Club Car 1997 DS Maintenance Service Supplement Download Page 84

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Page 76

Engine does not start
easily, continued:

Igniter failed

Section 12 - Gasoline Vehicle Electrical
System

Low cylinder compression

Section 13 - Engine

Water or dirt in the fuel
system and/or carburetor;
dirty or clogged fuel filter

Section 14 - Fuel System

Carburetor improperly
adjusted

Section 14 - Fuel System

Starter/generator belt
is slipping

Section 12 - Gasoline Vehicle
Electrical System

Engine starts but does not
run smoothly.

Spark plug is fouled or in
poor condition

Section 13 - Engine

Spark plug wire is damaged

Section 13 - Engine

Igniter failed

Section 12 - Gasoline Vehicle
Electrical System

Water or dirt in the fuel
system and/or carburetor;
dirty or clogged fuel filter

Section 14 - Fuel System

Fuel pump malfunction, fuel pressure
to engine too low

Section 14 - Fuel System

Engine turns but fails
to start.

Fuel tank is empty

Section 14 - Fuel System

Fuel line or filters
clogged

Section 14 - Fuel System

Fouled spark plug

Section 13 - Engine

Spark plug wire damaged

Section 13 - Engine

Loose wire connection
at igniter

Section 12 - Gasoline Vehicle
Electrical System

Igniter failed

Section 12 - Gasoline Vehicle
Electrical System

Engine flooded with fuel as result of
over-choking

Section 3 - General
Information

Kill circuit grounded

Section 12 - Gasoline Vehicle
Electrical System

Fuel pump malfunction
or failure

Section 14 - Fuel System

Engine overheats.

Fan screen is partially blocked or
plugged

Section 13 - Engine

Improper governor adjustment

Section 14 - Fuel System

Carburetor is too lean, check main jet
size

Section 14 - Fuel System

Engine pre-ignites.

Excessive carbon deposits on piston
head or in combustion chamber

Section 13 - Engine

Spark plug heat range is
incorrect for the engine

Section 13 - Engine

Unsuitable or contaminated fuel

Section 14 - Fuel System

SYMPTOM

POSSIBLE CAUSES

REFER TO

Summary of Contents for 1997 DS

Page 1: ...DS GOLF CARS GASOLINE ELECTRIC MANUAL NUMBER 1019345 04 PRINT CODE 0197C0398A 1997 MAINTENANCE SERVICE SUPPLEMENT ...

Page 2: ......

Page 3: ...aintenance and Service Manual you may obtain one from your Club Car dealer or distributor This supplement and the manual should be thoroughly studied prior to servicing the vehicle The procedures provided must be properly implemented and the NOTES CAUTIONS WARNINGS and DANGER statements must be heeded This supplement and the manual were written for the vehicle mechanic who already possesses basic ...

Page 4: ... OR MODIFI CATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF WILL VOID THE WARRANTY CLUB CAR INC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS MANUAL SEE THE LIMITED WARRANTY FOUND IN THE VEHICLE OWNER S MANUAL OR WRITE TO C...

Page 5: ... Vehicles 7 Lubrication Electric Vehicles 8 Vehicle Capacities 9 Periodic Service Gasoline Vehicles 10 Periodic Service Electric Vehicles 12 SECTION 5 BODY AND TRIM 14 See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 6 ACCELERATOR AND BRAKE PEDAL GROUP 15 Section 6 in this supplement supersedes Section 6 in the 1995 1996 DS Maintenance and Service Manual General Information 15 Peda...

Page 6: ...uide 75 SECTION 12 ELECTRICAL SYSTEM GASOLINE VEHICLE 81 Section 12 in this supplement supersedes Section 12 in the 1995 1996 DS Maintenance and Ser vice Manual General Information 82 FE 290 Gasoline Vehicle Electrical Circuit 82 Circuit Testing 87 Test Procedures 94 Electrical System Components 107 Starter Generator 107 Voltage Regulator 118 Key Switch 119 Solenoid 119 Fuse 120 Accelerator Starte...

Page 7: ...d below See Section 16 in the 1995 1996 DS Golf Car Maintenance and Service Manual for all other information General Information 142 Drive Clutch Disassembly 143 Drive Clutch Assembly 144 Assembly of the Driven Clutch 146 Clutch Alignment 146 SECTION 17 TRANSMISSION AND GOVERNOR Section 10 in this supplement supersedes Section 17 in the 1995 1996 DS Maintenance and Ser vice Manual SECTION 18 REAR ...

Page 8: ...anual SECTION 22 BATTERIES See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 23A ACCU POWER BATTERY CHARGER See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 23B POWERDRIVE BATTERY CHARGER See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 24 MOTOR See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 25 TRANSAXLE ELECTRIC VEHICLE See Section ...

Page 9: ...DIATE HAZARD WHICH COULD RESULT IN SEVERE PER SONAL INJURY A CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR PERSONAL INJURY OR DAMAGE TO THE VEHICLE OR OTHER PROPERTY A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDER STOOD OR IMPLEMENTED GASOLINE FLAMMABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE SERVICE AREA DO NOT OPERATE I...

Page 10: ... FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS 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 CA...

Page 11: ...reduction helical gear with 12 28 1 direct drive axle Electrical System 12 volt 460 cold cranking amp battery and 35 amp charging capacity Electrical System 48 volts DC reduced speed reverse Electrical System 36 volts DC reduced speed reverse Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Batteries High capacity deep cycle Trojan 6 volt 115 min capacity Charger Automa...

Page 12: ... 2 98 cm 38 1 2 98 cm 38 1 2 98 cm Weight Standard electric vehicle without batteries 455 lbs 206 kg 455 lbs 206 kg 448 lbs 203 kg Weight Fairway Villager electric vehicle without batteries 495 lbs 225 kg N A N A Weight Standard gasoline powered vehicle dry 593 lbs 269 kg Weight Fairway Villager gasoline powered vehicle dry 633 lbs 287 kg Forward Speed 12 15 mph 19 24 kph 12 15 mph 19 24 kph 12 15...

Page 13: ...lace See Vehicle Identification pages at the beginning of vehicle Owner s Manual Tires Check for proper tire pressure See Capacities Page 9 in this supplement DS Electric Batteries all models Check electrolyte to ensure that it is at its proper level See Fig ure 22 7 Section 22 Page 6 in the Maintenance and Service Manual Check battery posts Wires should be tight and free of corrosion Charge batte...

Page 14: ...URES EXACTLY AND HEED ALL WARNINGS STATED IN THIS SUPPLEMENT AND IN THE MANUAL TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR RESISTORS ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS ALWAY...

Page 15: ...Chassis Lube Annually by Trained Technician Only Every 200 rounds or 100 hours of operation Check fill unitized transaxle to plug level 5 27 oz 8 liter 80 90 WT API Class GL 5 or 80 90 WT AGMA Class EP Gear Lube Inspect front wheel bearings Repack as necessary 6 Chassis Lube First Change 100 Hours Additional Change Every 400 Rounds or Every 200 Hours of Operation or Annually Whichever Comes First ...

Page 16: ...everse switch shaft and contacts charger receptacle Do not lubricate forward and reverse switch on PowerDrive Plus vehicles 4 WD 40 Front Suspension 5 fittings 5 Chassis Lube Anually by Trained Technician Only Every 200 rounds or 100 hours of operation Check fill transaxle to plug level 6 22 oz 67 liter SAE 30 WT API Class SE SF or SG Oil or higher Inspect front wheel bearings Repack as necessary ...

Page 17: ...s Tire Pressure 12 14 psi 83 96 kPa 18 20 psi 124 138 kPa IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH 3 2 2 1 1 7 5 5 5 4 5 5 7 3 6 POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES WITH MULTI STEP POTENTIOMETERS AND V GLIDE 3...

