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1997 DS Golf M&S Supplement

1. INCORRECT CORRECT CHECK CONTINUITY READING CONTINUITY READING CAM ACTUATION REPLACE LIMIT SWITCH CHECK CONNECTIONS OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY CONNECT WIRES CORRECTLY OF CIRCUIT WIRES TEST PROCEDURE 8 NO CONTINUITY REPLACE WIRE FIGURE 12 15 Page 91 DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 TESTING THE REVERSE BUZZER CIRCUIT Use the chart below Figure 12 16 as a starting point for troubleshooting the reverse buzzer circuit REVERSE BUZZER WILL NOT FUNCTION CHECK FUSE TEST PROCEDURE 17 GOOD FUSE BAD FUSE DETERMINE CAUSE OF THE BLOWN FUSE REPLACE FUSE Page 92 REVERSE BUZZER WILL NOT FUNCTION AND ENGINE WILL NOT CRANK REVERSE BUZZER WILL NOT FUNCTION AND ENGINE WILL CRANK
2. 137 Procedure for Changing Main Jet 137 Accelerator Bod fic te teret nee doe tees in eo ee Ee 138 Govermo r Gables ettet iecit niei tbi sus aus efc assoi ss 139 Accelerator cable u uuu i M eee st ee expe ts pest aeo urs 140 SECTION 15 EXHAUST SYSTEM See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 16 TORQUE CONVERTER 142 Use this supplement for current information on the subjects listed below See Section 16 in the 1995 1996 DS Golf Car Maintenance and Service Manual for all other information General Information a ettet t ete Ee ve ie d rta de Lente e e ete Ras 142 Drive Clutch Disassembly entree nns 143 DriveClut h Assembly au der abd de 144 Assembly of the Driven Clutch 146 Clutch Alignment rer tenete ae ette Qe m eite ve EE 146 SECTION 17 TRANSMISSION AND GOVERNOR Section 10 in this supplement supersedes Section 17 in the 1995 1996 DS Maintenance and Ser vice Manual SECTION 18 REAR SUSPENSION GASOLINE VEHICLE 147 Section 18 in this supplement supersedes Section 18 in the 1995 1996 DS Maintenance and Ser vice Manual G neral Information oer taret e EE Te rco A Pr Pr E bea ropa ba SO e ede DA aaa ra
3. PRESS RAM PRESS IDLER SHAFT FROM BEARING USING 3 4 OR LESS O D ARBOR AND A WEDGE ATTACHMENT CLUB CAR 1012812 ATTACHMENT FIGURE 10 53 FIGURE 10 54 INTERMEDIATE GEAR ASSEMBLY 1 If the gear 58 was removed from the shaft install the key 57 into the slot and then position the gear on the shaft with keyway properly aligned with key Figure 10 43 Page 53 Press the gear into place on the key 2 Press the bearing 59 onto the end of the shaft next to the large gear that was installed in step one Figure 10 43 See CAUTION below A CAUTION e APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING 3 Press a new bearing 38 onto the other end of the shaft Figure 10 43 Page 53 Page 56 PRESS BEARING ONTO IDLER SHAFT itil SYNCHRO RING MUST BE REPLACED WHEN X DISTANCE IS LESS THAN 020 IN 0 51 MM MAAN TURN IDLER SHAFT OVER AND PRESS BEARING ON OTHER END id MK FIGURE 10 55 FIGURE 10 56 PRESS TOP OF SPLINE INSTALL SNAP RINGS RAM es ON BOTH SIDES OF MACHINED SYNCHRONIZER FACE OF C SLEEVE AS SHOWN INPUT SYNCHRO MS SLEEVE i SYNCHRONIZER SLEEVE E di TOP OF SPLINE PRESSED LEVEL WITH MACHINED FACE FRONT VIEW FIGURE 10 57 FIGURE 10 58 SYNCHRONIZER GEAR ASSEMBLY 1 Press the synchronizer sleeve 47 Figure 10 43
4. CHECK BATTERY SEE PAGE 87 CHECK GROUND STRAPS TEST PROCEDURE 3 CHECK REVERSE BUZZER LIMIT SWITCH TEST PROCEDURE 18 CORRECT CONTINUITY READING INCORRECT CONTINUITY READING CHECK WIRE CONNECTION TO THE REVERSE BUZZER TEST PROCEDURE 19 REPLACE LIMIT SWITCH WIRES CORRECTLY CONNECTED WIRES INCORRECTLY CONNECTED CHECK CONTINUITY OF CIRCUIT WIRES RECONNECT WIRES TO REVERSE BUZZER NO CONTINUITY CONTINUITY REPLACE WIRE REPLACE REVERSE BUZZER FIGURE 12 16 TESTING THE LOW OIL WARNING CIRCUIT Use the chart below Figure 12 17 as a starting point for troubleshooting the low oil warning circuit OIL LIGHT WILL NOT ILLUMINATE WHEN ENGINE OIL IS LOW CHECK WIRE CONNECTION TO THE OIL SENDING UNIT TEST PROCEDURE 20 WIRES INCORRECTLY WIRES CORRECTLY CONNECTED CONNECTED RECONNECT WIRES OVERRIDE OIL SENDING UNIT LOW OIL WARNING LIGHT LOW OIL WARNING LIGHT ILLUMINATES DOES NOT ILLUMINATE REPLACE OIL SENDING UNIT CHECK CONTINUITY H OF YELLOW WIRE TO LOW OIL WARNING LIGHT CONTINUITY NO CONTINUITY CHECK LOW OIL REPLACE YELLOW WIRE WARNING LIGHT TEST PROCEDURE 21 LOW OI
5. Synchronizer rings are worn damaged or jammed Section 10 Unitized Transaxle in this supplement Excessive vehicle vibration Page 78 Engine mounting nuts or bolts are loose Section 13 Engine Defective or worn engine mounts Section 13 Engine Rubber snubber on engine mounting plate is worn or damaged Section 13 Engine Misaligned muffler mounting clamp Section 15 Exhaust System Damaged drive belt or starter belt Section 16 Torque Converter Damaged drive clutch Section 16 Torque Converter SYMPTOM POSSIBLE CAUSES REFER TO Excessive vehicle vibration continued Damaged driven clutch Section 16 Torque Converter Damaged starter generator pulley Section 12 Gasoline Vehicle Electrical System Starter Generator Misaligned clutches RPM setting is incorrect Section 16 Torque Converter Section 14 Fuel System Torque converter does not shift smoothly Drive belt is worn cracked glazed or frayed Section 16 Torque Converter Drive clutch malfunction Section 16 Torque Converter Driven clutch malfunction Section 16 Torque Converter Governor is sticking Section 10 Unitized Transaxle Engine won t stop running Kill circuit wire is disconnected from the igniter Section 12 Gasoline Vehicle Electrical System Page 79 Page 80 SECTION 12 ELECTRICAL SYSTEM GAS
6. UPPER CALIBRATION SCREW LOWER CALIBRATION SCREW CALIBRATION SCREWS RE UNDER DECAL AT TARGET POINTS TEST BUTTON FIGURE 6 12 FIGURE 6 13 READS MICRO BREAK POINT 74 REPOSITION ACCELERATOR PEDAL ADJUSTMENT TOOL SO THAT MICRO BREAK POINT IS TOWARD FLOORBOARD DEPRESS THE ACCELERATOR PEDAL UNTIL A PEDAL HEIGHT OF 4 5 8 PLUS OR MINUS 3 32 IS REACHED USE A RUBBER STRAP TO HOLD PEDAL IN DEPRESSED POSITION FIGURE 6 14 Page 22 4 6 With the actuator in this position tighten the actuator bolt slightly 4 7 Using a 5 16 wrench loosen the potentiometer adjustment lock nut See Figure 6 17 4 8 Using a potentiometer adjustment tool or very small flat blade screwdriver electronics type turn the potentiometer adjustment screw until the test module reads from 3 38 to 3 42 volts Then tighten the potentiometer lock nut to 4 6 in Ibs 45 68 N m See Figure 6 18 4 9 Again loosen the actuator lever bolt and rotate the actuator lever counterclockwise until the red LED goes off 4 10 With the actuator lever in this position tighten the actuator lever bolt to 70 80 in lbs This step sequence ensures that the solenoid will not engage with the accelerator pedal in the up position and the park brake set If the red LED is illuminated at this point repeat step 4 9 4 11 Disconnect the Calibration Test Module from the vehicle and reconnect the three wire connector from the potentiometer to the wire harnes
7. 8 Carburetor Throttle Actuation 8 12 Page 19 Adjust the Accelerator Rod Gasoline Vehicles Continued NOTE AFTER THE PEDAL GROUP AND ACCELERATOR ROD ARE ADJUSTED THE FINAL GOV ERNED ENGINE RPM SHOULD BE SET PER SPECIFICATIONS IN SECTION 13 PAGE 13 50 4 5 f the events above occur as they should hold the ball joint at each end of the accelerator rod with pliers and tighten the accelerator rod jam nut against it 4 6 Again check that events occur as described in step 4 4 4 7 Install the electrical box cover Adjust the Accelerator Rod V Glide 36 Volt vehicles and also PowerDrive System 48 and Pow erDrive Plus vehicles serial numbers 9711 564736 and later DANGER BEFORE SERVICING TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSITION TO PREVENT ACCIDENTAL STARTING OF THE VEHICLE DISCONNECT THE BATTERIES AND DISCHARGE THE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES AS INSTRUCTED ON PAGE 6 SEE FIGURE 22 6 PAGE 22 5 IN THE MAINTENANCE AND SER VICE MANUAL THIS WILL PREVENT THE POSSIBILITY OF THE VEHICLE RUNNING OVER YOU WHEN YOU ARE ADJUSTING THE ACCELERATOR ROD 4 1 Remove the wiper switch cover A CAUTION e ADJUST THE ACCELERATOR ROD WIPER SWITCH ARM EXACTLY AS STATED IN STEP 4 2 OR THE WIPER SWITCH COULD BECOME DAMAGED AND NOT OPERATE PROPERLY 4 2 Slowly depress the accelerator pedal fully to the floor and hold
8. JAM NUT BRAIDED GROUND WIRE ae CUT A WAY VIEW OF E AXL GROUND SSS PLATE ON VEHICLES SERIAL NUMBER 9710 563353 AND LATER THE GROUND PLATE IS DELETED AND REPLACED BY A BRAIDED GROUND WIRE AND THE JAM NUT IS POSITIONED BELOW THE VOLTAGE REGULATOR FIGURE 12 59 Page 134 SECTION 13 FE 290 ENGINE GENERAL INFORMATION With the incorporation of the unitized transaxle on 1997 vehicles engine rotation changed from counterclock wise to clockwise Although the change in engine rotation does not change service procedures in the Mainte nance and Service Manual a number of engine parts were changed So that the parts for clockwise rotation engines will not be confused with parts for counterclockwise engines clockwise rotation parts have been marked as described below These descriptions and illustrations do not correspond with descriptions and illustrations in the Maintenance and Service Manual NOTE ENGINE ROTATION CLOCKWISE OR COUNTERCLOCKWISE IS AS VIEWED FROM THE CLUTCH SIDE OF THE ENGINE Fan Housing The baffle plate inside the fan housing for a clockwise engine is located on the right side of the inside surface of the housing as shown below FAN HOUSING FOR UNITIZED ee CLOCKWISE ROTATION ENGINE pe um UL N N BAFFLE PLATE MOUNTING WHEN o VIEWED FROM THE ENGINE SIDE OF THE FAN HOUSING wae of 1997 FE 290 FAN HOUSING
9. NO CONTINUITY REPLACE WIRE FIGURE 1 2 18 The fuse red 10 amp is located in the electrical component box Figure 12 2 Page 83 1 Page 94 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 3 Check that the wires are connected correctly and are tight If they are not rewire or tighten as neces sary Remove the fuse Using a multimeter set on ohms Q place the red probe on one terminal of the fuse and place the black probe on the other terminal of the fuse The reading should be continuity If the reading is incorrect check circuit to determine what caused the fuse to blow and make necessary repairs Then replace the fuse with a new 10 amp fuse Test Procedure 2 Key Switch Starter Circuit A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Remove the center dash assembly See Removing the Key Switch Page 119 Check that the wires are connected correctly and are
10. 2 10 2 1 Page 42 LOOSEN RETAINING NUTS TO REMOVE THROTTLE CABLE FROM ELECTRIC BOX REMOVE FUEL LINE USING A 1 4 NUT DRIVE OR FLAT BLADE SCREWDRIVER FIGURE 10 13 FIGURE 10 14 Use a 1 4 nut driver to loosen the hose clamp and then disconnect the fuel line from the carbure tor Figure 10 13 To prevent spilling of fuel the disconnected end of the line can be pushed onto the impulse nipple of the fuel pump Use a 5 16 nut driver to remove the cover from the electrical component box Then using a 10 mm wrench loosen the hardware securing the accelerator cable to the box Disconnect the cable from the actuator cam and remove it from the box Figure 10 14 Using a 10 mm wrench detach the ground cable from the oil filler tube mounting bracket on the engine cylinder head Figure 10 15 Use an 17 mm wrench to loosen the nuts securing the shifter cable to the shifter cable mounting bracket Then disconnect the shifter cable rod end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket Figure 10 16 Mark for proper reconnection and then disconnect the 6 gauge white wire F2 post 6 gauge black ground wire A2 post and 16 gauge yellow DF wire from starter generator Figure 10 17 Disconnect the engine oil level sending unit wire 18 gauge yellow from the sending unit located on the engine bene
11. Dee ceu ET 121 Neutral Lock out Limit Switch a a a nnn ananas 122 Neutral Lock out Cam a a a a 123 Reverse Warning BUzzer u an a den e a Log a det it 124 Reverse Buzzer Limit Switch uu t et A tt i ee a e e ORE eL dede 124 Oil Warning Eight kau iuit nci meet ceat erp a vate eerie el e e QT ue aiu e eee dd 125 cR 126 SECTION 13 FE 290 ENGINE 135 Use this supplement for current information on the subjects listed below See Section 13 in the 1995 1996 DS Golf Car Maintenance and Service Manual for all other information Generallnformoation eec oe teet over cec elt deo ies me eme e lose darte eld 135 SECTION 13 FE 290 ENGINE CONTINUED Engine Mounting Plate 137 Installation of Remaining Engine Component5s a 137 Engine Removal is uyu ertet ni der e teh tee E Een Eton eE SRAN 137 Engine Assembly uuu tice ce ha Lee EGO eR e ee eden eue EE e ees 137 SECTION 14 FUEL SYSTEM 137 Use this supplement for current information on the subjects listed below See Section 14 in the 1995 1996 DS Golf Car Maintenance and Service Manual for all other information u m n EEE
12. Electric Vehicles 12 SECTION 5 BODY AND TRIM 14 See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 6 ACCELERATOR AND BRAKE PEDAL GROUP 15 Section 6 in this supplement supersedes Section 6 in the 1995 1996 DS Maintenance and Service Manual General Informatio ua uu n u eet tr de nocentem ede te qa dated tuendae 15 Pedal Group Adjustment reniei nennen nnns en aai anA es 16 Pedal Group Disassembly and Assembly nnns rennen 25 SECTION 7 WHEEL BRAKE ASSEMBLIES See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 8 STEERING AND FRONT SUSPENSION See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 9 WHEELS AND TIRES See Section 10 in the 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 10 UNITIZED TRANSAXLE AND GOVERNOR 35 For gasoline vehicles only Section 10 in this supplement supersedes Section 9 and Section 17 in the 1995 1996 DS Maintenance and Service Manual General Information erunt e Aeterna 35 Axle Shattered mnn teat aiv us 37 Removing the Unitized Transaxle 1 u ennt nennen nennen 41 Unitized Transaxle Disassembly u nnne nennen rennes 47 Component Disassembly sn iu Siswa sia aussi aaa aa wakan 51 Component Assembly u a RR Eee sS u usq re kakunqa REP Ep hei Po quas 55 Unitized Transa
13. TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRICAL WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE ENGINE MOUNTING PLATE OR OTHER METAL COMPONENT TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG Accelerator Cable Removal 1 2 Remove the seat from the vehicle Remove the electrical box cover and loosen the cable housing retaining nuts See Figure 14 9 Page 14 10 in the Maintenance and Service Manual Page 140 BY cs CDM a jY REFERENCE EXHAUST SECTION 9 FIGURE 14 11 Disconnect the cable 1 Figure 14 11 from the cam in the electrical box See Figure 14 9 Page 14 10 in the Maintenance and Service Manual Remove the E ring 7 on the spring end of the cable at the accelerator cable bracket 5 Figure 14 11 Pull the cable housing out of the bracket Disconnect the spring 15 from the engine governor arm by rotating it counterclockwise one half turn Remove the cable assembly from the vehicle Figure 14 11 Page 141 13 18 Accelerator Cable In
14. 1 Clean the bearing and seal seats in the axle tube 75 or 76 Figure 10 6 Page 39 2 Place a new seal 72 Figure 10 6 in the axle tube with seal lip facing away from the bearing Use an axle seal tool Club Car Part No 1014162 to press it in until it seats firmly in position Figure 10 8 NOTE THE NEW SEAL CAN BE INSTALLED BY TAPPING THE AXLE SEAL TOOL WITH A MALLET 3 Clean the shaft splines and then insert the shaft splined end first through the seal and into the axle tube Be careful not to damage the seal Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differential side gear Continue advancing the shaft until the bearing seats against the axle tube shoulder Using snap ring pliers install the retaining ring 70 Figure 10 6 in the axle tube See Figure 10 9 Place a 1 4 to 3 8 6 to 10 mm diameter rod against the retaining ring and tap lightly at four to five locations to insure that it is properly seated A WARNING BE SURE THAT THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE IF THE RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS LOSS OF VEHICLE CON TROL COULD RESULT CAUSING SEVERE PERSONAL INJURY BEARING PULLER WEDGE ATTACHMENT PRESS RAM AXLE SEAL FIGURE 10 7 FIGURE 10 8 Page 40
15. Brake shaft bearings 1 Dry Moly Lube Club Car Part No 1012151 Brake Linkage and Pivots 2 Dry Moly Lube Club Car Part No 1012151 Quarterly by Owner or Trained Technician Accelerator push rod pivots and Dry Moly Lube Club Car Part No 1012151 shifter cable pivots Front Suspension 5 fittings Chassis Lube Check fill unitized transaxle to plug 27 oz 8 liter 80 90 WT API Class GL 5 or Annuit by Trained level 80 90 WT AGMA Class EP Gear Lube Technician Only Every 200 rounds or 100 hours of operation Inspect front wheel bearings Chassis Lube Repack as necessary First Change 100 Hours Change engine oil and oil filter 32 oz 97 liter without filter 38 oz 1 16 Additional Change Every liters with filter SAE 30 above 32 F 0 C 400 Rounds or Every 200 or SAE 5W20 below 32 F 0 C API Class Hours of Operation SE SF or SG Oil or higher or Annually Whichever Comes First See Figure 4 1 below LUBRICATION POINTS DS GASOLINE VEHICLE FIGURE 4 1 Page 7 1 9 LUBRICATION ELECTRIC VEHICLES DEI PERIODIC LUBRICATION SCHEDULE ELECTRIC VEHICLES EN REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT Brake shaft bearings 1 Dry Moly Lube Club Car Part No 1012151 Quarterly by Owner or Trained Technician Brake Linkage and Pivots 2 Dry Moly Lube Club C
16. DO NOT ATTEMPT TO SERVICE HOT MOTOR RESISTORS ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG Page 147 13 18 SHOCK ABSORBERS INSPECTING AND REMOVING SHOCK ABSORBERS 1 Check shock absorbers 7 for fluid leakage at the point where the shaft enters the shock absorber body Replace leaking shock absorbers Figure 18 1 2 To remove a shock absorber remove the nut 5 cup washer 9 and rubber bushing 10 from the stem at the top of the shock absorber Figure 18 1 BRAKE CABLE HANGER MOUNTING 1 u m vr AG 0 TYPICAL 2 J FIGURE 18 1 Page 148 3
17. Fan The fan for a clockwise engine is grey in color and marked with an arrow pointing counterclockwise as shown on page 136 fan for counterclockwise engine is black and marked with an arrow pointing clockwise Flywheel The flywheel for a clockwise engine is marked with an arrow pointing counterclockwise and also with the number MF3481 as shown on page 136 Page 135 General Information Continued Camshaft The lobes on the clockwise camshaft are arranged to operate in clockwise direction and the shaft between the lobes is marked with a B as shown below Crankshaft The crankshaft for a clockwise engine has left hand threads at the clutch mounting hole and there is a machined groove in the outside diameter of the counterweight as shown below Crankcase Oil pump oil passages in the clockwise crankcase are different from those in the counterclockwise case The clockwise case has an R stamped into the oil pump cavity as shown below FE 290 CLOCKWISE FLYWHEEL AND FAN FE290 CLOCKWISE CAMSHAFT NUMBER GREY FAN ARROW FLYWHEEL 1997 FE 290 FLYWHEEL AND FAN FE 290 CLOCKWISE UNITIZED CRANKSHAFT CLOCKWISE v GROOVE MACHINED INTO THE CRANKCASE OUTSIDE DIAMETER OF THE COUNTERWEIGHT 1997 FE 290 CRANKSHAFT 1997 FE 290 CRANKCASE Page 136 ENGINE MOUNTING PLATE On page 13 7 in the 1995 1996 Maintenance and Service Manual the reference changes as follows See Re
18. LOOSEN TUBE RETAINER THEN PULL FUEL OVERFLOW TUBE FROM CARBURETOR FIGURE 10 9 FIGURE 10 10 REMOVING THE UNITIZED TRANSAXLE A WARNING TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT THE BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE 1 Disconnect the battery cables negative first See WARNING above 2 Detach all wires hoses etc connecting the powertrain to the vehicle 2 1 Use pliers to expand the hose clamp and then disconnect the carburetor overflow tube from the carburetor Figure 10 10 2 2 Using a 5 16 nut driver disconnect the air intake hose from the carburetor Figure 10 11 2 3 Use pliers to expand hose clamp then disconnect impulse line from fuel pump Figure 10 12 SQUEEZE IMPULSE LINE RETAINER CLIP IN ORDER TO REMOVE LINE REMOVE AIR INTAKE HOSE CLAMP USING A 5 16 NUT DRIVER OR FLAT BLADE U SCREWDRIVER FIGURE 10 11 FIGURE 10 12 Page 41 Removing the Unitized Transaxle Continued EI sss 2 4 2 5 2 6 2 7 2 8 2 9
19. Page 86 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 If buzzer does not function and engine also does not start see Testing the Vehicle Battery Page 87 3 If the engine will start but the reverse buzzer does not function move the forward and reverse lever to reverse and listen for an audible click from the limit switch If there is no click check the switch for proper alignment and switch arm movement 4 If the switch is being activated but the buzzer does not function place the red probe of the multime ter on one terminal and the black probe on the other terminal of the limit switch Without the lever depressed the reading should be no continuity Depress the lever and the reading should be continuity If either reading is incorrect replace the limit switch Test Procedure 19 Reverse Buzzer 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Remove the center dash assembly See Removing the Reverse Warning Buzzer Page 124 3 Check for proper wiring and tight connections Using a multimeter check for continuity through each wire that connects to the reverse buzzer See Figure 12 7 Page 86 If the buzzer will not function when properly wired replace the buzzer Test Procedure 20 Oil Sending Unit 1 Place the neutral
20. S MANUAL FOR PROPER LOCATION OF ALL VEHICLE WARNING DECALS AND MAKE SURE THAT THEY ARE IN PLACE AND ARE EASILY READ ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR RESISTORS ENGINE OR EXHAUST SYSTEMS FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS GASOLINE VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLE
21. See Section 24 Front Wheel Bearings Transaxle Check front wheels for free play Inspect and replace or repack wheel bearings with chassis lube as neces sary See Section 8 Check fill transaxle to plug level See Electric Vehicle Lubrication Chart on Page 8 General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 8 Check all daily weekly monthly quarterly and semi annual items listed above SECTION 5 BODY AND TRIM All information in Section 5 of the 1995 1996 DS Maintenance and Service Manual Club Car Part Number 1019051 01 is current for 1997 However the following CAUTION which is not stated in the manual should also be heeded A CAUTION F A PRESSURE WASHER IS USED TO CLEAN THE VEHICLE DO NOT EXCEED 500 PSI 3448 KPA NOZZLE SHOULD BE SET TO WIDE ANGLE SPRAY Page 14 SECTION 6 ACCELERATOR AND BRAKE PEDAL EE GROUP EJ This supplemental section supersedes Section 6 in the 1995 1996 Maintenance and Service Manual GENERAL INFORMATION A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHIC
