Club Car Carryall 2 Plus Service Manual Download

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Manual Number 103897404

Edition Code 1211A00000

Turf 1, Turf 2, Turf 6, Carryall 1, Carryall 2, Carryall 2 Plus,

Carryall 6 G/E

2012 Turf/Carryall

Maintenance and Service

Manual

Summary of Contents for Carryall 2 Plus

Page 1: ...Manual Number 103897404 Edition Code 1211A00000 Turf 1 Turf 2 Turf 6 Carryall 1 Carryall 2 Carryall 2 Plus Carryall 6 G E 2012 Turf Carryall Maintenance and Service Manual ...

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Page 3: ... and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained tech nician It is the policy of Club Car LLC to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep resentatives vehicle service seminars p...

Page 4: ...products These improvements may affect servicing procedures Any modification and or signif icant change in specifications or procedures will be forwarded to all Club Car distribu tors and dealers and will when applicable appear in future editions of this manual Club Car LLC reserves the right to change specifications and designs at any time with out notice and without the obligation of making chan...

Page 5: ...mation 3 1 Serial Number Identification 3 1 Storage Gasoline Vehicle 3 2 Preparing the Gasoline Vehicle for Extended Storage 3 2 Returning the Stored Gasoline Vehicle to Service 3 4 Storage Electric Vehicle 3 4 Preparing the Electric Vehicle for Extended Storage 3 4 Returning the Stored Electric Vehicle to Service 3 6 SECTION 4 BODY AND TRIM Cleaning the Vehicle 4 1 Front Body Repair 4 2 Stress Li...

Page 6: ...4 12 Rear Fender Installation 4 13 Trailer Hitch Heavy Duty Optional on Some Models 4 15 Trailer Hitch Removal Heavy Duty 4 15 Trailer Hitch Installation Heavy Duty 4 15 Tailskirt 4 15 Tailskirt Removal 4 15 Tailskirt Installation 4 15 Floor Mat 4 15 Front Floor Mat Removal 4 15 Front Floor Mat Installation 4 16 Rear Floor Mat Removal Turf 6 and Carryall 6 Only 4 16 Rear Floor Mat Installation Tur...

Page 7: ...ually Adjusted Brakes 6 9 Brake Shoe Installation Manually Adjusted Brakes 6 10 Brake Adjustment Manually Adjusted Brakes 6 12 Brake Cluster Adjustment 6 13 Brake Cable Equalization 6 16 Final Brake Cluster Adjustment 6 17 Test Drive Vehicle 6 17 Brake Cluster Removal and Installation 6 17 Rear Brake Cluster Removal 6 17 Rear Brake Cluster Installation 6 18 Front Brake Cluster Removal 6 18 Front B...

Page 8: ...nk Installation MAINTENANCE FREE BALL JOINTS 7 14 Front Suspension 7 15 Lubrication 7 15 Wheel Alignment 7 15 Front Suspension Components 7 17 Leaf Spring Removal 7 17 Leaf Spring Installation 7 17 Kingpin and Steering Spindle Removal 7 17 Kingpin and Steering Spindle Installation 7 23 Delta A Plate Removal 7 23 Delta A Plate Installation 7 23 Shock Absorber Removal 7 23 Shock Absorber Installatio...

Page 9: ... and Removal 9 1 Shock Absorber Installation 9 2 Multi Leaf Springs 9 2 Multi Leaf Spring Removal 9 2 Multi Leaf Spring Installation 9 3 Snubber 9 6 Snubber Removal 9 6 Snubber Installation 9 6 Stabilizer Bar 9 7 Stabilizer Bar Removal 9 7 Stabilizer Bar Installation 9 8 Jounce Bumpers 9 8 Jounce Bumper Removal 9 8 Jounce Bumper Installation 9 8 SECTION i INDEX ...

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Page 11: ...hazardous situation that could result in property damage GENERAL WARNING The following safety statements must be heeded whenever the vehicle is being operated repaired or ser viced Service technicians should become familiar with these general safety statements Also other specific safety statements appear throughout this manual and on the vehicle ý DANGER Battery Explosive gases Do not smoke Keep s...

Page 12: ...h low resistance terminals to replace battery wires All vehicles Wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle Moving parts Do not attempt to service the vehicle while it is running Ensure battery c...

Page 13: ...ion 4 In addition chock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERY GASOLINE VEHICLES 1 Disable the vehicle See Disabling The Vehicle on page 1 3 2 Disconnect the battery cables negative cable first as shown Figure 1 1 Page 1 4 3 Disconnect the spark plug wire s from the spark plug s CONNECTING THE BATTERY GASOLINE VEHICLES 1 Connect the battery cables positive cable...

Page 14: ...inimize corrosion Figure 1 1 Gasoline Vehicle Figure 1 2 IQ System Vehicle Figure 1 3 Turf 2 Carryall 2 IQ Plus Electric Vehicle and Carryall 6 Electric Vehicle 1 2 TOW RUN WARNING 1 2 3 4 6 5 FRONT OF VEHICLE Place Tow Run Switch in TOW Remove negative cable first PLACE TOW RUN SWITCH IN THE TOW POSITION BEFORE DISCONNECTING OR CONNECTING BATTERY CABLES 1 3 5 7 8 2 4 6 T O W R U N W A R N IN G FR...

Page 15: ...ally released Self adjusting multi latch ratchet and pawl Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is automatically released Self adjusting multi latch ratchet and pawl BODY CHASSIS Frame chassis Twin I Beam welded aluminum Side and rear body All aluminum Front body ArmorFlex Front body finish Automotive grade paint Tires 18 x 8 50 8 tubel...

Page 16: ...m 27 625 in 70 cm 27 in 69 cm Seat height 30 in 76 cm 30 25 in 77 cm 30 in 76 cm Load bed size Box bed dimensions 37 6 in x 45 1 in x 9 3 in 96 x 115 x 23 cm 48 8 in x 49 8 in x 10 9 in 124 x126 x 28 cm 64 2 in x 44 in x 18 5 in 163 x 112 x 47 cm Load bed size Flat bed dimensions 35 8 in x 44 3 in 91 x 112 cm 46 9 in x 48 3 in 119 x 126 cm 67 6 in x 44 2 in 172 x 112 cm Vehicle rated capacity Leve...

