, flat-
blade screwdriver.
8.1. Remove key switch from the dash by holding the key switch and turning the nut on the outside of
the dash with a one-inch socket wrench. Remove the keyed washer with key switch.
Installing the Key Switch
Reconnect wires to key switch (See Figure 12-2, Page 12-3). Coat the connectors with Battery Protector
Spray (Club Car Part No. 1014305) to ward off corrosion. Reverse removal procedures to install key switch in
the dash. Be sure that key switch terminals cannot touch the frame and that panel is properly seated and
snapped in place.
Testing the Key Switch
See Test Procedure 17, Page 12-25.
SOLENOID
Removing the Solenoid
1. Remove seat from body.
2. Disconnect battery wires as shown (Figure 12-1, Page 12-2).
3. Remove electrical component box cover (Figure 12-53, Page 42).
4. Disconnect all the wires from the solenoid.
5. Remove the two screws that secure the solenoid in place.
6. Remove the solenoid.
Installing the Solenoid
1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box.
2. Connect the 6 gauge white wire and the 16 gauge red wire from the voltage regulator on the large post
on the solenoid. Connect the 6 gauge red wire and the 10 gauge red wire from the fuse block on the
other large post on the solenoid. Connect the 18 gauge blue wire from the key switch to the small post
on the solenoid. Connect the 18 gauge orange wire from the accelerator starter limit switch to the other
small post on the solenoid (Figure 12-2, Page 12-3).
3. Install the snap-on electrical box cover by firmly pressing down on all corners and install the screw. Re-
connect the battery wires.
4. Install the seat on the rear body.
• WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS:
- WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE THE KEY.
- PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL.
- DISCONNECT THE BATTERY AS SHOWN (FIGURE 12-1, PAGE 12-2).
• FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED.
• SEE THE SAFETY WARNINGS ON PAGE 12-1.
WARNING