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Club Car 2005 precendent, Maintenance And Service

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INDEX

Page i-2

2005 Precedent Gasoline Golf Car Maintenance and Service Manual

cylinder head

 ...................................................... 13-3

D

DANGER

definition of  ........................................................ 1-1

debris shields

 ....................................................... 5-3

diagram, schematic

 ............................................ 11-6

differential

see

 unitized transaxle

drive belt

inspection ........................................................ 17-2

installation ........................................................ 17-3

removal ............................................................ 17-2

drive clutch

assembly ....................................................... 17-10

cleaning and inspection  ........................17-7, 17-10

disassembly ..................................................... 17-7

installation ...................................................... 17-12

removal ............................................................ 17-4

drive unit

see

 unitized transaxle

driven clutch

assembly ....................................................... 17-16

disassembly ................................................... 17-14

inspection ...................................................... 17-16

installation ...................................................... 17-18

removal .......................................................... 17-13

E

electrical system

 .............................................. 11-11

engine ignition circuit  ..................................... 11-11

see also

 ignition coil

 and 

ignition, testing

engine kill circuit  ............................................ 11-11

fuel gauge/sending unit circuit  ....................... 11-11

generator circuit  ............................................. 11-11

hour meter circuit  ........................................... 11-11

low oil warning light circuit  ............................. 11-11

neutral lockout circuit  ..................................... 11-11

reverse buzzer circuit  .................................... 11-11

starter circuit  .................................................. 11-11

engine

ignition circuit  ................................................. 11-11

installation ........................................................ 13-9

removal ............................................................ 13-3

rotation ............................................................. 13-1

RPM adjustment  .............................................. 14-9

exhaust system

 .........................................14-1, 15-1

see also 

muffler

F

floor mat and retainers

 ........................................ 4-6

floor mat retainer

installation .......................................................... 4-7

removal .............................................................. 4-7

flywheel

installation ........................................................ 13-9

removal ............................................................ 13-7

foot deck (four-passenger)

installation ........................................................ 4-14

removal ............................................................ 4-14

forward/reverse

cable

adjustment ................................................ 16-24

installation ................................................. 16-22

removal ..................................................... 16-22

handle (lever) ................................................... 16-1

front body

 ............................................................. 4-4

see 

body, front

front bumper

 ......................................................... 4-4

front suspension

 ................................................ 7-10

camber adjustment  .......................................... 7-10

fuel filter

 .............................................................. 14-1

installation ...................................................... 14-14

removal .......................................................... 14-14

fuel gauge/hour meter

fuel gauge circuit  ........................................... 11-11

testing ....................................................... 11-35

fuel level sending unit

testing ....................................................... 11-34

installation ........................................... 12-22, 12-23

removal ............................................... 12-21, 12-23

fuel level sending unit

 ..................................... 12-23

testing ............................................................ 11-34

fuel lines

 ................................................... 14-1, 14-21

fuel pump

 ................................................. 14-1, 14-15

assembly ....................................................... 14-17

cleaning and inspection  ................................. 14-16

disassembly ................................................... 14-15

installation ...................................................... 14-17

removal .......................................................... 14-15

fuel shut-off valve

 ............................................ 14-21

fuel tank

disposal ......................................................... 14-19

installation ...................................................... 14-20

removal .......................................................... 14-18

storage ........................................................... 14-19

fueling instructions

 ............................................ 10-6

fuse

installation ...................................................... 12-15

removal .......................................................... 12-15

testing ............................................................ 11-15

Summary of Contents for 2005 precendent

Page 1: ...2005 Gasoline Vehicles Maintenance And Service Manual No 102680402 Edition Code 0205A00000...

Page 2: ......

Page 3: ...technician does not have such knowledge and skills attempted service or repairs to the vehicle may render the vehicle unsafe For this reason Club Car advises that all repairs and or service be perform...

Page 4: ...and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car dealers and will whe...

Page 5: ...g the Vehicle 4 1 Seat 4 1 Front and Rear Body Repair 4 2 Stress Lines or Streaks 4 2 Minor Impact Damage Deformations 4 2 Minor Scratches and Surface Blemishes 4 2 Gouges Punctures Tears Large Scratc...

Page 6: ...py Four Passenger 4 20 Four Passenger Canopy Removal 4 20 Four Passenger Canopy Installation 4 20 SECTION 5 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group 5 1 Pedal Group Removal 5 1 GCOR 5 3 Debris Sh...

Page 7: ...Front Suspension Components 7 12 Tie Rod End Removal 7 12 Tie Rod Installation 7 12 Leaf Spring Removal 7 13 Leaf Spring Installation 7 13 Kingpin and Steering Spindle Removal 7 13 Kingpin and Steeri...

Page 8: ...ssenger Vehicles 9 6 SECTION 10 PERIODIC MAINTENANCE General Information 10 1 Pre Operation and Daily Safety Checklist 10 1 Performance Inspection 10 2 Periodic Service Schedule 10 2 Periodic Lubricat...

Page 9: ...N 13 FE290 ENGINE General Information 13 1 Before Servicing 13 1 Engine Rotation 13 1 Spark Plug 13 1 Cylinder Head 13 3 General Information 13 3 Breather Valve Reed Valve 13 3 Crankcase 13 3 Engine R...

Page 10: ...lter 14 11 Fuel Filter 14 14 General Information 14 14 Fuel Filter Removal 14 14 Fuel Filter Installation 14 14 Fuel Pump 14 15 General Information 14 15 Fuel Pump Removal 14 15 Fuel Pump Disassembly...

Page 11: ...Shifter Cable Installation 16 22 Forward Reverse Shifter Cable Adjustment 16 24 SECTION 17 TORQUE CONVERTER General Information 17 1 Troubleshooting 17 1 Drive Belt 17 2 Drive Belt Removal 17 2 Drive...

Page 12: ......

Page 13: ...fety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operate...

Page 14: ...nections Use extreme caution to avoid shorting of components or wiring Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wir...

Page 15: ...General Warnings 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 1 3 1 Figure 1 1 Battery Cable Removal Remove negative cable first DISCONNECT BATTERY CABLES BEFORE WORKING ON VE...

Page 16: ...1...

Page 17: ...Suspension Front and rear tapered mono leaf springs with dual hydraulic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park bra...

Page 18: ...95 liter 32 oz 95 liter Engine crankcase with filter 38 oz 1 12 liters 38 oz 1 12 liters Unitized transaxle 27 oz 0 8 liter 27 oz 0 8 liter Fuel tank 6 7 gallons 25 4 liters 6 7 gallons 25 4 liters TI...

Page 19: ...o features specific to their vehicle s Refer to the owner s manual provided with the vehicle for information on the following topics Pre Operation and Daily Safety Checklist Controls and Indicators Dr...