Page 18: ...er element clean as necessary Engine Cooling Air Intake Check for clogging clean as necessary Fuel System Check fuel tank lines cap pump and carburetor for fuel leakage Park Brake Check proper operation See Performance Inspec tion Page 3 2 in Maintenance Service Manual Reverse Warning Buzzer Check for proper operation See NOTE Page 3 4 in the Maintenance and Service Manual Steering and Linkages Ch...

Page 19: ...n adjust as necessary See Section 6 Accelerator Governor Linkage and Cables Check for proper operation adjust as necessary Steering Lubricate per Gas Vehicle Lubrication Chart on Page 7 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 7 Check all daily weekly and monthly items listed above Semi annual Service by Trained Mechanic Only Every 100 rounds or 50 hours of operation Bra...

Page 20: ...heel bearings with chassis lube as neces sary Starter Generator Check brush length remove excess carbon dust replace as necessary See Section 12 Unitized Transaxle Check fill transaxle to plug level See Gas Vehicle Lubrication Chart on Page 7 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 7 Check all daily weekly monthly quarterly and semi annual items listed above IF ANY PROB...

Page 21: ...required Check maximum speed of vehicle Maximum vehicle speed should be 12 15 mph 19 24 kph Check all daily items listed above Monthly Service by Owner or Trained Mechanic Batteries Wash battery tops with baking soda water solution Brake System Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance Service Manual Check brake pedal free play Adjust as necessary See Secti...

Page 22: ...Electric Vehicle Lubrication Chart on Page 8 Check all daily weekly monthly and quarterly items listed above Annual Service by Trained Mechanic Only Every 200 rounds or 100 hours of operation Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for proper operation See Performance Inspec tion Page 3 2 DS Maintenance Service Manual Wiper switch type only Remove cover and che...

Page 23: ...STANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE GASOLINE VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIR...

Page 24: ...2 ADJUST PARK BRAKE RATCHET PAWL GAP AND PAWL ENGAGEMENT ALL DS VEHICLES 2 1 Using a 1 2 wrench adjust the retaining nut 7 on the spring support rod until there is a 060 plus or minus 030 inch gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 6 4 Read NOTES below and at top of page 17 before proceeding FIGURE 6 1 FIGURE 6 2 FIGURE 6 3 ON ALL POWERDR...

Page 25: ...d accelerator pedal height toward the floorboard then depress the accelerator pedal until the end of the tool rests against the floor board pedal height should be 5 5 8 plus or minus 1 8 Use a rubber strap to hold the pedal in position against the floorboard and then tighten the nut to 12 15 ft lbs 16 20 N m Figure 6 9 Page 18 For gasoline vehicles proceed to Step 4 For V Glide 36 volt vehicles an...

Page 26: ...OOR BOARD TO BACK OF ACCELERATOR 1 2 3 4 5 6 7 8 9 10 RATCHET B TOOTH LENGTH LOCKED POSITION A B MAKE SURE PAWL A ENGAGES AT LEAST 75 OF RACHET TOOTH LENGTH B ROTATE BALL JOINT 11 CLOCKWISE TO INCREASE PAWL TO RACHET ENGAGEMENT COUNTERCLOCKWISE TO DECREASE IT SNAP LOOSE BALL JOINT 11 FROM BEHIND PARK BRAKE PEDAL 11 1 2 INCH SOCKET 1 2 INCH WRENCH yyyy yyyy yyyy y PARK STOP GO 5 5 8 1 8 ACCELERATOR...

Page 27: ...RVICING TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION TO PREVENT ACCIDENTAL STARTING OF THE ENGINE DISCONNECT THE BATTERY CABLES NEGATIVE FIRST THIS WILL PREVENT THE POSSIBILITY OF THE VEHICLE RUNNING OVER YOU WHEN YOU ARE ADJUSTING THE ACCELERATOR ROD AFTER ACCELERATOR ROD ADJUSTMENT MAKE SURE THAT APPROXIMATELY THE SAME NUMBER OF THREADS IS EXPOSED AT...

Page 28: ... the accelerator rod is not adjusted correctly disconnect it from the ball stud at the wiper switch and manually rotate the bell crank until the wiper switch arm brush is positioned entirely on the last fixed contact 4 4 While holding the accelerator rod with pliers loosen the jam nut 20 and adjust the ball joint 21 sleeve to fit on the wiper switch ball stud with approximately the same number of ...

Page 29: ...tentiometer housing assembly Figure 6 13 Page 22 at the Forward and Reverse Limit Switch No 1 on standard PowerDrive System 48 vehicles or at the main wire harness under the charger receptacle on PowerDrive Plus vehicles with motor braking 4 1 4 Connect the green white wire from the potentiometer housing to the green lead from the Calibration Test Module Figure 6 13 4 1 5 If it is not already disc...

Page 30: ...LIBRATION SET MODE SWITCH TO POT CHECK INTERNAL 4 30 03 VOLT SIGNAL BY PRESSING TEST BUTTON CONNECT TEST SOCKET TO POT PLUG CONNECT GREEN LEAD TO GREEN WHITE POT LIMIT SWITCH LEAD CONNECT BLUE LEAD TO BATTERY POSITIVE ILLUMINATION OF THE L E D INDICATES A CLOSED PEDAL LIMIT SWITCH READ THE POTENTIOMETER SET VOLTAGE FROM THE L C D DISPLAY SEE SERVICE MANUAL FOR ADJUSTMENT PROCEDURE SET POWER SWITCH...

Page 31: ... will not engage with the accelerator pedal in the up position and the park brake set If the red LED is illuminated at this point repeat step 4 9 4 11 Disconnect the Calibration Test Module from the vehicle and reconnect the three wire connector from the potentiometer to the wire harness Reconnect the green white wire to the Forward and Reverse Limit Switch No 1 on standard PowerDrive System 48 ve...

Page 32: ... REQUIRE ADJUST MENT IF A PROBLEM IS SUSPECTED SEE SECTION 20A PAGE 20 17 IN THE MAINTENANCE AND SERVICE MANUAL FIGURE 6 19 NOTE TO WIRE HARNESS ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBER 9704 667832 AND LATER TWO WASHERS ITEM 8 AND ITEM 16 ARE DELETED POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBERS PRIOR TO 9711 564736 3 6 19 20 4 9 21 22 5 8 13 14 15 TYPI...

Page 33: ...ng the Brake Pedal Assembly 1 Install the brake pedal assembly 1 1 From the top side of the floorboard insert the brake pedal weldment assembly 6 Figure 6 20 through the opening in the floor as shown Figure 6 21 Page 27 and install the pedal stop 22 Figure 6 20 on the weldment 1 2 Attach the equalizer rod 26 to the brake pedal weldment assembly 6 as shown Figure 6 20 1 3 Position and attach the br...

Page 34: ...h is in neutral then disconnect the battery or batteries as shown In the Maintenance and Service Manual see Figure 12 1 Page 12 2 for gasoline vehicles or Figure 22 5 or 22 6 Page 22 5 for electric vehicles See CAUTION below FIGURE 6 20 BRAKE PEDAL FREE PLAY IS THE DISTANCE THE BRAKE PEDAL CAN BE DEPRESSED BEFORE THE BRAKE ACTUATOR ARM MOVES DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES PE...

Page 35: ...ark Brake Assembly 1 From the bottom side of the floorboard insert the park brake rod 9 through the brake pedal assembly opening as shown in Figure 6 22 Then install the park brake pawl 32 onto the shaft on the brake pedal assembly weldment 6 and also the park brake rod 9 into the park brake pawl Figure 6 22 2 Install the push nut 11 onto the park brake pawl shaft Figure 6 22 LIFT ONLY ONE END OF ...

Page 36: ...s as shown Figure 22 5 or 22 6 Page 22 5 in the Maintenance and Service Manual DS Gasoline powered vehicle disconnect both battery cables negative first 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See WARNING below 3 Using a 1 2...

