Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 387 / 544

Page 20-37
E
20A
CONTINUOUSLY VARIABLE POTENTIOMETER
Testing the Continuously Variable Potentiometer
See Test Procedure 9, Page 20-17.
Removing the Continuously Variable Potentiometer (Figure 20-18, Page 20-38)
1. Disconnect batteries (Figure 20-1, Page 20-2).
2. Discharge the 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 front body brace. Gently pry
center dash out slightly from under edge of front body 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.
4. Slide the 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 18 gauge blue wire (1) from the key switch.
6. Unplug the three pin connector (2) which connects the potentiometer to the wire harness (Figure 20-
18).
7. Unplug the 18 gauge green/white wire (3) from F&R limit switch No.1.
8. Remove the crescent retaining ring (4), which is located between the accelerator pedal (5) and the
actuator lever (6), from the pivot rod (7).
9. Remove the potentiometer housing cover (8) by removing the two No. 4 screws (9) (Figure 20-18).
10. Remove the 3/8 lock nut (10) on the ratchet (11) (Figure 20-18).
11. Remove the 5/16 bolt (12), two washers, and nut attaching the accelerator pedal (5) to the accelerator
pivot rod (7) (Figure 20-18).
12. Remove the 1/4 bolt (13) and nut attaching the spring retainer (14) to the accelerator pivot rod.
13. Remove the 1/4 bolt (15), washer, and nut attaching the actuator lever (6) to the accelerator pivot rod
(Figure 20-18).
14. Remove the pivot rod.
• FAILURE TO DISCHARGE THE CONTROLLER COULD RESULT IN A SHORT CIRCUIT SHOULD
THE WRENCH OR RATCHET TOUCH THE LARGE POST OF THE SOLENOID.
• 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 AROUND THE DASH.
• THERE IS A NYLON WASHER (16) BETWEEN THE ACTUATOR LEVER AND THE POTENTIOME-
TER HOUSING.
WARNING
NOTE NOTE
NOTE NOTE