Page 17: ...SPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front mono leaf and rear multi leaf springs with dual hydraulic shocks Suspension Front and rear multi leaf springs with dual hydraulic shocks Brakes Mechanical brake cable system to self adjusting drum brakes on each rear wheel Park brake is automatically released Self adjusting multi latch ratchet and pawl Manually Adjusted Brake...

Page 18: ... cm 30 in 76 cm Load bed size Box bed dimensions 37 6 in x 45 1 in x 9 3 in 96 x 115 x 23 cm 48 8 in x 49 8 in x 10 9 in 124 x126 x 28 cm 48 8 in x 49 8 in x 10 9 in 124 x126 x 28 cm 64 2 in x 44 in x 18 5 in 163 x 112 x 47 cm Load bed size Flat bed dimensions 35 8 in x 44 3 in 91 x 112 cm 46 9 in x 48 3 in 119 x 126 cm 46 9 in x 48 3 in 119 x 126 cm 67 6 in x 44 2 in 172 x 112 cm Vehicle rated ca...

Page 19: ...key switch are referred to as key start Refer to the owner s manual provided with the vehicle for information on the following topics Controls and Indicators Pre Operation and Daily Safety Checklist Driving Instructions Bed Latch Prop Rod Loading and Unloading Towing with a Vehicle Transporting on a Trailer Subsequent Owner Registration Warranties SERIAL NUMBER IDENTIFICATION The serial number of ...

Page 20: ...tteries with bulged cases Discard the battery Frozen batteries can explode ý CAUTION Batteries in a low state of charge will freeze at low temperatures PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking so...

Page 21: ...able fuel stabilizer such as Sta Bil 4 4 Disconnect fuel vent line from fuel tank vent nipple 4 5 Plug the fuel tank vent nipple so that it is air tight We recommend using a slip on vinyl cap 5 Disconnect battery and spark plug wire s See Disconnecting The Battery Gasoline Vehicles on page 1 3 6 To protect the engine remove spark plug and pour 1 2 ounce 14 2 mL of SAE 10 weight oil into engine thr...

Page 22: ...ation and Daily Safety Checklist See the vehicle owner s manual STORAGE ELECTRIC VEHICLE See General Warning Section 1 Page 1 1 ý WARNING Turn the key switch to the OFF position remove the key and leave the Forward Reverse switch in the NEUTRAL position during storage Place Tow Run switch in the TOW position This is to prevent unintentionally starting the vehicle or a fire hazard Do not attempt to...

Page 23: ...n front body rear body seats battery compartment and underside of vehicle 10 Do not engage the park brake Chock the wheels to prevent the vehicle from rolling NOTE It is recommended that the vehicles be plugged in and the electrolyte level main tained throughout the storage period If any of the following conditions exist how ever then disconnect the batteries for storage 1 The charger cannot remai...

Page 24: ...hat comes from the OBC and secure it in a way that ensures the cable will not come into contact with battery terminal Figure 1 2 Page 1 4 Figure 1 3 Page 1 4 RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE 1 If necessary connect batteries and tighten hardware to 110 in lb 12 4 N m 2 Fully charge batteries See Section 13 Batteries in the appropriate maintenance and service sup plement 3 Adjust tir...

Page 25: ...ilable aluminum cleaner paste and fine grade no 00 steel wool Club Car does not recommend any type of pressure washing or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure The seats of the vehicle will last longer with proper cleaning To preserve seat appearance clean regul...

Page 26: ... push block in the opposite direction of the deformation 3 Continue heating and bending the body until the original shape returns Under no circumstance should the gun be held closer than 6 inches 15 cm to the body See preceding CAUTION MINOR SCRATCHES AND SURFACE BLEMISHES For minor scratches or blemishes in the ArmorFlex body that do not penetrate the finish 1 Thoroughly clean the affected area u...

Page 27: ...ghtly buff the imperfection 5 Apply wax to the entire body part to restore luster and weather protection TOUCH UP PAINT COLOR CHART GOUGES PUNCTURES TEARS LARGE SCRATCHES AND ABRASIONS Touch up is not recommended Replace the entire body part or have it repaired by a professional paint and body repair shop with experience repairing TPO bodies COLOR CC P N Beige 101997201 White 101997202 Red 1019972...

Page 28: ...trim 13 align holes and finger tighten screws 14 holding front body against frame Figure 4 1 Page 4 5 2 Install carriage bolts 15 washers 16 and lock nuts 17 onto front body trim Tighten bolts to 11 ft lb 14 9 N m Tighten screws 14 to 20 in lb 2 3 N m See following NOTE NOTE If installing a new front body two 5 16 inch holes must be drilled after the body has been placed on the vehicle Use the bod...

Page 29: ... 4 5 4 Figure 4 1 Front Body Assembly Club Car r TURF 2 6 CARRYALL 2 2 PLUS AND 6 TYPICAL 2 PLACES TURF 2 6 CARRYALL 2 2 PLUS AND 6 TURF 1 AND CARRYALL 1 ONLY TYPICAL 2 PLACES TYPICAL 6 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 1 13 14 11 12 6 17 16 15 18 19 TYPICAL 2 PLACES 5 3 4 2 3 9 8 10 9 8 ...

Page 30: ...ges and remove the hinge bolts 9 from the hinge assemblies 4 Raise rear edge of bed approximately 6 inches 15 2 cm and pull bed assembly toward rear of vehicle approximately 3 inches 7 6 cm to release bed latch assembly 2 from latch plate 1 5 Lift bed from vehicle TILT BED INSTALLATION 1 Hold bed at a slight angle front of bed lower than rear of bed to vehicle and place front edge of bed onto vehi...

Page 31: ...BODY AND TRIM Front Body Repair 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 7 4 Figure 4 2 Tilt Bed Turf 1 2 Carryall 1 2 and 2 Plus TYPICAL 2 PLACES 9 3 10 25 22 23 18 17 2 1 ...