Page 37: ... 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 Figure 6 11 Page 21 3 Install the plastic spacer 22 on the pivot rod Figure 6 11 Page 6 21 4 Insert the pivot rod through the pivot rod suppor...

Page 38: ...key switch is off and that the Forward and Reverse Switch is in neutral then disconnect the batteries as shown Figure 22 6 Page 22 5 in the Maintenance Service Manual See CAU TION below 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stand...

Page 39: ... 27 and lock nuts 11 attaching the acceler ator pivot rod support 22 and potentiometer assembly 21 to the vehicle frame Figure 6 19 Page 24 and remove the pivot rod support and the potentiometer assembly INSTALLING THE ACCELERATOR PEDAL ASSEMBLY DS PowerDrive System 48 Vehicles and DS PowerDrive Plus Vehicles Serial Num bers Prior to 9711 564736 1 Position the accelerator pivot rod support 22 and ...

Page 40: ...e 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...

Page 41: ...e accelerator pedal to the pivot rod Figure 6 19 Page 24 and tighten with fingers only at this time 17 Adjust the accelerator pedal height See NOTE below 18 Adjust the actuator lever See NOTE below MAKE SURE THE ACTUATOR LEVER AND THE POTENTIOMETER LEVER ARE STILL MATED BEFORE TIGHTENING THE ACCELERATOR PIVOT ROD RETAINING NUT ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBER 9704...

Page 42: ...ection 8 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 9 WHEELS AND TIRES See Section 10 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 Because of incorporation of the unitized transaxle in 1997 DS gasoline vehicles Section 10 in the 1995 1996 DS Maintenance and Service Manual becomes Section 9 in this supplement ...

Page 43: ...m should not be required The governor system is a flyweight type and measures ground speed of the vehicle It is mounted inside the unitized transaxle and is driven by transmission gears Because the governor is mounted inside the trans axle it is protected from abuse and damage that is common to externally mounted governor systems If any of the governor linkage is removed in order to service other ...

Page 44: ...CH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS FIGURE 10 1 FIGURE 10 2 Hydraulic Floorjack or Chain Hoist 1 4 Diameter Drift or Metal Rod 1 2 Open End Wrench Jackstands 2 Small...

Page 45: ...seals If the unitized transaxle is to be removed from the vehicle then do not remove the wheels axle shafts or axle tubes first Instructions for removing the unitized transaxle from the vehicle begin on page 41 See NOTE below REMOVING THE AXLE SHAFT 1 Place chocks at the front wheels and lift the rear of the vehicle with a floorjack Then place jackstands under the axle tubes to support the vehicle...

Page 46: ... shaft between the wheel mounting flange and the bearing 2 Press the bearing 71 and collar 73 Figure 10 6 off together See Figure 10 7 Page 40 Installing the Axle Bearing 1 If it was removed install the retaining ring 70 on the axle shaft 67 or 68 Figure 10 6 2 Apply two drops of Loctite 271 to the inside of the collar See CAUTION at top of page 39 FIGURE 10 5 DO NOT SCAR OR DAMAGE THE INSIDE SURF...

Page 47: ...CTITE GETS ON OR IN THE BEARING THE BEARING MUST BE REPLACED THE COLLAR SHOULD BE REMOVED NO MORE THAN TWO TIMES IF A BEARING IS REMOVED A THIRD TIME THE SHAFT AND COLLAR WILL NOT FIT PROPERLY FIGURE 10 6 CAUTION ClubCar REFERENCE PASSENGER SIDE CASE 74 73 72 71 70 68 69 78 77 76 79 87 86 90 89 85 91 84 82 89 85 88 81 80 79 77 78 75 69 67 70 71 72 73 74 REFERENCE DRIVER SIDE CASE 83 ...

Page 48: ...the differential side gear Continue advancing the shaft until the bearing seats against the axle tube shoulder 4 Using snap ring pliers install the retaining ring 70 Figure 10 6 in the axle tube See Figure 10 9 5 Place a 1 4 to 3 8 6 to 10 mm diameter rod against the retaining ring and tap lightly at four to five locations to insure that it is properly seated IF THE BEARING WAS REMOVED FROM THE SH...

Page 49: ...NG OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT THE BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG 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 HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE...

Page 50: ... cable mounting bracket Figure 10 16 2 8 Mark for proper reconnection and then disconnect the 6 gauge white wire F2 post 6 gauge black ground wire A2 post and 16 gauge yellow DF wire from starter generator Figure 10 17 2 9 Disconnect the engine oil level sending unit wire 18 gauge yellow from the sending unit located on the engine beneath the starter generator Figure 10 18 2 10 Disconnect the engi...

Page 51: ... to the shackles Figure 10 23 Page 44 7 Remove the bolts securing the leaf springs to their front mounts Figure 10 24 Page 44 FIGURE 10 17 FIGURE 10 18 FIGURE 10 19 FIGURE 10 20 LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO ...

Page 52: ...he vehicle frame and lower it to the floor Figure 10 27 Now the powertrain should be completely disconnected from the vehicle and resting on the floor 12 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle Figure 10 28 13 Place blocks under the engine mounting plate so that they will completely support the engine and keep it level to the...

Page 53: ...taining bolt and then remove the driven clutch from the unitized transaxle Figure 10 31 Page 46 FIGURE 10 25 FIGURE 10 26 FIGURE 10 27 FIGURE 10 28 ClubCar Club Ca r RAISE REAR OF VEHICLE UNTIL DRIVE TRAIN CAN BE ROLLED OUT ClubCar Club Ca r WITH JACKSTANDS IN PLACE REMOVE FLOORJACK JACKSTAND JACKSTAND SNUBBER BRACKET VEHICLE BODY AND FRAME REMAIN STATIONARY ON JACKSTANDS WHILE DRIVETRAIN IS ROLLE...

Page 54: ...9 2 Remove the two bottom transaxle mounting bolts in the same way the top ones were removed Figure 10 35 19 3 Use one 14 mm wrench to remove the two middle transaxle mounting nuts as shown Figure 10 35 20 Remove the leaf springs wheels and brake assemblies from the transaxle FIGURE 10 29 FIGURE 10 30 THE GOVERNOR CABLE AND THE ACCELERATOR CABLE REMAIN ATTACHED TO THE GOV ERNOR ARM FIGURE 10 31 FI...

Page 55: ...lts 27 that hold the transaxle housing together Figure 10 36 Page 48 6 Pull the housing apart making sure that all gear assemblies inside the transaxle stay together in one either side of the casing See CAUTION below and NOTE at top of page 48 FIGURE 10 33 FIGURE 10 34 FIGURE 10 35 IT MAY BE NECESSARY TO TAP THE AXLE TUBE WITH A RUBBER MALLET TO BREAK IT FREE FROM THE TRANSAXLE CASING TO PREVENT D...

Page 56: ...bly Continued TO SEPARATE THE SECTIONS IT MAY BE NECESSARY TO TAP LIGHTLY WITH A RUBBER MALLET ON THE SPLINE OF THE INPUT PINION FIGURE 10 36 NOTE ClubCar 3 4 9 6 5 7 8 10 17 18 19 16 11 12 13 21 22 20 31 14 15 23 24 28 27 30 29 25 26 1 2 32 ...

Page 57: ...e Figure 10 41 Page 50 from the casing 13 Remove the shifter shaft Figure 10 41 Page 50 from the casing 13 1 Use snap ring pliers to remove the shaft retaining ring 11 on the outside of the casing as shown Figure 10 36 13 2 Remove the flat washer 12 from the shaft on the outside of the casing as shown Figure 10 36 then remove the shifter shaft by pushing it through the casing wall toward the inter...