Page 20: ...the committee feels necessary or appropriate Warning signs available from Club Car are listed below STORAGE See General Warnings Section 1 Page 1 1 DANGER Do not drain gasoline when the engine is hot...

Page 21: ...3 Disconnect fuel vent line from fuel tank vent nipple 2 4 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 3 Battery should be clean and free of corrosion...

Page 22: ...ure 3 5 Page 3 4 combined with the use of the choke can result in a fouled spark plug and engine failure 4 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the M...

Page 23: ...omponents can result in water damage and subsequent component failure Use non abrasive wax products Do not use abrasive leveling or rubbing compounds these will permanently dull the gloss Battery acid...

Page 24: ...to the one used to remove stress lines To remove deformations resulting from minor impact damage 1 Hold a heat gun 12 inches 30 cm away from the affected area with the gun on its lowest heat setting 2...

Page 25: ...DY AND TRIM Front and Rear Body Repair 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 3 4 Figure 4 1 Front Body 3 8 TYPICAL 5 PLACES 2 1 5 6 7 TYPICAL 4 PLACES TYPICAL 5 PLACES...

Page 26: ...l 3 over brow 5 Tabs on the forward edge of the front beauty panel should fit into slots between the fascia and the brow 4 Position brow cap 1 to cover the edge of both the brow 5 and the front beauty...

Page 27: ...2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 5 4 Figure 4 2 Front Bumper Figure 4 3 Instrument Panel UNDERBODY FRONT SUSPENSION 2 1 2 3 4 5 TYPICAL 2 PLACES TYPICAL 3 PLACES...

Page 28: ...the instrument panel 3 on the dash assembly Make sure tabs on upper edge properly engage with the corresponding slots on the dash assembly Ensure that there are no wires exposed or pinched during posi...

Page 29: ...he choke Figure 4 5 Page 4 8 2 Remove floor mat See Floor Mat and Retainers on page 4 6 3 Remove three screws 1 that hold the kick plate 4 to the vehicle 4 Remove the two front screws 7 that hold the...

Page 30: ...Module SAM includes two threaded inserts on both the driver side and the pas senger side Figure 4 6 Page 4 8 These inserts serve as common attachment points for various accessor ries Accessories that...

Page 31: ...o Passenger Vehicles 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 9 4 Figure 4 7 Backrest and SAM 10 TYPICAL 2 PLACES 6 7 8 5 12 9 9 12 11 2 3 4 1 TYPICAL 2 PLACES TYPICAL 4...

Page 32: ...moving two plastic barrel connectors 9 and one screw 12 3 Bag strap buckles 7 may be snapped out of bag hoop 6 Bag Rack Installation Installation is the reverse of removal Tighten screw 12 to 4 8 ft l...

Page 33: ...Golf Car Maintenance and Service Manual Page 4 11 4 Figure 4 8 Rear Body Components 13 16 TYPICAL 4 PLACES 14 2 3 1 5 4 5 7 6 11 11 10 12 15 BODY CLIPS 17 TWO PASSENGER VEHICLES ONLY 18 23 TYPICAL 4...

Page 34: ...Rear Underbody Removal 1 Remove four screws 5 attaching the rear underbody 4 to vehicle Figure 4 8 Page 4 11 2 Remove two screws 18 and washers 23 that attach the underbody to the two liners 8 and 9...

Page 35: ...estraints 6 and remove the hip restraints from the vehicle Figure 4 9 Page 4 13 2 Remove the screws 5 and bolts 4 from the seat support 3 and remove the seat support from the vehi cle Seat Support Ins...

Page 36: ...ip restraints from the vehicle Figure 4 9 Page 4 13 4 Remove the four bolts 2 securing the foot deck 1 to the vehicle frame Figure 4 10 Page 4 14 Foot Deck Installation 1 Install foot rest in reverse...

Page 37: ...upport Removal on page 4 13 2 Remove four screws 13 attaching the rear beauty panel 12 to the fuel bucket Figure 4 8 Page 4 11 3 Remove screw 15 and remove shift handle 14 from vehicle 4 Remove two sc...

Page 38: ...f the rear underbody 4 until the front portion slides out from beneath the front under body Remove the rear underbody from the vehicle Rear Underbody Installation 1 Install rear underbody 4 on the veh...

Page 39: ...BODY AND TRIM Canopy Two Passenger 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4 17 4 Figure 4 12 Precedent Two Passenger Canopy 13 14 4 5 3 9 11 7 12 6 10 1 8...

Page 40: ...ts 6 through the basket wall and into each support The bolts are color coded with blue thread lock Finger tighten the bolts to avoid cross threading the threads in the supports See following CAUTION C...

Page 41: ...ice Manual Page 4 19 4 Figure 4 13 Precedent Four Passenger Canopy TYPICAL 2 PLACES 5 4 2 TYPICAL 2 PLACES 1 6 13 9 6 11 9 1 10 12 14 16 16 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4...

Page 42: ...age 4 19 The lower profile of each support follows the profile of the vehicle If the supports are placed on the wrong side of the vehicle they will not follow the vehicle s profile 1 2 Align the holes...

Page 43: ...P REMOVAL 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove screws 1 Pull floor mat retainer 3 away from the v...

Page 44: ...PEDAL GROUP Pedal Group Page 5 2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 5 Figure 5 2 Pedal Group ACCELERATOR CABLE ATTACHMENT REMOVAL 2 TYPICAL 2 PLACES 1 TYPICAL 2 PLACES 3...

Page 45: ...edal group Figure 5 3 Page 5 3 GCOR The pedal group for the Precedent gasoline vehicle includes a Gasoline Controller Output Regulator GCOR mounted on the side of the pedal group The GCOR houses two l...

Page 46: ...y two crosspins Figure 5 4 Page 5 5 The assembly is replaced as a unit The replacement unit includes a pin that keeps the spring compressed so it can be installed in the pedal group Replace the assemb...

Page 47: ...LERATOR AND BRAKE PEDAL GROUP Pedal Group 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 5 5 5 Figure 5 4 Pedal Group 1 2 3 4 5 7 8 6 10 7 9 OPPOSITE SIDE VIEW 11 12 Typical 3 pl...

Page 48: ...Figure 5 2 Page 5 2 NOTE Connector will only fit together in one orientation 4 Position the pedal group in vehicle and secure with two screws 2 on the driver side and two screws 1 on the passenger sid...

Page 49: ...e in the bracket until there is no slack in the wire portion of the cable Tighten both nuts 1 to 9 in lb 1 N m to secure the cable in position Figure 5 9 Page 5 7 9 Adjust engine RPM See Engine RPM Ad...

Page 50: ...5...

Page 51: ...les as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the...

Page 52: ...ase the shoes from the backing plate allowing them to pivot away from the inside of the brake drum which should then allow the brake drum to be pulled free After completing step 8 skip step 9 NOTE Alt...

