Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 376 / 544

Page 20-26
20B
E
The Key Switch, Continued:
Removing the Key Switch
1. Disconnect batteries (Figure 20-1, Page 20-2).
2. Discharge the speed controller (See instructions in WARNING box on Page 20-25).
3. Remove center dash.
3.1. Remove the plastic cap covering the screw on each side of the center dash.
3.2. Loosen (but do not remove) the screw on each side of the center dash panel.
3.3. Insert screwdriver at top center of center dash between dash and cowl brace. Gently pry center
dash out slightly from under edge of cowl brace.
3.4. Pull center dash out approximately one inch from the frame and then bend the top right corner of
the center dash panel inward while pulling the top of the panel out and down. See NOTE below.
4. Slide center dash panel up the steering column by snapping out the top and then rotating the panel out
and up. There is sufficient slack in the wiring to allow for this.
5. Disconnect the wires from the key switch. Do not allow wires to touch.
6. Remove key switch from the dash:
• On vehicles manufactured prior to December 19, 1994 (serial numbers lower than 9522-436452), hold
the key switch and use the switch tool (Club Car Part No. 1012801) to turn the switch retaining nut on
the outside of the dash panel.
• On vehicles manufactured on December 19, 1994 and later (serial numbers 9522-436452 and greater),
from the back of the dash panel, push down on the retaining tabs surrounding the key switch and
remove the key switch cap (Item 8, Figure 19-11, Page 19-17). Hold the key switch and use a 1 inch
deep well socket to remove the switch retaining nut from the outside of the dash panel.
Installing the Key Switch
1. Position the key switch in the center dash, then install and tighten the switch retaining nut. If you have
the later model key switch, press the plastic cap into place on the outside of the center dash (Figure
19-11, Page 19-17).
2. Connect the wires to the key switch terminals (See Figure 20-2, Page 20-3, or Figure 20-3, Page 20-
4), and then coat the terminals with Battery Protector Spray (Club Car Part No. 1014305).
3. Install the center dash into the vehicle by reversing the removal procedure. Make sure that the key
switch terminals can not touch the frame and that the center dash panel is properly seated and
snapped into place. See NOTE below.
• BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT
WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE
METAL FRAME AROUNG THE DASH.
• BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE INSTALLING IT
WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE
METAL FRAME AROUND THE DASH.
NOTE NOTE
NOTE NOTE