Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 74 / 544

Page 6-28
6
E
G
INSTALLING THE ACCELERATOR PEDAL ASSEMBLY
DS PowerDrive System 48 Vehicles and DS PowerDrive Plus Vehicles (Serial Number
A9529 445799 and Later)
1. Position the accelerator pivot rod support (22) and the potentiometer assembly (21) on the vehicle
frame and install the four hex head cap screws (23), flat washers (8), and lock nuts (11). Tighten the
nuts with fingers only at this time (Figure 6-35, Page 6-22).
2. Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot
rod (6) through the uppermost hole in the pedal. Install the bolt (4), two washers (5), and nut (7)
through the lower hole in the pedal and through the pivot rod. Tighten the nut with fingers only at this
time. Install the actuator lever (17) (Figure 6-35, Page 6-22) on the pivot rod and position the pedal and
actuator lever on the rod so that about one-half of the total length of the pivot rod is protruding out of
the actuator lever.
3. Place the plastic washer (18) on the end of the accelerator pivot rod and align the pivot rod and washer
with the hole in the potentiometer housing (21), then insert the pivot rod through the potentiometer,
vehicle frame, and pivot rod support until the end of the pivot rod is flush with the outside surface of the
pivot rod support (22) (Figure 6-35, Page 6-22).
4. Rotate the potentiometer lever (27) clockwise until lever fork is at the two o’clock position (Figure 6-36).
The lever must be at approximately two o’clock in order for it to mate with the alignment pin on the actu-
ator lever.
5. Rotate the actuator lever until its alignment pin is aligned with the slot in the potentiometer lever fork
(Figure 6-36), then slide the actuator lever toward the potentiometer housing. See CAUTION below.
6. Push the accelerator pivot rod (6) through the potentiometer housing until the groove in the pivot rod is
even with the end of the actuator lever (Figure 6-35, Page 6-22).
7. Install the spring retainer (12) on the pivot rod (Figure 6-35, Page 6-22).
• DO NOT BEND THE LIMIT SWITCH LEVER. THE CAM ON THE ACTUATOR LEVER SHOULD BE
AT THE TWELVE O’CLOCK POSITION WHEN THE ACTUATOR LEVER IS IN POSITION TO
MATE WITH THE POTENTIOMETER LEVER, ALLOWING THE ACTUATOR LEVER TO SLIDE
PAST THE LIMIT SWITCH LEVER. IT MAY BE NECESSARY TO HOLD THE LIMIT SWITCH LEVER
BACK WITH A FLAT BLADE SCREWDRIVER (FIGURE 6-36).
FIGURE 6-36 FIGURE 6-37
CAUTION
POTENTIOMETER ASSEMBLY
(CUT-A-WAY VIEW THROUGH COVER)
POTENTIOMETER
LEVER (27)
ACTUATOR
LEVER (17)
POTENTIOMETER
HOUSING ASSEMBLY (21)
FLAT BLADE
SCREWDRIVER
RATCHET POINTED
TOWARDS REAR OF
VEHICLE
ROTATE RATCHET
CLOCKWISE
DEPRESS BRAKE PEDAL