Page 58: ...nor gear assembly 63 and 64 and flat washer 62 Figure 10 43 Page 53 by lightly tapping the gear shaft through the casing wall from the outside with a hammer and drift See Figure 10 44 Page 54 FIGURE 10 39 FIGURE 10 40 FIGURE 10 41 FIGURE 10 42 REMOVE SYNCHRONIZER GEAR ASSEMBLY AND SHIFTER FORK TOGETHER AS A UNIT INTERMEDIATE GEAR ASSEMBLY IDLER SHAFT ASSEMBLY PRY INPUT SHAFT OIL SEAL FROM CASTING ...

Page 59: ...ven through 5 Remove the differential gear 91 from the carrier case Figure 10 6 Page 39 6 If the bearings 79 are to be removed place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing and carrier casing 84 and press the bearing off as shown Figure 10 48 Page 55 Repeat the process for the carrier cover 87 Figure 10 6 Page 39 DISASSEMBLE THE SHIFTER FORK ASSEMBLY 1 Push t...

Page 60: ...0 43 and then slide the synchronizer clutch hub 49 Figure 10 43 from the input shaft 51 6 Remove the three synchronizer inserts 48 Figure 10 43 from the synchronizer sleeve 7 Press the synchronizer sleeve 47 from the input shaft Figure 10 43 DISASSEMBLE THE INTERMEDIATE GEAR ASSEMBLY 1 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 38 and shaft gear 56 Figure ...

Page 61: ...e 10 43 See CAUTION at bottom of page 52 3 Press the gear 58 from the shaft 56 then remove the key 57 Figure 10 43 FIGURE 10 43 ClubCar REFERENCE DRIVER SIDE CASE 37 38 39 40 41 42 44 45 41 46 33 34 35 36 47 48 46 50 51 45 41 52 53 39 54 38 56 57 58 59 62 63 64 60 61 66 65 66 49 55 43 43 REFERENCE PASSENGER SIDE CASE 48 ...

Page 62: ...age 56 FIGURE 10 44 FIGURE 10 45 FIGURE 10 46 DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF C lu b C a r USING A HAMMER AND A DRIFT LIGHTLY TAP GOVERNOR GEAR AND WASHER FROM CASTING C l u b C a ...

Page 63: ...r damage 5 Using a feeler gauge measure the distance X at several points around the assembly The synchro ring should be replaced when X is 020 inch 0 51 millimeter or less Figure 10 55 Page 57 COMPONENT ASSEMBLY IDLER SHAFT ASSEMBLY 1 Press a new bearing 66 Figure 10 43 Page 53 onto each end of the idler shaft See Figure 10 56 Page 57 See CAUTION at the top of page 56 FIGURE 10 47 FIGURE 10 48 FIG...

Page 64: ...GAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING FIGURE 10 51 FIGURE 10 52 FIGURE 10 53 FIGURE 10 54 APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING CAUTION USE A 7 8 O D OR SMALLER ARBOR AND A BEARING PULLER WEDGE ATTACHMENT CLUB CAR 1012812 TO PRESS BEARING FROM SHAFT ARBOR PRESS ...

Page 65: ...synchronizer sleeve Make sure that the gear end of the hub is oriented toward the long end of the input shaft as shown Figure 10 60 Page 58 5 On the long end of the shaft install the synchronizer ring 45 Figure 10 43 Page 53 with the smooth collar of the ring towards the clutch hub Make sure that the three notches in the collar mate with the synchronizer inserts in the synchronizer sleeve as shown...

Page 66: ... hub and the notches in it should mate with the synchronizer inserts as shown Figure 10 43 Page 53 11 Install the narrow bearing 44 wide bearing 45 and input gear 42 onto the shaft The smooth collar of the input gear should be oriented toward the synchronizer ring as shown Figure 10 43 The gear should seat inside the ring APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE...

Page 67: ...BLY 1 If the bearings 79 were removed press new ones onto the differential gear carrier case 84 and car rier case cover 87 Figure 10 6 Page 39 2 Install differential gear 91 into the carrier case 84 Figure 10 6 Page 39 as shown Figure 10 62 3 Start the differential pin 88 Figure 10 6 into the carrier case by lightly tapping it in with a hammer as shown Before the pin enters the inside of the carri...

Page 68: ...the carrier case cover Then tighten the bolts to 16 20 ft lbs 21 7 27 1 N m in the sequence shown Figure 10 67 GOVERNOR GEAR ASSEMBLY The governor gear is not assembled independently from the unitized transaxle casing The gear shaft is installed into the casing and then the rest of the assembly is installed on the shaft Proceed with unitized transaxle assembly UNITIZED TRANSAXLE ASSEMBLY 1 Make su...

Page 69: ...t driver side casing as shown Figure 10 73 Page 63 Then install the washer and retaining ring on the shifter shaft outside of the casing Figure 10 73 7 Install the gear assemblies into the left driver side casing 7 1 Stand the left side casing on the mounting plate then install the differential gear case assembly as shown Figure 10 74 Page 64 Do not seat the assembly in the bore but insert it just...

Page 70: ... gear 52 Figure 10 43 Page 53 on the synchronizer gear assembly and with the small gear on the idler shaft 65 Figure 10 43 Page 53 7 6 As a group while keeping the gears meshed work all of the gear assemblies into the bores until FIGURE 10 68 FIGURE 10 69 FIGURE 10 70 FIGURE 10 71 ClubCar PRESS OIL SEAL INTO RIGHT SIDE CASING INSTALL SHIFTER SHAFT AND GOVERNOR SHAFT SEALS INTO THEIR SEATS POSITION...

Page 71: ...75 and 76 on the transaxle casing Figure 10 6 Page 39 11 1 Make sure that the mating surfaces of the axle tubes and the transaxle casing are clean and free of oil grease or residue of any kind 11 2 Apply a continuous bead of Three Bond No 1215 around the opening on the mating surface of the right side axle tube as shown Figure 10 83 Page 66 Then position the axle tube on the right side of the tran...

Page 72: ...ASE INSERT THE IDLER GEAR ASSEMBLY INTO CASING BORE GEARS DO NOT MESH MATE TABS ON OIL GUIDE WITH SLOTS IN CASING IN INSERT OIL GUIDE PLACE A DROP OF CYANOACRYLATE ADHESIVE SUPER GLUE IN EACH OF THE OIL GUIDE SLOTS SLOT TAB POSITION SHIFTER FORK ON SYNCHRONIZER SLEEVE CUT A WAY VIEW OF SHIFTER FORK AND SYNCHRONIZER GEAR ASSEMBLY BEING INSERTED AS A UNIT INTO CASING ...

Page 73: ... GEAR DIFFERENTIAL RING GEAR SYNCHRONIZER INPUT DRIVE GEAR SMALL IDLER GEAR SEVERAL GEARS MESH AS YOU INSERT THE INTERMEDIATE GEAR ASSEMBLY THESE THREE GEARS MESH LARGE INTERMEDIATE GEAR OUTSIDE EDGES OF THE IDLER INTERMEDIATE AND DIFFERENTIAL BEARINGS ARE ON THE SAME PLANE THE SYNCHRONIZER BEARING PROTRUDES SLIGHTLY THE EDGES OF THE INPUT DRIVE GEAR AND LARGE INTERMEDIATE GEAR SHOULD BE FLUSH EDG...

Page 74: ...ATED IN ITS GROOVE IF THE RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS LOSS OF VEHICLE CON TROL COULD RESULT CAUSING SEVERE PERSONAL INJURY FIGURE 10 82 FIGURE 10 83 FIGURE 10 84 FIGURE 10 85 WARNING IN THE SEQUENCE SHOWN TORQUE TO 15 18 FT LBS 20 3 24 4 N m THE FIFTEEN BOLTS THAT SECURE THE CASING TOGETHER 1 3 ...

Page 75: ...gure 10 89 Use a 7 16 wrench to tighten the retaining bolt 8 Install the key onto the input shaft Figure 10 90 Page 68 9 Position the driven clutch on the transaxle and install the washer yellow side facing out and mounting bolt Figure 10 90 Use a 1 2 wrench to tighten the mounting bolt to 12 14 ft lbs 16 3 19 N m 10 Install the drive belt See Torque Converter Section 16 Page 16 4 in Maintenance M...