Page 53: ...Removal 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6 3 6 Figure 6 4 Self adjusting Wheel Brake Assembly 10 TYPICAL 4 PLACES 1 8 6 9 4 3 2 13 12 6 5 7 TYPICAL 2 PLACES 7 TYPIC...

Page 54: ...he brake shoes are under pressure and can release suddenly when brake shoe retainers are removed 10 Grasp both brake shoes and pull them together with the springs out of the brake assembly as shown Fi...

Page 55: ...uld cause diminished brake performance possibly resulting in property damage or severe personal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR...

Page 56: ...arked 17T should be facing out and be visible On the driver side the 17L on the leading shoe should be facing out and be visible When installed on the backing plate the leading shoe stamped 17L is alw...

Page 57: ...until it stops Figure 6 17 Page 6 7 Remove the screw driver 7 Install the rear axle onto the transaxle See following NOTE NOTE There is a LEFT and RIGHT side axle The splined portions on the axles th...

Page 58: ...Equalizer Adjustment on page 6 8 BRAKE CABLE EQUALIZER ADJUSTMENT See General Warnings Section 1 Page 1 1 See also Warning on Page 6 1 1 After maintenance on the the brake system is complete lower th...

Page 59: ...uckle 2 Figure 6 1 Page 6 2 Note that the forward jam nut 1 is a left hand thread Thread each nut approximately 1 2 inch 12 7 mm away from the turnbuckle 5 Loosen turnbuckle 2 to release tension on th...

Page 60: ...RNING Be sure retaining ring is properly seated in groove If ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of...

Page 61: ...ompress the retaining clips on the end of the cable housing enough to slide the cable end out of the hole in the frame 10 Remove bow tie locking pin 1 and the clevis pin 2 from the brake lever on each...

Page 62: ...upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position to capture the cable heads in the equalizer 3 Insert the rear cable hous...

Page 63: ...rews 8 Figure 7 3 Page 7 3 3 Remove the scorecard holder plate 1 4 Match mark the steering wheel 7 and steering column shaft 9 so when the steering wheel is removed it can be placed back in exactly th...

Page 64: ...ced on the wheel and steering column in step 4 above Figure 7 3 Page 7 3 2 Install the steering wheel bolt 6 and tighten to 13 ft lb 17 6 N m 3 Install the scorecard plate 1 4 If required install the...

Page 65: ...nt Gasoline Golf Car Maintenance and Service Manual Page 7 3 7 Figure 7 3 Steering Column 1 4 5 6 3 2 7 9 11 13 10 12 8 NOT REQUIRED FOR SOME SCORECARD HOLDERS APPEARANCE OF SCORECARD HOLDER MAY BE DI...

Page 66: ...joint through the front underbody Position uni versal joint over splined stud on the steering gear Leave bolt 11 loose until steering column is mounted to frame in step 3 Figure 7 3 Page 7 3 3 Align...

Page 67: ...and pinion is reassembled Use a plastic wire tie to secure the dust seal bellows 3 Remove the two hex nuts 11 and slide off both of the dust seal bellows 9 from ball joints 8 4 Remove rack screw nut...

Page 68: ...D FRONT SUSPENSION Rack and Pinion Page 7 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 7 Figure 7 5 Steering Gear 1 2 4 3 5 6 7 18 17 8 8 21 21 16 15 14 13 9 9 10 10 11 11 12 19 2...

Page 69: ...re 7 9 Page 7 7 11 Inspect the bushing 7 and needle bearing 6 for excessive wear If wear is excessive replace the entire assembly Figure 7 5 Page 7 6 12 Inspect the ball joints 8 for wear If one or bo...

Page 70: ...Page 7 6 7 Install the ball joints 8 onto the rack 18 by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage Tighten the ball joints...

Page 71: ...ion the assembly over the mounting holes and slide the universal joint over the square end of the steering column 4 Install three screws to secure the assembly to the vehicle Tighten screws to 22 ft l...

Page 72: ...sary Camber Adjustment 1 Check each front wheel with a framing square At the floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 14 Page 7 11 2 L...

Page 73: ...ould be even with the bottom surfaces of the vehicle frame 3 Measure the distance between the marks on the rear facing surfaces of the tires and then roll the vehicle forward one and one half wheel re...

Page 74: ...ng wheel should be at the center of its travel There should be equal travel to the left and right FRONT SUSPENSION COMPONENTS See General Warnings Section 1 Page 1 1 TIE ROD END REMOVAL 1 Loosen jam n...

Page 75: ...ing lug nuts using a crisscross pattern to 55 ft lb 74 6 N m 6 Adjust camber and toe in See Wheel Alignment on page 7 10 KINGPIN AND STEERING SPINDLE REMOVAL 1 Remove the front hub See Front Hub Remov...

Page 76: ...ll front hub and wheel See Hub Installation on page 7 18 CONTROL ARM REMOVAL 1 Loosen lug nuts on both front wheels and raise front of the vehicle with a chain hoist or floor jack Place jack stands un...

Page 77: ...T SUSPENSION Front Suspension Components 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7 15 7 Figure 7 18 Upper Front Suspension Assembly 4 8 11 10 2 3 5 6 7 9 6 4 3 1 2 14 15 1...

Page 78: ...SUSPENSION Front Suspension Components Page 7 16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 7 Figure 7 19 Lower Front Suspension Assembly 1 3 4 2 5 4 6 7 8 9 10 11 12 13 14 15 16...

Page 79: ...emoval procedure 2 Tighten the bolts to 20 ft lb 27 N m FRONT WHEEL BEARINGS AND HUBS See General Warnings Section 1 Page 1 1 NOTE The front wheel bearings are pressed into the spindle and are not ser...

Page 80: ...tall a new flanged lock nut 11 and tighten to 36 ft lb 50 N m 4 Rotate the hub The hub should rotate smoothly without binding side play or any indication of rough spots during rotation 5 Install the d...

Page 81: ...adjusted WARNING Tires affect vehicle handling When selecting a replacement tire use only original equipment or comparable tires WHEELS See General Warnings Section 1 Page 1 1 WHEEL REMOVAL 1 Slightly...

Page 82: ...into the rim well Figure 8 1 Page 8 2 Detail A 3 2 With the valve stem side of the wheel up use a tire tool to carefully start the upper bead over the edge of the wheel rim Figure 8 1 Page 8 2 Detail...

Page 83: ...r foreign matter 2 Where the tire beads seat clean the wheel rim with a wire brush Wipe away any debris with a clean cloth NOTE Because tubeless tires require a perfect seal in order to seat keeping t...

Page 84: ...Manual 8 Tire Installation Continued 7 Quickly remove the air nozzle and install the valve core 8 Adjust air pressure in tire to recommended pressure See Section 2 Vehicle Specifications 9 Immerse the...