Page 32: ...ed on vehicle with bed front edge 1 inch 2 5 cm from seat back support panel 7 and open access door 1 Figure 4 3 Page 4 9 2 Raise rear edge of bed 6 inches from vehicle frame and position bed so the left and right hand bed sup ports are resting on the support bumpers 8 3 Lower rear edge of bed onto vehicle and make sure hinge brackets align with bed hinge 4 Start the bolts 6 into left and right hi...

Page 33: ...RIM Flat Bed Turf 6 and Carryall 6 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 4 9 4 Figure 4 3 Flat Bed Turf 6 and Carryall 6 10 8 7 4 3 2 TYPICAL 2 PLACES TYPICAL 2 PLACES 5 6 14 1 9 12 13 11 ...

Page 34: ...flat washers 2 and lock nuts 3 from trim strips 4 on front and rear edge of bed Figure 4 4 Page 4 11 Remove trim strips from bed 5 Remove two bolts 5 and lock nuts 6 from the bracket 7 on driver side trim strip 8 Remove bracket from bed 6 Remove remaining hardware securing driver side trim strip and remove trim strip from bed 7 Repeat previous two steps to remove passenger side trim strip 9 and br...

Page 35: ...es 9 rotate them 180 degrees and open access door 1 Figure 4 3 Page 4 9 2 Remove three lock nuts 11 and bolts 12 from access door side of hinge 14 3 Remove access door 1 from cargo bed ACCESS DOOR INSTALLATION TURF 6 AND CARRYALL 6 1 Install access door 1 in the reverse order of removal Figure 4 3 Page 4 9 2 Tighten nuts 11 to 8 ft lb 10 8 N m 3 Close access door 1 and secure both door latches 9 F...

Page 36: ...cles 2 Remove two nylon lock nuts 3 flat washers 1 and 1 4 x 1 bolts 2 from front of fender 6 Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 3 Remove two nylon lock nuts 3 flat washers 1 and 1 4 x 1 bolts 2 and flat washers 1 from the top of fender 6 Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 Turf 6 and Carryall 6 only 4 Remove the rear reverse buzzer 4 1 Remove pan head screws 16 connecting rever...

Page 37: ... 4 13 4 REAR FENDER INSTALLATION 1 Install rear fender in the reverse order of removal Tighten bolts 2 to 35 in lb 4 0 N m Figure 4 5 Rear Fender Trailer Hitch Heavy Duty and Tailskirt Turf 1 2 Carryall 1 2 and 2 Plus 2 1 3 6 TYPICAL 2 PLACES 9 10 11 12 2 1 3 4 8 7 11 14 15 16 12 10 9 5 13 ...

Page 38: ...Service Manual 4 Figure 4 6 Rear Fender and Tailskirt Turf 6 and Carryall 6 6 10 11 TYPICAL 2 PLACES 11 10 11 12 TYPICAL 2 PLACES 9 12 8 3 1 TYPICAL 2 PLACES AT EACH FENDER 2 9 4 15 14 1 2 TYPICAL 2 PLACES AT EACH FENDER 3 5 TYPICAL 2 PLACES 4 REAR REVERSE BUZZER MOUNTING 17 16 13 ...

Page 39: ...N m TAILSKIRT See General Warning Section 1 Page 1 1 TAILSKIRT REMOVAL 1 Remove two thread forming screws 5 and flat washers 13 from tailskirt 4 and lift tailskirt from vehicle frame Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 TAILSKIRT INSTALLATION 1 Insert upper edge of tailskirt 4 under and in front of back edge of rear body Figure 4 5 Page 4 13 or Figure 4 6 Page 4 14 2 Align holes in tailski...

Page 40: ... under the lip of the body located directly behind the floor mat 2 Slightly bend the floor mat on each side of the vehicle to free it from the center body assembly located in front of the floor mat 3 Lift the floor mat from the vehicle REAR FLOOR MAT INSTALLATION TURF 6 AND CARRYALL 6 ONLY 1 Install the floor mat in the reverse order of removal BUMPER See General Warning Section 1 Page 1 1 BUMPER ...

Page 41: ...time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 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 the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 ...

Page 42: ...ure 5 1 Brake and Park Brake Pedal Assembly and Mounting Two Wheel Brake Vehicles STOP 29 5 11 7 TYPICAL 2 PLACES 3 6 2 27 TYPICAL 4 PLACES 28 14 26 TYPICAL 2 PLACES 31 32 30 33 35 TYPICAL 4 PLACES 25 21 20 12 TYPICAL 4 PLACES 30 17 22 13 10 23 34 15 16 24 18 19 17 29 5 11 7 TYPICAL 2 PLACES 3 6 2 TURF 1 AND CARRYALL 1 VEHICLES ONLY ...

Page 43: ...anual Page 5 3 5 Figure 5 2 Brake and Park Brake Pedal Assembly and Mounting Four Wheel Brake Vehicles 36 37 14 25 24 21 20 18 19 17 12 TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES 31 32 30 33 33 17 22 10 13 23 34 35 STOP 16 15 27 TYPICAL 4 PLACES 28 27 28 29 5 11 7 TYPICAL 2 PLACES 3 6 2 26 TYPICAL 2 PLACES ...

Page 44: ...all 2 Plus vehicles there are two equalizer rods The long rod 21 1 4 inches 54 cm is secured to the left driver side channel and the short rod 9 1 4 inches 23 5 cm is secured to the right passenger side channel on the brake pedal weldment On Turf 6 and Carryall 6 vehicles there are two equalizer rods The long rod 42 1 4 inches 107 3 cm is secured to the left driver side channel on the brake pedal ...

Page 45: ... New push nuts 19 and 32 must be used when reassembling the park brake Figure 5 4 Page 5 4 3 2 To remove the park brake pedal 1 remove the push retainer nut 32 disconnect the torsion spring 22 Figure 5 4 Page 5 4 and slide the pedal off of the shaft See preceding NOTE 3 3 Inspect all parts for wear and damage and replace as necessary PARK BRAKE INSTALLATION 1 From the bottom side of the floorboard...

Page 46: ... the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Disconnect the accelerator rod assembly 17 25 and 24 Figure 5 6 Page 5 7 at the front and rear ball studs and remove it from the vehicle 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 7 two washers 5 and bolt 4 secur ing the accelerator pedal ...