22. Spark plug wire is damaged Section 13 Engine Unsuitable fuel or incorrect rich fuel mixture Section 14 Fuel System Igniter failed Section 12 Gasoline Vehicle Electrical System Dirt entering combustion chamber Section 14 Fuel System Rings worn out low cylinder pressure Section 13 Engine Carburetor floods Inlet valve or seat is leaking dirty worn or damaged Section 14 Fuel System Float is damaged or filled with gasoline Section 14 Fuel System Carburetor vent is clogged Section 14 Fuel System Starter fails to operate Neutral lock out cam is in the wrong position Section 12 Gasoline Vehicle Electrical System Neutral lock out circuit Fuse is blown Section 12 Gasoline Vehicle Electrical System Starter circuit Battery is dead Section 12 Gasoline Vehicle Electrical System Starter control circuit is not operating Section 12 Gasoline Vehicle Electrical System Starter circuit Starter generator failed Section 12 Gasoline Vehicle Electrical System Starter generator Troubleshooting Guide Continued on Next Page Page 77 SYMPTOM POSSIBLE CAUSES REFERTO Starter fails to operate continued Starter solenoid failed Section 12 Gasoline Vehicle Electrical System Starter circuit Accelerator limit switch failed Section 12 Gasoline Vehicle Electrical System S
23. pedal shaft Figure 6 20 3 5 Remove the nut 31 and brake stop 22 Figure 6 20 3 6 Lift the pedal assembly 6 up through the floorboard Figure 6 20 Page 26 Installing the Brake Pedal Assembly 1 Install the brake pedal assembly 1 1 From the top side of the floorboard insert the brake pedal weldment assembly 6 Figure 6 20 through the opening in the floor as shown Figure 6 21 Page 27 and install the pedal stop 22 Figure 6 20 on the weldment 1 2 Attach the equalizer rod 26 to the brake pedal weldment assembly 6 as shown Figure 6 20 1 3 Position and attach the brake pedal assembly and mounting blocks 23 to the vehicle frame as shown Tighten the bolts and nuts to 40 60 in Ibs 4 5 7 N m Figure 6 20 See NOTE below NOTE EACH HALF OF EACH MOUNTING BLOCK ASSEMBLY IS MARKED WITH AN A OR B THE HALVES MARKED A SHOULD BE ORIENTED TO THE TOP LEFT HAND AND BOTTOM RIGHT HAND SIDES OF THE BRAKE PEDAL ASSEMBLY AND THE HALVES MARKED B SHOULD BE ORIENTED TO THE TOP RIGHT HAND SIDE AND BOTTOM LEFT HAND SIDE OF THE BRAKE PEDAL ASSEMBLY FIGURE 6 20 PAGE 26 Page 25 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES FIGURE 6 20 1 4 Install the brake cables 14 on the equalizer rod using new cotter pins 16 and the clevis pins 17 that were removed when the brake pedal assembly was disassembled Figure 6 20 Tighten the nut 24 on the eq
24. pertaining to gasoline vehicles SECTION 26 REAR SUSPENSION ELECTRIC VEHICLE See Section 25 in the 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 1 SAFETY To insure the safety of those servicing Club Car DS Golf Cars and to protect the vehicles from possible dam age resulting from improper service or maintenance the procedures in this manual must be followed It is important to note that throughout this manual there are statements which are contained within boxes labeled DANGER WARNING or CAUTION These special statements relate to specific safety issues and must be read understood and heeded before proceeding with procedures There are also boxes labeled NOTE which provide other essential service or maintenance information A DANGER A DANGER INDICATES AN IMMEDIATE HAZARD WHICH WILL RESULT IN SEVERE PER SONAL INJURY OR DEATH A WARNING A WARNING INDICATES AN IMMEDIATE HAZARD WHICH COULD RESULT IN SEVERE PER SONAL INJURY A CAUTION ACAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR PERSONAL INJURY OR DAMAGE TO THE VEHICLE OR OTHER PROPERTY NOTE A NOTE PROVIDES KEY INFORMATION TO MAKE PROCEDURES MORE EASILY UNDER STOOD OR IMPLEMENTED Service technicians should become familiar with the following general safety statements These will be found frequently throughout this manual DANGER GASOLINE FLAMM
25. weekly monthly and quarterly items listed above Check engine oil level change as required See Gas Vehicle Lubrication Chart Page 7 Check for leaks around gaskets fill plugs etc Inspect clean and regap spark plug replace if necessary Engine Air Intake Check air filter element clean or replace Fuel Filters Replace Annual Service by Trained Mechanic Only Every 200 rounds or Front Wheel Bearings 100 hours of operation Check front wheels for free play Inspect and replace or repack wheel bearings with chassis lube as neces sary Starter Generator Unitized Transaxle Check brush length remove excess carbon dust replace as necessary See Section 12 Check fill transaxle to plug level See Gas Vehicle Lubrication Chart on Page 7 General Vehicle Lubricate per Gas Vehicle Lubrication Chart on Page 7 Check all daily weekly monthly quarterly and semi annual items listed above PERIODIC SERVICE ELECTRIC VEHICLES A WARNING F ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH e ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THIS MANUAL PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Accelerator Pedal Ro
26. 10 31 Page 46 Page 45 Removing the Transaxle Continued USING WOODEN BLOCKS PROP ENGINE PAN UP SO THAT IT IS LEVEL WITH FLOOR GRASP BELT MIDWAY BETWEEN DRIVE AND DRIVEN CLUTCHES i DRIVEN CLUTCH DRIVE CLUTCH N FIGURE 10 29 FIGURE 10 30 APROX 6 lt Sa 16 Use a 7 16 wrench to loosen the governor arm retaining bolt then remove the governor arm from the shaft Figure 10 32 See NOTE below NOTE THE GOVERNOR CABLE AND THE ACCELERATOR CABLE REMAIN ATTACHED TO THE GOV ERNOR ARM 17 Use a 3 8 socket to remove the screws securing the governor cable bracket to the transaxle Figure 10 33 18 Use a 3 8 socket to remove the screws securing the accelerator cable bracket to the transaxle Figure 10 34 19 Remove the six bolts mounting the unitized transaxle to the engine 19 1 Use two 14 mm wrenches to remove the two top transaxle mounting bolts one at each upper cor ner of the transaxle mounting plate as shown Figure 10 35 19 2 Remove the two bottom transaxle mounting bolts in the same way the top ones were removed Figure 10 35 19 3 Use one 14 mm wrench to remove the two middle transaxle mounting nuts as shown Figure 10 35 20 Remove the leaf springs wheels and brake assemblies from the transaxle USE A 7 16 WRENCH TO LOOSEN NUT THEN WITH REMOVE 5 16 BOLT GOVERNOR AND ACCELERATOR CABLES STILL ATTACHED AE I REMOVE THE GOVERNOR ARM FROM T
27. 12 7 PAGE 86 The reverse buzzer is a safety warning device that sounds when the vehicle is in reverse Its functions are to remind the operator not to leave the vehicle in reverse and to warn anyone in the area that the vehicle is in reverse The reverse buzzer circuit consists of a reverse buzzer reverse buzzer limit switch key switch the fuse block and connecting wires The battery supplies power through the fuse block and is controlled by the reverse buzzer limit switch that is activated by a cam located on the back of the forward and reverse assembly When the forward and reverse lever is placed in reverse a cam depresses the reverse limit switch closing the circuit The reverse buzzer sounds Page 85 LOW OIL WARNING CIRCUIT FIGURE 12 8 go GROUND Pd FORWARD REVERSE ASSEMBLY f dx za FRAME ore REVERSE BUZZER LIMIT SWITCH FRAME GROUND SWITCH SX A OF Ry REVERSE BUZZER FIGURE 12 7 FIGURE 12 8 The low oil warning circuit consists of an oil sending unit in the engine a dash mounted oil light and connect ing wires The light picks up power from the key switch when the key switch is turned to the ON position When the oil level in the crankcase is low the oil sending unit closes the circuit to the ground and illuminates the oil light NEUTRAL LOCK OUT CIRCUIT FIGURE 12 9 FORWARD REVERSE ASSEMBLY NEUTRAL LOCK OUT LIMIT SWITCH ACCELERATOR S
28. 71 and collar 73 Figure 10 6 off together See Figure 10 7 Page 40 NOTE IT MAY BE NECESSARY TO HEAT THE COLLAR TO REMOVE IT Installing the Axle Bearing 1 If it was removed install the retaining ring 70 on the axle shaft 67 or 68 Figure 10 6 2 Apply two drops of Loctite 271 to the inside of the collar See CAUTION at top of page 39 Page 38 A CAUTION APPLY LOCTITE 271 TO THE INSIDE OF THE COLLAR ONLY NOT TO THE SHAFT SO THAT THE LOCTITE WILL BE PUSHED AWAY FROM THE BEARING AS THE COLLAR AND BEARING ARE PRESSED ON IF LOCTITE GETS ON OR IN THE BEARING THE BEARING MUST BE REPLACED THE COLLAR SHOULD BE REMOVED NO MORE THAN TWO TIMES IF A BEARING IS REMOVED A THIRD TIME THE SHAFT AND COLLAR WILL NOT FIT PROPERLY REFERENCE PASSENGER SIDE SE REFERENCE DRIVER SIDE FIGURE 10 6 Page 39 E Installing the Axle Bearing Continued 3 Place a new sealed bearing 71 and collar 73 on the shaft 67 or 68 Figure 10 6 Page 39 CAUTION IF THE BEARING WAS REMOVED FROM THE SHAFT REPLACE WITH NEW ONE DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT IN STEP 4 THIS COULD DAMAGE THE AXLE SHAFT WHEN THE BEARING AND COLLAR ARE PRESSED ON 4 Place the bearing puller wedge attachment against the collar and press both the bearing and collar on then install the retaining ring 74 INSTALLING THE AXLE SHAFT
29. AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF THE BATTERY WHEN SERVICING THE VEHICLE BATTERY POISON DANGER CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING EXTERNAL FLUSH WITH WATER CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 General Information 1 The DS gasoline vehicle is equipped with a 12 volt low maintenance battery When replacing the bat tery in a Club Car gasoline powered vehicle the new battery must be the same size as the original Page 126 2 Club Car recommends a group 70 side post battery Club Car Part No 1012328 with a 460 cold cranking amp rating and a reserve capacity of 85 minutes The group 70 classification indicates battery size 8 1 4 inches W x 6 1 2 inches D x 7 1 4 inches H It is important to use the proper size to ensure that the battery hold down will fit correctly and will pro
30. AND PAWL B FIGURE 6 4 2 2 With the park brake unlocked measure and note the distance from the top of the accelerator pedal to the floorboard and then lock the park brake See Figure 6 5 Page 18 2 3 With the park brake locked make sure that at least 75 of ratchet tooth length engages the pawl Figure 6 6 Page 18 2 4 With the park brake still locked again measure the distance from the top of the accelerator pedal to the floorboard If the measurement has changed ratchet tooth engagement is too deep and must be adjusted 2 5 If ratchet pawl engagement must be adjusted disconnect the ball joint at the top of the brake brake rod and rotate the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement Reconnect ball joint Figure 6 7 Page 18 2 6 If the accelerator push rod was disconnected from the accelerator pedal reconnect it 3 ADJUST ACCELERATOR PEDAL HEIGHT ALL DS VEHICLES 3 1 Using a 1 2 socket and 1 2 wrench loosen the nut and bolt Figure 6 8 Page 18 securing the accelerator pedal to the pivot plate Clamp the accelerator pedal adjustment tool Club Car Part No 1018710 01 to the accelerator pedal with the end marked accelerator pedal height toward the floorboard then depress the accelerator pedal until the end of the tool rests against the floor board pedal height should be 5 5 8 plus or minus 1 8 Use a rubber strap to hold the pedal in position again
31. AND PULL THE BRUSHES BACK FROM THE CENTER OF THE COMMUTATOR END COVER THE SPRINGS WILL REST ON THE SIDES OF THE BRUSHES AND HELP PREVENT THEM FROM SLIDING TOWARDS THE CENTER FIGURE 12 41 PAGE 110 2 Remove brush covers 29 and 30 screws 25 and lockwashers 26 brush springs 28 and brushes 27 Figure 12 39 See Note below NOTE CLEAN AND INSPECT THE ARMATURE COMMUTATOR AND THE BEARINGS SEE DISASSEM BLY OF STARTER GENERATOR TO SERVICE THE ARMATURE COMMUTATOR PAGE 110 STARTER GENERATOR 7 BRUSH WEAR LINE 7C BRUSH HOLDER FIGURE 12 38 TYPICAL 4 PLACES FIGURE 12 39 Cleaning Inspection and Replacement of Brushes 1 Visually inspect brushes Replace brushes which are cracked or severely chipped 2 There is a wear line on the side of the brush If the end of the brush is within 1 16 inch 1 6 millimeters of the wear line replace all four brushes Figure 12 38 Page 108 Cleaning Inspection and Replacement of Brush Springs A CAUTION WHEN CHECKING BRUSH SPRING TENSION DO NOT PUSH SPRINGS BEYOND THE POINT THEY WOULD NORMALLY BE IF THERE WERE NEW BRUSHES INSTALLED EXERTING EXCES SIVE FORCE OR PUSHING BRUSH SPRINGS BEYOND THEIR NORMAL RESTING POINT WILL DAMAGE SPRINGS 1 Visually inspect springs Replace all four springs if any spring is discolored from heat straw or bluish in color 2 Install the four brushes 27 into their holders and insert the fou
32. CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF THE BATTERY WHEN SERVICING THE VEHICLE BATTERY POISON DANGER CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING EXTERNAL FLUSH WITH WATER CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY Page 128 A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 A CAUTION DO NOT ALLOW BATTERY ACID FROM BATTERY CAPS OR HYDROMETER TO DRIP ONTO THE FRONT OR REAR BODY BATTERY ACID WILL CAUSE PERMANENT BLEMISHES WASH OFF IMMEDIATELY 1 Be sure that the battery has sufficient water to cover the plates by approximately 5 inch 12 7 millime ters and is fully charged prior to beginning the test If water must be added recharge the battery before performing the hydrometer test 2 Remove the vent cap 3 Using a battery thermometer Club Car Part No 1011767 record the elec
33. EXHAUST CAN CAUSE SEVERE BURNS MOVING PARTS KEEP HANDS CLOTHING AND ALL OTHER OBJECTS AWAY FROM MOVING PARTS DO NOT WEAR JEWELRY OR LOOSE CLOTHING SECTION 15 EXHAUST SYSTEM See 1995 1996 DS Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 16 TORQUE CONVERTER GENERAL INFORMATION With the incorporation of the unitized transaxle on 1997 vehicles the engine and therefore the torque con verter assembly rotates clockwise Because of this the take up springs part of item 10 in the drive clutch shown in Figure 16 5 on page 16 7 in the 1995 1996 DS Maintenance and Service Manual are now posi tioned on the opposite sides of the clutch cover 1 ribs Also the drive buttons 7 in the driven clutch shown in Figure 16 16 on page 16 13 in the 1995 1996 DS Maintenance and Service Manual are now oppo site their former positions The following illustrations and instructions supersede those in the 1995 1996 DS Maintenance and Service Manual Page 142 DRIVE CLUTCH DISASSEMBLY 13 18 Drive Clutch Disassembly Continued REMOVE THESE ITEMS FROM RIBS 10 24 SCREW FLAT WASHER a DRIVE BUTTON wo DRIVE BUTTON m TAKE UP SPRING FIGURE 16 8 DRIVE CLUTCH ASSEMBLY DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED FIGURE 16 15 Page 144 Step 13 on page 16 12 in the 1995 1996 Maintenance and Service Manual under the heading DRIVE CLUTCH ASSEMBLY changes as follows 13
34. Figure 12 49 A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 Ce ELECTRICAL OR ai 8 COMPONENT BOX VEHICLES WITH j VEHICLES WITH SERIAL NUMBERS SERIAL NUMBERS LESS THAN GREATER 9710 563353 THAN 9710 563353 FIGURE 12 49 Remove the seat from the rear body Disconnect battery cables as shown Figure 12 1 Page 82 Remove the electrical component box cover R ONST mounting screw 8 Figure 12 49 e 563353 and later Figure 12 49 7 Remove regulator 6 Installing the Voltage Regulator FIGURE 12 49 1 Place the voltage regulator 6 into the electrical component box with the 1 4 inch screw 8 through the regulator Page 118 Remove locknut 1 and jam nut 2 on vehicles prior to serial number 9710 563353 from the regulator Disconnect the red wire from the solenoid and unplug the yellow wire from wire harness 6 Remove 18 gauge black wires 3 and 5 and braided ground wire 4 on vehicles serial number 9710 2 Connect regulator red wire to solenoid and plug in yellow wire to the harness 3 Install black wire 3 and black wire 5 and braided ground wire 4 on vehicles serial number 9710 563353 a
35. GUIDE FIGURE 10 76 Page 64 INSERT THE IDLER GEAR ASSEMBLY INTO CASING BORE GEARS DO NOT MESH FIGURE 10 75 POSITION SHIFTER FORK ON SYNCHRONIZER SLEEVE CUT A WAY VIEW OF SHIFTER FORK AND SYNCHRONIZER GEAR ASSEMBLY BEING INSERTED AS A UNIT INTO CASING FIGURE 10 77 AS YOU INSERT THE SYNCHRONIZER GEAR ASSEMBLY COMPLETE WITH SHIFTER FORK INTO THE CASING SEVERAL GEARS MUST MESH TOGETHER SPUR GEAR AND GOVERNOR GEAR LARGE IDLER GEAR AND SYNCHRONIZER SHIFTER SHIFTER ARM AND THE SHIFTER FORK SLOTTED ARM ALSO MESH FIGURE 10 78 THE EDGES OF THE INPUT DRIVE GEAR AND LARGE INTERMEDIATE GEAR SHOULD BE FLUSH OUTSIDE EDGES OF THE IDLER INTERMEDIATE AND DIFFERENTIAL BEARINGS ARE ON THE SAME PLANE THE SYNCHRONIZER BEARING PROTRUDES SLIGHTLY FIGURE 10 80 SEVERAL GEARS MESH AS YOU INSERT THE INTERMEDIATE GEAR ASSEMBLY THE SMALL GEAR ON THE INTERMEDIATE GEAR ASSEMBLY MESHES WITH THE DIFFERENTIAL RING GEAR INTERMEDIATE GEAR THESE THREE GEARS MESH DIFFERENTIAL RING GEAR SMALL IDLER GEAR FIGURE 10 79 CLEAN MATING SURFACES OF ANY OIL DIRT GREASE OR RESIDUE OF ANY KIND AFTER CLEANING MATING SURFACES APPLY A CONTINUOUS BEAD OF THREE BOND NO 1215 COMPLETELY AROUND THE MATING SURFACE OF THE RIGHT SIDE CASING FIGURE 10 81 Page 65 Unitized Transaxle Assembly Continued 11 3 Duplicate
36. Page 53 onto the splines of the input shaft No par ticular orientation of the sleeve is necessary but toward the short end of the shaft the machined circu lar face surrounding the ends of the internal splines in the sleeve must be flush with the machined lip of the shaft at the ends of the shaft splines See Figure 10 57 2 Install the snap rings 46 Figure 10 43 Page 53 in the sleeve as shown Figure 10 58 NOTE MAKE SURE THAT THE ENDS OF THE SNAP RINGS ARE POSITIONED BETWEEN THE SYN CHRONIZER INSERT SLOTS 3 Install the three synchronizer inserts 48 into the slots in the sleeve as shown Figure 10 43 Page 53 Make sure the notched surfaces of the inserts are facing outward as shown Figure 10 59 4 Install the synchronizer clutch hub 49 Figure 10 43 onto the synchronizer sleeve Make sure that the gear end of the hub is oriented toward the long end of the input shaft as shown Figure 10 60 Page 58 5 On the long end of the shaft install the synchronizer ring 45 Figure 10 43 Page 53 with the smooth collar of the ring towards the clutch hub Make sure that the three notches in the collar mate with the synchronizer inserts in the synchronizer sleeve as shown Figure 10 61 Page 58 Page 57 Synchronizer Gear Assembly Continued 6 Install the thrust washer 41 and two bearings 43 as shown Figure 10 43 Page 53 Install the input gear assembly 52 with the smooth collar toward the sy
37. Push the starter down so it is at the lowest part of its adjustment travel With the starter belt fully in place around the drive clutch pulley this pulley is the one closest the crankcase cover on the engine install the starter belt 3 around the pulley 10 on the end of the starter generator 1 Place the ten sion tool 13 Club Car Part No 1016867 between the starter generator and the starter generator mounting bracket 2 so that the tension tool will lift up the starter generator 4 Install a standard 1 2 inch 12 7 millimeters drive torque wrench 14 into the tension tool 13 Through the access opening in the rear body position the wrench and tension tool as shown Figure 12 48 Pull up on the wrench and tension tool until 70 ft Ibs 95 N m of torque has been applied for a new belt Apply only 40 ft Ibs 54 N m for a previously used belt 5 Tighten the adjustment nut 12 to 12 ft Ibs 16 N m of torque Tighten the two pivot screws 5 and torque nuts 7 to 21 25 ft Ibs 28 5 34 N m Figure 12 48 See CAUTION below and NOTE at top of Page 118 A CAUTION REMOVE TENSION TOOL BEFORE STARTING ENGINE Page 117 Belt Tension Adjustment Continued NOTE IF A BURROUGHS GAUGE IS USED TENSION SHOULD BE ADJUSTED TO 120 LBS FOR A NEW BELT OR 80 100 LBS FOR A PREVIOUSLY USED BELT 6 Reinstall the access panel Figure 12 35 Page 106 VOLTAGE REGULATOR Removing the Voltage Regulator
38. Remove the cotter pin 1 and the clevis pin 2 at the brake lever and brake cable connection and pull the clevis 3 away from the lever Figure 18 3 Detach the brake cable from the shock mount bracket 16 Figure 18 1 5 Remove the nut 5 cup washer 9 and rubber bushing 10 from the lower mounting stem of the shock absorber Figure 18 1 6 Remove the nuts 14 lock washers 13 and the U bolt 11 securing the spring to the transaxle Fig ure 18 1 Remove the shock mount bracket and the U bolt Page 149 13 18 Removing the Mono leaf Springs Continued 7 Remove the bolt 15 and nut 2 attaching the rear spring to the shackle 1 Figure 18 1 Page 148 Remove the nut 2 and bolt 15 attaching the front of the spring to the vehicle frame Figure 18 1 Page 148 and remove the spring Inspect the bushings 4 and spacers 3 in the spring eyes and replace them if they are worn or dam aged Figure 18 1 Page 148 INSTALLING THE MONO LEAF SPRINGS 1 To install the springs reverse the removal procedure See CAUTION below A CAUTION WHEN POSITIONING THE SPRING ON THE TRANSAXLE BE SURE TO INSERT THE LOCAT ING BOLT ON THE SPRING IN THE LOCATING HOLE IN THE TRANSAXLE SADDLE 2 Tighten the nuts on the U bolts to 31 38 ft Ibs 42 51 5 N m THE SNUBBER A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAV
39. STOPS SOUNDING THE CONTROLLER IS DISCHARGED NOTE CONTINUOUSLY VARIABLE POTENTIOMETERS WERE STANDARD ON EARLY 1997 DS POW ERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES ON DS POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NO 9711 564736 AND LATER THE MULTI STEP POTENTIOMETER IS STANDARD Page 15 1 9 PEDAL GROUP ADJUSTMENT EN 1 ADJUST BRAKE PEDAL HEIGHT ALL DS VEHICLES 1 1 To provide slack in the brake cables loosen hex nuts on the brake equalizer rod Figure 6 1 AFTER LOOSENING JAM NUT 31 WITH A 7 16 SOCKET ROTATE PEDAL STOP 22 UPWARD TO DECREASE DISTANCE BETWEEN PEDAL AND FLOORBOARD ROTATE IT DOWNWARD TO INCREASE 00000000 FIGURE 6 2 CORRECT PEDAL POSITION IS 5 3 4 INCHES 14 6 FROM FLOORMAT TO BACK OF BRAKE PEDAL FIGURE 6 3 1 2 Using a 7 16 socket loosen the brake stop jam nut 31 then relieve pedal pressure on the stop by pushing down slightly on the pedal Then adjust the brake stop bumper 22 up or down Fig ure 6 2 Adjusting the bumper upward decreases distance between pedal and floorboard Adjusting the bumper downward increases distance between pedal and floorboard Proper brake pedal height is 5 3 4 inches 14 6 cm plus or minus 1 4 inch 6 cm Figure 6 3 1 3 Ti