Page 85: ...nut 5 cup washer 9 and rubber bushings 10 from the stem at the top of the shock absorber 3 Remove the nut 5 cup washer 9 and rubber bushings 10 from lower mounting stem 4 Compress the shock absorber t...

Page 86: ...edent Gasoline Golf Car Maintenance and Service Manual 9 Figure 9 1 Rear Suspension Assembly and Mounting Two Passenger Vehicles 16 TYPICAL 2 PLACES 9 10 10 9 5 6 8 7 4 3 4 17 1 14 4 2 4 2 11 3 4 12 1...

Page 87: ...essing them 3 Remove the tire and wheel assembly on the side from which the spring is to be removed 4 Remove the bow tie locking pin 1 and the clevis pin 2 at the brake lever and brake cable connectio...

Page 88: ...kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on...

Page 89: ...enance and Service Manual Page 9 5 9 Figure 9 4 Rear Suspension Assembly and Mounting Four Passenger Vehicles 15 26 27 REAR OF VEHICLE 9 10 10 9 5 4 3 4 11 3 4 12 20 13 15 2 17 17 REF REF TYPICAL ON E...

Page 90: ...HICLES 1 To install the springs reverse the removal procedure See following CAUTION CAUTION When positioning the spring on the transaxle be sure to insert the locating bolt on the spring in the locati...

Page 91: ...ehicle This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Periodic Service Schedule on page 10 2 Any problems should be corrected...

Page 92: ...e Forward Reverse handle is in the REVERSE position Steering The vehicle should be easy to steer and should not have any play in the steering wheel General Listen for any unusual noises such as squeak...

Page 93: ...lean terminals and wash dirt from casing Apply Battery Terminal Protector Spray CCI P N 1014305 to battery terminals Check electrolyte level See Section 12 Battery Front wheel alignment and camber Che...

Page 94: ...ual Dry Moly Lube CCI P N 1012151 white lithium grease NLGI 2 Front suspension two fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only every 100 hours of operation or every 200 r...

Page 95: ...l filler tube and wipe oil from the stick Figure 10 1 See fol lowing CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil level by fully inserting the dipstick into the oil fille...

Page 96: ...le must be grounded to the pump before and during the fueling operation Be sure the fuel tank ground wire located next to the fuel shut off valve is properly connected before fueling the vehicle If th...

Page 97: ...emove seat bottom 3 The fuel tank is located on the driver side of the vehicle Figure 10 2 Page 10 5 Remove fuel cap and fill the fuel tank with fresh unleaded fuel only See preceding CAUTION and NOTE...

Page 98: ...10...

Page 99: ...used in making these checks can be found in the referenced sections in this maintenance and service manual TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start easily Spark pl...

Page 100: ...led Section 11 Troubleshooting and Electrical System Test Procedures 13 14 and 15 Engine flooded with fuel as result of excess choking Section 3 General Information in the appropriate maintenance and...

Page 101: ...4 Fuel System Rings are heavily worn low cylinder pressure Section 13 FE290 Engine Carburetor floods Inlet valve or seat is leaking dirty worn or damaged Section 14 Fuel System Float is damaged and fi...

Page 102: ...age is binding or is out of adjustment Section 16 Unitized Transaxle Idle RPM setting is set too high Section 14 Fuel System Insufficient low level of lubricant or wrong type of lubricant in transmiss...

Page 103: ...disconnected from the ignition coil Test Procedure 12 Disconnected Kill Wire on page 11 23 Key switch failure Section 11 Troubleshooting and Electrical System Test Procedures 4 5A Carburetor is too le...

Page 104: ...T PANEL CONTROLS AND INDICATORS SEE FIGURE 11 5 3 PIN CONNECTORS 16 BLK 3 PIN CONNECTORS 16 BRN 16 WHITE 16 BLK WHITE 16 BRN WHITE 16 YELLOW 18 BLUE WHITE 12 BLUE 12 BLK 18 RED 18 BLUE 16 RED 16 YELLO...

Page 105: ...FORWARD REVERSE LIMIT SWITCHES GREEN 101837301 10 RED 18 YELLOW 10 WHITE 10 RED 16 BLACK 18 ORANGE 16 BLUE 16 WHITE COM NO COM NO 16 RED WHT 16 ORANGE 16 GREEN NC NO COM 1 3 PIN CONNECTORS 18 BLUE 18...

Page 106: ...NAL SWITCH NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN USED WHEN THERE ARE TURN SIGNALS SONIC WELD NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN USED WHEN THERE ARE LIGHTS BUT NO TURN SIGNAL A L T E R...

Page 107: ...D 11 2 VOLTAGE LIMITER SONIC WELD LIGHT SWITCH SONIC WELD HORN SONIC WELD HEADLIGHT ASSEMBLY BRAKE LIGHT RELAY DIODE DIODE 16 GREEN 16 BLK 16 BLUE 16 BLK 16 BLUE 16 BLK 16 RED 16 BLK 16 ORANGE 16 BLAC...

Page 108: ...5 Precedent Gasoline Vehicle Instrument Panel Wiring Diagram I S G 9 POSITION CONNECTOR CONNECTS TO MAIN HARNESS SEE FIGURES 11 1 AND 11 2 M 1 M 2 SONIC WELD FUEL GAUGE KEY SWITCH SONIC WELD REVERSE...

Page 109: ...rstanding the function of each of these circuits will help to quickly isolate the source of an electrical problem Use the troubleshooting flow charts in the circuit testing section to find the proper...

Page 110: ...milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately NOTE The battery must be properly maintained...

Page 111: ...o that the float rides free of the bottom but does not strike the bottom of the rubber bulb Remove the hydrometer from the cell and release the pressure from the bulb 6 Hold the hydrometer vertically...

Page 112: ...2 4 volts or if the specific gravity of a cell is still less than 1 225 after charging replace the battery See following NOTE NOTE A fully charged battery that is in good condition should have a speci...

Page 113: ...fuse with a properly rated new one TEST PROCEDURE 3 GROUND CABLES See General Warnings Section 1 Page 1 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in...

Page 114: ...good and the reading is incorrect check that the in line connector is secure repair or replace the cable 5 Check the fuel tank ground 5 1 A 16 gauge wire runs from the fuel tank to the wire harness wh...

Page 115: ...ll limit switch These two switches are sealed and cannot be repaired or replaced A four pin connector provides electrical connections to both switches Test procedures for the two switches are found in...

Page 116: ...eral Warnings Section 1 Page 1 2 2 Check for proper wiring and tight connections 3 Separate the electrical connector at the GCOR and test the limit switch for continuity Place the red probe of the mul...

Page 117: ...he ON position With the accelerator in the UP position the reading on the multimeter should be no continuity Press the accelerator pedal and listen for the solenoid click There should be continuity If...