Page 47: ...pivot rod 6 and spacer 20 from the accelerator pivot rod supports 21 12 Inspect the accelerator pivot rod supports 21 for wear and damage and replace if necessary If the pivot rod supports do not require replacement loosen but do not remove the four bolts 22 and lock nuts 18 to make installation of the pivot rod easier 13 Remove the accelerator pedal 1 from the vehicle 14 Inspect all parts for wea...

Page 48: ...n the nut to 75 in lb 8 5 N m 8 Press 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 downward Figure 5 7 Page 5 8 The ratchet should now rotat...

Page 49: ...nce and service supplement 4 Use a 9 16 inch socket and 9 16 inch wrench to remove the nut 7 two washers 5 and bolt 4 secur ing the accelerator pedal 1 to the pivot rod 6 Figure 5 8 Page 5 10 5 Remove the nut 10 and bolt 8 from the accelerator pivot rod assembly 6 6 Slide the spring retainer 11 off of the accelerator pivot rod 7 Inspect the pivot support bearing 9 for wear and replace if necessary...

Page 50: ...ccelerator Pedal Electric Vehicles Page 5 10 2012 Turf Carryall Vehicle Maintenance and Service Manual 5 Figure 5 8 Accelerator Pedal Electric Vehicle GO 3 2 11 10 7 5 4 5 1 8 9 6 15 16 21 TYPICAL 4 PLACES 20 21 22 24 23 TYPICAL 4 PLACES ...

Page 51: ...the brake pedal and allow the ratchet to rotate until its tip is pointed down ward Figure 5 7 Page 5 8 The ratchet should now rotate freely on the rod 9 Rotate the ratchet clockwise until it touches the park brake pawl then slide the ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet m...

Page 52: ... pawl or ratchet is damaged both must be replaced 3 2 Adjust retaining nut 7 on spring support rod until there is a 0 060 inch 1 5 mm gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 5 13 Page 5 13 The gap should be consistent through range of pawl movement If the gap is not con sistent loosen the four bolts 6 securing the accelerator pivot rod sup...

Page 53: ...ark brake still locked measure the distance from the top of accelerator pedal to floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 3 6 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnec...

Page 54: ...l in position against the floorboard and then tighten nut to 26 ft lb 35 3 N m Figure 5 18 Page 5 14 5 Adjust the accelerator rod See following DANGER ý DANGER Before servicing turn the key switch to the OFF position and place the Forward Reverse handle in the NEUTRAL position To prevent accidentally starting the vehicle disconnect the battery cables as instructed in WARNING To avoid unintentional...

Page 55: ...ing jam nuts on the accelerator rod with one end disconnected hold the disconnected accelerator rod with locking pliers When tightening jam nuts on the accelerator rod hold the disconnected ball joint with locking pliers 5 3 Reconnect the accelerator rod at the accelerator pedal 5 4 Before tightening jam nuts on accelerator rod set park brake to first ratchet and pawl position Press accelerator pe...

Page 56: ...s on page 1 3 2 Adjust brake pedal height 2 1 Chock wheels and release park brake Lift rear of vehicle and place jack stands under the axle tubes to support the vehicle 2 2 To provide slack in the brake cables loosen the equalizer retaining nuts 2 and 3 on the equalizer rod 1 Figure 5 20 Page 5 16 2 3 Four wheel brake vehicles only Loosen the front brake equalizer rod Figure 5 21 Page 5 16 2 4 Loo...

Page 57: ... loosen the four bolts 6 securing the accelerator pivot rod supports and adjust the supports If the gap becomes smaller as the park brake pedal is pressed move the pivot rod supports slightly rearward until the gap is consistent If the gap becomes larger as the park brake pedal is pressed move the pivot rod supports slightly forward until gap is consistent 3 3 With the park brake unlocked measure ...

Page 58: ...ball joint Figure 5 27 Page 5 18 3 7 Check for proper brake operation prior to driving the vehicle 4 Adjust accelerator pedal height 4 1 Loosen the nut and bolt Figure 5 28 Page 5 18 securing the accelerator pedal to the pivot plate Clamp the accelerator pedal adjustment tool CC P N 101871001 to the accelerator pedal with the end marked accelerator pedal height closest to the floorboard Press the ...

Page 59: ... Page 5 19 5 5 Adjust the brakes See Brake Adjustment Self Adjusting Brakes Section 6 Page 6 8 or Brake Adjustment Manually Adjusted Brakes Section 6 Page 6 12 Figure 5 29 Accelerator Pedal Height Adjustment STOP PARK GO ACCELERATOR PEDAL ADJUSTMENT TOOL CCI P N 101871001 RUBBER STRAP GO STOP PARK MICRO BREAK POINT MICRO BREAK POINT ...

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Page 61: ...ing the negative pressure enclosure hepa vacuum system or low pressure wet cleaning method per OSHA 29 CFR 1910 1001 GENERAL INFORMATION The Club Car vehicles covered in this manual are equipped with two wheel self adjusting brakes or four wheel manually adjusted brakes See Section 2 Specifications BRAKE SHOE REMOVAL See General Warning Section 1 Page 1 1 See also Warning on Page 6 1 1 To remove r...

Page 62: ...remove sealant material around the head of each pin 4 2 Insert a 1 2 x 5 8 inch cold chisel under the head of each pin and shear them off as illustrated Figure 6 2 Page 6 2 This will release the shoes from the backing plate allowing them to pivot away from the inside of the brake drum and allow the brake drum to be pulled free After completing step 5 skip step 6 5 Remove the axle 5 1 Using 90 snap...

Page 63: ...Warning Section 1 Page 1 1 See also Warning on Page 6 1 1 Carefully clean the brake backing plate and all of its mechanical components 2 Remove the rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate the slide 1 and slide plate 2 with dry moly lubricant CC P N 1012151 on both sides of the backing plate After lubricating work the slide back and forth to ensure it slides smoo...

Page 64: ...f the six raised bosses on brake backing plate Figure 6 8 Page 6 4 See pre ceding WARNING 5 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 9 Page 6 4 See preceding WARNING 6 Use a small brush to carefully apply a light coat of wh...