40. This section supersedes Sections 9 and 17 in the 1995 1996 DS Maintenance and Service Manual GENERAL INFORMATION All 1997 model gasoline powered DS Golf Cars are equipped with heavy duty fully synchronized Unitized Transaxles The unitized transaxle replaces the transmission transaxle combination that was used previ ously and performs the functions of both utilizing fully synchronized internal gearing to change vehicle direc tion Because the unitized transaxle is used to reverse vehicle direction the engine drive clutch belt and driven clutch rotate in one direction and therefore engine and clutches are not subjected to reversing loads This reduces maintenance requirements on the engine and clutches With the unitized transaxle power is transfered from the engine through the drive clutch the drive belt the driven clutch and then through the unitized transaxle to the wheels A shifter lever connected to a shifter arm on the unitized transaxle is used to change the gears to one of three shift positions forward F neutral N or reverse R Figure 10 1 Page 36 See NOTE below NOTE DURING NORMAL VEHICLE OPERATION A NEUTRAL LOCK OUT FEATURE PREVENTS THE ENGINE FROM RUNNING WHEN THE FORWARD AND REVERSE SWITCH IS IN THE NEUTRAL POSITION SEE NEUTRAL LOCK OUT CIRCUIT SECTION 12 PAGE 12 6 IN THE MAINTE NANCE AND SERVICE MANUAL A SPECIAL NEUTRAL LOCKOUT CAM IS PROVIDED TO ALLOW MAINTENANCE PERSONNEL TO RUN THE ENGI
41. as shown Figure 12 1 Page 82 Page 123 Removing the Neutral Lock out Cam Continued 12 3 Remove the external snap ring 14 E 4 Remove the plastic washer 12 and the spring 13 5 Remove the cam 11 Installing the Neutral Lock out Cam Figure 12 52 1 Install the cam 11 Install the spring 13 and the plastic washer 12 Install the external snap ring 14 onto the shaft Be sure the snap ring is installed in the groove on the shaft Connect battery cables positive cable first Install the seat on the rear body REVERSE WARNING BUZZER Removing the Reverse Warning Buzzer Figure 12 53 1 Disconnect the battery cables as shown Figure 12 1 Page 82 2 Remove the plastic cap covering the screw on each side of the center dash 3 Loosen but do not remove the screw on each side of the center dash panel 4 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out slightly from under edge of cowl brace 5 Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down See NOTE below oar wh NOTE BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH 6 Slide center dash panel up the steering column by snapping out the to
42. available secure a bearing puller Club Car Part No 1012811 to the wedge attachment tool and pull the bearing off of the end of the armature shaft Support the arma ture so that it will not drop when the bearing is removed Figure 12 44 2 Discard the bearings 3 Slide the bearing retainer 32 off of the output end of the shaft Figure 12 42 Page 111 Removing the Field Coils 1 Remove the retaining nut from each field coil terminal and slide the insulator out of the slots in the housing Remove the four pole piece screws from the housing Remove the four pole pieces from inside the housing Remove the field coils from the inside of the housing Figure 12 45 See NOTE below NOTE DO NOT REMOVE THE INSULATORS OR THE FIELD COILS UNLESS ELECTRICAL TEST INDI CATES THAT IT IS NECESSARY FIGURE 12 45 SEE TEST PROCEDURE NO 7 PAGE 99 WEDGE D ATTACHMENT TOOL Z x A 1 2 DIAMETER Lor BEARING SUPPORT ARBOR PULLER INNER RACE ea gx TOOL OF BEARING UN a d ARMATURE aie WEDGE Z USE A 1 2 DIAMETER ARBOR ATTACHMENT TOOL NOTE BEARING IS SECTIONED FOR CLARITY FIGURE 12 44 Visual Inspection of Armature Obvious defects can be seen by examining the armature If an armature has frayed or charred insulation broken wires or thrown solder it is obvious without testing tha
43. for mineral content analysis Vibration Damage The battery hold down should always be tight enough to keep the battery from bouncing Battery life may be severely shortened if the battery hold down is too loose Excessive vibration shortens the life of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced The battery hold down should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry up a cell or cause internal shorts Inspect the hold down bracket for rust corrosion or damage If both ends of the bracket cannot be fastened securely to the main frame replace it with a new stainless steel battery hold down Club Car Part No 1013882 stainless steel flat washers Club Car Part No 1011964 and stainless steel nylon insert locknuts Club Car Part No 1015068 HYDROMETER TEST A hydrometer measures the specific gravity The higher the specific gravity the higher the state of charge of the battery A fully charged battery should read between 1 250 and 1 280 at 80 F Never add acid to the bat tery to obtain a higher specific gravity Figure 12 56 Performing the Hydrometer Test DANGER WEAR A FULL FACE SHIELD WHEN WORKING AROUND A BATTERY BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES
44. it controls the amount of charge going to the battery WHITE STARTER VOLTAGE REGULATOR FIGURE 12 4 ENGINE IGNITION CIRCUIT widi GENERATOR x FRAME GROUND BATTERY The engine ignition circuit is independent of all other circuits except the kill circuit It consists of the ignition coil with internal igniter spark plug RPM limiter and connecting wires Figure 12 5 Page 84 SPARK PLUG IF RPM LIMITER GROUND IGNITION COIL WITH IGNITER ENGINE KILL WIRE BULLET CONNECTOR FIGURE 12 5 ENGINE KILL CIRCUIT FIGURE 12 6 The exciter coil in the ignition coil supplies electrical power for the spark plug therefore the proper way to stop the engine is to run this electrical power to ground by passing the spark plug The engine kill circuit consists of the key switch a kill limit switch that is activated by the accelerator pedal a neutral lock out limit switch that is activated by a cam located on the back of the forward and reverse assem bly and connecting wires The engine can be stopped by releasing the accelerator pedal by turning the key switch to the OFF position or by shifting the forward and reverse assembly to neutral 7 FORWARD REVERSE S E 7 _ ASSEMBLY FRAME CO Ve GROUND FRAME TGS am 1 Seay T i gt Z BED aoe O S KEY GROUND SWITCH W NEUTRAL LOCK OUT LIMIT SWITCH oh KILL LIMIT SWITCH FIGURE 12 6 REVERSE BUZZER CIRCUIT FIGURE
45. it in this position With the acceler ator pedal fully depressed the wiper switch arm brush should be positioned entirely on the last fixed contact It is acceptable for the wiper switch arm to come into contact with the wiper switch housing provided there is no excessive pressure against the housing To check wiper arm pres sure against the housing keep the accelerator pedal fully depressed and disconnect the acceler ator rod from the wiper switch ball stud Then try to reconnect it If the accelerator pedal must be released in order to reconnect the accelerator rod then the wiper switch arm is exerting excessive pressure against the housing proceed to step 4 3 If the accelerator rod can be easily con nected it is correctly adjusted 4 3 If the accelerator rod is not adjusted correctly disconnect it from the ball stud at the wiper switch and manually rotate the bell crank until the wiper switch arm brush is positioned entirely on the last fixed contact 4 4 While holding the accelerator rod with pliers loosen the jam nut 20 and adjust the ball joint 21 sleeve to fit on the wiper switch ball stud with approximately the same number of threads show ing at each end of the rod Then tighten jam nut 20 against the sleeve Figure 6 11 4 5 Depress the accelerator pedal several times and then check to be sure that the wiper switch arm brush is positioned entirely on the eighth fixed contact and that the wiper switch arm is not exert in
46. lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check that the wire is connected correctly and is tight If it is not rewire or tighten as necessary Fig ure 12 8 Page 86 3 Disconnect the wire from the cord connector on the back of the engine that goes to the oil sending unit Using an alligator clip jumper wire connect the wire to the frame Turn the key switch ON closing the circuit The oil light should illuminate If not check the yellow wire for continuity If there is no continuity replace the wire If the wire tests okay then check the oil light See Test Procedure 21 If the oil light does illuminate with the jumper wire the oil sending unit needs to be replaced See Crankcase Cover Removal Section 13 Page 13 24 in the Maintenance and Service Manual Test Procedure 21 Oil Warning Light 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Remove the center dash assembly See Removing the Oil Warning Light Page 125 Page 105 Test Procedure 21 Oil Warning Light Continued 3 4 Check that the wires are connected correctly and are tight If they are not rewire or tighten as neces sary Figure 12 8 Page 86 Disconnect the yellow wire to the oil sending unit from the terminal on the oil light Using an alligator clip jumper wire con
47. m Figure 12 37 Page 108 8 Install the brushes into the holders Place 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 covers 29 in the openings in the commutator end cover 23 Figure 12 39 Page 108 9 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 then install the the lockwasher 40 and M14 nut 41 Tighten the nut to 25 30 ft Ibs 34 41 N m of torque Figure 12 42 Page 111 Installing the Starter Generator Figure 12 48 A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 1 Install the two 3 8 hex head pivot screws 5 into the mounting bracket with the heads of the screws fac ing towards the driver side of the vehicle Position the starter generator in the mounting bracket so that the screws will go through the bracket before going through the starter generator Install a lockwasher 6 early 1997 vehicles only and 3 8 nut 7 onto each screw Tighten the screws and nuts to finger tight Figure 12 48 2 Install the adjustment screw 11
48. parts of the casing are clean and free of any contaminants Make sure that the machined mating surfaces are free of residue and are not scored or damaged in any way Press two new oil seals 13 and 22 Figure 10 36 Page 48 into the left driver side casing and one new oil seal 55 Figure 10 43 Page 53 into the right passenger side casing See Figure 10 68 Page 62 Page 60 THERE IS A DOWEL PIN IN THE RING GEAR ALIGN THE DOWEL PIN WITH DOWEL PIN HOLE IN DIFFERENTIALGEAR CASE APPLY A FEW DROPS OF LOCTITE TO THE ENDS OF THE EIGHT RETAINING BOLTS BEFORE INSTALLING THEM IN SEQUENCE SHOWN BELOW TORQUE RETAINING BOLTS Peer TO 16 20 FT LBS THEN TAP RING GEAR ONTO THE DIFFERENTIAL GEAR CASE DOWEL PIN HOLE FIGURE 10 66 FIGURE 10 67 3 Position the governor gear shaft installation tool Club Car Part No 1019331 01 over the shaft bore in the inside of the left driver side casing and insert the governor gear shaft into the tool long end from the groove first as shown Figure 10 69 Page 62 Make sure the shaft is started into the bore and then using a light hammer carefully tap the governor gear shaft into bore until the end on which you are tapping is flush with the end of the tool 4 Install the washer and then the governor gear and sleeve together onto the governor shaft Figure 10 70 Page 62 Make sure the sleeve is properly positio
49. pedal in the UP position the reading should be no continuity With the accelerator pedal depressed the reading should be continuity If readings are incorrect replace the switch Test Procedure 5 Solenoid 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Remove the electrical component box cover 3 Check that the wires are connected correctly and are tight If they are not rewire or tighten as neces sary Set a multimeter to ohms Q Place the red probe on one of the small posts of the solenoid and place the black probe on the other small post The reading should be 14 to16 ohms If the reading is not within limits replace the solenoid Disconnect the black battery cable from the battery Do not allow the cable to touch the frame or other components of the vehicle Remove the 6 gauge white wire and the 16 gauge red wire from the large post of the solenoid Do not allow the wires to touch the frame or other components of the vehicle Figure 12 21 Set the multimeter to ohms Q Connect the red probe to one of the large posts of the solenoid and connect the black probe to the other large post Figure 12 22 Page 98 6 GAUGE WHITE WIRE ASSEMBLY 16 GAUGE RED WIRE ASSEMBLY SOLENOID N ELECTRICAL COMPONENT FIGURE 12 21 8 Connect the black cable to the battery negati
50. the black wire to common COM terminal the green wire to the normally open NO terminal and the white wire to the normally closed NC terminal of the neutral lock out limit switch 3 Connect battery cables positive cable first 4 Place the forward and reverse lever in the NEUTRAL position The neutral lock out cam should be in the OPERATE position Make sure everyone is clear of the moving parts of the vehicle Turn the key switch to the ON position The engine should not crank when depressing the accelerator If the engine does crank turn off the key switch and re adjust the shift linkage FORWARD AND REVERSE ASSEMBLY J o JA Oo 2 FORWARD AND REVERSE ASSEMBLY FIGURE 12 51 FIGURE 12 52 5 Install the seat on the rear body 6 Test drive the vehicle in both forward and reverse for proper operation NEUTRAL LOCK OUT CAM If the cam lobes have worn to the point where they will no longer actuate the neutral lock out limit switch the cam must be replaced A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 Removing the Neutral Lock out Cam Figure 12 52 1 Remove the seat from the rear body 2 Disconnect the battery wires
51. the narrow bearing 44 wide bearing 45 and input gear 42 onto the shaft The smooth collar of the input gear should be oriented toward the synchronizer ring as shown Figure 10 43 The gear should seat inside the ring Page 58 12 Install thrust plate 41 onto the shaft and the dowel pin 50 into the shaft as shown Figure 10 43 13 Install the spur governor drive gear 40 onto the shaft with either side down Mate the notch in the gear with the dowel pin as shown Figure 10 43 Page 53 EJ 14 Install the spring Belleville washer 39 onto shaft with the raised center toward the end of the shaft 15 Press a new bearing 38 onto the end of the shaft until it seats Figure 10 43 Make sure that the input gears turn freely A CAUTION e APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING SHIFTER FORK ASSEMBLY 1 Install the spring 35 and ball 36 into the shift fork 34 as shown Figure 10 43 Page 53 2 Use a very small phillips head screwdriver to depress the ball and spring while inserting shift rod 33 into the shift fork Remove screwdriver when the shift rod is inserted far enough for it to depress the ball and spring then continue to insert rod until the ball is positioned in the middle detent on the rod DIFFERENTIAL GEAR CASE ASSEMBLY 1 If the bearings 79 were removed press new ones onto the differential gear carrier c
52. 0 107 4 Remove cable from the vehicle REFERENCE TRANSMISSION SHIFTER LEVER REFERENCE TRANSMISSION CABLE SUPPORT BRACKET FIGURE 10 107 INSTALLATION OF THE FORWARD AND REVERSE SHIFTER CABLE 1 From the forward and reverse switch route the cable toward the driver side of the vehicle so that it lies against the side of the front body and runs between the battery and intake expansion chamber turns 90 runs over the fender and then turns again in front of the rear post of the body support to connect with the shifter arm on the transaxle Figure 10 105 Page 71 2 Secure the cable with retaining nut 22 and washer 23 on each side of the shifter cable support bracket at the transaxle Figure 10 107 Page 72 3 Secure the cable with retaining nut 22 and washer 23 on each side of the shifter cable support bracket at the forward and reverse assembly Figure 10 107 4 Install the ball joint socket 20 on the shifter lever ball stud 19 on the transaxle Figure 10 107 5 Install the ball joint socket 2 on the forward and reverse shifter assembly ball stud 3 Figure 10 107 ADJUSTMENT OF THE FORWARD AND REVERSE SHIFTER CABLE With the shifter lever of the transmission in the neutral position Figure 10 106 Page 71 the forward and reverse handle 21 Figure 10 107 should be straight up For minor adjustments the nut 1 may be loos ened and the ball joint 2 rotated in the proper direction to g
53. 014162 Club Car Part No 1019331 01 UNITIZED TRANSAXLE LUBRICATION There are two plugs located on the right driven clutch side of the unitized transaxle Figure 10 2 When the vehicle is on a level surface the upper plug is used as a lubricant level indicator The lubricant level should be even with the bottom of this upper plug hole The lower plug is used for draining lubricant from the transaxle When draining lubricant the upper plug should be removed also to allow the lubricant to drain faster Be sure the drain plug is cleaned and reinstalled before filling the transaxle with new lubricant Tighten the plug to 18 25 ft lbs 24 34 N m Use a funnel when filling the transaxle through the lubricant level indicator hole Fill with 27 oz 8 liter 80 90 WT API Class GL or 80 90 WT AGMA Class 5 EP gear lubricant FIGURE 10 3 FIGURE 10 4 AXLE SHAFT Removal of the unitized transaxle is not required for servicing or replacing of the axle shafts axle bearings and axle shaft oil seals If the unitized transaxle is to be removed from the vehicle then do not remove the wheels axle shafts or axle tubes first Instructions for removing the unitized transaxle from the vehicle begin on page 41 See NOTE below NOTE DO NOT REMOVE THE WHEELS AXLE SHAFTS OR AXLE TUBES IF THE UNITIZED TRAN SAXLE IS TO BE REMOVED FROM THE VEHICLE SEE PAGE 41 FOR TRANSAXLE REMOVAL PROCEDURES REMOVING THE AXLE SHAFT 1 Place chocks at th
54. 1 4 ohms replace the coil Page 102 A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 DATA HOLD PATROL T A AC DC 500V A AC DC 500V MAX A nii 250V MAX A 250V MAX ACV n LI PRIMARY COIL SECONDARY COIL FIGURE 12 30 FIGURE 12 31 4 Using a multimeter set on ohms Q measure the secondary coil resistance Place the red probe of the meter on the plug lead 3 and place the black probe on the primary wire terminal connector 2 Figure 12 31 5 If the resistance is not within 6 0 11 0 k ohms Q replace the coil 6 The first five steps will find 9096 of the bad coils Some coils may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the coil and then run the engine If the engine runs properly keep the new coil in the circuit NOTE BECAUSE THE IGNITER IS LOCATED WITHIN THE COIL HOUSING AND IS IN PARALLEL WITH THE COIL IT CANNOT BE TESTED SEPARATELY HOWEVER IF THE RPM LIMITER TEST PROCEDURE 12 IS GOOD AND THERE IS NO CURRENT TO THE SPARK PLUG LEAD IT CAN BE ASSUMED THAT EITHER THE COIL OR THE IGNI
55. 2 Page 83 3 Depress the accelerator pedal to make sure that the switch is being actuated when the pedal is released 4 Connect battery cables positive cable first 5 Install the seat on the rear body TYPICAL 2 PLACES aces BLACK WIRE ASSEMBLY TYPICAL 2 PLACES FIGURE 12 50 KILL LIMIT SWITCH Removing the Kill Limit Switch Figure 12 50 1 Remove seat from body 2 Disconnect battery wires as shown Figure 12 1 Page 82 3 Remove electrical component box cover 1 Page 121 Removing the Kill Limit Switch Continued A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 Remove the two nuts 9 and washers 10 that secure the accelerator starter limit switch 11 Do not disconnect the wires Disconnect the two white black wires and the black wire from the kill limit switch 12 Remove the kill limit switch 12 Installing the Kill Limit Switch Figure 12 50 Page 121 1 2 Install the kill limit switch 12 onto the two screws 16 Connect the two white black wires to the common COM terminal and the black wire to the normally open NO terminal of the kill limit switch 12 Install the accelerator s
56. 28 If the reading is lower than 14 7 volts and not rising and the starter generator is good or if the reading is over 15 3 volts and continues to rise replace voltage regulator Figure 12 27 VOLTAGE REGULATOR IGNITION GAP TEST TOOL SOLENOID SPARK PLUG BATTERY FIGURE 12 27 FIGURE 12 28 Test Procedure 11 Ignition Spark NOTE LEAVE THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 11 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Page 101 Test Procedure 11 Ignition Spark Continued 2 Remove the plug wire from the spark plug Using an ignition spark gap test tool Thexton 404 or equivalent check for correct spark Figure 12 28 Page 101 2 1 Adjust the tester probes to approximately 18 000 volts 18 Kv setting Connect the tester to the spark plug wire and connect the alligator clip to the frame 2 2 Turn the key switch to the ON position and crank the engine by depressing the accelerator There should be a strong blue spark between the probes of the spark gap tester If there is no spark or if the spark is a faint yellow or white color test components of the ignition circuit If the spark gap tester tool indicates a strong blue spark it is possible the spark plug has failed inter nally Replace the spark plug with a new part and test the engine for prope
57. 31 inch 0 8 millimeter Dielectric strength 500 VAC for one minute Armature insulation resistance 0 2MQ at 500 VDC Starter field coil resistance 0 006 0 01 Q Generator field coil resistance 4 5 5 5 Page 114 Assembly of the Starter Generator 1 Place the field coil inside of the housing The two insulators that look the same fit into the slots next to the F1 and F2 markings on the outside of the housing The insulator that looks different slides into the slot next to the DF marking After the insulators are seated in the slots install the threaded terminals through the wire connectors and then through the insulators Install a flat washer and a lockwasher onto each threaded terminal on the outside of the housing Use a nut to secure the washers and insu lator to the housing Tighten nuts to 43 52 in Ibs 4 8 5 9 N m Figure 12 45 Page 113 A CAUTION ROUTE THE FIELD TERMINAL WIRES SO THAT THEY WILL NOT CONTACT THE ARMATURE 2 Install the four pole pieces into the housing Use the four screws to secure pole pieces to the inside of the housing to retain the field wires Tighten screws to 9 ft Ibs 12 N m Figure 12 45 Page 113 METER READS 10 00 Tni DATA HOLD acipc 500V A gt 250V MAX ARMATURE SHAFT FIGURE 12 47 3 Slide the bearing retainer onto the output end of the armature shaft 33 so that it will hold the outside of the be