Page 118: ...incorrect replace the limit switch Figure 11 18 Page 11 20 4 Check to be sure the lobes on the cam are pressing the neutral lockout limit switch as the Forward Reverse handle is being shifted The lim...

Page 119: ...A1 terminal and the black probe on the A2 terminal The reading should be continuity If the reading is incorrect a possible open or poor contact in a brush assembly and or open armature windings may b...

Page 120: ...position and chock the wheels 2 Ensure that the 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 star...

Page 121: ...te wires crimped together from the voltage regulator attached Place the black probe on the negative battery post Figure 11 21 Page 11 23 Turn the key switch to the ON position Press the accelerator to...

Page 122: ...e 13 Ignition Spark on page 11 24 TEST PROCEDURE 13 IGNITION SPARK See General Warnings Section 1 Page 1 1 NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lock...

Page 123: ...Check the spark plug gap The gap should be set at 0 027 to 0 031 of an inch 0 69 to 0 79 mm If the gap is correct replace the spark plug with a new part and test the engine for proper operation Figure...

Page 124: ...ine runs properly keep the new RPM Limiter in the circuit TEST PROCEDURE 15 IGNITION COIL See General Warnings Section 1 Page 1 1 The following test procedures will properly detect a coil that has fai...

Page 125: ...measure the resistance of the secondary coil and spark plug cap together 3 1 Place the red probe of the meter into the end of the spark plug cap that normally connects to the spark plug and place the...

Page 126: ...l removed 5 Test the secondary coil separately from the spark plug cap 5 1 Using a multimeter set to 20k ohms place the red probe of the meter into the end of the spark plug wire and place the black p...

Page 127: ...to the spark plug 3 and place the black probe on the core 2 Figure 11 32 Page 11 29 3 2 If the resistance is between 6 0k 11 0k ohms the secondary coil and spark plug cap are within acceptable limits...

Page 128: ...probe on the core 2 Figure 11 33 Page 11 30 If the resistance is between 6 0k 11 0k ohms the secondary coil is within acceptable limits If the resis tance is not between 6 0k 11 0k ohms the ignition...

Page 129: ...ch Figure 11 34 Page 11 31 5 Connect wires to key switch Make sure wires are connected correctly and are tight If they are not rewire or tighten as necessary 6 Install instrument panel in reverse orde...

Page 130: ...les as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Remove the instrument panel See Key Switch Removal Section 12 Page 12 13 3 Check for proper wir...

Page 131: ...Reverse handle is being shifted The limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobes Be sure the cam has snapped fully back into place If the c...

Page 132: ...ng unit Place the black probe on the ground connection of the sending unit Figure 11 35 Page 11 34 4 The following resistance readings in ohms should be obtained depending on the position of the float...

Page 133: ...Set a multimeter to 20 volts DC and place the red probe of the multimeter on the positive post of the battery Place the black probe on the negative post of the battery Record the voltage reading 5 Se...

Page 134: ...11...

Page 135: ...ction on page 11 20 and Test Procedure 10 Starter Generator Generator Function on page 11 22 Starter Generator Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionall...

Page 136: ...es and commutator as the commutator end cover is being removed or installed could damage the brushes Lift the brush springs out of the notches in the brushes and pull the brushes back from the center...

Page 137: ...Using a spring scale test brush spring tension If any spring has a tension less than 24 ounces 6 67 N replace all four springs Figure 12 5 Page 12 3 See following CAUTION CAUTION When checking brush s...

Page 138: ...own into the holders Position springs into the notches in the brushes Install the brush cover 30 that has the drain hole in it next to the A2 terminal Install the remaining three brush cov ers 29 in t...

Page 139: ...Page 12 5 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 o...

Page 140: ...crews from the housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of the housing Figure 12 10 Page 12 7 See following NOTE NOTE Do not remove the insula...

Page 141: ...eck for loose or raised commutator bars Slight roughness of the commutator can be polished away with 400 grit or finer sandpaper See following CAUTION CAUTION Do not use emery cloth on the commutator...

Page 142: ...r set on 200 ohms place the positive probe on the commutator bars and the neg ative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and...

Page 143: ...washer lock washer and nut onto each threaded terminal on the outside of the housing Tighten nuts to 47 5 in lb 5 4 N m Figure 12 10 Page 12 7 CAUTION Route the field terminal wires so that they will...

Page 144: ...cover 23 Figure 12 3 Page 12 2 11 Slide the spacer 37 onto the end of the shaft Insert the shaft key 34 into the shaft Install the belt pulley 39 onto the shaft and install the lock washer 40 and M14...

Page 145: ...end of the starter generator 6 Position a pry bar 13 between the top of the starter generator mounting bracket 2 and the underside of the starter generator by passing the pry bar under the exhaust hea...

Page 146: ...voltage regulator 1 Voltage Regulator Installation 1 Position the voltage regulator 1 and install the mounting screw 2 Figure 12 15 Page 12 12 Tighten screw to 23 in lb 2 6 N m 2 Connect the voltage...

Page 147: ...l 2 1 Remove three screws 1 from the instrument panel 2 Figure 12 16 Page 12 13 2 2 Rotate the instrument panel up and away from the dash to disengage the tabs at the top of the instrument panel 2 3 D...

Page 148: ...tery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 1 2 Disconnect all the wires from the solenoid 3 Remove the two screws securing the solenoi...

Page 149: ...ted fuse if a fuse with a higher amp rating is used damage to the vehicle electrical system may occur 2 Install the cover on the fuse holder 3 Connect battery cables positive cable first and tighten h...

Page 150: ...gs Section 1 Page 1 1 Testing the Kill Limit Switch See Test Procedure 5B Section 11 Page 11 18 The kill limit switch is housed inside the GCOR The GCOR is mounted on the pedal group and cannot be rep...

Page 151: ...imit switch Figure 12 18 Page 12 17 3 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat terminals with Battery Terminal Prote...

Page 152: ...Figure 12 19 Page 12 17 2 Install the spring 13 and the plastic washer 12 3 Install the external snap ring 14 onto the shaft Be sure the snap ring is installed in the groove on the shaft 4 Connect bat...

Page 153: ...ly Ensure that there are no wires exposed or pinched during positioning 4 3 Secure instrument panel to the dash assembly with three screws 1 Tighten screws to 1 8 ft lb 2 5 N m 5 Connect battery cable...

Page 154: ...e over tightened limit switches could be damaged 3 Place the Forward Reverse handle in REVERSE and make sure that both switches actuate 4 Connect the orange wire to the common COM terminal and the red...

Page 155: ...dash assembly with three screws 1 Tighten screws to 1 8 ft lb 2 5 N m 4 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Figure 1 1 Section 1 Page 1 3 Coat ter...

Page 156: ...ith the fuel gauge casing 3 Connect the blue wire from the wire harness to the I terminal the orange wire from the wire harness to the S terminal and the black wire from the wire harness to the G term...

