Club Car 1996 DS Golf Car Gasoline, Service Manual

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G
Liquid Gasket and Non-permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used.
Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example
of a non-permanent locking agent commonly available in North America is Loctite ®, Lock’n Seal (Blue).
Ball Bearing Installation
When installing a ball bearing, the bearing race which has the press fit should be pushed by a suitable driver.
This prevents severe stress on the balls and races, and prevents races and balls from being damaged. Press
a ball bearing until it is seated against the shoulder in the hole or on the shaft.
Circlip, Retaining Ring
Replace with new ones any circlips and retaining rings that were removed, as removal weakens and deforms
them. When installing circlips and retaining rings, take care to compress or expand them only enough to
install them.
High Flash-point Solvent
To reduce fire danger a high flash-point solvent is recommended. A commercial solvent commonly available
in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions
regarding the use of any solvent.
Molybdenum Disulfide (MoS2) Grease
Engine Rotation
When turning the crankshaft by hand, always turn it counterclockwise as viewed from the front (flywheel end)
of the engine. This will ensure proper adjustments.
ELECTRICAL SYSTEM
1. Always minimize shock hazards when working on electrical equipment. Work in a clean, dry environ-
ment with dry hands.
2. The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard sur-
face. Such a shock can damage an electrical part.
3. Never replace a defective electrical component without first determining what caused the failure. If the
failure was brought on by some other item or items, they too must be repaired or replaced before using
the vehicle.
4. Make sure all connectors in the circuit are clean and tight, and examine wires for signs of overheating,
fraying, etc. Poor wires and bad connections will affect electrical system operation.
5. Measure coil and winding resistance when the part is cold (at room temperature).
6. All the electrical leads are either single-color or two-color and, with only a few exceptions, must be con-
nected to leads of the same color. On any of the two-color leads, there is a greater amount of one color
and a lesser amount of a second color, so a two-color lead is identified by first the primary color and
then the secondary color. For example, a yellow wire with a thin red stripe is referred to as a “yellow/
red” wire; it would be a “red/yellow” wire if the colors were reversed to make red the main color.
• THIS MANUAL MAKES REFERENCE TO MOLYBDENUM DISULFIDE GREASE IN THE ASSEM-
BLY OF CERTAIN ENGINE AND CHASSIS PARTS. ALWAYS CHECK MANUFACTURER RECOM-
MENDATIONS BEFORE USING SUCH SPECIAL LUBRICANTS.
WARNING