58. 5 mph 19 24 kph 12 15 mph 19 24 kph 12 15 mph 19 24 kph 12 15 mph 19 24 kph Clearance Circle diameter 17 6 533 cm 17 68 533 cm 17 6 533 cm 17 6 533 cm Braking Distance At 12 mph 19 kph Page 4 14 427 cm 14 427 cm 14 427 cm 14 427 cm SECTION 3 GENERAL INFORMATION Because continuously variable potentiometers were used on some early 1997 DS PowerDrive System 48 and PowerDrive Plus Golf Cars the Pre Operation Checklist on Page 3 2 in the 1995 1996 DS Maintenance and Service Manual should read as follows PRE OPERATION CHECKLIST Your CLUB CAR has been thoroughly inspected and adjusted at the factory and also by your CLUB CAR distributor dealer However upon arrival of your new CLUB CAR s you should become familiar with its con trols and operation and carefully inspect each vehicle to be satisfied that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect your new vehicle Any problems should be corrected only by your CLUB CAR distributor dealer or a trained technician General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight On the DS Gasoline vehicle check all hose clamps for tight fit as well as the starter belt for tightness Warning Labels Check to ensure that all warning and operation labels are in p
59. 995 1996 DS Golf Car Maintenance and Service Manual you may obtain one from your Club Car dealer or distributor This supplement and the manual should be thoroughly studied prior to servicing the vehicle The procedures provided must be properly implemented and the NOTES CAUTIONS WARNINGS and DANGER statements must be heeded This supplement and the manual were written for the vehicle mechanic who already possesses basic knowledge and skills in electrical and mechanical repair If the mechanic does not have such basic knowledge and skills attempted service or repairs to the vehicle may render it unsafe For this reason we advise that all repairs and or service be performed by an autho rized Club Car distributor dealer representative or by a Club Car factory trained mechanic This supplement in conjunction with the maintenance and service manual covers all aspects of DS Golf Car service However unique situations do sometimes arise when servicing golf cars If it appears that a service question is not answered in this supplement or in the manual you may write to us or contact a Club Car tech nical service representative by phone at 706 863 3000 ext 580 A WARNING READ SECTION 1 SAFETY BEFORE ATTEMPTING ANY SERVICE ON THIS VEHICLE BEFORE SERVICING VEHICLE READ COMPLETE SECTION S AND ANY REFERENCED INFORMATION RELEVANT TO SERVICE OR REPAIR TO BE PERFORMED 1996 Club Car Inc Club Car Armorflex PowerDrive Powe
60. A 1 4 NUT DRIVER OR FLAT BLADE SCREWDRIVER FIGURE 10 100 CONNECT IMPULSE LINE AND SQUEEZE CLAMP IN ORDER TO POSITION IT CONNECT AIR INTAKE HOSE AND TIGHTEN CLAMP USING A 5 16 NUT DRIVER OR FLAT BLADE SCREWDRIVER FIGURE 10 102 FIGURE 10 103 Page 70 CONNECT TUBE TO CARBURETOR SQUEEZE CLAMP TO POSITION IT FIGURE 10 104 FORWARD AND REVERSE SHIFTER CABLE If the forward and reverse shifter cable is jammed or is damaged in any way it must be replaced A WARNING WHEN MAKING TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE KEY DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST DISCONNECT BATTERY AS SHOWN FIGURE 12 1 PAGE 82 REMOVE SPARK PLUG WIRE CLEAN FORWARD AND REVERSE SHIFTER CABLE CONNECTIONS BEFORE DISASSEMBLY SEE SAFETY WARNINGS PAGES 1 AND 2 REMOVAL OF THE FORWARD AND REVERSE SHIFTER CABLE FIGURE 10 107 INTAKE EXPANSION CHAMBER SHIFTER ARM SHIFTER SHIFTER LEVER BATTERY CABLE FIGURE 10 105 FIGURE 10 106 1 Remove the ball joint socket 2 from the forward and reverse shifter assembly ball stud 3 Figure 10 107 Page 72 Page 71 Removal of the Forward and Reverse Shifter Cable Continued 2 Remove the ball joint socket 20 from the shifter arm ball stud 19 on the transaxle Figure 10 107 EN 3 Loosen the retaining nuts 22 on both ends of the cable Figure 1
61. ABLE EXPLOSIVE DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY FROM THE VEHICLE SERVICE AREA DO NOT OPERATE IN AN ENCLOSED AREA WITHOUT PROPER VENTILATION ENGINE PRO DUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POISON BATTERY EXPLOSIVE GASES DO NOT SMOKE KEEP SPARKS AND FLAMES AWAY VEN TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR FULL FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES BATTERY POISON CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING ANTIDOTES EXTERNAL FLUSH WITH WATER CALL A PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR FIFTEEN MINUTES CALL PHYSICIAN IMMEDIATELY Page 1 General Safety Statements Continued A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL IMPROPER USE OF THIS VEHICLE OR FAILURE TO MAINTAIN IT PROPERLY COULD RESULT IN DECREASED PERFORMANCE OR SEVERE PERSONAL INJURY ANY MODIFICATION OR CHANGE TO THE VEHICLE WHICH AFFECTS THE STABILITY OR INCREASES THE SPEED BEYOND FACTORY SPECIFICATIONS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CHECK THE OWNER
62. AL position and chock the wheels 2 Remove the center dash assembly See Removing the Key Switch Page 119 3 Check that the wires are connected correctly and are tight If they are not rewire or tighten as neces sary 4 Place the red probe of the multimeter on the M terminal of the key switch and the black probe Page 104 on the M terminal With the key switch turned OFF the reading should be continuity With the key switch turned ON the reading should be no continuity If either reading is incorrect replace the key switch Test Procedure 17 Fuse The fuse red 10 amp is located in the electrical component box See Removing the Fuse Page 120 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Remove the cover on the electrical component box Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 4 Remove the fuse Using a multimeter set on ohms Q place the red probe on one fuse terminal and the black probe on the other fuse terminal The reading should be continuity If the reading is incorrect determine what caused the fuse to blow and replace it with a new one of proper load rating e Test Procedure 18 Reverse Buzzer Limit Switch Limit switch is located on the forward and reverse assembly red white and orange wires are connected to it Figure 12 7
63. ALLING THE SNUBBER 1 To install the snubber reverse the removal procedure REFERENCE ENGINE SECTION 13 TYPICAL 2 PLACES REFERENCE UNITIZED TRANSAXLE SECTION 10 FIGURE 18 4 Page 151 Page 152 SECTION 19A ELECTRICAL SYSTEM V GLIDE 36 VOLT VEHICLE See Section 19 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 19B ELECTRICAL COMPONENTS V GLIDE 36 VOLT VEHICLE See Section 19B of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 20A ELECTRICAL SYSTEM POWERDRIVE SYSTEM 48 VEHICLE See Section 20A of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 20B ELECTRICAL COMPONENTS POWERDRIVE SYSTEM 48 VEHICLE See Section 20B of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 21A ELECTRICAL SYSTEM POWERDRIVE PLUS VEHICLE See Section 21A of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 21B ELECTRICAL COMPONENTS POWERDRIVE PLUS VEHICLE See Section 21B of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 22 BATTERIES See Section 22 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 Page 153 19 25 SECTION 23A ACCU POWER BATTERY EE CHARGER See Section 23A of the 1995 1996 Maintenance and Se
64. ATTERY USING ANOTHER BATTERY AND JUMPER CABLES GROUND STRAPS VEHICLE FRAME SEAT BACK SUPPORT THE ENGINE GROUND IS ATTACHED TO THE OIL FILLER BRACKET FRAME I BEAM FIGURE 12 57 FIGURE 12 58 A WARNING F GROUND STRAPS ARE NOT SECURELY CONNECTED TO FRAME AND IN THE PROPER ORI ENTATION A POTENTIAL FIRE HAZARD WILL EXIST BE SURE ALL GROUND CONNECTIONS ARE SECURELY CONNECTED AT ALL TIMES There are three ground straps on the DS Gasoline which ground the electrical system to the frame 1 One of the straps is attached to the A2 terminal of the starter generator and to the frame seat support Figure 12 57 2 The engine ground is attached to the oil filler bracket on the engine and to the frame Figure 12 58 3 Athird ground plate is in the bottom of the electrical component box where the bolt secures the voltage regulator to the box The other end of this ground plate attaches through the side of the electrical box and is bolted into the frame Figure 12 59 See NOTE at top of Page 134 Be sure all these ground straps are securely connected at both ends of each strap Page 133 Ground Straps Continued NOTE VEHICLES SERIAL NUMBER 9710 563353 AND GREATER DO NOT HAVE A GROUND PLATE UNDER THE VOLTAGE REGULATOR IN THE ELECTRICAL COMPONENT BOX INSTEAD A BRAIDED GROUND WIRE ATTACHES TO THE VOLTAGE REGULATOR MOUNTING BOLT AND GROUNDS TO THE VEHICLE FRAME AT THE SAME PLACE AS THE BATTERY GROUND
65. CE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL e ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES e TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING Page 35 Unitized Transaxle General Information Continued TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEV
66. CE THE VEHICLE WHILE IT IS RUNNING HOT DO NOT ATTEMPT TO SERVICE HOT MOTOR RESISTORS ENGINE OR EXHAUST SYSTEM FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE BURNS e ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS GASOLINE VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT ELECTRIC VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE DISCONNECT BATTERIES AS SHOWN IN THE MAINTENANCE AND SERVICE MANUAL FIGURE 22 5 PAGE 22 5 FOR V GLIDE VEHICLES OR FIGURE 22 6 PAGE 22 5 FOR POWERDRIVE VEHICLES THEN DIS CHARGE THE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED Page 6 LUBRICATION GASOLINE VEHICLES PERIODIC LUBRICATION SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE PLACE RECOMMENDED LUBRICANT
67. Club Car 1997 MAINTENANCE SERVICE SUPPLEMENT isis NES m ii he DS GOLF CARS GASOLINE ELECTRIC MANUAL NUMBER 1019345 04 PRINT CODE 0197C0398A USING THIS SUPPLEMENT The following pages are supplemental to the 1995 1996 DS Golf Car Maintenance and Service Manual Club Car Part No 1019051 01 This supplement documents only those sections of the manual requiring changes or additions describing features and procedures specific to 1997 DS Golf Cars All other information in the 1995 1996 Maintenance and Service Manual pertaining to DS Golf Cars unless noted as specific to another particular vehicle applies to 1997 DS Golf Cars as well Sections 2 4 6 9 for gasoline vehicles only 11 12 17 and 18 in the maintenance and service manual have been entirely superseded by sections in this supplement This supplement also includes updates to information in Sections 3 13 14 and 16 All other sections in the maintenance and service manual are unchanged With the exception of sec tions 9 10 25 and 26 the placement of sections in this supplement corresponds to the placement of sec tions in the maintenance and service manual References in this supplement refer to information elsewhere within the supplement unless they state specifically that they refer to the 1995 1996 Maintenance and Ser vice Manual or other publication for example See Figure 12 50 Page 12 37 in the Maintenance and Ser vice Manual If you do not have a 1
68. DES OF AND NUTS VEHICLE THEN D INSTALL WASHERS AND NUTS ON BOLTS TORQUE BOLTS TO 12 18 FT LBS FIGURE 10 92 FIGURE 10 93 Page 68 CONNECT SHOCK ABSORBERS TO LOWER MOUNTS 20 21 22 23 24 25 26 t CONNECT WIRE D WHITE BLACK i B WIRE BLACK d WIRE C IGNITION i FIGURE 10 94 CONNECT YELLOW WIRE CONNECT GROUND WIRE AT A2 TERMINAL CONNECT OIL SENDING _ UNIT WIRE WHITE WIRE FIGURE 10 96 FIGURE 10 97 Connect the engine kill switch wire 18 gauge white black stripe to the bullet connector at the lower right front of the engine Figure 10 95 Connect the engine oil level sending unit wire 18 gauge yellow to the sending unit located on the engine beneath the muffler Figure 10 96 Connect 6 gauge white wire to the F2 post the 6 gauge black ground wire to the A2 post and the 16 gauge yellow wire to the DF post on the starter generator Figure 10 97 Position the shifter cable in the shifter cable mounting bracket on the transaxle and use two 11 16 wrenches to tighten the mounting nuts Then connect the shifter cable rod end to the shifter arm Fig ure 10 98 Page 70 Attach the ground cable to the mounting screw on the oil filler tube mounting bracket on the engine cyl inder head Figure 10 99 Page 70 Tighten with a 10 mm wrench Connect the a
69. E KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRICAL WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE ENGINE MOUNTING PLATE OR OTHER METAL COMPONENT TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG REMOVING THE SNUBBER 1 Support the drive train with blocks under the engine mounting plate so that the snubber is raised slightly and does not rest on the vehicle frame Use a 1 2 wrench and 1 2 socket to remove the two bolts 12 and two nuts 13 securing the snubber bracket to the engine mounting plate Figure 18 4 then remove the snubber and bracket from the vehicle Pull the snubber from the bracket and replace it with a new one Page 150 INST
70. E NEUTRAL POSITION TO PREVENT ACCIDENTAL STARTING OF THE ENGINE DISCONNECT THE BATTERY CABLES NEGATIVE FIRST THIS WILL PREVENT THE POSSIBILITY OF THE VEHICLE RUNNING OVER YOU WHEN YOU ARE ADJUSTING THE ACCELERATOR ROD 4 1 Remove the electrical box cover 4 2 Disconnect the accelerator rod at the accelerator pedal then loosen the jam nuts 20 and adjust the length of the rod 19 Figure 6 11 Page 21 to obtain an accelerator cable cam position of 15 17 as shown Figure 6 10 See CAUTION below A CAUTION AFTER ACCELERATOR ROD ADJUSTMENT MAKE SURE THAT APPROXIMATELY THE SAME NUMBER OF THREADS IS EXPOSED AT EACH END OF THE ROD F THE LEVER ON THE LIMIT SWITCH IN THE ELECTRICAL BOX IS BENT REPLACE THE LIMIT SWITCH WHEN LOOSENING OR TIGHTENING JAM NUTS ON THE ACCELERATOR ROD WHEN ONE END IS DISCONNECTED HOLD THE DISCONNECTED BALL JOINT SLEEVE WITH PLIERS 15 TO 17 TOP VIEW OF THE ELECTRICAL COMPONENT BOX o FIGURE 6 10 4 3 Reconnect the accelerator rod at the accelerator pedal 4 4 Before tightening the jam nuts on the accelerator rod set the park brake to the first ratchet and pawl position Depress the accelerator pedal and make sure that the following events occur in the exact order shown See NOTE at the top of Page 20 EVENT APPROXIMATE PEDAL TRAVEL REFERENCE ONLY Park Brake Release 2 4 Solenoid Activation 4
71. EN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE ENGINE MOUNTING PLATE OR OTHER METAL COMPONENT HOT DO NOT ATTEMPT TO SERVICE HOT ENGINE OR EXHAUST CAN CAUSE SEVERE BURNS ALWAYS ALLOW ENGINE AND EXHAUST TO COOL PRIOR TO SERVICING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST AS SHOWN FIGURE 12 1 PAGE 82 DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG Page 81 E Electrical System Gasoline Vehicles Continued EN A CAUTION e BEFORE REMOVAL AND DISASSEMBLY CLEAN THE ENGINE ANY DIRT ENTERING THE ENGINE CARBURETOR OR OTHER PARTS WILL WORK AS AN ABRASIVE AND SHORTEN THE LIFE OF THE ENGINE FOR THE SAME REASON BEFORE INSTALLING A NEW PART CLEAN OFF ANY DUST OR METAL FILINGS GENERAL INFORMATION 4 FRONT OF VEHICLE REMOVE NEGATIVE CABLE FIRST REMOVE BOTH OF THESE BATTERY CABLES BEFORE WORKING ON VEHICLE FIGURE 12 1 The electrical syst
72. ENERATOR Removal of the Starter Generator 1 2 Remove access panel from the body Figure 12 35 Disconnect the wires from the starter generator 1 Mark wires before disconnecting Loosen the pivot nuts 7 and bolts 5 Figure 12 36 Remove the mounting adjustment nut 12 washer 9 and bolt 11 Lower the starter generator and slip the belt 4 off the pulley 10 Figure 12 36 See NOTE below NOTE e SEE FIGURE 12 36 BELOW ON SOME EARLY 1997 VEHICLES THE BOLT 5 WAS INSERTED FROM INSIDE THE BRACKET 2 AND A NUT AND LOCK WASHER INSTALLED OUTSIDE THE BRACKET WERE USED INSTEAD OF THE LOCK NUT 7 SEE NOTE ABOVE FRAME CONNECTION FIGURE 12 36 4 Support the starter generator so that when the pivot bolts are removed the starter generator will not fall to the ground Remove the two pivot nuts 7 lockwashers 6 if present and bolts 5 from the mount ing bracket 5 Remove the starter generator up through the access opening Page 107 12 Disassembly of the Starter Generator to Service the Brushes 1 Remove the two bolts 20 and washers 21 and 22 and pull commutator end cover 23 free of starter housing 24 Figure 12 37 See NOTE below NOTE IF THE BRUSHES ARE NOT REMOVED CONTACT BETWEEN THE BRUSHES AND COMMUTA TOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD POSSI BLY DAMAGE THE BRUSHES LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN THE BRUSHES
73. ENT DAMAGE TO THE MATING SEAL SURFACES OF THE CASING USE CARE WHEN SEPARATING THE HALVES Page 47 Unitized Transaxle Disassembly Continued NOTE TO SEPARATE THE SECTIONS IT MAY BE NECESSARY TO TAP LIGHTLY WITH A RUBBER MALLET ON THE SPLINE OF THE INPUT PINION FIGURE 10 36 Page 48 7 Turn the case section containing the gearing on edge as shown Figure 10 37 While holding it in this position gently rock all of the gear assemblies to loosen them slightly in their seating A CAUTION TO PREVENT DAMAGE TO THE GEARS USE EXTREME CARE WHEN HANDLING THEM 12 13 15 HOLD CASING UPRIGHT AND GENTLY ROCK EACH GEAR ASSEMBLY UNTIL ALL ARE SLIGHTLY LOOSENED IN THEIR SEATINGS DIFFERENTIAL GEAR CASE ASSEMBLY WHILE GENTLY ROCKING DIFFERENTIAL GEAR CASE PULL IT FROM ITS SEATING FIGURE 10 37 FIGURE 10 38 When all of the gear assemblies are slightly loosened remove the differential gear case assembly by gently rocking it while pulling it from the casing Figure 10 38 Continue to rock and loosen the remaining gear assemblies until the intermediate gear assembly can be removed from the casing Figure 10 39 Page 50 Then remove the idler shaft assembly Remove the synchronizer gear assembly and shift fork assembly as a unit from the casing Figure 10 39 Page 50 Use a seal puller Club Car Part No 1012809 or rolling wedge bar to remove the input shaft oil seal from t
74. ER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS LUBRICANT SHOULD BE LEVEL WITH BOTTOM OF LEVEL INDICATOR SHIFTER L ARM BN N SHIFTER LEVER FIGURE 10 1 FIGURE 10 2 TOOLS REQUIRED FOR THIS SECTION Hydraulic Floorjack or Chain Hoist 1 4 Diameter Drift or Metal Rod 1 2 Open End Wrench Jackstands 2 Small Ball Peen Hammer 9 16 Open End Wrench Hydraulic Press Wooden or Rubber Mallet 11 16 Open End Wrench Bench Vise Ratchet Wrench 3 8 Drive 10 mm Open End Wrench Standard Slip Joint Pliers Torque Wrench 3 8 Drive 14 mm Open End Wrenches 2 Small External Snap Ring Pliers 3 8 Socket 3 8 Drive 17 mm Open End Wrench 90 Internal Snap Ring Pliers 7 16 Socket 3 8 Drive Small Flat Blade Screwdriver Feeler Gauge 1 2 Socket 3 8 Drive Medium Flat Blade Screwdrivers 2 Seal Puller Club Car Part No 1012809 9 16 Socket 3 8 Drive Small Phillips Head Screwdriver 16 Rolling Wedge Bar 5 8 Socket 3 8 Drive 1 4 Nut Driver Page 36 TOOLS CONTINUED Small Punch or Scratch Awl 12 mm Socket 3 8 Drive 5 16 Nut Driver 12 to 18 Straight Edge 7 16 Open End Wrench Small Knife or Wire Snippers Bearing Puller Wedge Attachment Club Car Axle Seal Tool Club Car Part No Governor Gear Shaft Installation Tool Part No 1012812 1
75. FETY WARNINGS ON PAGE 81 TESTING THE ENGINE IGNITION CIRCUIT Use the chart below Figure 12 13 as a starting point for troubleshooting problems with the engine ignition circuit ENGINE CRANKS CAR WILL NOT RUN CHECK SPARK USING SPARK TEST TOOL TEST PROCEDURE 11 GOOD SPARK REPLACE SPARK PLUG DISCONNECT ENGINE KILL WIRE ENGINE RUNS ENGINE DOES NOT RUN GOOD SPARK NO SPARK CHECK FUEL SYSTEM CHECK FOR CHECK IGNITER SEE SECTION 14 GROUNDED WIRE TEST PROCEDURE 13 TEST PROCEDURE 8 CHECK CHECK RPM LIMITER COMPRESSION REPAIR OR REPLACE TEST PROCEDURE 12 SEE SECTION 13 PAGE 13 50 IN MAINTENANCE AND SERVICE MANUAL CHECK PLUG GAP TEST PROCEDURE 11 CHECK COIL TEST PROCEDURE 13 FIGURE 12 13 TESTING THE ENGINE KILL CIRCUIT Use the chart on page 90 Figure 12 14 and the chart on page 91 Figure 12 15 as starting points for trou bleshooting problems with the engine kill circuit See DANGER and WARNING at top of page 90 Page 89 Circuit Testing Continued A DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES
76. FLOOR USE A HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE 6 Raise the vehicle just enough to relieve tension from the leaf springs then remove the bolts securing the leaf springs to the shackles Figure 10 23 Page 44 7 Remove the bolts securing the leaf springs to their front mounts Figure 10 24 Page 44 Page 43 Removing the Transaxle Continued POSITION FLOORJACK UNDER BUMPER SUPPORT DISCONNECT SHOCK ABSORBERS FROM LOWER MOUNTS FIGURE 10 21 FIGURE 10 22 8 Continue raising the vehicle until the rear bumper is higher than the top of the unitized transmission high enough to allow the transaxle and engine to be rolled under it and out of the vehicle Figure 10 25 9 Position jackstands adjusted to support the vehicle at this height under the frame cross member between the leaf spring mounts and side stringers just forward of each rear wheel Lower the floorjack to allow the jackstands to support the vehicle Figure 10 26 10 Pull the floorjack from beneath the vehicle and move it away 11 Lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor Figure 10 27 Now the powertrain should be completely disconnected from the vehicle and resti
