Club Car 1997 DS, Maintenance Service Supplement

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1-9
E
G
Pedal Group Disassembly and Assembly, Continued:
4. Rotate the potentiometer lever (27) clockwise until lever fork is at the two o’clock position (Figure 6-25).
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 6-25), 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 6-19, Page 24).
7. Install the spring retainer (12) on the pivot rod (Figure 6-19, Page 24).
8. Slide the pivot rod toward the passenger side of the vehicle until approximately one-half of the length of
the pivot rod splines is exposed (Figure 6-19, Page 24).
9. Depress the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is
pointed toward the rear of vehicle, slide the ratchet onto the pivot rod (do not slide the ratchet onto the
pivot rod splines). Release the brake pedal and allow the ratchet to rotate until its tip is pointed down-
ward (Figure 6-26). The ratchet should now rotate freely on the rod.
10. Rotate the ratchet clockwise until it touches the park brake pawl, then slide the ratchet onto the splines
of the pivot rod (it may be necessary to push the pivot rod toward the driver side of the vehicle to make
the splines accessible). The ratchet may have to be rotated counterclockwise slightly to align the
splines.
11. Tighten the four bolts that secure the potentiometer assembly and pivot rod support to the vehicle
frame to 70-80 in.lbs. (8/9 N-m).
12. Use a feeler gauge to check the gap between the ratchet and the pawl. The gap should be .060” plus or
minus .030”. Turn the nut (7) on the spring retainer (12) clockwise to widen the gap or counterclockwise
to reduce the gap (Figure 6-19, Page 24). If the gap is .125” or more, slide the ratchet off the splines,
rotate the ratchet clockwise one spline, and then slide the ratchet back onto the splines before adjust-
ing with the spring retainer nut.
• 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 6-25).
FIGURE 6-25 FIGURE 6-26
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