Page 157: ...re 16 Hour Meter on page 11 30 The hour meter displays the number of hours of use in increments of 0 1 hour Hour Meter Removal 1 Disconnect the battery cables as instructed See WARNING To avoid uninte...

Page 158: ...miter damper on the front of the RPM limiter mounting bracket Figure 12 24 Page 12 24 2 Place the RPM limiter on the damper squarely so that RPM limiter fits tightly against the damper 3 Place the ban...

Page 159: ...ction 1 Page 1 2 4 Remove the governor guard 1 Figure 12 25 Page 12 25 5 Remove the muffler See Muffler Removal Section 15 Page 15 1 6 Cut the wire tie holding the wire harness to the stiffener 1 and...

Page 160: ...age 12 27 2 Remove the cap 2 from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire 3 Remove the gasket 1 and protector tube 3 from the old co...

Page 161: ...e the fan housing to the engine crankcase Tighten all seven mounting bolts to 90 in lb 10 2 N m Figure 12 27 Page 12 26 15 Install the stiffener with four hex head bolts and lock nuts Tighten the hard...

Page 162: ...d service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Battery Poison Contains acid Causes severe b...

Page 163: ...2 29 3 Maintain proper water level See Water Level on page 12 29 4 Check battery periodically to see that it is in a full state of charge See Charging the Battery on page 12 30 5 Keep battery hold dow...

Page 164: ...so DANGER on page 12 28 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 2 Remove the battery hold down clamp from the...

Page 165: ...ery into the vehicle Make sure the battery posts are facing the engine 2 Secure the battery to the vehicle with the clamp Install bolt washer and lock nut and tighten to 12 ft lb 16 3 N m 3 Connect ba...

Page 166: ...o charging The battery will not charge effectively in cold temperatures for the same reasons that it does not discharge as rapidly in cold temperatures Charging a Dead Battery See General Warnings Sec...

Page 167: ...complete instruction on engine disassembly repair rebuilding and reassembly see the Engines and Drivetrain Components Repair and Rebuild Manual CCI P N 102396501 BEFORE SERVICING Carefully read the a...

Page 168: ...ug electrode are an indication of worn rings valve guides cylinder wall etc Also examine the spark plug wire Remove rubber boot and inspect internal spring for damage Inspect spark plug wire for damag...

Page 169: ...r inspection and repair BREATHER VALVE REED VALVE General Information The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through...

Page 170: ...ing hole 4 Remove muffler See Muffler Removal Section 15 Page 15 1 5 Remove engine mounting hardware items 1 2 5 and 6 Figure 13 2 Page 13 4 6 Lift engine from the mounting plate 7 Remove crankcase oi...

Page 171: ...crankcase cover gasket completely It may stick to the flanged surface of the crankcase OIL LEVEL SENSOR Testing the Oil Level Sensor See Test Procedure 21 Section 11 Page 11 32 Oil Level Sensor Remova...

Page 172: ...ll and tighten crankcase cover bolts as instructed Failure to do so could cause the cover to become warped 1 Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation an...

Page 173: ...d take out the ignition coil Figure 13 9 Page 13 8 3 Hold the flywheel 4 not the fan 7 with a strap wrench 5 and using a 25 mm socket remove the fly wheel nut and flat washer by turning it countercloc...

Page 174: ...is the reverse of removal 2 While tightening the two bolts 3 use a bronze feeler gauge to adjust the ignition coil air gap to 0 012 inch 0 304 mm Figure 13 11 Page 13 8 3 Tighten the two ignition coil...

Page 175: ...to damage the fan blades Use a strap wrench to hold flywheel Do not place screwdriver or pry bar between fan blades 3 Install the fan housing and tighten the screws to 90 in lbs 10 N m ENGINE INSTALL...

Page 176: ...dip stick and clean with cloth Figure 13 13 Page 13 10 9 2 Reinsert dip stick until fully seated 9 3 Oil must be in the SAFE LEVEL range CAUTION Do not overfill with oil 10 Install a new or cleaned sp...

Page 177: ...ain plug M14 20 ft lb 27 1 N m Fan housing screws M6 90 in lb 10 N m Fan shroud screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3...

Page 178: ...13...

Page 179: ...ir Section 13 Page 13 2 Air filter element See Air Filter on page 14 11 Fuel filter See Fuel Filter on page 14 14 Choke and air intake system for restriction of air flow See Choke and Air Intake Syste...

Page 180: ...Page 14 3 When removing the carburetor body the throttle return spring 11 must be disconnected Note its proper orientation so that it can be replaced in the same orientation The carburetor must be ke...

Page 181: ...carburetor body when the fuel bowl is removed Figure 14 2 Page 14 4 During normal operation the fuel bowl retains the float pivot pin 6 Make sure that the float pivot pin does not fall out of the carb...

Page 182: ...es ignation on the jet to make sure it is the correct part 8 Install the new main jet and tighten it to 12 in lb 1 4 N m See following CAUTION and NOTE Figure 14 2 Changing the Main Jet Drain carburet...

Page 183: ...when the carburetor is installed on the engine 12 Install the carburetor on the engine Figure 14 1 Page 14 3 12 1 Attach the throttle return spring 11 to the carburetor and then to the throttle brack...

Page 184: ...r and remove the cable from the vehicle Governor Cable Installation and Adjustment 1 Insert the ends of cable 8 into the respective holes on the carburetor and the governor lever arm Figure 14 3 Page...

Page 185: ...ol Linkage 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 7 14 Figure 14 3 Governor and Accelerator Cables 3 10 6 4 5 11 7 7 8 3 9 1 2 TYPICAL 2 PLACES GOVERNOR LEVER ARM CARB...

Page 186: ...ble housing lock nuts make sure the engine RPM adjustment is correct See Engine RPM Adjustment on page 14 9 6 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See...

Page 187: ...7 Be sure both lock nuts are locked against the bracket and then check the RPM again If the RPM needs to be adjusted repeat step 6 8 If more adjustment is required than the cable housing will allow ma...

Page 188: ...Precedent Gasoline Golf Car Maintenance and Service Manual 14 Figure 14 5 Air Intake and Choke Assembly Figure 14 6 Air Intake and Choke Assembly AIR INTAKE HOSE TO CARBURATOR CHOKE CHOKE CHOKE BUTTO...

Page 189: ...ck Plate and Choke Button Section 4 Page 4 7 AIR INTAKE COMPONENTS INSTALLATION WARNING Intake hose is made from a special fire retardant neoprene material Use of any hose that does not meet CCI speci...

Page 190: ...firmly to engage the seals and rotate the cover clockwise until the yellow tab is at the 11 o clock position 8 Press in the yellow tab 1 to lock the cover on the housing See following CAUTION CAUTION...