Page 76: ...the shock mounts and install cushions mounting washers and nuts Figure 10 94 16 Connect the brake cables See Page 147 FIGURE 10 90 FIGURE 10 91 FIGURE 10 92 FIGURE 10 93 INSTALL KEY ONTO INPUT SHAFT INSTALL DRIVEN CLUTCH WASHER YELLOW SIDE OUT AND RETAINING BOLT TIGHTEN BOLT TO 12 14 FT LBS SNUBBER BRACKET ClubCar ROLL POWERTRAIN UNDER VEHICLE THEN LIFT SNUBBER INTO THE SNUBBER BRACKET SNUBBER POS...

Page 77: ...n with a 10 mm wrench 22 Connect the accelerator cable to the actuator cam in the electrical box Then position the accelerator cable in the mounting slot in the wall of the electrical box and tighten the mounting nuts using a 10 mm wrench Figure 10 100 Page 70 Install the electrical box cover and tighten the mounting screw 23 Pull the fuel line from the outlet nipple of the fuel pump and connect i...

Page 78: ...URE 10 98 FIGURE 10 99 FIGURE 10 100 FIGURE 10 101 FIGURE 10 102 FIGURE 10 103 PULL SPRING RELEASE BACK TO CONNECT SHIFTER CABLE TO LEVER TIGHTEN NUTS TOP VIEW ClubCar CONNECT ENGINE GROUND AND TIGHTEN RETAINING NUT WITH A 10MM WRENCH CONNECT CABLE TO CAM AND TIGHTEN RETAINING NUTS TOP VIEW CONNECT FUEL LINE AND TIGHTEN CLAMP USING A 1 4 NUT DRIVER OR FLAT BLADE SCREWDRIVER Club Car CONNECT IMPULS...

Page 79: ...FIGURE 10 104 WHEN MAKING TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE KEY DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST DISCONNECT BATTERY AS SHOWN FIGURE 12 1 PAGE 82 REMOVE SPARK PLUG WIRE CLEAN FORWARD AND REVERSE SHIFTER CABLE CONNECTIONS BEFORE DISASSEMBLY SEE SAFETY WARNINGS PAGES 1 AND 2 FIGURE 10 105 FIGURE 10 106 Club Car CONNECT TUBE TO CARBURETOR SQUE...

Page 80: ...ard the driver side of the vehicle so that it lies against the side of the front body and runs between the battery and intake expansion chamber turns 90 runs over the fender and then turns again in front of the rear post of the body support to connect with the shifter arm on the transaxle Figure 10 105 Page 71 2 Secure the cable with retaining nut 22 and washer 23 on each side of the shifter cable...

Page 81: ...age 71 the forward and reverse handle 21 Figure 10 107 should be straight up For minor adjustments the nut 1 may be loos ened and the ball joint 2 rotated in the proper direction to get proper adjustment Figure 10 107 For major adjustments the cable retaining nuts 22 Figure 10 107 must be loosened and adjusted When the cable is properly adjusted with the forward and reverse handle 21 Figure 10 107...

Page 82: ...Page 74 10 G ...

Page 83: ...CLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS 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 LI...

Page 84: ... fails to start 1 Fuel tank is empty Section 14 Fuel System 2 Fuel line or filters clogged Section 14 Fuel System 3 Fouled spark plug Section 13 Engine 4 Spark plug wire damaged Section 13 Engine 5 Loose wire connection at igniter Section 12 Gasoline Vehicle Electrical System 6 Igniter failed Section 12 Gasoline Vehicle Electrical System 7 Engine flooded with fuel as result of over choking Section...

Page 85: ...uel mixture Section 14 Fuel System 4 Igniter failed Section 12 Gasoline Vehicle Electrical System 5 Dirt entering combustion chamber Section 14 Fuel System 6 Rings worn out low cylinder pressure Section 13 Engine Carburetor floods 1 Inlet valve or seat is leaking dirty worn or damaged Section 14 Fuel System 2 Float is damaged or filled with gasoline Section 14 Fuel System 3 Carburetor vent is clog...

Page 86: ...ose or slipping Section 12 Gasoline Vehicle Electrical System Starter generator 5 Voltage regulator failed Section 12 Gasoline Vehicle Electrical System Generator circuit 6 Battery failed Section 12 Gasoline Vehicle Electrical System Transmission does not engage or disengage smoothly 1 Transmission shifter linkage is binding or is out of adjustment Section 10 Unitized Transaxle in this supplement ...

Page 87: ... incorrect Section 14 Fuel System Torque converter does not shift smoothly 1 Drive belt is worn cracked glazed or frayed Section 16 Torque Converter 2 Drive clutch malfunction Section 16 Torque Converter 3 Driven clutch malfunction Section 16 Torque Converter 4 Governor is sticking Section 10 Unitized Transaxle Engine won t stop running 1 Kill circuit wire is disconnected from the igniter Section ...

Page 88: ...Page 80 G 11 ...

Page 89: ...EN WORKING WITH BATTERY TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERY OR ELECTRICAL CON NECTIONS FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABL...

Page 90: ...CIRCUIT FIGURE 12 2 THE STARTER CIRCUIT FIGURE 12 3 PAGE 84 BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE ANY DIRT ENTERING THE ENGINE CARBURETOR OR OTHER PARTS WILL WORK AS AN ABRASIVE AND SHORTEN THE LIFE OF THE ENGINE FOR THE SAME REASON BEFORE INSTALLING A NEW PART CLEAN OFF ANY DUST OR METAL FILINGS FIGURE 12 1 THE STARTER CIRCUIT IS COMPLETELY INDEPENDENT OF THE IGNITION CIRCUIT THE BAT TE...

Page 91: ...een the positive post of the battery and the F2 post of the starter The starter then turns and cranks the engine through belt driven pulleys FIGURE 12 2 BATTERY FRAME GROUND FRAME GROUND BLACK YELLOW YELLOW F2 DF F1 A2 A1 RED YELLOW WHITE BLACK YELLOW GREEN WHITE BLACK OIL SENDING UNIT STARTER GENERATOR RPM LIMITER WHITE WHITE WHITE ENGINE RED WHITE WHITE WHITE FRAME GROUND OIL LIGHT REVERSE BUZZE...

Page 92: ...ectronic switch it controls the amount of charge going to the battery ENGINE IGNITION CIRCUIT The engine ignition circuit is independent of all other circuits except the kill circuit It consists of the ignition coil with internal igniter spark plug RPM limiter and connecting wires Figure 12 5 FIGURE 12 3 FIGURE 12 4 BATTERY FRAME GROUND FRAME GROUND BLACK F2 DF F1 A2 A1 ENGINE WHITE WHITE FRAME GR...

Page 93: ...in reverse Its functions are to remind the operator not to leave the vehicle in reverse and to warn anyone in the area that the vehicle is in reverse The reverse buzzer circuit consists of a reverse buzzer reverse buzzer limit switch key switch the fuse block and connecting wires The battery supplies power through the fuse block and is controlled by the reverse buzzer limit switch that is activate...

Page 94: ...ed for the convenience of the trained and experienced mechanic If the neutral lock out cam is pulled out approximately 3 8 inch 10 millimeters and rotated one half turn until it snaps back into place the vehicle will be in the SERVICE position Figure 12 10 This allows the mechanic to run the engine in neutral for certain maintenance procedures With the cam in the SERVICE position the engine will s...

Page 95: ...he battery and then check the specific gravity again If there is still a 50 point differ ence replace the battery FIGURE 12 10 FIGURE 12 11 DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOUL...