77. Figure 14 11 Governor Cable Installation and Adjustment 1 6 Install the cable onto the governor cable transmission bracket 10 and the engine bracket 11 and attach an E ring 7 at each end Figure 14 11 Install the clevis pin 8 and spring cotter 9 through the clevis and carburetor throttle at the carburetor Figure 14 11 Install the clevis pin 8 and spring cotter 9 through the rear clevis and governor lever arm With the governor lever arm loose on the governor shaft use a flat blade screwdriver to turn the gover nor arm shaft counterclockwise until it stops Then pull the governor lever arm rearward until the carbu retor throttle is in the wide open throttle WOT position While holding the arm and shaft in the fully counterclockwise position tighten the governor arm lever nut to 36 in Ibs 4 0 N m Check governed speed adjustment as instructed on Page 14 14 in the Maintenance amp Service Manual ACCELERATOR CABLE A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI
78. Fully charge the battery prior to storage 4 Store in a cool area The colder the area in which the battery is stored the less the battery will self dis charge A battery stored at O F will discharge very little over a four month period A battery stored at 80 F will have to be recharged every few weeks 5 Check the state of charge periodically A battery that is discharged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the battery should be recharged See WARNING at top of Page 133 Page 132 A WARNING IF THE BATTERY IS FROZEN OR THE CONTAINER IS BULGED DISCARD BATTERY A FRO ZEN BATTERY CAN EXPLODE 6 The frequency of recharging required will depend on the temperature of the storage area but it is rec ommended that the battery be monitored for state of charge every month Also if the storage area is unheated in a cold climate and recharge is required it is recommended that the area be heated to at least 60 F prior to charge The battery will not charge effectively in cold temperatures for the same rea sons that it does not discharge as rapidly in cold temperatures JUMP STARTING THE BATTERY The vehicle is equipped with a starter generator The generator is not designed to charge a dead battery If the vehicle battery has become discharged it must be charged using a properly rated automotive type charger A WARNING DO NOT JUMP START A VEHICLE WITH A DEAD B
79. HE SHAFT WASHER LEAVE CABLE CONNECTED LEAVE CABLE CONNECTED FIGURE 10 31 FIGURE 10 32 Page 46 USE A 3 8 SOCKET OR WRENCH TO REMOVE TWO SCREWS HOLDING ACCELERATOR CABLE RETAINING BRACKET USE A 3 8 WRENCH OR SOCKET TO REMOVE TWO SCREWS HOLDING GOVER NOR CABLE BRACKET FIGURE 10 34 TRANSAXLE MOUNTING lt M 00 BOLT AND NUT TYPICAL 4 PLACES j 4 WOODEN BLOCKS FIGURE 10 35 UNITIZED TRANSAXLE DISASSEMBLY 1 Remove the drain plug and gasket Drain and dispose of the oil properly Figure 10 2 Page 36 2 Using 90 internal snap ring pliers remove the internal retaining rings 74 Figure 10 6 Page 39 from the axle tubes See Figure 10 3 Page 37 3 Pull the axles 67 and 68 out of the axle tubes Figure 10 6 Page 39 4 Using a 17mm wrench or socket remove seven bolts 77 with lock washers mounting each axle tube to the transaxle casing Figure 10 6 Page 39 Then remove the axle tubes from the transaxle casing NOTE IT MAY BE NECESSARY TO TAP THE AXLE TUBE WITH A RUBBER MALLET TO BREAK IT FREE FROM THE TRANSAXLE CASING 5 Using a 12 mm wrench or socket remove the fifteen bolts 27 that hold the transaxle housing together Figure 10 36 Page 48 6 Pull the housing apart making sure that all gear assemblies inside the transaxle stay together in one either side of the casing See CAUTION below and NOTE at top of page 48 A CAUTION TO PREV
80. HICLES REGULAR INTERVAL SERVICE Semi annual Service by Trained Mechanic Only Every 100 rounds or 50 hours of operation Batteries Check specific gravity electrolyte level and on charge voltage See Section 22 Brake System Electrical Wiring Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Check brake pedal free play Adjust as necessary See Section 6 Check brake shoes replace if necessary Lubricate slide plates with graphite See Section 7 Check for cracked or worn insulation Forward and Reverse Switch Check condition of contacts and wire connections Make sure connections are tight Front Wheel Alignment and Camber Check and adjust as required See Section 8 General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 8 Check all daily weekly monthly and quarterly items listed above Annual Service by Trained Mechanic Only Every 200 rounds or 100 hours of operation Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for proper operation See Performance Inspec tion Page 3 2 DS Maintenance amp Service Manual Wiper switch type only Remove cover and check contacts for burns excessive heat or arcing check brush for wear Batteries Perform discharge test See Section 22 Motor Check motor brushes replace as necessary
81. ICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Wash battery top with baking soda water solution Battery See Section 22 Check brake cables for damage replace as required Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Check brake pedal free play Adjust as necessary See Section 6 Brake System Monthly Service by Owner Make sure that both ground wires are tight or Trained Mechanic and properly connected Engine Check engine oil level change as required See Gas Vehicle Lubrication Chart on Page 7 Exhaust System Check for leaks Check for wear and damage Tires Check air pressure and adjust as necessary See Vehicle Capacities Chart on Page 9 Check all daily and weekly items listed above Check engine oil level change as required Engine See Gas Vehicle Lubrication Chart on Page 7 Engine Air Intake Hose Check clamps for tightness check hose for cracks Check for proper operation adjust as necessary Accelerator Pedal Rod See Section 6 Quarterly Service by Owner or Trained Mechanic Accelerator Governor Linkage and Cables Check for proper operation adjust as necessary Lubricate per Gas Vehicle Lubrication Chart Steering on Page 7 Lubricate per Gas Vehicle Lubrication Chart General Vehicle on Page 7 Check all daily weekly and monthly item
82. IELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine does not start Spark plug is partially fouled or in poor Section 13 Engine easily condition Spark plug wire is damaged Section 13 Engine Loose wire connection at Section 12 Gasoline Vehicle Electrical igniter unit System Troubleshooting Guide Continue
83. ING INTERMEDIATE GEAR ASSEMBLY FIGURE 10 40 USE A SMALL CHISEL OR SIMILAR TOOL TO PRY OUT THE PIVOT ARM OIL SEAL SF D OIL FLOW GUIDE N VAS FIGURE 10 41 FIGURE 10 42 Page 50 COMPONENT DISASSEMBLY DISASSEMBLE THE GOVERNOR GEAR NOTE IT IS NECESSARY TO DISASSEMBLE THE GOVERNOR GEAR ASSEMBLY IN ORDER TO REIN STALL IT INTO THE TRANSAXLE CASING 1 Secure the governor gear assembly in a vise as shown Figure 10 45 Page 54 2 Use two small screwdrivers to pry the gear and fly weight off of the shaft as shown Figure 10 45 DISASSEMBLE THE DIFFERENTIAL GEAR CASE ASSEMBLY A CAUTION MARK PARTS FOR IDENTIFICATION AS THEY ARE DISASSEMBLED PARTS MUST BE REAS SEMBLED IN THEIR ORIGINAL LOCATIONS AND ORIENTATIONS 1 Use a 12mm wrench or socket to remove eight ring gear retaining bolts 80 Figure 10 6 Page 39 then remove the ring gear from the assembly It may be necessary to tap the ring gear off with a wooden or rubber mallet Figure 10 46 Page 54 See NOTE below NOTE BECAUSE LOCTITE WAS APPLIED TO THE BOLTS WHEN THE DIFFERENTIAL GEAR CASE WAS ASSEMBLED IT MAY BE NECESSARY TO PLACE THE ASSEMBLY IN A VISE WHEN REMOVING THE BOLTS 2 Pull the cover 87 and thrust plate 86 from the differential gear carrier case Figure 10 6 Page 39 3 Remove the differential gear 90 from the differential gear carrier case Figure 10 6 Page 39 4 Remove
84. ION WITH BRUSH SPRING FIGURE 12 41 Page 110 Disassembly of the Starter Generator to Service Armature Commutator Continued 2 To separate armature 33 from output end cover 36 remove nut 41 lockwasher 40 pulley 39 shaft key 34 spacer 37 and bearing retainer screws 43 Figure 12 42 EJ Clean and Inspect the Bearings 1 Using a clean cloth wipe the carbon dust off of the two bearings Inspect bearings by spinning them by hand and checking for both axial A and radial B play Figure 12 43 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnormal color change in the metal of the bearing Bearings should be replaced if there is extreme wear or pitting on the balls or on the rolling surfaces Do not remove the bearings unless they are to be replaced TYPICAL 3 PLACES Starter Generator with a keyed shaft FIGURE 12 42 FIGURE 12 43 Page 111 12 Removing the Bearings EN A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE ARMATURE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF 1 Place the wedge attachment tool Club Car Part No 1012812 between the bearing and the armature Make sure the wedge attachment tool is supporting the inner race of the bearing but is not contacting the armature shaft If a press is not
85. ISASSEMBLE THE IDLER SHAFT ASSEMBLY 1 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 66 Fig ure 10 43 Page 53 and the small gear on the idler shaft then press the bearing off the shaft as shown Figure 10 52 Page 56 A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF 2 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing and the larger gear on the idler shaft then press the bearing off the shaft as shown Figure 10 53 Page 56 A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF Page 54 INSPECT UNITIZED TRANSAXLE COMPONENTS BJ 1 Clean all of the component parts of the transaxle in a high flash point solvent and then dry them Inspect all components for excessive wear or damage 2 Inspect all bearings by spinning them by hand Check the bearings for excessive axial A and radial B play Figure 10 54 Page 56 Replace bearings if they do not spin smoothly if they are noisy or if they have excessive play Replace bearings if they are rusted worn cracked pitted or discolored 3 Gears should be inspected for tooth surface damage or fractures 4 Synchronizer ring teeth should be inspected for severe wear fractures or other damage 5 Using
86. Install the remaining four mounting bolts and four nuts one bolt and nut at each corner of the mounting plate Use two 14 mm wrenches to tighten them 4 Torque the four corner nuts with bolts to 27 33 ft lbs 36 6 44 7 N m Torque the two center nuts on the studs to 15 18 ft lbs 20 3 24 4 N m 5 Install the accelerator cable bracket on transaxle casing Use a 3 8 socket to install the mounting screws Figure 10 87 6 Install the governor cable bracket on transaxle casing Use a 3 8 socket to install the mounting screws Figure 10 88 7 Install governor arm on governor shaft Figure 10 89 Use a 7 16 wrench to tighten the retaining bolt 8 Install the key onto the input shaft Figure 10 90 Page 68 9 Position the driven clutch on the transaxle and install the washer yellow side facing out and mounting bolt Figure 10 90 Use a 1 2 wrench to tighten the mounting bolt to 12 14 ft lbs 16 3 19 N m 10 Install the drive belt See Torque Converter Section 16 Page 16 4 in Maintenance Manual 11 Remove the blocks from under the engine and roll the drive train into position under the vehicle Then lift the front of the drive train and place the snubber into the snubber bracket in the vehicle frame Fig ure 10 91 Page 68 USE A 3 8 SOCKET OR WRENCH TO INSTALL MOUNTING TWO ACCELERATOR CABLE RETAINING BRACKET MOUNTING SCREWS BLOCKS la S AN MOUNTING NUT ON TYPICAL 2 PLACES 3 FIGURE 10 87 USE A 7 16 WRE
87. Install the three drive button take up springs 10 Figure 16 5 Page 143 on the ribs of the clutch cover The springs must be installed on the right sides of the button mounting posts when looking into the interior of the clutch cover with the rib at the 12 o clock position as shown See Figure 16 15 FIGURE 16 16 Page 145 USING EXTERNAL SNAP RING PLIERS REMOVE RETAINING RING 13 18 Drive Clutch Assembly Continued FIGURE 16 18 FIGURE 16 19 ASSEMBLY OF THE DRIVEN CLUTCH Step 6 on page 16 16 in the 1995 1996 Maintenance and Service Manual under the heading ASSEMBLY OF THE DRIVEN CLUTCH changes as follows 6 Place the clutch assembly in a press and position the cam press tool Club Car Part No 1018091 01 on the cam as shown Figure 16 21 this supplement Hold the fixed face assembly and rotate the moveable face assembly 1 one third of a turn clockwise then press the cam 2 onto the fixed face assembly FIRMLY ROTATE MOVABLE FACE CAM PRESS TOOL ASSEMBLY 1 1 3 OF A TURN CLOCKWISE THEN PRESS CAM 2 PS J ON FIXED FACE N ASSEMBLY 3 O FIGURE 16 21 Page 146 SECTION 17 TRANSMISSION Because the unitized transaxle which takes the place of both the transaxle and transmission used on earlier gasoline vehicles was incorporated in 1997 DS gasoline vehicles Section 17 and Secti
88. L WARNING LIGHT LOW OIL WARNING LIGHT DOES NOT ILLUMINATE ILLUMINATES CONTINUITY REPLACE OIL SENDING UNIT REPLACE LOW OIL WARNING LIGHT FIGURE 12 17 TESTING THE NEUTRAL LOCK OUT CIRCUIT Use the chart on page 94 Figure 12 18 as a starting point for troubleshooting the neutral lock out circuit See DANGER below and WARNING at the top of page 94 DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON Page 93 Circuit Testing Continued A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 TEST PROCEDURES Test Procedure 1 Fuse ENGINE WILL CRANK WHEN SHIFTER IS IN NEUTRAL POSITION CHECK NEUTRAL LOCK OUT LIMIT SWITCH TEST PROCEDURE 6 INCORRECT CONTINUITY READING CORRECT CONTINUITY READING REPLACE LIMIT SWITCH CHECK CONNECTION OF BLACK WIRE WIRE CORRECTLY CONNECTED WIRE INCORRECTLY CONNECTED CHECK CONTINUITY OF BLACK WIRE TEST PROCEDURE 8 RECONNECT WIRE
89. LE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE GASOLINE VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT ELECTRIC VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF VEHICLE DISCONNECT BATTERIES AS SHOWN IN FIGURE 22 5 OR FIGURE 22 6 PAGE 22 5 IN THE MAINTENANCE amp SERVICE MANUAL THEN DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER
90. 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 6 25 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 6 19 Page 24 7 Install the spring retainer 12 on the pivot rod Figure 6 19 Page 24 POTENTIOMETER ASSEMBLY CUT A WAY VIEW THROUGH COVER DEPRESS BRAKE PEDAL ACTUATOR POTENTIOMETER LEVER 17 HOUSING ASSEMBLY 21 RATCHET POINTED TOWARDS REAR OF VEHICLE D ROTATE RATCHET CLOCKWISE Ji s NL RGSS y POTENTIOMETER FLAT BLADE LEVER 27 SCREWDRIVER FIGURE 6 25 FIGURE 6 26 8 Slide the pivot rod toward the passenger side of the vehicle until approximately one half of the length of the pivot rod splines is exposed Figure 6 19 Page 24 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 6 26 The ratchet should now rotate freely on the rod 10 Rotate the ratchet clockwise until it touches the park brake pawl then slid
91. N TRY AGAIN INTERIOR WASHER GOVERNOR ARM EXTERIOR WASHER 2 INSERT SHIFTER SHAFT FROM INSIDE OF LEFT SIDE CASING INSIDE VIEW OF LEFT SIDE CASTING COTTER PIN FIGURE 10 72 FIGURE 10 73 10 Install and thread to finger tight the fifteen bolts 27 Figure 10 36 Page 48 that secure the left and right sides of the casing together Then in sequence shown tighten the bolts to 15 18 ft Ibs 20 3 24 4 N m See Figure 10 82 Page 66 11 Install the axle tubes 75 and 76 on the transaxle casing Figure 10 6 Page 39 11 1 Make sure that the mating surfaces of the axle tubes and the transaxle casing are clean and free of oil grease or residue of any kind 11 2 Apply a continuous bead of Three Bond No 1215 around the opening on the mating surface of the right side axle tube as shown Figure 10 83 Page 66 Then position the axle tube on the right side of the transaxle casing as shown and install eight mounting bolts 77 with lock washers 78 Figure 10 6 Page 39 finger tight In the sequence shown tighten the bolts to 33 39 ft lbs 40 7 48 7 N m Figure 10 84 Page 66 Page 63 KUN Unitized Transaxle Assembly Continued INSTALL DIFFERENTIAL GEAR ASSEMBLY INTO BORE IN THE LEFT SIDE CASE FIGURE 10 74 PLACE A DROP OF CYANOACRYLATE ADHESIVE SUPER GLUE IN EACH OF THE OIL GUIDE SLOTS MATE TABS ON OIL GUIDE WITH SLOTS IN CASING IN INSERT OIL
92. NCH TO INSTALL THE TIGHTEN THE RETAINING BOLT GOVERNOR ARM ON THE GOVERNOR USE A 3 8 WRENCH OR SOCKET TO INSTALL TWO GOVERNOR CABLE BRACKET MOUNTING SCREWS FIGURE 10 88 FIGURE 10 89 Page 67 Unitized Transaxle Installation Continued ROLL POWERTRAIN UNDER VEHICLE THEN LIFT SNUBBER INTO THE SNUBBER BRACKET SNUBBER SNUBBER BRACKET FIGURE 10 90 FIGURE 10 91 12 Position the floorjack under the trailer hitch bracket and raise the jack high enough to support the vehi cle Make sure the vehicle is stable on the jack then remove the jackstands 13 After the jackstands are removed lower the vehicle to approximately its normal height Then position the leaf springs in the front spring mounts and install the bolts washers and nuts Figure 10 92 14 Using the floorjack adjust vehicle height to position the leaf springs for mounting in the shackles Then install the mounting bolts washers and nuts Figure 10 93 15 Position shocks in the shock mounts and install cushions mounting washers and nuts Figure 10 94 16 Connect the brake cables See Page 147 POSITION FLOORJACK UNDER TRAILER HITCH TRAILER HITCH BRACKET THEN BRACKET LOWER VEHICLE UNTIL FRONT SPRING AND SHACKLES ARE IN ALIGNMENT CONTINUE USING FLOORJACK TO LOWER OR RAISE THE VEHICLE IN ORDER TO ALIGN THE REAR SHACKLES INSERT BOLTS THROUGH AND LEAF SPRINGS LEAF SPRINGS AND BEFORE INSTALLING FRONT MOUNTS ON BOLTS WASHERS BOTH SI
93. NE IN NEUTRAL FOR CERTAIN TESTS AND MAINTENANCE PROCEDURES WHEN THE NEUTRAL LOCK OUT CAM IS IN THE SERVICE POSITION THE VEHICLE WILL RUN WHEN THE FORWARD AND REVERSE SWITCH IS IN THE NEUTRAL POSITION BUT WILL NOT RUN WHEN THE FORWARD AND REVERSE SWITCH IS IN THE FORWARD OR REVERSE POSITION SEE NEUTRAL LOCK OUT CIRCUIT SECTION 12 PAGE 12 6 IN THE MAINTE NANCE AND SERVICE MANUAL The unitized transaxle is extremely durable and should require very little service under normal operating con ditions The vehicle should always be stopped before changing vehicle direction The only service required on the unitized transaxle is to maintain proper lubricant level See Gasoline Vehicle Lubrication Page 7 in this supplement Under normal operating conditions weekly adjustment to the system should not be required The governor system is a flyweight type and measures ground speed of the vehicle It is mounted inside the unitized transaxle and is driven by transmission gears Because the governor is mounted inside the trans axle it is protected from abuse and damage that is common to externally mounted governor systems If any of the governor linkage is removed in order to service other components readjustment of the governor link age is required See Governor Cable Installation and Adjustment Page 140 in this supplement A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVI
94. NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 Before testing the electrical circuits to determine the source of an electrical problem test the vehicle battery to determine whether or not it is the source of the problem A hydrometer multimeter and 160 ampere load tester will be required Testing the Vehicle Battery 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check for loose or corroded battery terminal connections Clean tighten and replace connections as necessary 3 Take hydrometer readings of all six cells If there is a 50 or more point difference between any two cells recharge the battery and then check the specific gravity again If there is still a 50 point differ ence replace the bat
95. OLINE VEHICLES This section supersedes Section 12 in the 1995 1996 DS Maintenance and Service Manual A DANGER GASOLINE VAPORS FLAMMABLE DO NOT SMOKE KEEP SPARKS FLAMES CIGA RETTES AWAY TOOLS WIRES AND METAL OBJECTS CAN CAUSE SPARKS WHEN SHORTED ACROSS A BATTERY INSULATED TOOLS SHOULD BE USED EXTREME CARE SHOULD BE TAKEN WHEN DISCONNECTING OR CONNECTING BATTERY WHEN WIRES ARE DISCONNECTED BE SURE TO KEEP THEM AWAY FROM BATTERY POSTS AND OTHER WIRES SERVICE ONLY IN WELL VENTILATED AREAS DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERY TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERY OR ELECTRICAL CON NECTIONS FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WH
96. OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 ENGINE WILL NOT STOP RUNNING WHEN FOOT IS OFF ACCELERATOR PEDAL CHECK KILL LIMIT SWITCH TEST PROCEDURE 15 INCORRECT CORRECT CONTINUITY READING CONTINUITY READING REPLACE LIMIT SWITCH CHECK WIRE CONNECTION OF CIRCUIT WIRES WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CHECK CONTINUITY CONNECT WIRES CORRECTLY OF CIRCUIT WIRES EU es lS TEST PROCEDURE 8 NO CONTINUITY REPLACE WIRE FIGURE 12 14 Page 90 ENGINE WILL NOT STOP RUNNING WHEN KEY SWITCH IS IN OFF POSITION CHECK KEY SWITCH TEST PROCEDURE 16 INCORRECT CORRECT CONTINUITY READING CONTINUITY READING REPLACE KEY SWITCH CHECK CONNECTIONS OF CIRCUIT WIRING WIRES CORRECTLY WIRES INCORRECTLY CONNECTED CONNECTED CONNECT WIRES CORRECTLY CHECK CONTINUITY OF CIRCUIT WIRES TEST PROCEDURE 8 NO CONTINUITY REPLACE WIRE ENGINE WILL NOT STOP RUNNING WHEN SHIFTER IS INNEUTRAL POSITION CHECK NEUTRAL LOCK OUT LIMIT SWITCH TEST PROCEDURE 6
97. PAGE 81 Remove electrical component box cover Figure 12 50 Disconnect all the wires from the solenoid Figure 12 2 Page 83 Remove the two screws that secure the solenoid in place 6 Remove the solenoid ak wo Installing the Solenoid 1 Position the solenoid in the electrical component box and install the two mounting screws Tighten the screws to 12 18 in Ibs 1 36 1 7 N m 2 Connect the 6 gauge white wire and the 16 gauge red wire from the voltage regulator on the large post on the solenoid Connect the 6 gauge red wire and the 10 gauge red wire from the fuse block on the other large post on the solenoid Install the retaining nuts and tighten to 55 65 in Ibs 6 2 7 35 N m Figure 12 2 Page 83 3 Connect the 18 gauge blue wire from the key switch to the small post on the solenoid Connect the 18 gauge orange wire from the accelerator starter limit switch to the other small post on the solenoid Install the retaining nuts and tighten to 18 25 in Ibs 2 0 2 8 N m Figure 12 2 Page 83 4 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw Re connect the battery wires 5 Install the seat on the rear body FUSE Removing the Fuse 1 Remove seat from body 2 Disconnect battery wires as shown Figure 12 1 Page 82 3 Remove electrical component box cover 4 Remove the fuse from the fuse block Installing the Fuse 1 Install the fuse Use a 10 amp fuse onl