Page 65: ...arning on Page 6 1 Turf 1 and Carryall 1 vehicles 1 Turn the adjusting wheel screw so the shoe slot is vertical then position the trailing shoe in the slots in the shoe mounting block and adjuster assembly Figure 6 12 Page 6 6 See following NOTE Figure 6 11 Self Adjusting Brake Assembly 1 19 20 8 8 6 15 9 4 3 2 5 17 16 7 7 6 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 4 PLACES 14 14...

Page 66: ...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 always ori ented toward the rear of the vehicle 2 Install the shoe retainer clip 1 Compress clip while turning retainer pin 2 into position Figure 6 13 Page 6 6 3 Attach the springs onto the trailing shoe already installed Hold the leading shoe next to the...

Page 67: ... are positioned vertically so that the tips of the shoes are positioned flush at the top with the top surfaces of the wedge shapes on the shoe mounting blocks as shown Figure 6 16 Page 6 7 6 Place a flat blade screwdriver under the adjusting arm and raise arm off of the adjusting wheel While holding the arm up turn the wheel upward until it stops Figure 6 17 Page 6 7 Remove the screw driver See fo...

Page 68: ... is installed make sure the axle and drum turn freely then install wheel and tire assembly See Section 8 Wheels and Tires BRAKE ADJUSTMENT SELF ADJUSTING BRAKES See General Warning Section 1 Page 1 1 See also Warning on Page 6 1 Turf 1 and Carryall 1 vehicles 1 When cleaning or repair on both wheels is complete and with brake cable still loose lower vehicle to floor 2 Make the brake shoe and drum ...

Page 69: ...ll mechanical components 2 Remove rubber boot from backing plate and wipe with a clean damp cloth 3 Lubricate slide 1 and slide plate 2 with dry moly lubricant CC P N 1012151 on both sides of the back ing plate After lubricating work slide back and forth to ensure it slides smoothly and easily Figure 6 19 Page 6 9 Reinstall rubber boot onto backing plate See following WARNING Figure 6 18 Brake Ped...

Page 70: ...hite lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to each end of both brake shoes and into the slots in the brake shoe mounting block as shown Figure 6 21 Page 6 10 See preceding WARNING 6 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent to the brake actuator assembly as shown Figure 6 22 Page 6 10 See preceding WARNING...

Page 71: ...old the other shoe next to it correctly oriented and attach the springs to it Figure 6 25 Page 6 12 See following NOTE NOTE With brake shoe tips marked J10 oriented to the mounting block the stamping will be visible on one shoe only The other J10 stamping will be facing the backing plate and will not be visible 4 While maintaining spring attachment on both shoes position the tips of the second sho...

Page 72: ...ically in the mounting slots 8 After the drum is installed make sure the axle and drum turn freely BRAKE ADJUSTMENT MANUALLY ADJUSTED BRAKES See General Warning Section 1 Page 1 1 See also Warning on Page 6 1 ý CAUTION Pedal group adjustment must be within specifications prior to beginning brake adjustment Perform the appropriate pedal group adjustment For gasoline vehicles refer to Pedal Group Ad...

Page 73: ... 29 Page 6 13 and Figure 6 30 Page 6 13 4 Use a torque wrench and a 7 mm 8 point socket or Club Car brake adjustment tool CC P N 1013582 to turn the brake adjustment bolt 5 on each brake clockwise until it is tightened to 15 ft lb 20 3 N m then back off 5 clicks See following NOTE NOTE If a wheel can still be turned by hand after step 4 inspect the brake clusters and clean and or replace all parts...

Page 74: ... Page 6 14 2012 Turf Carryall Vehicle Maintenance and Service Manual 6 Figure 6 31 Rear Manually Adjusted Brake Assembly 13 22 17 11 21 10 11 1 20 TYPICAL 2 PLACES TYPICAL 2 PLACES 16 9 19 10 TYPICAL 4 PLACES TYPICAL 4 PLACES 5 4 TYPICAL 2 PLACES 3 6 8 7 18 12 14 2 ...

Page 75: ...12 Turf Carryall Vehicle Maintenance and Service Manual Page 6 15 6 Figure 6 32 Front Manually Adjusted Brake Assembly 20 10 19 21 23 9 22 11 10 11 16 17 14 2 TYPICAL 2 PLACES TYPICAL 2 PLACES 13 1 3 TYPICAL 4 PLACES 4 5 6 7 TYPICAL 2 PLACES TYPICAL 2 PLACES 8 18 15 12 ...

Page 76: ...28 Page 6 13 2 2 Tighten the jam nut 5 on the rear equalizer rod 2 clockwise to 35 in lb 4 N m Figure 6 27 Page 6 13 2 3 Repeat steps 2 1 and 2 2 until the nuts remain on the torque setting 2 4 Hold the lock nut 6 on the front equalizer rod 2 in place with a wrench and tighten the jam nut 1 to 13 ft lb 17 6 N m Figure 6 28 Page 6 13 2 5 Hold the jam nut 5 on the rear equalizer rod 2 in place with ...

Page 77: ...edal is fully pressed under mod erate pressure it should not go more than halfway to floor and the vehicle should come to a smooth straight stop If the brake pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop check pedal group adjustment and readjust cable tension and brakes See Brake Cable Equal ization on page 6 16 See also Final Brake Cluster Adjustment on page...

Page 78: ...0 6 N m See following WARNING ý WARNING Be sure retaining ring is properly seated in groove If ring is not properly installed axle assembly will separate from transaxle and damage axle assembly and other components Loss of vehicle control could result in severe personal injury or death 4 Adjust brakes as previously described in this section for the appropriate vehicle See Brake Adjustment Self Adj...

Page 79: ...6 32 Page 6 15 9 Remove brake cluster assembly from spindle FRONT BRAKE CLUSTER INSTALLATION 1 Install in reverse order of removal Use bolts 22 cone washers 21 lock washers 20 and hex nuts 19 to mount brake assembly Figure 6 32 Page 6 15 2 Tighten bolts to 30 ft lb 41 N m Adjust brakes as previously described in this section for the appropriate vehicle Use new bow tie pins when reconnecting brake ...