Page 96: ... replaced with a good one test the electrical circuits TESTING THE STARTER CIRCUIT AND THE GENERATOR CIRUIT Use the chart below Figure 12 12 as a starting point for troubleshooting problems with the starter and gen erator circuits A FULLY CHARGED BATTERY THAT IS IN GOOD CONDITION SHOULD HAVE A SPECIFIC GRAVITY OF AT LEAST 1 225 IN ALL CELLS AND THE DIFFERENCE IN THE SPECIFIC GRAV ITY OF ANY TWO CE...

Page 97: ...RS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 FIGURE 12 13 DANGER WARNING GOOD SPARK REPLACE SPARK PLUG ENGINE CRANKS CAR WILL NOT RUN CHECK SPARK USING SPARK TEST TOOL TEST PROCEDURE 11 CHECK FUEL...

Page 98: ...RAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 FIGURE 12 14 DANGER WARNING ENGINE WILL NOT STOP RUNNING WHEN FOOT IS OFF ACCELERATOR PEDAL CHECK KILL LIMIT SWITCH TEST PROCEDURE 15 CHECK WIRE CONNECTION OF CIRCUIT WIRES INCORRECT CONTINUITY READING CORRECT CONTINUITY READING WIRES INCORRECTLY CONNECTED WIRES CO...

Page 99: ...Y CONNECTED REPLACE LIMIT SWITCH CONNECT WIRES CORRECTLY REPLACE WIRE CHECK CONTINUITY OF CIRCUIT WIRES TEST PROCEDURE 8 NO CONTINUITY ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CHECK KEY SWITCH TEST PROCEDURE 16 CHECK CONNECTIONS OF CIRCUIT WIRING INCORRECT CONTINUITY READING CORRECT CONTINUITY READING WIRES INCORRECTLY CONNECTED WIRES CORRECTLY CONNECTED REPLACE KEY SWITCH C...

Page 100: ...TED SEE THE SAFETY WARNINGS ON PAGE 81 FIGURE 12 16 DANGER WARNING REVERSE BUZZER WILL NOT FUNCTION GOOD FUSE CHECK REVERSE BUZZER LIMIT SWITCH TEST PROCEDURE 18 BAD FUSE REVERSE BUZZER WILL NOT FUNCTION AND ENGINE WILL NOT CRANK CHECK BATTERY SEE PAGE 87 CHECK FUSE TEST PROCEDURE 17 DETERMINE CAUSE OF THE BLOWN FUSE REPLACE FUSE CHECK GROUND STRAPS TEST PROCEDURE 3 REVERSE BUZZER WILL NOT FUNCTIO...

Page 101: ...BON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON OIL LIGHT WILL NOT ILLUMINATE WHEN ENGINE OIL IS LOW CHECK WIRE CONNECTION TO THE OIL SENDING UNIT TEST PROCEDURE 20 CHECK LOW OIL WARNING LIGHT TEST PROCEDURE 21 REPLACE OIL SENDING UNIT REPLACE OIL SENDING UNIT REPLACE LOW OIL WARNING LIGHT REPLACE YELLOW WIRE WIRES INCORRECTLY CONNECTED WIRES CORRECTLY CONNECTED LOW OIL WARNING LIGHT ILLUMINATES ...

Page 102: ... PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 FIGURE 12 18 WARNING CHECK NEUTRAL LOCK OUT LIMIT SWITCH TEST PROCEDURE 6 CHECK CONNECTION OF BLACK WIRE INCORRECT CONTINUITY READING CORRECT CONTINUITY READING WIRE INCORRECTLY CONNECTED WIRE COR...

Page 103: ...he readings are incorrect replace the key switch Figure 12 19 Page 96 Test Procedure 3 Ground Straps 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Set the multimeter to ohms Ω Place the red probe on the A2 terminal of the starter generator and place the black probe on the frame of the vehicle The reading s...

Page 104: ... 18 gauge green wire and an 18 gauge orange wire connected to this limit switch 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check for proper wiring and tight connections Figure 12 3 Page 84 3 Set the multimeter to ohms Ω Place the red probe on the common COM terminal green wire of the limit switch and pl...

Page 105: ...ultimeter to ohms Ω Connect the red probe to one of the large posts of the solenoid and connect the black probe to the other large post Figure 12 22 Page 98 8 Connect the black cable to the battery negative post 9 Place the forward and reverse lever in NEUTRAL and place the neutral lock out cam in the SERVICE position Turn the key switch to the ON position With the accelerator in the up position t...

Page 106: ...EMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 FIGURE 12 24 SOLENOID ELECTRICAL COMPONENT BOX OFF DC V DATA HOLD AC V AC DC 500V MAX 250V MAX SOLENOID ELECTRICAL COMPONENT BOX OFF DC V DATA HOLD AC V AC DC 500V MAX 250V MAX FRAME WARNING OFF DC V DATA HOLD...

Page 107: ... a qualified technician See Removal of the Starter Generator Page 107 An incorrect reading from A1 or A2 terminal indicates three possible problems 1 a grounded A1 or A2 terminal 2 a grounded wire in the brush area or 3 a grounded armature commutator If the F1 or F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it in...

Page 108: ...ICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the yellow wire from the DF terminal on the starter generator Cover the connector on the yellow wire to make sure the yellow wire will not short to ground Then using a jumper wire ground the...

Page 109: ...g ative post of battery Depress the accelerator to start the engine and run it at full governed speed If the reading is between 14 7 and 15 3 volts the regulator is good If the reading is lower than 14 7 volts but rising steadily check battery condition See Hydrometer Test Page 128 If the reading is lower than 14 7 volts and not rising and the starter generator is good or if the reading is over 15...

Page 110: ...he wheels 2 Disconnect the bullet terminal Using a multimeter set on ohms Ω place the red probe on the brown ground wire and place the black probe on the black wire bullet connector The reading should be continuity If the reading is not correct replace the RPM Limiter 3 This test will find 90 of bad RPM Limiters Some of them may bench test okay but fail under a load due to heat while operating Ano...

Page 111: ...04 or equivalent check for correct spark to plug Adjust the tester probes to approximately to 18 000 volts 18 Kv setting Connect the tester to the spark plug wire and connect the alligator clip to the top of the spark plug Figure 12 28 Page 101 WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL ...

Page 112: ...t the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check for proper wiring and tight connections 3 Place the red probe of the multimeter on the common COM terminal white black wire of the limit switch Place the black probe on the normally open NO terminal black wire of the limit switch Without the lever depressed the reading should be no continuity Depress the lever an...

Page 113: ... ter on one terminal and the black probe on the other terminal of the limit switch Without the lever depressed the reading should be no continuity Depress the lever and the reading should be continuity If either reading is incorrect replace the limit switch Test Procedure 19 Reverse Buzzer 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL po...

Page 114: ...cted correctly and are tight If they are not rewire or tighten as necessary 4 Insert the key and turn the switch to ON Place the red probe of the multimeter on the No 2 terminal and the black probe on the No 1 terminal of the key switch The reading should be continuity If the reading is incorrect replace the key switch Figure 12 34 Test Procedure 23 Neutral Lock out Cam Check to be sure the lobes ...

Page 115: ... Remove access panel from the body Figure 12 35 2 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 12 36 3 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and slip the belt 4 off the pulley 10 Figure 12 36 See NOTE below 4 Support the starter generator so that when the pivot bolts are...

Page 116: ... replace all four brushes Figure 12 38 IF THE BRUSHES ARE NOT REMOVED CONTACT BETWEEN THE BRUSHES AND COMMUTA TOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD POSSI BLY DAMAGE THE BRUSHES LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN THE BRUSHES AND PULL THE BRUSHES BACK FROM THE CENTER OF THE COMMUTATOR END COVER THE SPRINGS WILL REST ON THE SIDES OF THE BRUSHES AND HELP PREVENT...

Page 117: ...is installed and possible damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 41 Page 110 WHEN CHECKING BRUSH SPRING TENSION DO NOT PUSH SPRINGS BEYOND THE POINT THEY WOULD NOR...