98. Remove the nut 5 cup washer 9 and rubber bushing 10 from lower mounting stem Figure 18 1 4 Compress the shock absorber to remove it INSTALLING SHOCK ABSORBERS 1 To install reverse the removal procedure 2 On the upper and lower shock absorber mounting stems tighten the nuts until the rubber bushing expands to the size of the cup washer MONO LEAF SPRINGS REMOVING THE MONO LEAF SPRINGS 1 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Position jackstands under the frame cross member between the spring mount and the side stringer just forward of each rear wheel Lower the vehicle to let the jackstands support the vehicle Figure 18 2 See WARNING below A WARNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE FIGURE 18 2 FIGURE 18 3 2 Place a floorjack under the transaxle differential casing to support but not lift the drivetrain Raise it just enough to relieve tension on the shock absorbers without compressing them 3 Remove the tire and wheel assembly on the side from which the spring is to be removed 4
99. S OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE OR OTHER METAL COMPONENT ELECTRIC VEHICLES ONLY TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE DISCONNECT BATTERIES AS SHOWN IN FIGURE 22 5 OR 22 6 PAGE 22 5 IN THE MAINTENANCE AND SERVICE MANUAL THEN DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES AS FOLLOWS TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE REVERSE POSITION SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE REVERSE WARNING BUZZER CAN NO LONGER BE HEARD WHEN THE BUZZER STOPS SOUNDING THE CONTROLLER IS DISCHARGED Page 2 SECTION 2 VEHICLE SPECIFICATIONS Club Car Inc reserves the right to change specifications and design of either gasoline or electric vehicles at any time without notice and without obligation to make these changes on units previously sold ps POWERDRIVE POWERDRIVE DS SPECIFICATIONS GASOLINE SYSTEM 48 PLUS 36 VOLT ELECTRIC ELECTRIC ELECTRIC POWER SOURCE Engine 4 cycle OHV 286 cc 9 0 hp rated single cylinder air cooled with pressure lubrication system Drive Motor Direct drive 48 volts DC series wound 3 1 hp Drive Motor Direct drive 48 volts DC shunt wound 3 2 hp Drive Motor Direct drive 36 volts DC series wound 2 97 hp Fuel System Side draft carburetor with float bowl fixed jets fuel filter and impulse fuel pump Governor Aut
100. T LOSE THESE INSERTS 6 Remove the three synchronizer inserts 48 Figure 10 43 from the synchronizer sleeve 7 Press the synchronizer sleeve 47 from the input shaft Figure 10 43 DISASSEMBLE THE INTERMEDIATE GEAR ASSEMBLY 1 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 38 and shaft gear 56 Figure 10 43 then press bearing off the shaft as shown Figure 10 51 Page 56 A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF Page 52 O V CR M lt lt A REFERENCE DRIVER SIDE CASE REFERENCE PASSENGER SIDE CASE FIGURE 10 43 2 Place the bearing puller wedge attachment under the bearing 59 and press the bearing from the shaft Figure 10 43 See CAUTION at bottom of page 52 3 Press the gear 43 Figure 10 57 then remove the key 56 from the shaft 58 Page 53 ELN Component Disassembly Continued PRY GOVERNOR GEAR ASSY FROM ITS SHAFT USING TWO SMALL SCREWDRIVERS USING A HAMMER AND A DRIFT LIGHTLY TAP GOVERNOR GEAR AND WASHER FROM CASTING FIGURE 10 45 USING A 12MM WRENCH THEN TURN DIFFERENTIAL OR SOCKET REMOVE GEAR ASSEMBLY OVER AND EIGHT RING GEAR TAP AROUND RING GEAR WITH RETAINING BOLTS A RUBBER OR WOODEN MALLET TO LOOSEN AND REMOVE THE RING GEAR FIGURE 10 46 D
101. TARTER LIMIT SWITCH GROUND SOLENOID FIGURE 12 9 The neutral lock out circuit prevents the operator from starting the vehicle in neutral Also if the vehicle is started in forward or reverse and then shifted to neutral the engine automatically stops running The neutral lock out circuit consists of a limit switch that is located on the forward and reverse assembly and is activated by a neutral lock out cam a limit switch that is located in the electrical component box and is acti vated by the accelerator pedal and the connecting wires The neutral lock out cam is a feature included for the convenience of the trained and experienced mechanic If the neutral lock out cam is pulled out approximately 3 8 inch 10 millimeters and rotated one half turn until it snaps back into place the vehicle will be in the SERVICE position Figure 12 10 This allows the mechanic to run the engine in neutral for certain maintenance procedures With the cam in the SERVICE position the engine will start in neutral If the forward and reverse switch is shifted to either the forward or reverse position the engine will stop running To put the vehicle back in the OPERATE position pull the cam out approximately 3 8 inch 10 millimeters and rotate one half turn until it snaps back into place Figure 12 11 Page 86 NEUTRAL FORWARD NEUTRAL FORWARD SERVICE POSITION OPERATE POSITION FIGURE 12 10 FIGURE 12 11 CIRCUIT TESTING DANGER DO
102. TE IN POSITION ROTATE COVER AND POSITION IT ON CARRIER CASE FIGURE 10 64 FIGURE 10 65 Position the other thrust plate 85 and idler gear 89 Figure 10 6 Page 39 in the carrier case as shown Figure 10 64 and then continue to drive the pin through them and the wall of the carrier case until the ends of the pin are flush with the sides of the carrier case Figure 10 64 Install the thrust plate 86 and idler gear 90 into the carrier case cover 87 Figure 10 6 Page 39 as shown Figure 10 65 Then while holding the thrust plate and idler gear in place position the car rier case cover on the carrier case as shown Figure 10 65 Position the ring gear 81 Figure 10 6 Page 39 on the carrier case visually aligning the dowel hole in the ring gear with the pin in the carrier Then using a wooden mallet tap the ring gear into place on the dowel pin as shown Figure 10 66 Apply Loctite 277 on the threads of the eight mounting bolts and install them through the ring gear carrier case and into the carrier case cover Then tighten the bolts to 16 20 ft Ibs 21 7 27 1 N m in the sequence shown Figure 10 67 GOVERNOR GEAR ASSEMBLY The governor gear is not assembled independently from the unitized transaxle casing The gear shaft is installed into the casing and then the rest of the assembly is installed on the shaft Proceed with unitized transaxle assembly UNITIZED TRANSAXLE ASSEMBLY 1 Make sure that both
103. TER IS BAD IN EITHER CASE THE COIL ASSEMBLY MUST BE REPLACED Test Procedure 14 Disconnected Kill Wire 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Remove the spark plug wire from the spark plug Using an ignition spark gap test tool Thexton 4049 or equivalent check for correct spark to plug Adjust the tester probes to approximately to 18 000 volts 18 Kv setting Connect the tester to the spark plug wire and connect the alligator clip to the top of the spark plug Figure 12 28 Page 101 Page 103 Test Procedure 14 Disconnected Kill Wire Continued 3 Disconnect engine kill white black wire at bullet connector located by the RPM limiter Figure 12 32 4 With the neutral lock out cam placed in the SERVICE position and the wheels chocked connect the 6 gauge red wire to the positive post on the battery then connect the 6 gauge black wire to the negative post Turn the key switch to the ON position In a well ventilated area depress the accelerator to start the engine 5 If there is a strong blue spark across the spark gap tester tool and the engine begins to run test the engine kill circuit for a shorted wire or other failed components in the engine kill circuit See Testing the Engine Kill Circuit Page 89 See Warning below A WARNING WHEN THE WHITE BLACK ENGINE KILL WIRE IS DISCONNECTED THE ENGINE WILL NOT STOP R
104. THE DASH 6 Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up There is sufficient slack in the wiring to allow for this 7 Disconnect the wires from the key switch Do not allow wires to touch 8 Remove the key switch 8 1 Remove the cover over the key switch with a small flat blade screwdriver 8 2 Remove key switch from the dash by holding the key switch and turning the nut on the outside of the dash with a one inch socket wrench Remove the keyed washer with key switch Testing the Key Switch See Test Procedure 16 Page 104 Installing the Key Switch Reconnect wires to key switch See Figure 12 2 Page 83 Coat the connectors with Battery Protector Spray Club Car Part No 1014305 to ward off corrosion Reverse removal procedures to install key switch in the dash Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place SOLENOID Removing the Solenoid 1 Remove seat from body 2 Disconnect battery wires as shown Figure 12 1 Page 82 Page 119 Removing the Solenoid Continued A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON
105. Test Procedure 10 Voltage Regulator A DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON NOTE LEAVE THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 10 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check that the wires are connected correctly and are tight If they are not rewire or tighten as neces sary 3 Start the engine and check engine governored RPM The reading should be between 2670 2730 RPM If itis not adjust the accelerator cable at the electrical component box See Fuel System Section 14 4 With the battery in good condition and fully charged and with proper ventilation run the engine for sev eral minutes to bring the voltage regulator to operating temperature then release the accelerator pedal to stop the engine Using a multimeter set to DC volt DCV place the red probe on the large post of the solenoid with the red wire from the voltage regulator attached Place the black probe on the neg ative post of battery Depress the accelerator to start the engine and run it at full governed speed If the reading is between 14 7 and 15 3 volts the regulator is good If the reading is lower than 14 7 volts but rising steadily check battery condition See Hydrometer Test Page 1
106. UNNING AFTER THE ACCELERATOR PEDAL IS RELEASED IT WILL BE NECESSARY TO DEPRESS AND HOLD THE CHOKE COVER CLOSED UNTIL THE ENGINE STOPS RUNNING 6 If there is no spark or the spark is a faint yellow or white color test the ignition circuit components Test Procedure 15 Kill Limit Switch The kill limit switch is located inside the electrical component box The accelerator kill switch is the lower of the two limit switches and has a white black wire and black wire connected to it 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check for proper wiring and tight connections x LEVER UP e 2 JA iS NOP AS NM RPM DATA SD concer JT e LIMITER a scmestor ue M pj com WHITE BLACK 3 ih C VN KILL LIMIT ENGINE M t g SWITCH 224 FIGURE 12 32 FIGURE 12 33 3 Place the red probe of the multimeter on the common COM terminal white black wire of the limit switch Place the black probe on the normally open NO terminal black wire of the limit switch Without the lever depressed the reading should be no continuity Depress the lever and the reading should be continuity If either reading is incorrect replace the limit switch Figure 12 33 Test Procedure 16 Key Switch 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TR
107. VEHICLE BATTERY POISON DANGER CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING EXTERNAL FLUSH WITH WATER CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 1 Place the battery into the vehicle Make sure the battery posts are facing the engine 2 Secure the battery to the vehicle with the hold down washers and the two locknuts Tighten both nuts finger tight then torque to 14 20 in Ibs 1 6 2 3 N m 3 Connect battery cables positive cable first Tighten the posts to 9 10 ft Ibs 12 18 N m of torque 4 Reinstall the intake expansion chamber 5 Install the seat on the rear body BATTERY STORAGE 1 Keep the battery clean and free of corrosion as outlined in Preventive Maintenance Page 12 47 in the Maintenance and Service Manual 2 The battery cables should be disconnected before battery is connected to the charger The battery can be left in the vehicle while charging 3
108. Y AND HEED ALL WARNINGS STATED IN THIS MANUAL e ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY BEFORE SERVICING THE VEHICLE MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS FRAME GROUND DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING NEVER ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME ENGINE ENGINE MOUNTING PLATE OR OTHER METAL COMPONENT TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE ALWAYS BEFORE SERVICING DISCONNECT BATTERY CABLES NEGATIVE FIRST DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG Removing the Governor Cable 1 Remove the seat from the vehicle 2 Remove the governor guard 6 Figure 14 6 3 Remove the spring cotter 25 and clevis pin 24 at the carburetor throttle bracket Figure 14 6 Page 138 Page 139 13 18 Removing the Governor Cable Continued 4 Remove the E ring 7 at the governor cable engine bracket 11 and governor cable transmission 6 bracket 10 Figure 14 11 Remove the spring cotter 9 and clevis pin 8 at the rear governor lever arm Figure 14 11 Remove the cable 2
109. a feeler gauge measure the distance X at several points around the assembly The synchro ring should be replaced when X is 020 inch 0 51 millimeter or less Figure 10 55 Page 57 USE A 1 3 8 O D ARBOR AND A BEARING PULLER WEDGE ATTACHMENT CLUB CAR 1012812 TO PRESS BEARING FROM GEAR CASE WEDGE xm ATTACHMENT PUSH x DIFFERENTIAL PIN THROUGH DIFFERENTIAL GEAR CASE FIGURE 10 47 FIGURE 10 48 USING A 7 8 O D OR PRESS SMALLER ARBOR AND RAM A BEARING PULLER uc WEDGE ATTACHMENT PRESS INPUT ARBOR PRESS BEARING FROM SHAFT FROM INPUT SHAFT BEARING BEARING PULLER P Ir AMET I FIGURE 10 49 FIGURE 10 50 COMPONENT ASSEMBLY IDLER SHAFT ASSEMBLY 1 Press a new bearing 66 Figure 10 43 Page 53 onto each end of the idler shaft See Figure 10 56 Page 57 See CAUTION at the top of page 56 Page 55 A CAUTION APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING E USE A 7 8 O D OR PRESS SMALLER ARBOR AND RAM V A BEARING PULLER WEDGE ATTACHMENT CLUB CAR 1012812 ARBOR TO PRESS BEARING FROM SHAFT PRESS RAM PRESS IDLER SHAFT FROM BEARING USING A 3 4 O D OR LESS ARBOR AND A WEDGE ATTACHMENT CLUB CAR 1012812 WEDGE a ATTACHMENT N m AV zm Z
110. ading should be continuity If the reading is incorrect repair or replace the wire Test Procedure 9 Starter Generator Generator Function Figure 12 26 A DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON NOTE LEAVE THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 9 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary Disconnect the yellow wire from the DF terminal on the starter generator Cover the connector on the yellow wire to make sure the yellow wire will not short to ground Then using a jumper wire ground the DF terminal to the A2 terminal Using a multimeter set to Volts DC 20v range place the red probe on the positive post of the battery and place the black probe on the negative post Turn the key switch to the ON position and depress the accelerator to start the engine Run the engine at full governed speed The reading should show voltage rising on the meter If voltage rises see Test Proce dure 10 Voltage Regulator If the voltage does not rise see Starter Generator Repair Pages 107 116 Reconnect the yellow wire to the DF terminal on the starter generator Page 100
111. and Connections Check for tightness and damage General Vehicle Check for loose hardware and tighten as required Check maximum speed of vehicle Maximum vehicle speed should be 12 15 mph 19 24 kph Check all daily items listed above Monthly Service by Owner or Trained Mechanic Batteries Wash battery tops with baking soda water solution Brake System Tires Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Check brake pedal free play Adjust as necessary See Section 6 Check brake cables for damage and replace as required Check for wear and damage Check air pressure and adjust as necessary See Vehicle Capacities Chart on Page 9 Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for cracks or other damage make sure switch is securely fastened to frame Check all daily and weekly items listed above Quarterly Service by Owner or Trained Mechanic Accelerator Pedal Rod Check for proper operation adjust as necessary See Section 6 Steering General Vehicle Lubricate per Electric Vehicle Lubrication Chart on Page 8 Lubricate per Electric Vehicle Lubrication Chart on Page 8 Check all daily weekly and monthly items listed above Periodic Service Schedule Continued on Next Page Page 13 PERIODIC SERVICE SCHEDULE ELECTRIC VE
112. ar Part No 1012151 Accelerator pivots Dry Moly Lube Club Car Part No 1012151 Forward and reverse switch shaft and contacts charger receptacle Do not lubricate forward and reverse Switch on PowerDrive Plus vehicles Front Suspension 5 fittings Chassis Lube Anually by Trained Check fill transaxle to plug level E 22 oz 67 liter SAE 30 WT API Technician Only Class SE SF or SG Oil or higher Every 200 rounds or 100 hours of operation Inspect front wheel bearings Chassis Lube Repack as necessary See Figure 4 2 below and Figure 4 3 on Page 9 LUBRICATION POINTS POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES WITH CONTINUOUSLY VARIABLE POTENTIOMETERS DO NOT LUBRICATE y ey FORWARD amp REVERSE iue 55 POWERDRIVE PLUS VEHICLES L F FIGURE 4 2 Page 8 LUBRICATION POINTS POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES WITH MULTI STEP POTENTIOMETERS AND V GLIDE 36 VOLT VEHICLES 97 u Ir k ES DO NOT LUBRICATE FORWARD amp REVERSE SWITCH ON POWERDRIVE PLUS VEHICLES FIGURE 4 3 VEHICLE CAPACITIES CAPACITIES GASOLINE VEHICLES ELECTRIC VEHICLES Engine Crankcase without filter 32 oz 98 liters Engine Crankcase with filter 38 oz 1 16 liters Unitized Transaxle gas vehicle 27
113. ar Suspension Gasoline Vehicle Section 18 in the 1997 Maintenance and Service supple ment INSTALLATION OF REMAINING ENGINE COMPONENTS On page 13 22 in the 1995 1996 Maintenance and Service Manual step 7 under the heading above changes as follows 7 Install the spark plug and thread it in until finger tight then tighten the plug to 20 ft Ibs 27 N m ENGINE REMOVAL Because the 1997 engine has only one drain plug step 15 on page 13 24 in the 1995 1996 Maintenance and Service Manual under the heading above changes as follows 15 Remove the crankcase oil drain plug and filler tube Tip the engine slightly to allow the oil to drain from the crankcase Dispose of oil properly ENGINE ASSEMBLY Because the 1997 engine has only one drain plug the NOTE under step 18 on page 13 47 in the 1995 1996 Maintenance and Service Manual under the heading above changes as follows NOTE DRAIN PLUG IS TO BE TIGHTENED TO 18 25 FT LBS 24 34 N M OF TORQUE SECTION 14 FUEL SYSTEM CARBURETOR The last paragraph under the heading above on page 14 4 in the 1995 1996 Maintenance and Service Man ual should read as follows For elevations above 3000 feet main jets other than standard operate more effectively Therefore the follow ing chart lists the elevation ratings for various jet sizes No adjustment is required for the pilot jet f the vehi cle runs roughly at low speeds turn the pilot screw 8 Figure 14 4 out
114. are a black wire a green wire and a white wire connected to this limit switch A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 LEVER UP LEVER DEPRESSED EAN NEGATIVE _ POSITIVE NEGATIVE __ POSITIVE TESTER LIGHT IS ON METER READS APPROXIMATELY 7 IN 9 OHMS TESTER LIGHT IS OUT METER READS 10 00 1 FLASHES FIGURE 12 24 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Page 98 2 Check for proper wiring and tight connections ED 3 Place the red probe of the multimeter on the common COM terminal of the limit switch Place the black probe on the normally open NO terminal of the limit switch Without the lever depressed the reading should be no continuity Depress the lever and the reading should be continuity If either read EJ ing is incorrect replace the limit switch Figure 12 24 4 Check to be sure the lobes on the cam are depressing the neutral lock out limit switch as the forward and reverse lever is being shifted T
115. aring 35 only Press a new ball bearing 35 onto the output end of the armature Figure 12 42 Page 111 Press a new ball bearing onto the commutator end of the armature shaft A CAUTION TO PREVENT DAMAGE TO THE RETAINER USE CARE WHILE PRESSING NEW BEARING ON TO THE OUTPUT END OF THE SHAFT PRESS AGAINST THE INNER RACE OF THE NEW BEARING UNTIL IT IS FULLY SEATED 4 Install the output end cover 36 into the armature Secure the bearing retainer 32 to the cover using the three M5 x 18mm screws 43 Tighten the screws to 35 43 in Ibs 3 9 4 8 N m Figure 12 42 Page 111 Page 115 EE Starter Generator Assembly Continued 5 Slide the housing with field coils over the armature Use the locating pin to align housing to the cover wor THE TERMINAL INSULATORS SHOULD BE ON THE COMMUTATOR END OF THE HOUSING 6 To prevent contact between brushes and commutator as the commutator cover is installed and possi ble damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 41 Page 110 7 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install the two M6 x 180mm screws 20 and tighten them to 95 104 in Ibs 10 6 11 6 N
116. ase 84 and car rier case cover 87 Figure 10 6 Page 39 A CAUTION APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING DIFFERENTIAL ayes GEAR INTO DIFFERENTIAL IN CARRIER DIFFERENTIAL GEAR CARRIER GEAR CARRIER 25 CASE EM INSERT Qo POSTION IDLER THEN TAP DIFFERENTIAL PIN INTO CARRIER CASE THROUGH THRUST PLATE AND IDLER GEAR THEN CONTINUE TO TAP DIFFERENTIAL PIN ABOUT ANOTHER INCH PAST IDLER GEAR FIGURE 10 62 FIGURE 10 63 2 Install differential gear 91 into the carrier case 84 Figure 10 6 Page 39 as shown Figure 10 62 3 Start the differential pin 88 Figure 10 6 into the carrier case by lightly tapping it in with a hammer as shown Before the pin enters the inside of the carrier case position the thrust plate 85 and idler gear 89 Figure 10 6 Page 39 in the case and then continue tapping the pin through the thrust plate and idler gear as shown Figure 10 63 Page 59 Differential Gear Case Assembly Continued POSITION SECOND y POSITION THRUST PLATE AND DIFFERENTIAL SECOND IDLER GEAR i KINN GEAR AND IN DIFFERENTIAL THRUST PLATE GEAR CARRIER e T IN CARRIER CASE T CASE THEN CONTINUE TAPPING PIN THROUGH SECOND IDLER GEAR AND THRUST PLATE UNTIL PIN IS FLUSH WITH OUTSIDE OF HOUSING THEN WHILE HOLDING GEAR AND THRUST PLA