Page 80: ...s pin 3 from brake lever arm on front brake cluster Figure 6 35 Page 6 20 2 Remove E clip 1 from brake cable housing at the front spindle bracket and remove cable from spindle Figure 6 35 Page 6 20 3 Remove cotter pin 9 clevis pin 10 and E clip 8 from brake cable at equalizer 18 Figure 6 36 Page 6 21 4 Remove bolt 4 and nut 6 from brake cable clamp 5 Figure 6 35 Page 6 20 5 Remove cable from vehic...

Page 81: ...able should also pass over the accelerator rod Turf 2 Carryall 2 and Carryall 2 Plus vehicles The cable should pass over the inside I beam Figure 6 37 Page 6 22 4 Route cable along I beam towards front of the vehicle and secure as shown Figure 6 37 Page 6 22 Turf 2 and Carryall 2 electric and all Turf 6 and Carryall 6 vehicles Route cable through hole in I beam crossmember 5 Route brake cable betw...

Page 82: ...ving 2 Release park brake if latched and loosen equalizer retaining nuts 1 on equalizer rod 2 to slightly loosen brake cables 3 Figure 6 38 Page 6 23 3 Rotate brake cables upward and pull ends through holes in top of equalizer 4 Disconnect brake cables at rear wheels 4 1 Remove bow tie pins 1 clevis pins 2 and E clips 3 Figure 6 39 Page 6 23 4 2 Remove cable 4 from cable support bracket 5 4 3 Note...

Page 83: ...ugh hangers in the same manner as the ones removed 2 At the rear wheel brakes connect the cables to the brake actuator arms using clevis pins 2 and new bow tie pins 1 Figure 6 39 Page 6 23 3 Place cables in cable support bracket 5 and secure with E clips 4 Adjust brakes as described in this section for the appropriate vehicle Figure 6 38 Loosen Equalizer Nut Figure 6 39 Disconnect Cables at Rear B...

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Page 85: ... the two mounting screws 1 and plate 2 Figure 7 1 Page 7 2 3 Match mark the steering wheel 3 and steering column shaft 4 so when the steering wheel is removed it can be placed back in exactly the same position on steering column shaft 4 Loosen the steering wheel nut 5 and back it off approximately 1 4 inch 6 mm Do not remove the nut 5 Use the steering wheel puller CC P N 102061201 to remove steeri...

Page 86: ...d on the wheel and steering column shaft in step 3 above Figure 7 1 Page 7 2 2 Install the steering wheel nut 5 and tighten to 156 in lb 17 6 N m 3 Install the plate 2 and screws 1 Tighten screws to 16 in lb 1 8 N m 4 Connect the battery cables See Connecting The Batteries Electric Vehicles on page 1 4 See Con necting The Battery Gasoline Vehicles on page 1 3 STEERING COLUMN See General Warning Se...

Page 87: ...teering Column 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 3 7 Figure 7 3 Steering Column 22 17 16 18 20 18 16 14 12 21 19 17 15 13 11 10 7 8 6 4 1 9 7 5 2 3 TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 35 ...

Page 88: ...sconnect the wires from the electrical components mounted on the dash panel Do not allow wires to touch See following NOTE 3 5 Take care to prevent key switch terminals and wires from touching the metal frame around the dash 3 6 Slide center dash panel up the steering column 4 Remove the driver side dash pocket 4 1 Remove the flange lock screw from the top of the dash pocket 4 2 Drill out the two ...

Page 89: ... 18 using a steering column bearing press tool CC P N 1014264 or a metal tube approximately six inches 15 2 cm long with a maximum outer diam eter of 1 3 16 inches 3 3 cm and a minimum inside diameter of 7 8 inch 2 2 cm Be sure the bearing is installed in the bearing seat as shown Figure 7 5 Page 7 6 so the wedge 16 will ride against the inner race of the bearing 3 Install the wedge 16 spring 15 w...

Page 90: ... Figure 7 3 Page 7 3 7 Tighten the bolt 2 on the upper universal joint to 15 ft lb 20 N m Figure 7 3 Page 7 3 8 Check the other two bolts of the universal joint 1 to ensure that they are properly tightened to 15 ft lb 20 N m Figure 7 3 Page 7 3 9 Reinstall dash pocket and related hardware 10 Reinstall center dash panel in reverse order of disassembly Make sure the key switch terminals do not touch...

Page 91: ...ee following CAUTION CAUTION The drag link has both left and right hand threads The end of the drag link toward the spindle has left hand threads and the end toward the rack has right hand threads To prevent damage to threaded parts care should be taken when servicing the drag link 3 When all adjustments have been completed tighten the nuts 27 and 29 on the drag link assembly with an open end wren...

Page 92: ...e rod check the steering gear for abnormal free play noise binding or clunking while it is under a load With the steering system fully assembled and all four tires on the ground floor turn the steering wheel from stop to stop While turning feel for any binding clunking or tight loose spots Listen for unusual noises Replace the rack and pinion as an assembly if any is found In the event of an known...

Page 93: ... from the steering rack assembly mounting bracket Figure 7 8 Page 7 9 4 Remove the bolt 2 and flat washer 3 on the upper universal joint then remove the rack assembly and universal joint from the vehicle Figure 7 3 Page 7 3 Figure 7 8 Steering Gear 23 27 28 25 29 1 2 3 4 12 11 10 9 7 5 8 13 14 15 16 32 30 31 6 17 18 19 21 TYPICAL 3 PLACES TYPICAL 3 PLACES 2 20 33 ...

Page 94: ... is removed replace with a new one 9 Use snap ring pliers to remove the internal snap ring 11 Figure 7 8 Page 7 9 10 Install the universal joint onto the pinion and place a large open end wrench under the universal joint Figure 7 9 Page 7 10 Use the wrench as a lever to pull the pinion from the housing 11 If the ball bearing 9 has been damaged remove the external snap ring 10 Figure 7 8 Page 7 9 a...

Page 95: ... the stop washer 18 and retaining ring 19 to the end of the rack Figure 7 8 Page 7 9 CAUTION In step 4 do not press against the outer race of the bearing 4 If the bearing 9 was removed press on a new bearing exerting all pressure on the inner race grease the bearing before installing it Then install the external snap ring 10 Figure 7 8 Page 7 9 See pre ceding CAUTION 5 If the needle bearing 7 is d...