Page 191: ...YSTEM Choke and Air Intake System 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14 13 14 Figure 14 8 Fuel and Vent Lines TO CRANKCASE 7 9 5 1 4 14 11 13 15 12 6 6 3 10 8 2 16 2...

Page 192: ...inage turn the fuel shut off valve 5 on the fuel tank 1 Figure 14 8 Page 14 13 to the closed OFF position Figure 14 12 Page 14 21 5 Remove the clamps 6 and fuel lines 9 and 10 from the filter 7 and pl...

Page 193: ...tery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 4 Turn fuel shut off valve on top of the fuel tank to the closed OFF position Figure 14 1...

Page 194: ...ations and remove them Figure 14 9 Page 14 16 5 Remove the pumping chamber 30 6 Remove the back cover 36 the fuel diaphragm 34 and gasket 35 Figure 14 9 Page 14 16 FUEL PUMP CLEANING AND INSPECTION 1...

Page 195: ...uel lines as shown Figure 14 8 Page 14 13 NOTE Be sure to connect the fuel line 10 that comes from the fuel filter 7 to the inlet nipple on the pump Direction of fuel flow is indicated by the arrows o...

Page 196: ...sconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warnings Section 1 Page 1 2 5 Return the neutral lockout cam to the OPERATE position 6 Loosen but do...

Page 197: ...ng fuel 3 In a well ventilated area set the tank upside down so that the water can drain out of it To make sure that the tank dries completely allow the tank to sit for 24 hours See following CAUTION...

Page 198: ...ause arching and ignite fuel vapors Ensure that ground wire is properly connected 6 Add fuel to the tank 7 Connect battery cables positive cable first and tighten hardware to 12 ft lb 16 3 N m See Fig...

Page 199: ...the carburetor A screw band clamp 15 should be used at the carburetor FUEL SHUT OFF VALVE See General Warnings Section 1 Page 1 1 The fuel shut off valve is located on top of the fuel tank The fuel s...

Page 200: ...ine Golf Car Maintenance and Service Manual 14 Figure 14 13 Open Fuel Shut off Valve Position Figure 14 14 Incorrect Fuel Shut off Valve Position VIEWED FROM SELECTOR SIDE OF VALVE FULL OPEN ON POSITI...

Page 201: ...d flat washer 9 5 Remove the muffler clamp 6 from the muffler bracket 2 6 Remove the muffler 1 and muffler clamp 6 from the vehicle MUFFLER INSTALLATION NOTE Any time the muffler is removed from the v...

Page 202: ...Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAIN TENANCE position Start the engine and check for exhaust leaks and proper engine operation See fol lowi...

Page 203: ...om ponents Repair and Rebuild Manual CCI P N 102396501 Shifter Lever A shifter lever connected to a shifter arm is used to change the gears to one of three shift positions FOR WARD F NEUTRAL N or REVE...

Page 204: ...lic press Plastic or rubber mallet 1 2 in combination wrench Bench vise Ratchet wrench 3 8 in drive 9 16 in combination wrench Standard slip joint pliers Torque wrench 3 8 in drive 11 16 in combinatio...

Page 205: ...oval of the unitized transaxle is not required for servicing or replacing axle shafts axle bearings or axle shaft oil seals If the unitized transaxle is to be removed from the vehicle do not remove th...

Page 206: ...RING Axle Bearing Removal 1 Use external retaining ring pliers 0 047 inch tip to remove the retaining ring 74 Place a bearing puller wedge attachment CCI P N 1012812 on the axle shaft between the whee...

Page 207: ...nance and Service Manual Page 16 5 16 Figure 16 6 Differential Gear Case Axle Tubes 74 73 70 71 ClubCar REFERENCE PASSENGER SIDE CASE 74 73 70 68 69 78 77 76 79 87 86 90 89 85 91 84 82 89 85 88 81 80...

Page 208: ...aring was removed from the shaft replace it with a new one Do not tighten the bearing puller wedge attachment against the axle shaft This could damage the axle shaft when the bearing and collar are pr...

Page 209: ...RANSAXLE REMOVAL See General Warnings Section 1 Page 1 1 1 Turn the key switch to the OFF position and remove the key and place the Forward Reverse handle in the NEUTRAL position 2 Disconnect the batt...

Page 210: ...the line can be plugged with a 1 4 inch bolt Figure 16 12 Page 16 8 4 5 Disconnect the throttle cable from the pedal group See Pedal Group Removal Section 5 Page 5 1 Loosen the cable mounting nuts 1 a...

Page 211: ...ck ground wire A2 post and 16 gauge yellow wire DF post from starter generator Figure 16 16 Page 16 9 4 9 Disconnect the engine oil level sensor wire 18 gauge yellow at the connector just to the rear...

Page 212: ...ress tangs on cable end and remove cable from bracket 3 Figure 16 19 Page 16 10 6 Remove the lower shock mounting hardware from both rear shocks Figure 16 20 Page 16 11 7 Position a floor jack under t...

Page 213: ...ue raising vehicle until frame is higher than the top of the unitized transmission enough to allow transaxle and engine to be rolled under and out of vehicle Figure 16 24 Page 16 12 11 Position jack s...

Page 214: ...vehicle and roll the powertrain out from under the vehicle Figure 16 27 Page 16 13 15 Place blocks under the engine pan so they will completely support the engine and keep it level to the floor Figure...

Page 215: ...Loosen but do not remove the governor arm retaining bolt 1 Figure 16 31 Page 16 14 Remove the governor arm from the shaft Do not disconnect cables Figure 16 26 Snubber Figure 16 27 Remove Powertrain F...

Page 216: ...wing NOTE NOTE The governor cable and the accelerator cable should remain attached to the governor arm 22 Remove the six bolts mounting the unitized transaxle to the engine 22 1 Remove four transaxle...

Page 217: ...e mounting plate on the two mounting studs at the rear of the engine and then install the two mounting nuts finger tight Figure 16 36 Page 16 16 5 Install the remaining four mounting bolts four flat w...

Page 218: ...Manual 16 Figure 16 35 Transaxle Gear Casing and Brackets Figure 16 36 Transaxle Mounting Figure 16 37 Accelerator Cable Bracket 30 29 ClubCar 3 4 9 6 5 7 8 10 17 18 19 16 11 12 13 21 22 20 31 14 15 2...

Page 219: ...lding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 35 in lb 4 0 N m Figure 16 39 Page 16 17 10 Install the key onto the input shaft Figure 16 40 Page...

Page 220: ...e installed Tighten lock nuts to 15 ft lb 20 3 N m Figure 16 42 Page 16 18 16 Using the floor jack adjust vehicle height to position the leaf springs for mounting in the shackles Install the mounting...

Page 221: ...druff key 10 on the shifter shaft 9 Figure 16 35 Page 16 16 22 3 Place the shifter lever 6 aligned with the woodruff key onto the Forward Reverse shaft 9 22 4 Install the nut 3 washer 4 and bolt 7 on...