117. ath the starter generator Figure 10 18 Disconnect the engine kill switch wire 18 gauge white black stripe from the bullet connector at the lower right front of the engine Figure 10 19 Cut away the wire ties securing the kill switch wire at the lower right front of the engine below the exhaust header the wire harness at the governor cable bracket and the wire harness to the motor mount beneath the muffler TOP VIEW USE A 10 MM WRENCH TO REMOVE ENGINE GROUND RETAINING NUT PULL SPRING RELEASE BACK TO REMOVE SHIFTER LOOSEN NUTS CABLE FROM LEVER FIGURE 10 15 FIGURE 10 16 REMOVE YELLOW WIRE REMOVE GROUND WIRE 2 TERMINAL REMOVE Se PULL OIL SENDING UNIT M WIRE FROM ENGINE UNPLUG IGNITION ILL WIRE WHITE BLACK 5 WIRE E BLACK 7 WIRE FIGURE 10 19 FIGURE 10 20 3 Disconnect the brake cables 3 1 Remove the cotter pins 1 brake cable clevis pins 2 and cable retaining E clips 3 Figure 10 20 3 2 Remove the cable from the cable support bracket Figure 10 20 4 Remove only the lower shock mounting hardware from both rear shocks Figure 10 21 Page 44 5 Position a floorjack under the trailer hitch bracket in the frame as shown Figure 10 22 Page 44 See WARNING below A WARNING LIFT ONLY ONE END OF THE VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE
118. ating Capacity 2 persons Fairway Villager Seating Capacity 4 persons Fuel Tank 7 gallons 26 5 liters unleaded gasoline only Specifications Continued on Next Page Page 3 SPECIFICATIONS DS GASOLINE POWERDRIVE SYSTEM 48 ELECTRIC POWERDRIVE PLUS ELECTRIC DS 36 VOLT ELECTRIC DIMENSIONS WEIGHT Overall Length 91 1 2 232 cm 91 1 2 232 cm 91 1 2 232 cm 91 1 2 232 cm Overall Width Overall Height At Steering Wheel 47 1 4 120 cm 48 122 cm 47 1 4 120 cm 48 122 cm 47 1 4 120 cm 48 122 cm 47 1 4 120 cm 48 122 cm Wheelbase 65 1 2 166 cm 65 1 2 166 cm 65 1 2 166 cm 65 1 2 166 cm Ground Clearance 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm 4 1 2 11 cm Front Wheel Tread 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm 34 1 2 88 cm Rear Wheel Tread 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm 38 1 2 98 cm Weight Standard electric vehicle without batteries Weight Fairway Villager electric vehicle without batteries 455 Ibs 206 kg 495 lbs 225 kg 455 lbs 206 kg 448 lbs 203 kg Weight Standard gasoline powered vehicle dry 593 Ibs 269 kg Weight Fairway Villager gasoline powered vehicle dry 633 Ibs 287 kg Forward Speed 12 1
119. bolts 24 Figure 6 11 Page 21 attaching the pivot rod supports to the frame to 70 80 in Ibs 8 9 N m 6 Install the ball stud 18 through the pivot rod Using needle nose pliers install the pivot support bear ing 9 and the spring retainer 11 onto the ball stud Secure these parts with the washer 8 and nut 10 Figure 6 11 Page 21 Tighten the nut to 45 55 in Ibs 5 6 2 N m See CAUTION below A CAUTION MAKE SURE THAT THE HARDWARE IS INSTALLED WITH THE FLAT WASHER POSITIONED ON THE PASSENGER SIDE OF THE SPRING RETAINER FAILURE TO DO SO COULD RESULT IN THE ACCELERATOR BECOMING DISCONNECTED 7 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 6 26 Page 32 The ratchet should now rotate freely on the rod Page 29 Pedal Group Disassembly and Assembly Continued 8 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 9 Move the pivot rod back toward the driver side
120. ccelerator cable to the actuator cam in the electrical box Then position the accelerator cable in the mounting slot in the wall of the electrical box and tighten the mounting nuts using a 10 mm wrench Figure 10 100 Page 70 Install the electrical box cover and tighten the mounting screw Pull the fuel line from the outlet nipple of the fuel pump and connect it to the carburetor then use a 1 4 nut driver to secure the hose clamp Figure 10 101 Page 70 Connect the impulse line to the fuel pump and secure it with the hose clamp Figure 10 102 Page 70 Connect the air intake hose to the carburetor and secure the hose clamp Figure 10 103 Connect the overflow tube to the carburetor and secure it with the hose clamp Figure 10 104 Page 69 Unitized Transaxle Installation Continued 27 Install the drain plug and tighten to 21 ft lbs 28 5 N m 28 Fill transaxle with 27 oz 8 liter of 80 90 WT API Class GL3 or 80 90 WT AGMA Class EP gear lube 29 Install and tighten the level indicator hole plug to 21 ft lbs 28 5 N m 30 Connect the battery cables positive first Connect the spark plug wire CONNECT ENGINE GROUND AND TIGHTEN RETAINING NUT WITH A 10MM WRENCH PULL SPRING RELEASE BACK TO CONNECT SHIFTER TIGHTEN NUTS CABLE TO LEVER FIGURE 10 98 CONNECT CABLE TO CAM CONNECT FUEL LINE AND AND TIGHTEN RETAINING NUTS TIGHTEN CLAMP USING
121. cian See Removal of the Starter Generator Page 107 An incorrect reading from A1 or A2 terminal indicates three possible problems 1 a grounded A1 or A2 terminal 2 a grounded wire in the brush area or 3 a grounded armature commutator If the F1 or F2 reading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a grounded field coil 4 Disconnect the ground wire from the A2 terminal and the green wire from the A1 terminal on the starter generator Using a multimeter set to ohms place the red probe on the 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 maybe the cause The starter generator will need to be removed from the vehicle and disas sembled by a qualified technician See Removal of the Starter Generator Page 107 5 Disconnect the green wire from the F1 terminal and the white wire from the F2 terminal on the starter generator Using a multimeter set on ohms Q place the red probe on the F1 terminal and the black probe on the F2 terminal The reading should be continuity If the reading is incorrect a possible open field coil or bad connections at terminals may be the cause The starter generator will need to be removed from the vehicle and disas
122. d Check for proper operation See Section 6 Adjust as necessary Daily Service by Owner Accelerator Switch Wiper Switch or Continuously Variable Potentiometer Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Periodic Service Schedule Continued on Next Page Page 12 PERIODIC SERVICE SCHEDULE ELECTRIC VEHICLES REGULAR INTERVAL SERVICE Daily Service by Owner Continued Batteries Brake System Charge batteries Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Adjust as necessary Charger and Receptacle Check for damage and snug fit Park Brake Reverse Warning Buzzer Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Adjust as necessary See Section 6 Check for proper operation See NOTE Page 3 4 in the Maintenance amp Service Manual Steering and Linkages Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Tires Vehicle Warning Decals Check for wear and damage Make sure all are in place See Electric Vehicle Fea ture Identification in the DS Owner s Manual Weekly Service by Owner Batteries Clean terminals and wash dirt from casing check electrolyte level See Section 22 Electrical Wiring
123. d 32 remove the push on nut 11 and disconnect the ball joint sleeve 13 from the park brake pedal 1 Remove the ball joint sleeve 13 from the rod and pawl assembly Figure 6 20 See NOTE below NOTE A NEW PUSH ON NUT 11 FIGURE 6 22 MUST BE USED WHEN REASSEMBLING THE PARK BRAKE 3 2 To remove the park brake pedal 1 remove the push on retainer nut 4 disconnect the torsion spring 20 Figure 6 22 and slide the pedal off of the shaft See NOTE below NOTE A NEW PUSH ON NUT 4 Figure 6 22 MUST BE USED WHEN REASSEMBLING THE PARK BRAKE 3 3 Inspect all parts for wear or damage and replace as necessary FIGURE 6 21 FIGURE 6 22 Installing the Park Brake Assembly 1 From the bottom side of the floorboard insert the park brake rod 9 through the brake pedal assembly opening as shown in Figure 6 22 Then install the park brake pawl 32 onto the shaft on the brake pedal assembly weldment 6 and also the park brake rod 9 into the park brake pawl Figure 6 22 2 Install the push nut 11 onto the park brake pawl shaft Figure 6 22 Page 27 Installing the Park Brake Assembly Continued 3 Install the spacer 21 and torsion spring 20 on the park brake pedal shaft on the brake pedal weld ment Figure 6 22 Page 27 4 Install the two bushings 2 in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment Figure 6 22 Then a
124. d more often When storing the battery keep in a cool place See Battery Storage Page 132 Water Level Add water only after charging unless the water is below the level of the plates Filling a battery before charg ing will result in overfilling because the electrolyte level will rise during charging and some of the electrolyte may bubble out of the cap This reduces the battery capacity and corrodes the metal parts around it The water level should be checked weekly to be sure water is at its proper level Figure 12 55 Page 129 Never allow the water level to fall below the tops of the plates because this will cause the exposed part of the plate to become permanently inactive Check the water level more frequently in hot weather or when the bat tery becomes old Mineral Content For the longest battery life distilled water should be used in the battery However if tap water is to be used contact your local water department to be sure the mineral contents are below the levels listed in the table ALLOWABLE CONTENT IN PARTS PER MILLION IMPURITY SUSPENDED MATTER TRACE TOTAL SOLIDS 100 0 CALCIUM AND MAGNESIUM OXIDES 40 0 IRON 5 0 AMMONIA 8 0 ORGANIC MATTER 50 0 CHART CONTINUED ON PAGE 128 Page 127 Mineral Content Continued ALLOWABLE CONTENT IN PARTS PER MILLION IMPURITY NITRATES 10 0 NITRITES CHLORIDE NOTE Contact your local water department
125. d on Next Page Page 75 SYMPTOM POSSIBLE CAUSES REFERTO Engine does not start easily continued Igniter failed Section 12 Gasoline Vehicle Electrical System Low cylinder compression Section 13 Engine Water or dirt in the fuel system and or carburetor dirty or clogged fuel filter Section 14 Fuel System Carburetor improperly adjusted Section 14 Fuel System Starter generator belt is slipping Section 12 Gasoline Vehicle Electrical System Engine starts but does not run smoothly Spark plug is fouled or in poor condition Section 13 Engine Spark plug wire is damaged Section 13 Engine Igniter failed Section 12 Gasoline Vehicle Electrical System Water or dirt in the fuel system and or carburetor dirty or clogged fuel filter Section 14 Fuel System Fuel pump malfunction fuel pressure to engine too low Section 14 Fuel System Engine turns but fails to start Engine overheats Fuel tank is empty Section 14 Fuel System Fuel line or filters clogged Section 14 Fuel System Fouled spark plug Section 13 Engine Spark plug wire damaged Section 13 Engine Loose wire connection at igniter Section 12 Gasoline Vehicle Electrical System Igniter failed Section 12 Gasoline Vehicle Electrical System Engine flooded with fuel as result of over choking Section 3 General In
126. e Pedal Assembly 1 Make sure key switch is off and that the Forward and Reverse Switch is in neutral then disconnect bat tery or batteries as shown In the Maintenance and Service Manual see Figure 12 1 Page 12 2 for gasoline vehicles or Figure 22 5 or 22 6 Page 22 5 for electric vehicles See CAUTION below A CAUTION DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES PER WARNINGS ON PAGE 15 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See WARNING below A WARNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE 3 Remove the brake pedal assembly 3 1 Disconnect the brake cables from the equalizer rod 26 Figure 6 20 Page 26 3 2 Remove the pedal return spring 27 from the equalizer rod 26 Figure 6 20 3 3 Remove the nuts 33 flat washers 25 bolts 28 and bearing blocks 23 Figure 6 20 3 4 Loosen the brake equalizer rod hex nut 24 five turns then disconnect the rod 26 from the
127. e front wheels and lift the rear of the vehicle with a floorjack Then place jackstands under the axle tubes to support the vehicle See WARNING on page 36 2 Remove the rear wheel and brake drum 3 Using 90 internal snap ring pliers remove the internal retaining ring from the axle tube Figure 10 3 4 Carefully pull the axle shaft straight out of the axle tube Page 37 Removing the Axle Shaft Continued INSERT WEDGE BAR UNDER SEAL THEN PRY SEAL OUT OF ITS AXLE TUBE SEAT FIGURE 10 5 5 Use a 16 inch 40 cm rolling wedge bar Figure10 4 to remove the oil seal Insert the wedge bar under the seal and pry it out Figure 10 5 A CAUTION DO NOT SCAR OR DAMAGE THE INSIDE SURFACES OF THE TUBE WHEN REMOVING THE OIL SEAL A DAMAGED TUBE MIGHT HAVE TO BE REPLACED 6 Inspect the axle shaft assembly to be sure that the bearing 71 and collar 73 Figure 10 6 have not slipped and are still seated against the shoulder on the axle shaft 7 Inspect the bearing If the bearing is damaged or worn replace it AXLE BEARING Removing the Axle Bearing 1 Remove the retaining ring 74 then place a bearing puller wedge attachment Club Car Part No 1012812 on the axle shaft between the wheel mounting flange and the bearing A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE AXLE SHAFT IT COULD DAMAGE THE AXLE SHAFT WHEN PRESSING THE BEARING AND COLLAR OFF 2 Press the bearing
128. e the ratchet onto the splines of the pivot rod it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines accessible The ratchet may have to be rotated counterclockwise slightly to align the splines 11 Tighten the four bolts that secure the potentiometer assembly and pivot rod support to the vehicle frame to 70 80 in Ibs 8 9 N m 12 Use a feeler gauge to check the gap between the ratchet and the pawl The gap should be 060 plus or minus 030 Turn the nut 7 on the spring retainer 12 clockwise to widen the gap or counterclockwise to reduce the gap Figure 6 19 Page 24 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 adjust ing with the spring retainer nut Page 32 13 Install the nut 24 Figure 6 19 Page 24 on the accelerator pivot rod and tighten it to 16 20 ft Ibs 22 27 N m See NOTE below NOTE MAKE SURE THE ACTUATOR LEVER AND THE POTENTIOMETER LEVER ARE STILL BEFORE TIGHTENING THE ACCELERATOR PIVOT ROD RETAINING NUT 14 Using needle nose pliers install the crescent retaining ring 16 See NOTE below on the pivot shaft Figure 6 19 Page 24 NOTE ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBER 9704 667832 AND LATER ITEMS 8 AND 16 FIGURE 6 19 ARE NO LONGER USED 15 Install the hex head cap
129. ea 147 ShockcADSOIDOrS 2 5 dia iier aire vp ee die edi bei eu 148 Mono Leaf Springs an ma i umu A stint sentes entres aa a s nnns 149 TMS SMUD DSF au uapa S os TERRE E sua ore UE 150 SECTION 19A ELECTRICAL SYSTEM V GLIDE 36 VOLT VEHICLE See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 19B ELECTRICAL COMPONENTS V GLIDE 36 VOLT VEHICLE See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 20A ELECTRICAL SYSTEM POWERDRIVE SYSTEM 48 See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 20B ELECTRICAL COMPONENTS POWERDRIVE SYSTEM 48 VEHICLE See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 21A ELECTRICAL SYSTEM POWERDRIVE PLUS See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 21B ELECTRICAL COMPONENTS POWERDRIVE PLUS See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 22 BATTERIES See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 23A ACCU POWER BATTERY CHARGER See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 23B POWERDRIVE BATTERY CHARGER See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 24 MOTOR See 1995 1996 DS Golf Car Maintenance and Service Manual SECTION 25 TRANSAXLE ELECTRIC VEHICLE See Section 9 in the 1995 1996 DS Golf Car Maintenance and Service Manual Disregard information
130. em on the DS Gasoline is a 12 volt DC negative ground to frame system The electrical system consists of seven readily identifiable circuits They are e Starter Circuit Generator Circuit Engine Ignition Circuit Engine Kill Circuit Reverse Buzzer Circuit Low Oil Warning Circuit Neutral Lock out Circuit Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an electrical problem FE 290 GASOLINE VEHICLE ELECTRICAL CIRCUIT FIGURE 12 2 THE STARTER CIRCUIT FIGURE 12 3 PAGE 84 NOTE THE STARTER CIRCUIT IS COMPLETELY INDEPENDENT OF THE IGNITION CIRCUIT THE BAT TERY DOES NOT SUPPLY POWER FOR IGNITION THE BATTERY SUPPLIES POWER TO THE STARTER WHICH IN TURN STARTS THE ENGINE COMPONENTS ROTATING ONCE THE ENGINE IS RUNNING THE IGNITION CIRCUIT SUPPLIES POWER TO THE SPARK PLUG SEE ENGINE IGNITION CIRCUIT PAGE 84 Page 82 The starter circuit consists of a twelve volt battery fuse key switch accelerator starter limit switch neutral lock out limit switch solenoid starter and connecting wires The battery is the source of power for the system The fuse provides protection to the solenoid activating cir cuit The starter circuit is activated when the key switch is turned to the ON position the accelerator pedal is depressed and the forward and reverse lever is placed in forward or reverse position thus actuating the neu tral lock out li
131. end the top right corner of the center dash inward while pulling the top of the panel out and down BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND THE DASH Page 125 Removing the Oil Warning Light Continued 6 Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up There is sufficient slack in the wiring to allow for this 7 Disconnect the wires from the oil warning light 11 Do not allow wires to touch 8 Depress the two retaining tabs and remove the light from the center dash Testing the Oil Warning Light See Test Procedure 21 Page 105 Installing the Oil Warning Light Figure 12 54 1 Push a new unit into hole in dash until plastic locks engage dash 2 Connect yellow wire from the key switch and yellow wire from the oil sending unit to the oil light 11 3 Reinstall the center dash in reverse order of removal Be sure that key switch terminals cannot touch the frame and that panel is properly seated and snapped in place 4 Connect battery cables positive cable first 5 Install the seat on the rear body BATTERY A DANGER WEAR A FULL FACE SHIELD WHEN WORKING AROUND A BATTERY BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN
132. er gear assembly and with the small gear on the idler shaft 65 Figure 10 43 Page 53 7 6 As a group while keeping the gears meshed work all of the gear assemblies into the bores until Page 62 they are seated When all of the assemblies are correctly seated the outside edges of the input drive gear 52 and the intermediate gear 58 See Figure 10 43 Page 53 should be flush in the same plane as shown Figure 10 80 Page 65 Also the outside surfaces of the idler gear bearing the intermediate gear bearing and the differential gear bearing should be flush Figure 10 80 Page 65 A CAUTION IF THE EDGES OF THE INPUT DRIVE GEAR AND INTERMEDIATE GEAR ARE NOT FLUSH THEN THE OIL GUIDE 37 FIGURE 10 43 PAGE 53 MAY NOT BE PROPERLY POSITIONED IN THE BORE 8 Make sure that the mating surfaces of the left and right sides of the casing are clean and free of oil grease or residue of any kind and that they are not scored or damaged in any way 9 Then apply a continuous bead of Three Bond No 1215 sealant to the mating surface around the com plete profile of the right passenger side casing See Figure 10 81 Page 65 See CAUTION below A CAUTION USE ONLY THREE BOND NO 1215 SEALANT TO SEAL CASING DO NOT USE A SUBSTITUTE F THE TWO SIDES OF THE CASING CANNOT BE EASILY CLOSED OR DO NOT MAKE COM PLETE CONTACT DO NOT FORCE THEM TOGETHER CHECK THAT ALL INTERNAL COMPO NENTS ARE PROPERLY SEATED AND THE
133. eration See Section 13 Engine Air Intake System Check air filter element clean as necessary Daily Service by Owner Engine Cooling Air Intake Check for clogging clean as necessary Check fuel tank lines cap pump and carburetor for Fuel System fuel leakage Check proper operation See Performance Inspec Brake tion Page 3 2 in Maintenance amp Service Manual Check for proper operation See NOTE Page 3 4 in Reverse Warning Buzzer the Maintenance and Service Manual Check for proper operation See Performance Inspec Steering and Linkages tion Page 3 2 in the Maintenance amp Service Manual Tires Check for wear and damage Unitized Transaxle Check shift linkage for proper operation Make sure all are in place See Gasoline Vehicle Vehicle Warning Decals Feature Identification in DS Owner s Manual Clean terminals and wash dirt from casing check Battery electrolyte level See Section 22 Electrical Wiring and Connections Check for tightness and damage Torque Converter Rinse with water Check for loose hardware and tighten Weekly Service by Owner as required Check maximum speed of vehicle Maximum vehicle General Vehicle speed should be 12 15 mph 19 24 kph Wash engine compartment and underside of vehicle Check all daily items listed above Periodic Service Schedule Continued on Next Page Page 10 PERIODIC SERV
134. ers 9 from the reverse buzzer limit switch 4 and slide the reverse buzzer limit switch off the screws Installing the Reverse Buzzer Limit Switch Figure 12 51 Page 123 1 Install the reverse buzzer limit switch 4 and then install the two spacers 9 up against the limit switch 2 Install neutral lock out limit switch 5 and install two washers 6 and two nuts 2 Torque to 5 in lbs 0 6 N m Place the forward and reverse lever in reverse to make sure that both switches are actuated 3 Connect the orange wire to common COM terminal and the red white wire to the normally open NO terminal of the reverse buzzer limit switch 4 4 Connect battery cables positive cable first 5 Turn the key switch to the ON position Shift the forward and reverse lever to the reverse position The buzzer should sound 6 Install the seat on the rear body REVERSE BUZZER VIEWED WITH FRONT BODY REMOVED FIGURE 12 53 FIGURE 12 54 OIL WARNING LIGHT Removing the Oil Warning Light Figure 12 54 1 Disconnect the battery wires as shown Figure 12 1 Page 82 Remove the plastic cap covering the screw on each side of the center dash 2 3 Loosen but do not remove the screw on each side of the center dash panel 4 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out slightly from under edge of cowl brace 5 Pull center dash out approximately one inch from the frame and then b