Page 96: ...9 11 1 Reposition the rack and pinion in a vise 11 2 Insert a 3 8 inch deep well socket into the steering column end of the universal joint 2 and tighten the bolt 1 to 15 ft lb 20 3 N m Figure 7 14 Page 7 12 11 3 Use a torque wrench connected to the 3 8 inch deep well socket to measure the resistance of the rack and pinion Rotational resistance should measure 7 to 15 in lb 0 8 to 1 7 N m 11 4 If m...

Page 97: ...eads are identified by a groove in the tie rod or drag link 17 Install the ball joint 23 Figure 7 8 Page 7 9 See preceding CAUTION RACK AND PINION INSTALLATION 1 Position the steering gear box assembly on the shock and gear support and install the bolts 30 wash ers 31 and nuts 32 Do not tighten the mounting bolts Figure 7 8 Page 7 9 2 For ease of assembly and to prevent corrosion apply a light coa...

Page 98: ...e 7 22 Page 7 21 See following WARNING and CAUTION ý WARNING The ball joints must be threaded into the rod at least 5 16 of an inch 8 mm Failure to thread ball joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being operated possibly resulting in loss of vehicle control and severe personal injury CAUTION The tie rod and drag link have right hand threa...

Page 99: ...lize the turning radius in both directions See Steering Adjustment on page 7 7 See following NOTE NOTE Prior to making any front suspension adjustments inspect components for wear and damage and repair or replace as necessary 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 Figu...

Page 100: ...y as possible the center of the tread face that is oriented toward the rear of the vehicle The marks should be even with the bottom surfaces of the vehicle frame I beams 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 revolutions until the marks appear on the forward facing surfaces of the tires at about the...

Page 101: ...ed leaf spring 6 6 Check the condition of the urethane bushings 27 and steel sleeves 28 Replace any that are worn or damaged LEAF SPRING INSTALLATION 1 Install urethane bushings 27 and steel sleeves 28 into leaf spring eyes Figure 7 21 Page 7 20 or Figure 7 23 Page 7 22 2 Install tapered leaf spring 6 bottom spring plate 29 four bolts 30 four lock washers 31 and four nuts 32 Using a crisscross pat...

Page 102: ...r 20 and inspect it If the washer is broken or has a wave bottom to wave crest height dimension of less than 0 040 inch 0 10 cm it must be replaced 7 Remove bolt 25 and nut 14 from bottom of kingpin 26 and remove kingpin 8 Inspect the kingpin and spindle If either is worn or damaged it must be replaced 9 Inspect the bushings 3 and 4 If the bushings are worn or damaged remove them and press in new ...

Page 103: ...ON Front Suspension Components 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 19 7 Figure 7 20 Two Wheel Brake Vehicle Upper Portion 1 2 2 2 2 2 4 4 5 23 15 3 2 14 10 17 16 10 6 7 11 9 5 14 20 24 5 32 8 18 12 13 ...

Page 104: ...ON Front Suspension Components Page 7 20 2012 Turf Carryall Vehicle Maintenance and Service Manual 7 Figure 7 21 Two Wheel Brake Vehicle Lower Portion 16 15 16 1 14 2 5 7 4 20 14 8 26 27 28 27 25 30 6 31 32 29 11 12 3 37 38 35 36 ...

Page 105: ...ION Front Suspension Components 2012 Turf Carryall Vehicle Maintenance and Service Manual Page 7 21 7 Figure 7 22 Four Wheel Brake Vehicle Upper Portion 17 20 1 2 2 2 2 4 4 15 3 2 2 10 5 14 11 5 13 12 10 32 18 7 6 9 16 8 5 23 24 ...

Page 106: ...pension Components Page 7 22 2012 Turf Carryall Vehicle Maintenance and Service Manual 7 Figure 7 23 Four Wheel Brake Vehicle Lower Portion 1 25 26 14 2 5 7 4 20 27 8 30 31 32 6 29 28 27 11 21 22 24 12 10 9 10 23 13 15 14 16 35 3 16 37 38 36 ...

Page 107: ... 1 Loosen lug nuts on both front wheels and raise front of the vehicle with a chain hoist or floor jack Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands 2 Remove wheel Remove bolts 10 and 24 A Plate straps 14 and nuts 5 Figure 7 20 Page 7 19 or Figure 7 22 Page 7 21 3 Remove the lower shock absorber mounting nut 9 then slide the shock abs...

Page 108: ... 1 1 FRONT WHEEL FREE PLAY INSPECTION 1 Raise the front of the vehicle 2 Using your hands attempt to rock the wheel and hub assembly back and forth on the spindle If there is any observable movement of the wheel and hub on the spindle remove dust cap 1 and cotter pin 2 and then tighten the spindle nut 3 until the bearing 5 fully seats in the bearing race 7 3 Loosen spindle nut one cotter pin posit...

Page 109: ...rings 5 and hub cavities and lubricate cups 7 with wheel bearing grease or chas sis lube Make sure the grease is forced between the rollers Figure 7 24 Page 7 24 2 If bearing cups 7 were removed press new ones in squarely against stops in the hub See following NOTE NOTE Install new cups when new bearings are installed 3 Install the wheel bearings 5 into the hub and install a new seal 6 with the me...

Page 110: ...7 ...

Page 111: ...s 30 34 psi 2 07 2 34 Bars for all other vehicles Keep lug nuts properly tightened Keep the front end properly aligned and adjusted WHEELS See General Warning Section 1 Page 1 1 WHEEL REMOVAL 1 Slightly loosen the lug nuts on the wheel to be removed 2 Raise the end of the vehicle from which the wheel is to be removed Make sure the wheels are off the ground See WARNING Lift only one end of the vehi...

Page 112: ...nd 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 B See following CAUTION CAUTION To avoid damage to the tire do not use excessive force when starting the bead over the edge of the rim 3 3 When top bead is free of the rim pull the bead from the bo...

