Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 280 / 544

Page 16-12
16
G
Drive Clutch Assembly, Continued:
12. Install the 1/4-20 screws and washers (2) and tighten them to 10 ft.lbs. (13 N-m). See NOTE below
(Figure 16-5, Page 16-7).
13. Install one drive button take-up spring.
13.1. Install spring on left side of any one of the three button mounting posts (when looking into the
interionr of the clutch cover with the rib at the twelve o’clock posiiton) as shown (See Figure 16-
15, Page 16-11).
14. While compressing the take-up spring, install a drive button over the rib and take-up spring as shown.
Install remaining two buttons. (Figure 16-15, Page 16-11).
15. Install a No. 10-24 button retaining screw with flat washer (10) (Figure 16-5, Page 16-7) through each
button and into the rib. Tighten the screws to 30-60 in.lbs. (3.39/4.07 N-m) (Figure 16-15, Page 16-11).
16. Install the thrust washer (11) onto the moveable face assembly (Figure 16-5, Page 16-7).
17. Install the hub assembly (1) into the moveable face assembly and align the match marks made before
disassembling the clutch. Press the hub assembly on by hand (Figure 16-5, Page 16-7).
INSTALLATION OF THE DRIVE CLUTCH
1. Place the drive clutch assembly on the crankshaft taper. Position the lock washer (18) and the mount-
ing washer (19) on the bolt (17) and start the bolt into the crankshaft. Tighten the bolt to 23-28 ft.lbs.
(31/38 N-m) (Figure 16-5, Page 16-7).
2. Install the starter/generator belt and adjust belt tension as instructed on Page 12-37. Tighten the
mounting hardware to 21-25 ft.lb. (28.4/40 N-m) and adjusting hardware to 12-14 ft. lbs. (16/19 N-m).
3. Install the drive belt as instructed on Page 16-4.
4. Connect the battery cables, positive (+) cable first.
5. Connect the spark plug wire to the plug.
6. Drive the vehicle and check for proper operation.
DRIVEN CLUTCH
• MAKE SURE THAT THERE IS AT LEAST A (MINIMUM) GAP OF .020 INCHES (0.51 MM)
BETWEEN EACH END OF THE MOUNTING PIN AND THE MOUNTING SCREW.
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL MECHANICAL REPAIR.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERY.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERY OR ELECTRICAL CON-
NECTIONS.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
NOTE
WARNING