Club Car Carryall 500, Maintenance And Service Manual

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5
Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP
ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLES
1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the
four bolts (22), flat washers (16), and lock nuts (15)
(Figure 5-8, Page 5-9) . Finger-tighten nuts at this time.
2. Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6)
through the uppermost hole in the pedal.
3. Install plastic spacer (20) on pivot rod (6).
4. Insert the pivot rod through the pivot rod supports (21) on the vehicle frame.
5. Tighten the four bolts (22) attaching the pivot rod supports to the frame to 75 in·lb (8.5 N·m).
6. Insert the bolt (4), two washers (5), and a new lock nut (7) through the lower hole in the pedal and through the
pivot rod. Finger-tighten lock nut at this time.
7. Install the bolt (8) through the pivot rod (6) bearing (9) and spring retainer (11). Secure these parts with the nut
(10). Tighten the nut to 50 in·lb (5.5 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 the 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 5-7) . 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 may have to be rotated counterclockwise slightly to align the splines.
10. Install lock nut (23) on pivot rod (Figure 5-8, Page 5-9) . Tighten to 18 ft·lb (24.5 N·m).
11. Install the MCOR (2) and drive bar (3) as instructed. See MCOR Installation, Section 13, Page 13-6.
12. Adjust the accelerator pedal height. See Pedal Group Adjustment – Electric Vehicles on page 5-16.
PEDAL GROUP ADJUSTMENT – GASOLINE VEHICLES
See General Warnings on page 1-1.
1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-5.
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 (1) on the equalizer rod (2) (Figure
5-9, Page 5-11) .
Page 5-10 2017 Carryall 500 and 700 Maintenance and Service Manual