Page 118: ...ator end cover 23 free of the starter housing 24 Figure 12 37 Page 108 See WARNING and NOTE below WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 IF THE BRUSHES A...

Page 119: ...by spinning them by hand and checking for both axial A and radial B play Figure 12 43 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bearings should be replaced if there is extreme wear or pitting on the balls or on the rolling surfaces Do not...

Page 120: ... the housing Remove the field coils from the inside of the housing Figure 12 45 See NOTE below Visual Inspection of Armature Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or thrown solder it is obvious without testing that it should be replaced Faults seen during the visual inspection can aid in diagnosing the original cause of t...

Page 121: ... Clean the carbon dust dirt and oil from the commutator Visually inspect the commutator for worn burned or glazed areas Check for loose or raised commutator bars Slight roughness of the commuta tor can be polished away with 400 or finer sandpaper See Caution at the top of page 114 FIGURE 12 45 FIGURE 12 46 RETAINING NUT INSULATOR FIELD COIL TERMINAL HOUSING FIELD COIL POLE PIECE SCREW POLE PIECE A...

Page 122: ...ure the insulators are tight in the housing Reworking the Starter Generator Any rework must be performed by a qualified technician Starter Generator service specifications are listed in the following table NEVER USE EMERY CLOTH ON THE COMMUTATOR PARTICLES OF EMERY ARE CONDUC TIVE AND MAY SHORT CIRCUIT THE COMMUTATOR BARS NEVER USE OIL OR LUBRICANTS ON THE COMMUTATOR OR BRUSHES DO NOT SUBMERGE ARMA...

Page 123: ...ng to retain the field wires Tighten screws to 9 ft lbs 12 N m Figure 12 45 Page 113 3 Slide the bearing retainer onto the output end of the armature shaft 33 so that it will hold the outside of the bearing 35 only Press a new ball bearing 35 onto the output end of the armature Figure 12 42 Page 111 Press a new ball bearing onto the commutator end of the armature shaft 4 Install the output end cov...

Page 124: ...he driver side of the vehicle Position the starter generator in the mounting bracket so that the screws will go through the bracket before going through the starter generator Install a lockwasher 6 early 1997 vehicles only and 3 8 nut 7 onto each screw Tighten the screws and nuts to finger tight Figure 12 48 2 Install the adjustment screw 11 through the adjusting bracket 4 and then through the sta...

Page 125: ... of the starter generator 1 Place the ten sion tool 13 Club Car Part No 1016867 between the starter generator and the starter generator mounting bracket 2 so that the tension tool will lift up the starter generator 4 Install a standard 1 2 inch 12 7 millimeters drive torque wrench 14 into the tension tool 13 Through the access opening in the rear body position the wrench and tension tool as shown ...

Page 126: ... 9710 563353 and later Figure 12 49 7 Remove regulator 6 Installing the Voltage Regulator FIGURE 12 49 1 Place the voltage regulator 6 into the electrical component box with the 1 4 inch screw 8 through the regulator IF A BURROUGHS GAUGE IS USED TENSION SHOULD BE ADJUSTED TO 120 LBS FOR A NEW BELT OR 80 100 LBS FOR A PREVIOUSLY USED BELT WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY G...

Page 127: ...from under edge of cowl brace 5 Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down 6 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 7 Disconnect the wires from th...

Page 128: ...tighten to 18 25 in lbs 2 0 2 8 N m Figure 12 2 Page 83 4 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw Re connect the battery wires 5 Install the seat on the rear body FUSE Removing the Fuse 1 Remove seat from body 2 Disconnect battery wires as shown Figure 12 1 Page 82 3 Remove electrical component box cover 4 Remove the fuse from the fuse ...

Page 129: ...ing the two washers 10 and the two nuts 9 Torque to 5 in lbs 0 6 N m 2 Connect green wire to common COM terminal and the orange wire to the normally closed NC termi nal of the accelerator starter limit switch Figure 12 2 Page 83 3 Depress the accelerator pedal to make sure that the switch is being actuated when the pedal is released 4 Connect battery cables positive cable first 5 Install the seat ...

Page 130: ...IT SWITCH Removing the Neutral Lock out Limit Switch Figure 12 51 1 Remove seat from rear body 2 Disconnect the battery wires as shown Figure 12 1 Page 82 3 Disconnect the green white and black wires from the neutral lock out limit switch 5 located on the back of the forward and reverse assembly 4 Remove the two nuts 2 and washers 6 from the neutral lock out limit switch 5 and slide the neutral lo...

Page 131: ...hicle in both forward and reverse for proper operation NEUTRAL LOCK OUT CAM If the cam lobes have worn to the point where they will no longer actuate the neutral lock out limit switch the cam must be replaced Removing the Neutral Lock out Cam Figure 12 52 1 Remove the seat from the rear body 2 Disconnect the battery wires as shown Figure 12 1 Page 82 DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE N...

Page 132: ... and down See NOTE below 6 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 7 Disconnect the wires from the reverse warning buzzer Do not allow wires to touch Figure 12 53 8 Remove the two mounting screws 3 that secure the buzzer to the center dash Figure 12 53 Testing the Reverse...

Page 133: ... white wire to the normally open NO terminal of the reverse buzzer limit switch 4 4 Connect battery cables positive cable first 5 Turn the key switch to the ON position Shift the forward and reverse lever to the reverse position The buzzer should sound 6 Install the seat on the rear body OIL WARNING LIGHT Removing the Oil Warning Light Figure 12 54 1 Disconnect the battery wires as shown Figure 12...

Page 134: ...icle is equipped with a 12 volt low maintenance battery When replacing the bat tery in a Club Car gasoline powered vehicle the new battery must be the same size as the original WEAR A FULL FACE SHIELD WHEN WORKING AROUND A BATTERY BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WE...

Page 135: ...bration Damage Page 128 Self Discharge 1 Dirt and battery acid can provide a path for a small current draw that can slowly discharge the battery To prevent self discharge the battery should always be kept clean 2 Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will discharge In hotter climates therefore the battery should be checke...

Page 136: ...METER TEST A hydrometer measures the specific gravity The higher the specific gravity the higher the state of charge of the battery A fully charged battery should read between 1 250 and 1 280 at 80 F Never add acid to the bat tery to obtain a higher specific gravity Figure 12 56 Performing the Hydrometer Test IMPURITY ALLOWABLE CONTENT IN PARTS PER MILLION NITRATES 10 0 NITRITES 5 0 CHLORIDE 5 0 C...

Page 137: ...d the hydrometer vertically insuring that the float is not contacting the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 12 56 7 Record the reading 8 Return the electrolyte to the cell from which it was taken 9 Repeat steps 2 8 on all cells Hydrometer Calibration WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROV...

Page 138: ...y posts 2 Read the battery voltage after the load tester has been on the battery for 15 seconds Compare the battery s voltage reading with the table below Make sure you have the correct ambient temperature REMOVING THE BATTERY 1 Remove the seat from the rear body 2 Disconnect the air hose that is clamped to the carburetor Remove the retention strap and lift the intake expansion chamber out of the ...

Page 139: ... WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY KEEP THE BATTERY IN AN UPRIGHT POSITION TO PREVENT ELECTROLYTE LEAKAGE TIP PING THE BATTERY BEYOND A 45 ANGLE IN ANY DIRECTION CAN ALLOW A SMALL AMOUNT OF ELECTROLYTE TO LEAK OUT THE VENT HOLE DO NOT EXCEED THIS 45 ANGLE WHEN LIFTING CARRYING OR INSTALLIN...

Page 140: ...ged every few weeks 5 Check the state of charge periodically A battery that is discharged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the battery should be recharged See WARNING at top of Page 133 WEAR A FULL FACE SHIELD WHEN WORKING AROUND A BATTERY BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTE...