Page 113: ...sh Wipe away any debris with a clean cloth See following NOTE NOTE Because tubeless tires require a perfect seal in order to seat keeping the tire and rim clean is very important 3 Apply a light coating of tire mounting lubricant soap and water solution to both tire beads and rim flanges 4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber malle...

Page 114: ...l the valve core 8 Adjust air pressure in the tire to 16 18 psi 1 10 1 24 Bars for Turf 1 and Carryall 1 gasoline vehicles 18 20 psi 1 24 1 38 Bars for Turf 1 and Carryall 1 electric vehicles 30 34 psi 2 07 2 34 Bars for all other vehicles 9 Immerse the wheel and tire assembly in water to make sure there are no leaks Figure 8 2 Inflate Tire Push tire against wall ...

Page 115: ...r limits the mounting plate motion The rear suspension on the gasoline Turf 2 6 Carryall 2 2 Plus and 6 vehicles also includes a stabilizer bar that reduces side to side sway SHOCK ABSORBERS See General Warning Section 1 Page 1 1 SHOCK ABSORBER INSPECTION AND REMOVAL 1 Check shock absorbers 7 for damage and fluid leakage around the lower housing of the shock absorber body Replace damaged or leakin...

Page 116: ...ral Warning Section 1 Page 1 1 NOTE Turf 1 and Carryall 1 vehicles are equipped with jounce bumpers Figure 9 3 Page 9 4 MULTI LEAF SPRING REMOVAL 1 Loosen the lug nuts on the wheel s to be removed 2 Place chocks at the front wheels and lift rear of vehicle with a chain hoist or floor jack Figure 9 2 Page 9 2 Position jack stands under the frame crossmember between the rear leaf spring front frame ...

Page 117: ...dle 23 is 1 inch 2 5 cm above spring Figure 9 3 Page 9 4 9 Remove bolt 15 and lock nut 2 attaching the leaf spring 12 to the rear shackle 1 Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 10 Allow rear of leaf spring 12 to rest on the ground and remove the bolt 24 and lock nut 25 attaching the front of the spring to the vehicle frame Figure 9 3 Page 9 4 or Figure 9 4 Page 9 5 Remove spring from vehicle...

Page 118: ...Figure 9 3 Rear Suspension Turf 1 and Carryall 1 Vehicles 14 13 19 21 11 23 TYPICAL 2 PLACES 9 10 10 9 5 7 4 3 4 3 2 1 2 4 3 4 15 4 12 16 22 20 TYPICAL ON BOTH SIDES 17 REAR BRAKE CABLE TURF 1 CARRYALL 1 GAS ONLY ELECTRIC VEHICLES ONLY 1 24 18 TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE 25 5 9 10 10 9 ...

Page 119: ...nual Page 9 5 9 Figure 9 4 Rear Suspension All Turf and Carryall Vehicles Except Turf 1 and Carryall 1 4 ELECTRIC VEHICLES ONLY 1 4 3 15 4 3 4 9 10 10 9 7 TYPICAL 2 PLACES 5 14 16 12 3 4 24 18 25 REAR BRAKE CABLE TYPICAL BOTH SIDES OF VEHICLE 2 1 2 5 9 10 10 9 11 ELECTRIC VEHICLES ONLY 16 ...

Page 120: ... ft lb 34 N m Figure 9 4 Page 9 5 6 Install shock absorber See Shock Absorber Installation on page 9 2 See following NOTE NOTE When installing shock absorbers make sure rear shocks have identical part numbers SNUBBER See General Warning Section 1 Page 1 1 NOTE The snubber is installed on the gasoline vehicle only SNUBBER REMOVAL 1 Support the powertrain with a floor jack under the engine mounting ...

Page 121: ... floor jack Position jack stands under the frame crossmember between the spring mount and the side stringer just forward of each rear wheel Lower vehicle to let the jack stands support the vehicle See General Warning Section 1 Page 1 1 2 Remove bolt 6 lock washer 7 flat washers 4 compression mounts 3 and spacer 2 from left and right stabilizer bar links 5 Do not remove the stabilizer bar links fro...

Page 122: ...t steps 1 2 and 3 for the other side of the stabilizer bar 5 Place lock washer 7 flat washer 4 spacer 2 and compression mount 3 onto bolt 6 Install bolt through mounting hole in stabilizer bar and place another compression mount 3 and flat washer 4 onto bolt Figure 9 6 Page 9 7 6 Install the bolt 6 with hardware into the stabilizer bar link 5 and finger tighten 7 Repeat steps 5 and 6 for the other...

Page 123: ...l 6 22 cluster front adjustment 6 13 installation 6 19 removal 6 18 cluster rear adjustment 6 13 installation 6 18 removal 6 17 pedal height adjustment electric 5 16 height adjustment gas 5 11 installation 5 4 removal 5 1 shoe installation manually adjusted brakes 6 10 installation self adjusting brakes 6 5 removal 6 1 bumper installation 4 16 removal 4 16 C CAUTION definition of 1 1 cleaning brak...

Page 124: ...embly 7 5 disassembly 7 5 installation 7 5 removal 7 2 steering wheel installation 7 2 removal 7 1 storage electric vehicle 3 4 gasoline vehicle 3 2 suspension front camber adjustment 7 15 components 7 17 delta a plate installation 7 23 removal 7 23 kingpin and steering spindle installation 7 23 removal 7 17 leaf spring installation 7 17 removal 7 17 shock absorber installation 7 24 removal 7 23 w...

Page 125: ...e Maintenance and Service Manual Page i 3 removal 4 6 tire installation 8 3 pressure 8 1 removal 8 2 repair 8 3 trailer hitch installation 4 15 removal 4 15 W WARNING definition of 1 1 wheel see also tire installation 8 1 removal 8 1 ...

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Page 127: ...ormation 3 Clarity of Illustrations Photos 4 Index Usability In order to help us better serve you please rate this publication in the following categories Poor Fair Average Good Excellent 5 If you are reviewing a Kit Instruction were all indicated parts included in your kit Yes No I am Distributor Dealer Individual Owner Club Car Associate Representative Technician Golf Course Superintendent Other...

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Page 132: ...Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web www clubcar com Phone 1 706 863 3000 1 800 ClubCar Int l 1 706 863 3000 Fax 1 706 863 5808 ...

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