Page 6-13
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bearing bracket (21) (Figure 6-5, Page 6-3).
3. Secure the bearing brackets to the I-beam frame using the existing four 1/4 - 20 hex head bolts (19)
and nuts (18). Tighten the bolts and nuts to 70-80 in.lbs. (8/9 N-m) (Figure 6-5, Page 6-3).
4. Place the plastic spacer (22) on the accelerator pivot rod. Push the pivot rod into the spacer until the
end of the rod is even with the end of the spacer (Figure 6-5, Page 6-3).
5. Install the accelerator pedal assembly (1) down through the floorboard. Slide the accelerator pivot rod
into the accelerator pedal assembly (Figure 6-5, Page 6-3).
6. Align the hole in the end of the rod with the hole that runs through the pedal assembly. Install the 1/4
inch bolt (17) through the hole. Secure the flatwasher (24) and locknut (18) onto the end of the bolt.
Tighten the bolt and nut to 50 in.lbs. (6 N-m) (Figure 6-5, Page 6-3).
7. Install the accelerator return spring (23) through the mounting hole in the hanger (5) at the bottom of
the accelerator pedal (Figure 6-5, Page 6-3).
8. Install the ball joint socket (11) with the accelerator rod to the ball stud (6) on the accelerator pedal
(Figure 6-5, Page 6-3).
• Installing the Accelerator Pedal Assembly - Early 1995 Electric Vehicles:
1. Install the 1/2 inch spacer (20) onto the accelerator pivot rod (13) (Figure 6-7, Page 6-5).
2. Slide the accelerator pivot rod through the outside bearing bracket (21), I-beam frame, and the inside
bearing bracket (21) (Figure 6-7, Page 6-5).
3. Secure the bearing brackets to the I-beam frame using the existing four 1/4 - 20 hex head bolts (19)
and nuts (18). Tighten the bolts and nuts to 70-80 in.lbs. (8/9 N-m) (Figure 6-7, Page 6-5).
4. Place the plastic spacer (22) on the accelerator pivot rod. Push the pivot rod into the spacer until the
end of the rod is even with the end of the spacer (Figure 6-7, Page 6-5).
5. Install the accelerator pedal assembly (2) down through the floorboard. Slide the accelerator pivot rod
into the accelerator pedal assembly (Figure 6-7, Page 6-5).
6. Install the pivot rod into the pedal. Secure the pivot rod to the pedal with a 1/4 inch bolt (17) and a lock-
washer (24). Tighten the bolt to 50 in.lbs. (6 N-m) (Figure 6-7, Page 6-5).
7. Install the accelerator return spring (23) through the mounting hole in the hanger (5) at the bottom of
the accelerator pedal (Figure 6-7, Page 6-5).
8. Install the ball joint socket (11) with the accelerator rod to the ball stud (6) on the accelerator pedal
(Figure 6-7, Page 6-5).
PEDAL GROUP ADJUSTMENT - LATE 1995 AND 1996 VEHICLES
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY
AND HEED ALL WARNINGS STATED IN THIS MANUAL.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY BEFORE SERVICING THE VEHICLE.
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
WARNING
Summary of Contents for 1996 DS Golf Car Gasoline
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Page 544: ...Golf Cars Club Car Inc P O Box 204658 Augusta GA 30917 4658...