Club Car CARRYALL 1 2000, Maintenance And Service Manual

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ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly
2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-21
5
5. Rotate the actuator lever until its alignment pin is aligned with the slot in the potentiometer lever fork
(Figure 5-29, Page 5-21) , then slide the actuator lever toward the potentiometer housing. See follow-
ing CAUTION.
6. Push the accelerator pivot rod (6) through the potentiometer housing until the groove in the pivot rod is
even with the end of the actuator lever (Figure 5-15, Page 5-10) .
7. Install the spring retainer (11) on the pivot rod (6) (Figure 5-15, Page 5-10) .
8. Slide the pivot rod toward the passenger’s side of the vehicle until approximately one-half of the length
of the pivot rod splines is exposed (Figure 5-15, Page 5-10) .
9. Depress the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is
pointed toward the rear of vehicle, slide the ratchet onto the pivot rod (do not slide the ratchet onto the
pivot rod splines). Release the brake pedal and allow the ratchet to rotate until its tip is pointed down-
ward (Figure 5-28, Page 5-21) . The ratchet should now rotate freely on the rod.
10. Rotate the ratchet clockwise until it touches the park brake pawl, then slide ratchet onto the splines of
the pivot rod (it may be necessary to push the pivot rod toward the driver side of the vehicle to make the
splines accessible). The ratchet may have to be rotated counterclockwise slightly to align the splines.
11. Tighten the four bolts that secure the potentiometer assembly and pivot rod support to the vehicle
frame to 75 in-lb (8.5 N·m).
12. Use a feeler gauge to check the gap between the ratchet and the pawl. The gap should be .060". Turn
the nut (16) on the spring retainer (11) clockwise to widen the gap or counterclockwise to reduce the
gap
(Figure 5-15, Page 5-10) . If the gap is .125" or more, slide the ratchet off the splines, rotate the
ratchet clockwise one spline, and then slide the ratchet back onto the splines before adjusting with the
spring retainer nut.
• DO NOT BEND THE LIMIT SWITCH LEVER. THE CAM ON THE ACTUATOR LEVER SHOULD BE
AT THE TWO O’CLOCK POSITION WHEN THE ACTUATOR LEVER IS IN POSITION TO MATE
WITH THE POTENTIOMETER LEVER, ALLOWING THE ACTUATOR LEVER TO SLIDE PAST THE
LIMIT SWITCH LEVER. IT MAY BE NECESSARY TO HOLD THE LIMIT SWITCH LEVER BACK
WITH A FLAT BLADE SCREWDRIVER
(Figure 5-29, Page 5-21) .
Figure 5-28 Ratchet Installation Figure 5-29 Potentiometer Assembly
CAUTION
RATCHET POINTED
TOWARDS REAR OF
VEHICLE
ROTATE RATCHET
CLOCKWISE
DEPRESS BRAKE PEDAL
POTENTIOMETER ASSEMBLY
(CUTAWAY VIEW THROUGH COVER)
POTENTIOMETER
LEVER (27)
ACTUATOR
LEVER (17)
POTENTIOMETER
HOUSING ASSEMBLY (21)
FLAT BLADE
SCREWDRIVER