Page 141: ... of the starter generator and to the frame seat support Figure 12 57 2 The engine ground is attached to the oil filler bracket on the engine and to the frame Figure 12 58 3 A third ground plate is in the bottom of the electrical component box where the bolt secures the voltage regulator to the box The other end of this ground plate attaches through the side of the electrical box and is bolted into...

Page 142: ...D GROUND WIRE ATTACHES TO THE VOLTAGE REGULATOR MOUNTING BOLT AND GROUNDS TO THE VEHICLE FRAME AT THE SAME PLACE AS THE BATTERY GROUND FIGURE 12 59 NOTE CUT A WAY VIEW OF FRAME JAM NUT BRAIDED GROUND WIRE ON VEHICLES SERIAL NUMBER 9710 563353 AND LATER THE GROUND PLATE IS DELETED AND REPLACED BY A BRAIDED GROUND WIRE AND THE JAM NUT IS POSITIONED BELOW THE VOLTAGE REGULATOR GROUND PLATE ...

Page 143: ... the Maintenance and Service Manual Fan Housing The baffle plate inside the fan housing for a clockwise engine is located on the right side of the inside surface of the housing as shown below Fan The fan for a clockwise engine is grey in color and marked with an arrow pointing counterclockwise as shown on page 136 fan for counterclockwise engine is black and marked with an arrow pointing clockwise...

Page 144: ... of the counterweight as shown below Crankcase Oil pump oil passages in the clockwise crankcase are different from those in the counterclockwise case The clockwise case has an R stamped into the oil pump cavity as shown below 1997 FE 290 FLYWHEEL AND FAN 1997 FE 290 CAMSHAFT 1997 FE 290 CRANKSHAFT 1997 FE 290 CRANKCASE M F 3 4 8 1 NUMBER ARROW GREY FAN FLYWHEEL FE 290 CLOCKWISE FLYWHEEL AND FAN CL...

Page 145: ...the NOTE under step 18 on page 13 47 in the 1995 1996 Maintenance and Service Manual under the heading above changes as follows SECTION 14 FUEL SYSTEM CARBURETOR The last paragraph under the heading above on page 14 4 in the 1995 1996 Maintenance and Service Man ual should read as follows For elevations above 3000 feet main jets other than standard operate more effectively Therefore the follow ing...

Page 146: ...the sub heading above Figure 14 8 shows the previous accelerator pedal configuration as well as the current one The revised Figure 14 8 at the top of page 139 shows only the current pedal configuration FIGURE 14 6 yy yy yy yyy yyy yyy yyy yyy 1 2 3 4 10 11 12 25 24 13 14 26 23 22 21 21 15 16 17 18 19 20 TYPICAL 2 PLACES 7 6 5 8 ...

Page 147: ...D EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NO...

Page 148: ...Page 14 14 in the Maintenance Service Manual ACCELERATOR CABLE Accelerator Cable Removal 1 Remove the seat from the vehicle 2 Remove the electrical box cover and loosen the cable housing retaining nuts See Figure 14 9 Page 14 10 in the Maintenance and Service Manual ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EX...

Page 149: ...ring 7 on the spring end of the cable at the accelerator cable bracket 5 Figure 14 11 Pull the cable housing out of the bracket 5 Disconnect the spring 15 from the engine governor arm by rotating it counterclockwise one half turn Remove the cable assembly from the vehicle Figure 14 11 FIGURE 14 11 8 7 11 9 6 10 9 7 8 7 15 6 5 3 1 4 2 REFERENCE EXHAUST SECTION 9 12 13 14 ...

Page 150: ...lockwise Because of this the take up springs part of item 10 in the drive clutch shown in Figure 16 5 on page 16 7 in the 1995 1996 DS Maintenance and Service Manual are now posi tioned on the opposite sides of the clutch cover 1 ribs Also the drive buttons 7 in the driven clutch shown in Figure 16 16 on page 16 13 in the 1995 1996 DS Maintenance and Service Manual are now oppo site their former p...

Page 151: ...Page 143 G 13 18 DRIVE CLUTCH DISASSEMBLY FIGURE 16 5 20 21 17 19 2 1 3 10 13 4 5 6 7 11 12 12 16 15 14 9 8 18 ...

Page 152: ...e Clutch Disassembly Continued DRIVE CLUTCH ASSEMBLY FIGURE 16 8 FIGURE 16 15 REMOVE THESE ITEMS FROM RIBS 10 24 SCREW FLAT WASHER DRIVE BUTTON DRIVE BUTTON TAKE UP SPRING RIBS DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED ...

Page 153: ...s 13 Install the three drive button take up springs 10 Figure 16 5 Page 143 on the ribs of the clutch cover The springs must be installed on the right sides of the button mounting posts when looking into the interior of the clutch cover with the rib at the 12 o clock position as shown See Figure 16 15 FIGURE 16 16 3 2 4 5 6 7 8 9 13 1 12 10 11 ...

Page 154: ...the cam press tool Club Car Part No 1018091 01 on the cam as shown Figure 16 21 this supplement Hold the fixed face assembly and rotate the moveable face assembly 1 one third of a turn clockwise then press the cam 2 onto the fixed face assembly FIGURE 16 18 FIGURE 16 19 FIGURE 16 21 KEY USING EXTERNAL SNAP RING PLIERS REMOVE RETAINING RING 4 CAM PRESS TOOL FIRMLY ROTATE MOVABLE FACE ASSEMBLY 1 1 3...

Page 155: ...S OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS MO...

Page 156: ...ters the shock absorber body Replace leaking shock absorbers Figure 18 1 2 To remove a shock absorber remove the nut 5 cup washer 9 and rubber bushing 10 from the stem at the top of the shock absorber Figure 18 1 FIGURE 18 1 TYPICAL 2 PLACES 9 10 10 9 5 6 8 7 1 15 4 3 4 14 13 11 4 3 15 2 1 2 4 3 4 15 2 16 17 17 BRAKE CABLE HANGER MOUNTING 12 5 9 10 ...

Page 157: ...to relieve tension on the shock absorbers without compressing them 3 Remove the tire and wheel assembly on the side from which the spring is to be removed 4 Remove the cotter pin 1 and the clevis pin 2 at the brake lever and brake cable connection and pull the clevis 3 away from the lever Figure 18 3 Detach the brake cable from the shock mount bracket 16 Figure 18 1 5 Remove the nut 5 cup washer 9...

Page 158: ...HEN POSITIONING THE SPRING ON THE TRANSAXLE BE SURE TO INSERT THE LOCAT ING BOLT ON THE SPRING IN THE LOCATING HOLE IN THE TRANSAXLE SADDLE 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 ...

Page 159: ...ALLING THE SNUBBER 1 To install the snubber reverse the removal procedure FIGURE 18 4 TYPICAL 2 PLACES ClubCar 14 13 11 12 1 REFERENCE ENGINE SECTION 13 15 ClubCar TYPICAL 4 PLACES 16 REFERENCE UNITIZED TRANSAXLE SECTION 10 ...

Page 160: ...Page 152 13 18 G ...

Page 161: ...ce and Service Manual Club Car Part Number 1019051 01 SECTION 20B ELECTRICAL COMPONENTS POWERDRIVE SYSTEM 48 VEHICLE See Section 20B of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 21A ELECTRICAL SYSTEM POWERDRIVE PLUS VEHICLE See Section 21A of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 21B ELECTRICAL COMPONENTS POW...

Page 162: ...r 1019051 01 SECTION 24 MOTOR See Section 24 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 25 TRANSAXLE ELECTRIC VEHICLE For electric vehicles only see Section 9 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 Disregard information pertaining to gasoline vehicles SECTION 26 REAR SUSPENSION ELECTRIC VEHICLE See Section 25 of ...

Page 163: ......

Page 164: ...Golf Cars Club Car Inc P O Box 204658 Augusta GA 30917 4658 ...

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