Page 222: ...re portion of the cable Tighten mounting nuts to 23 in lb 2 6 N m Figure 16 50 Page 16 20 26 Remove the 1 4 inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a h...

Page 223: ...GL 3 or 80 90 WT AGMA class EP gear lube Install and tighten the level indicator hole plug to 21 ft lb 28 5 N m 32 Ensure that all wiring is secured properly See following WARNING WARNING If wires ar...

Page 224: ...ble attaches to the shifter Figure 16 55 Page 16 23 Push in the end of the ball joint socket 27 to release the cable from the ball stud 17 4 Loosen retaining nuts 28 to release cable from bracket 10 5...

Page 225: ...erse Shifter Cable 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16 23 16 Figure 16 55 Forward Reverse Cable 19 18 27 26 28 28 17 15 16 7 20 10 8 8 11 13 12 12 14 14 2 6 5 9 4 3...

Page 226: ...wing CAUTION CAUTION Be sure threads of cable are engaged in ball joint socket at least 1 4 inch 6 35 mm If ball joint socket comes loose from the cable the Forward Reverse shifter will not operate pr...

Page 227: ...overned top speed the ratio of drive clutch to driven clutch is 0 92 to 1 On steep grades or when the vehicle is heavily loaded higher torques are achieved through the use of a torque sensing ramp dev...

Page 228: ...spected semiannually for wear and or glazing If it is excessively worn frayed or glazed replace the belt As the drive belt wears the engine RPM will increase to compensate for the change in torque con...

Page 229: ...sure fingers are not underneath the belt when rolling the belt off the driven clutch 4 Remove the belt from the drive clutch DRIVE BELT INSTALLATION 1 Position the new belt on the drive clutch then st...

Page 230: ...rter generator mounting and adjusting hardware and then remove the starter belt See WARNING Moving parts Do not in General Warnings Section 1 Page 1 1 Figure 17 3 Loosen Retaining Bolt Figure 17 4 Dri...

Page 231: ...pproved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels...

Page 232: ...NVERTER Drive Clutch Page 17 6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual 17 Figure 17 7 Drive Clutch Assembly 2 1 3 13 4 5 6 7 9 8 11 12 12 16 15 14 22 20 21 17 19 TYPICAL 3 PLAC...

Page 233: ...nced as an assembly Before disassembly make match marks on the drive clutch hub and on the moveable face assembly so they can be reassembled in the same positions Figure 17 8 Page 17 7 1 Make match ma...

Page 234: ...7 11 Page 17 8 5 1 Remove the screws and flat washers attaching the weights as shown Figure 17 11 Page 17 8 5 2 Pull the weight assemblies with pins from the clutch 5 3 Before removing note the orient...

Page 235: ...essary Figure 17 7 Page 17 6 8 If necessary remove idler bearing Use a press to remove the bearing Figure 17 14 Page 17 9 See following NOTE NOTE Do not remove the idler bearing unless it needs to be...

Page 236: ...laced 6 Inspect the pins on the primary weights 2 There should be no measurable wear Replace them if they are worn scratched or damaged 7 Inspect the drive belt pulley sheaves for excessive wear or da...

Page 237: ...in position Figure 17 16 Page 17 11 12 Install the 1 4 20 bolts and washers 2 and tighten them to 10 ft lb 13 N m Figure 17 7 Page 17 6 See following NOTE NOTE Make sure there is at least a minimum ga...

Page 238: ...belt and adjust belt tension as instructed See Belt Tension Adjustment Section 12 Page 12 11 Tighten the starter generator mounting hardware to 23 ft lb 31 2 N m and the adjusting hardware to 13 ft lb...

Page 239: ...ector Spray CCI P N 1014305 to minimize corrosion 9 Connect the spark plug wire to the plug 10 Drive the vehicle and check for proper operation DRIVEN CLUTCH See General Warnings Section 1 Page 1 1 DR...

Page 240: ...spin when the cam buttons release from the cam ramps resulting in severe personal injury 2 Insert a puller plug CCI P N 1014507 Figure 17 21 Page 17 14 into the shaft bore and use a driven clutch cam...

Page 241: ...TORQUE CONVERTER Driven Clutch 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17 15 17 Figure 17 22 Driven Clutch Assembly 2 3 4 5 6 7 8 11 12 1 10 9 TYPICAL 3 PLACES...

Page 242: ...the moveable face assembly 7 onto the fixed face shaft 8 3 Place the end of the spring 5 into the hole in the moveable face assembly 4 Install the key 3 into the keyway of the fixed face assembly 8 s...

Page 243: ...body 5 until the threaded bolt washers bearing and hub guide are against the fixed face hub Figure 17 24 Page 17 17 5 2 4 Hold the clutch assembly and cam installation tool together and place the fixe...

Page 244: ...e 17 22 Page 17 15 Secure with a new bolt 11 See following NOTE NOTE The bolt 11 must be replaced with a new bolt CCI P N 102242101 containing a locking patch that will prevent the bolt from loosening...

Page 245: ...ter level 12 29 belt drive see drive belt body front see also repair front and rear body installation 4 4 removal 4 4 body rear see also repair front and rear body removal 4 8 brake return spring 5 3...

Page 246: ...ignition circuit 11 11 installation 13 9 removal 13 3 rotation 13 1 RPM adjustment 14 9 exhaust system 14 1 15 1 see also muffler F floor mat and retainers 4 6 floor mat retainer installation 4 7 rem...

Page 247: ...emoval 4 4 K key switch engine kill circuit testing 11 31 installation 12 14 removal 12 13 starter circuit 11 11 kick plate removal 4 7 kick plate and choke button installation 4 7 kill circuit engine...

Page 248: ...oval 4 10 schematic diagram 11 6 seat back four passenger installation 4 13 removal 4 12 seat support four passenger installation 4 13 removal 4 13 serial number vehicle 3 1 service schedule see perio...

Page 249: ...ger leaf spring installation 9 4 removal 9 1 sweater basket 4 10 T test procedure accelerator pedal limit switch 11 17 battery 11 12 11 33 engine kill circuit 11 18 11 23 engine kill circuit wire 11 3...

Page 250: ...cessory mounting 4 8 V voltage regulator installation 12 12 removal 12 12 testing 11 23 W WARNING definition of 1 1 wheel installation 8 1 removal 8 1 see also tire wheel liner installation 4 12 remov...

Page 251: ...Clarity of Illustrations 4 Index Usability 5 Troubleshooting Chart Usability Poor Fair Average Good Excellent Comments Suggestions In order to help us better serve you please rate this publication in...

Page 252: ......

Page 253: ...Club Car R NOTES...

Page 254: ...Club Car R NOTES...

Page 255: ......

Page 256: ...Club Car Inc P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int I 1 706 863 3000 Fax 1 706 863 5808...

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