135. et proper adjustment Figure 10 107 A CAUTION BE SURE THREADS OF CABLE ARE ENGAGED IN BALL JOINT AT LEAST 25 INCH 6 35 MILLI METERS IF BALL JOINT COMES LOOSE FROM THE CABLE THE FORWARD AND REVERSE SHIFTER WILL NOT OPERATE PROPERLY For major adjustments the cable retaining nuts 22 Figure 10 107 must be loosened and adjusted When the cable is properly adjusted with the forward and reverse handle 21 Figure 10 107 in the neutral posi tion the shift lever of the transmission will be in the neutral position Figure 10 106 Page 71 Page 73 Page 74 SECTION 11 TROUBLESHOOTING THE GASOLINE VEHICLE ELE Your Club Car DS vehicle will operate for a longer period of time without repairs if it is given proper care and preventive maintenance The following check list will be helpful in identifying operating difficulties should they occur The check list includes the symptom probable causes and suggested checks to make The proce dures used in making these checks can be found in the sections of the Service Manual that are referred to A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SH
136. f the vehicle frame and lower the vehicle onto the jack stands See WARNING below A WARNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE 3 Using a 1 2 socket and 1 2 wrench remove the nut 7 two washers 5 and bolt 4 securing the accelerator pedal 1 to the pivot rod 6 Figure 6 11 Page 21 4 Disconnect the accelerator rod assembly 19 20 and 21 Figure 6 11 Page 21 at the front and rear ball studs and remove it from the vehicle Page 28 5 Remove the nut 10 flat washer 8 ball stud 18 and pivot support bearing 9 from the accelerator pivot rod assembly 6 Figure 6 11 Page 21 6 Slide the spring retainer 11 off of the accelerator pivot rod BE 7 Use a scribe to mark the position of the park brake ratchet 26 on the accelerator pivot rod 6 Figure 6 11 Page 21 See NOTE below FAILURE TO MARK POSITION OF THE RATCHET COULD CAUSE IT TO BE REINSTALLED IMPROPERLY RESULTING IN IMPROPER ADJUSTMENT AND POSSIBLE FAILURE OF THE PARK BRAKE 8 Remove the lock nut 25 from the accelerator pivot shaft Figure 6 11 Page 6 21 9 Depres
137. formation Kill circuit grounded Section 12 Gasoline Vehicle Electrical System Fuel pump malfunction or failure Fan screen is partially blocked or plugged Section 14 Fuel System Section 13 Engine Improper governor adjustment Section 14 Fuel System Carburetor is too lean check main jet size Section 14 Fuel System Engine pre ignites Page 76 Excessive carbon deposits on piston head or in combustion chamber Section 13 Engine Spark plug heat range is incorrect for the engine Section 13 Engine Unsuitable or contaminated fuel Section 14 Fuel System SYMPTOM POSSIBLE CAUSES REFER TO Loss of engine power Exhaust valve is restricted with carbon deposit Section 13 Engine Muffler or exhaust pipe restricted with carbon or other substance Section 15 Exhaust System Igniter failed Section 12 Gasoline Vehicle Electrical System Air filter is dirty or clogged Section 14 Fuel System Governor is improperly adjusted Section 14 Fuel System Throttle linkage out of adjustment Section 14 Fuel System Low cylinder compression Spark plug failed Section 13 Engine Section 13 Engine Restricted fuel flow Section 14 Fuel System Torque converter is not backshifting properly Section 16 Torque Converter Spark plug fouls repeatedly Incorrect plug Section 13 Engine
138. ft the hold down off of the battery 5 Use a battery strap to lift the battery out of the vehicle See DANGER and WARNING on Page 131 Page 130 A DANGER WEAR A FULL FACE SHIELD WHEN WORKING AROUND A BATTERY BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF THE BATTERY WHEN SERVICING THE VEHICLE BATTERY POISON DANGER CONTAINS ACID CAUSES SEVERE BURNS AVOID CONTACT WITH SKIN EYES OR CLOTHING EXTERNAL FLUSH WITH WATER CALL PHYSICIAN IMMEDIATELY INTERNAL DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOW WITH MILK OF MAG NESIA OR VEGETABLE OIL CALL PHYSICIAN IMMEDIATELY EYES FLUSH WITH WATER FOR 15 MINUTES CALL PHYSICIAN IMMEDIATELY A WARNING KEEP THE BATTERY IN AN UPRIGHT POSITION TO PREVENT ELECTROLYTE LEAKAGE TIP PING THE BATTERY BEYOND A 45 ANGLE IN ANY DIRECTION CAN ALLOW A SMALL AMOUNT OF ELECTROLYTE TO LEAK OUT THE VENT HOLE DO NOT EXCEED THIS 45 ANGLE WHEN LIFTING CARRYING OR INSTALLING THE BATTERY THE BATTERY ACID COULD CAUSE SEVERE PERSONAL INJURY WHEN ACCIDENTALLY COMING IN CONTACT WITH THE SKIN OR EYES OR COULD DAMAGE CLOTHING CHARGING THE BATTERY 1 Charge the battery using an automotive type 12 volt battery charger Follow all warnings and proce dures su
139. g excessive pressure against the wiper switch housing 4 6 Install the wiper switch cover Page 20 TYPICAL 4 PLACES TYPICAL 4 PLACES Gz D on HON 7 TYPICAL 4 PLACES ALL 1997 GASOLINE AND V GLIDE 36 VOLT VEHICLES ALSO POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBERS 9711 564736 AND LATER FIGURE 6 11 PowerDrive System 48 and PowerDrive Plus Vehicles Serial Numbers Prior to 9711 564736 Adjust the Actuator Lever There is no accelerator rod on PowerDrive System 48 or PowerDrive Plus vehicles prior to serial number 9711 564736 4 1 Connect the Calibration Test Module Club Car Part No 1018871 01 Figure 6 12 Page 22 to the vehicle 4 1 1 4 1 2 4 1 3 Disconnect the 3 wire connector to the potentiometer from the wire harness as shown Fig ure 6 13 Page 22 Connect the 3 wire plug of the Calibration Test Module to the 3 wire connector from the potentiometer Figures 6 12 and 6 13 Page 22 Disconnect the green white wire from the potentiometer housing assembly Figure 6 13 Page 22 at the Forward and Reverse Limit Switch No 1 on standard PowerDrive System 48 vehicles or at the main wire harness under the charger receptacle on PowerDrive Plus vehicles with motor braking Connect the green white wire from the potentiometer housing to the green lead from the Calibration Test Module Figure 6 13 If it is not already disconnected disconnect t
140. g should be con tinuity If the reading is incorrect clean and tighten wire connections If the connections are good and the reading is incorrect repair or replace the wire See Figure 12 58 Page 133 Open the electrical component box Place the red probe of the multimeter on the nut on top of the voltage regulator and place the black probe on the frame of the vehicle See Figure 12 59 Page 134 The reading should be continuity If the reading is incorrect check and tighten the bolt and nut that hold the voltage regulator and the ground wire to frame to the electrical component box Page 95 Test Procedure 3 Ground Straps Continued DATA HOLD AC DC 500V MAX EN S WHITE A A gt 250V MAX DISCONNECT THE 6 GAUGE BLACK WIRE KEY SWITCH FROM THE BATTERY PLACE RED PROBE ON DISCONNECTED END OF WIRE FIGURE 12 19 FIGURE 12 20 5 Check the 6 gauge black wire that connects the negative post of the battery to the frame The frame connection should be clean and tight Visual inspection of the connection on the frame is very difficult The best check for tightness is to pull on the black wire If the wire moves at the connection end disas semble the frame connection clean off the bolt ring terminal and nut Then reinstall the frame connec tion 6 Set the multimeter to ohms Q Place the red probe on the unconnected end of the 6 gauge b
141. ghten the jam nut 31 to 7 9 ft lbs 9 10 N m Figure 6 2 2 ADJUST PARK BRAKE RATCHET PAWL GAP AND PAWL ENGAGEMENT ALL DS VEHICLES 2 1 Using a 1 2 wrench adjust the retaining nut 7 on the spring support rod until there is a 060 plus or minus 030 inch gap between the pawl and the tips of the ratchet teeth Use a feeler gauge to verify the gap Figure 6 4 Read NOTES below and at top of page 17 before proceeding NOTE ON ALL POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES PRIOR TO SERIAL NO 9711 564736 THE ACTUATOR LEVER MUST ALSO BE ADJUSTED IF THE RATCHET PAWL GAP IS ADJUSTED SEE STEP 4 PAGE 21 Page 16 ON ALL 1997 DS GASOLINE VEHICLES AND V GLIDE 36 VOLT ELECTRIC VEHICLES AND ON 1997 POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NO 9711 564736 AND LATER THE ACCELERATOR ROD ADJUSTMENT MUST ALSO BE CHECKED IF THE RATCHET PAWL GAP IS ADJUSTED SEE STEP 4 PAGE 19 OR STEP 4 PAGE 20 ON ALL 1997 DS GASOLINE VEHICLES AND V GLIDE 36 VOLT ELECTRIC VEHICLES AND ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NO 9711 564736 AND LATER THE ACCELERATOR ROD MUST BE DISCONNECTED BEFORE PROCEEDING TO STEP 2 2 Y CUT A WAY SIDE VIEW C CS M a DS ADJUST RETAINING NUT 7 WITHA 060 030 1 2 INCH SOCKET UNTIL THERE IS A USE FEELER GAUGE er 060 INCH GAP PLUS OR MINUS 030 INCH TOCHECKGAP VIEW las BETWEEN RACHET A
142. he 6 gauge red wire from the positive post of battery No 6 Connect the Calibration Test Module s alligator clip to the end of the 6 gauge red wire Page 21 Adjusting Actuator Lever on PowerDrive System 48 and PowerDrive Plus Vehicles Continued 4 2 Position and clamp the Accelerator Pedal Adjustment tool on the accelerator pedal with the end marked micro break point toward the floorboard then depress the pedal until the end of the tool rests against the floorboard pedal height should be 4 5 8 plus or minus 3 32 Use a rubber strap to hold the pedal in depressed position and proceed to step 4 3 Figure 6 14 Use a 1 4 socket or nut driver to remove two screws 20 and detach the potentiometer housing cover Figure 6 15 Using a 7 16 deep well socket slightly loosen the bolt 9 Figure 6 16 attaching the actuator lever to the adjustment bracket Rotate the actuator lever 17 on the pivot rod weldment 6 Figure 6 19 Page 24 counterclock wise until the red LED on the test module goes out limit switch clicks off Then slowly rotate the actuator lever clockwise until the red LED is illuminated again limit switch clicks on 4 3 4 4 4 5 WIRE HARNESS TO THE F amp R SWITCH ALLIGATOR CLIP NO 18 WHITE WIRE GREEN WHITE WIRE FROM POTENTIOMETER N 3 WIRE PLUG MALE TERMINAL NO 18 GREEN WIRE 3 WIRE CONNECTOR TO POTENTIOMETER L C D DISPLAY WINDOW
143. he casing Figure 10 40 Page 50 Remove the oil flow guide Figure 10 41 Page 50 from the casing Remove the shifter shaft Figure 10 41 Page 50 from the casing 13 1 Use snap ring pliers to remove the shaft retaining ring 11 on the outside of the casing as shown Figure 10 36 13 2 Remove the flat washer 12 from the shaft on the outside of the casing as shown Figure 10 36 then remove the shifter shaft by pushing it through the casing wall toward the interior of the tran saxle 13 3 Use a seal puller to remove the shifter shaft oil seal 13 from the casing Figure 10 36 Use a 14 mm open end wrench to remove the breather 31 from the casing Figure 10 36 Remove the governor assembly from the casing 15 1 Remove the cotter pin 20 and flat washer 21 from the pivot arm Figure 10 36 Page 49 Unitized Transaxle Disassembly Continued 15 3 Use a small chisel or similar pointed instrument to pry the pivot arm oil seal 22 Figure 10 36 Page 48 out of the casing See Figure 10 42 15 4 Remove the governor gear assembly 63 and 64 and flat washer 62 Figure 10 43 Page 53 by lightly tapping the gear shaft through the casing wall from the outside with a hammer and drift See Figure 10 44 Page 54 15 2 Remove the pivot arm by pulling it through the wall to the interior of the casing REMOVE SYNCHRONIZER GEAR ASSEMBLY AND SHIFTER FORK TOGETHER AS A UNIT PRY INPUT SHAFT OIL SEAL FROM CAST
144. he limit switch should make an audible click as it is depressed If it does not check for wear on the cam lobes Be sure the cam snaps fully back into place If the cam lobes still do not activate the limit switch replace the cam Test Procedure 7 Starter Generator Starter Function Figure 12 25 Page 100 A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary 3 Disconnect the wires from all the terminals on the starter generator Then place the black probe of a multimeter set to ohms on the starter generator housing scratch through the paint to insure a good ground While holding the black probe against the housing place the red probe one at a time on the A1 A2 F1 F2 and DF terminals respectively Figure 12 25 Page 100 The readings should be no continuity If the readings are incorrect the starter generator will need to be removed from the vehicle and disassembled by a qualified techni
145. icle frame and lower the vehicle onto the jack stands See WARNING below A WARNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE Page 30 3 Remove the two hex head screws 20 attaching the potentiometer housing cover Figure 6 15 Page 23 to the potentiometer and remove the cover 4 Remove the bolt 9 washer 8 See NOTE below and lock nut 11 from the spring retainer 12 with the pivot support bearing 10 Figure 6 19 Page 24 NOTE ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBER 9704 667832 AND LATER ITEMS 8 AND 16 FIGURE 6 19 ARE NO LONGER USED 5 Remove the hex head cap screw 4 two flat washers 5 and lock nut 7 from the accelerator pedal and pivot rod assembly 6 Figure 6 19 Page 24 6 Remove the bolt 9 flat washer 8 See NOTE above and captured lock nut 11 from the actuator lever 17 and pivot rod assembly Figure 6 19 Page 24 7 Remove the brake ratchet retaining nut 24 from the pivot rod assembly 6 Figure 6 19 Page 24 8 Disconnect the spring retainer 12 from the accelerator pivot rod assembly 6 Fig
146. input shaft as shown Figure 10 49 Page 9 55 See CAUTION above A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF 2 Pull the spring Belleville washer 39 spur gear 40 dowel pin 50 thrust plate 41 input gear assembly 42 large needle bearing 43 small needle bearing 44 synchronizer ring 45 and thrust plate 41 from the input shaft Figure 10 43 Page 53 3 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 54 and input gear assembly 52 Figure 10 43 then press the bearing off the input shaft as shown Figure 10 50 Page 55 A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF 4 Pull the spring Belleville washer 39 thrust washer 53 input gear assembly 52 two needle bear ings 43 and 44 thrust plate 41 and synchronizer ring 45 from the input shaft Figure 10 43 5 Use a small flat blade screwdriver to remove two synchronizer springs snap rings 46 Figure 10 43 and then slide the synchronizer clutch hub 49 Figure 10 43 from the input shaft 51 NOTE THERE ARE THREE SYNCHRONIZER INSERTS 48 SET INTO SLOTS IN THE SYNCHRONIZER SLEEVE 47 Figure 10 43 THESE MAY FALL FREE WHEN THE SYNCHRONIZER CLUTCH HUB 49 IS REMOVED TAKE CARE TO NO
147. inued INSTALL SHIFTER SHAFT AND GOVERNOR SHAFT SEALS INTO THEIR SEATS POSITION THE GOVERNOR GEAR SHAFT TOOL OVER THE SHAFT BORE IN THE CASING THEN INSERT LONG END OF THE GOVERNOR GEAR SHAFT THROUGH TOOL AND INTO BORE TAP GOVERNOR GEAR PRESS OIL SEAL INTO RIGHT SIDE CASING FIGURE 10 68 SHAFT THROUGH THE TOOL AND INTO BORE IN LEFT SIDE CASING UNTIL END OF SHAFT IS EVEN WITH END OF TOOL FIGURE 10 69 PUSH ONTO SHAFT UNTIL YOU HEAR THE GOVERNOR GEAR ASSEMBLY _ SLEEVE POSITION SLEEVE BETWEEN gt FLYWEIGHT BRACKETS Ps SNAP INTO PLACE INSERT WASHER AND GOVERNOR GEAR COMPLETE WITH SLEEVE ONTO GOVERNOR SHAFT FIGURE 10 70 FIGURE 10 71 7 4 Position the shifter fork assembly on the synchronizer gear assembly as shown and install them together bearing end first into the bore containing the guide Figure 10 77 Page 64 Do not seat the assembly but make sure that the spur gear 40 is meshed with the governor gear 63 Figure 10 43 Page 53 and that the shifter lever 14 Figure 10 36 Page 48 is positioned in the bracket on the shifter fork See Figure 10 78 Page 65 7 5 Install the intermediate gear assembly into the casing as shown Figure 10 79 Page 65 Do not seat the assembly into the bore but make sure that the ring gear meshes with the input drive gear 52 Figure 10 43 Page 53 on the synchroniz
148. lace See Vehicle Identification pages at the beginning of vehicle Owner s Manual NOTE e SEVERAL VEHICLE SAFETY DECALS HAVE BEEN RELOCATED FROM BENEATH THE SEAT ON THE VEHICLE FRONT BODY TO THE VEHICLE FRAME INSIDE THE ENGINE OR BATTERY COMPARTMENT Tires Check for proper tire pressure See Capacities Page 9 in this supplement DS Electric Batteries all models Check electrolyte to ensure that it is at its proper level See Fig ure 22 7 Section 22 Page 6 in the Maintenance and Service Manual Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle DS V Glide Speed Switch and PowerDrive System 48 Multi step Potentiometer Be sure speed Switch or potentiometer cover is properly secured prior to operating the vehicle NOTE CONTINUOUSLY VARIABLE POTENTIOMETERS WERE STANDARD ON EARLY 1997 DS POW ERDRIVE SYSTEM 48 VEHICLES ON DS POWERDRIVE SYSTEM 48 VEHICLES SERIAL NO 9711 564736 AND LATER THE MULTI STEP POTENTIOMETER IS STANDARD DS Gasoline Engine Check for proper engine oil level See Section 13 Page 47 in the Maintenance and Service Manual DS Gasoline Fuel Check fuel level e BE SURE THE PLASTIC HAS BEEN REMOVED FROM THE SEAT BOTTOM BEFORE OPERAT ING THE VEHICLE FAILURE TO DO SO COULD RESULT IN A FIRE PROPERTY DAMAGE PERSONAL INJURY OR DEATH Page 5 SECTION 4 PERIODIC MAINTENANCE It is important to imp
149. lack wire and place the black probe on the frame of the vehicle The reading should be continuity If the reading is incorrect check that terminals connections are clean and tight If the connections are good and the reading is incorrect repair or replace the wire Figure 12 20 Test Procedure 4 Accelerator Starter Limit Switch A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 The accelerator starter limit switch is the top switch located in the electrical component box There are an 18 gauge green wire and an 18 gauge orange wire connected to this limit switch 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels 2 Check for proper wiring and tight connections Figure 12 3 Page 84 3 Set the multimeter to ohms Q Place the red probe on the common COM terminal green wire of the limit switch and place the black probe on the normally closed NC terminal orange wire of the limit switch 4 Make sure the battery is disconnected With the key switch in the OFF position the forward and reverse Page 96 lever in NEUTRAL and the accelerator
150. lement and follow a Preventive Maintenance program for your vehicle s Preventive Maintenance consists of the regular performance of scheduled vehicle service and maintenance procedures and is the only way to insure that the vehicle provides the safe reliable and economical service that it is designed to deliver The following charts provide recommended service intervals for the lubrication and main tenance of DS vehicles Note that critical areas such as brake operation accelerator operation steering and tires should be performed daily Any car that is not functioning properly should be removed from use until it is properly repaired A WARNING IF ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS SUPPLEMENT AND IN THE MANUAL TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE SWITCH IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING MOVING PARTS DO NOT ATTEMPT TO SERVI
151. mit switch See Neutral Lock out Circuit Page 86 Electrical current is then supplied to the solenoid which completes the circuit between the positive post of the battery and the F2 post of the starter The starter then turns and cranks the engine through belt driven pulleys FORWARD REVERSE ASSEMBLY FRAME GROUND LIMIT SWITCHES REVERSE BUZZER lt LIMIT SWITCHES NK RED WHITE FRAME GROUND REGULATOR STARTER gt GENERATO BRAIDED GROUND WIRE ON VEHICLES SERIAL NO 9710 563353 AND GREATER YELLOW J BATTERY GROUND FIGURE 12 2 Page 83 FORWARD REVERSE FRAME ASSEMBLY GROUND NEUTRAL LOCK OUT LIMIT SWITCH BATTERY FIGURE 12 3 THE GENERATOR CIRCUIT FIGURE 12 4 ACCELERATOR 5 e ac e e ul x ea STARTER GENERATOR The generator circuit consists of the starter generator voltage regulator solenoid the battery and connect ing wires When battery power is first supplied to the starter generator the starter generator turns the engine at low RPM approx 700 Once the engine starts running it then drives the starter generator At any engine RPM over 1215 3000 starter generator RPM the starter generator functions as a generator supplying charging current to the battery To prevent battery overcharging the voltage regulator senses battery voltage and by opening and closing an electronic switch
152. mpared with the reality of severe personal injury Your safety and satisfaction are of the utmost importance to Club Car That is why we urge you to study this supplement and the maintenance and service manual and to read understand and heed the warnings in this manual as well as the safety decals on your vehicle before operating the vehicle Take time to understand the language of safety It is a language that can save your life CONTENTS SECTION 1 SAFETY 1 SECTION 2 VEHICLE SPECIFICATIONS 3 Section 2 in this supplement supersedes Section 2 in the 1995 1996 DS Maintenance and Service Manual SECTION 3 GENERAL INFORMATION 5 Use this supplement for current information on the subjects listed below See Section 3 in the 1995 1996 DS Golf Car Maintenance and Service Manual for all other information Pre Operation Checklist notet da paite efie POR aad debe baad EE ER 5 SECTION 4 PERIODIC MAINTENANCE 6 Section 4 in this supplement supersedes Section 2 in the 1995 1996 DS Maintenance and Service Manual Lubrication Gasoline Vehicles a a aa 7 Lubrication Electric Vehicles ss te ee eres t i er ge us d eite b de dae 8 Vehicle Capacities 2 i e RD ea Eee ege OE Lace e Lees edat ere ua etn a RU Esc REDE eevee 9 Periodic Service Gasoline Vehicles nnne nint nnn nsns 10 Periodic Service
153. n the cam lobes Be sure the cam has snapped fully back into place If the cam lobes still do not actuate the limit switch replace the cam DATA HOLD A AC DC 500V MAX A A gt 250V MAX ACV KEY SWITCH FIGURE 12 34 FIGURE 12 35 Test Procedure 24 Battery Test Under Load NOTE LEAVE THE BATTERY CONNECTED WHILE PERFORMING TEST PROCEDURE 24 Place the neutral lockout cam in the SERVICE position put the forward and reverse switch in NEU TRAL and chock the wheels Seta multimeter to volts and place the red probe on the F2 white wire terminal on the starter gen erator Place the black probe on the negative terminal post on the battery Page 106 3 Turn the key switch to the ON position leave the forward and reverse switch in the neutral position and depress the accelerator pedal with the accelerator pedal depressed the battery is under load If the ED voltage reading is over 8 volts check the starter generator See Starter Generator below Pages 107 116 If the reading is below 8 volts check the battery See page 126 If the reading is zero there may be no continuity across the large posts of the solenoid See Test Procedure 5 If all of the test results are good there may be a broken or damaged white 6 gauge wire from the sole noid to the starter generator See Test Procedure 8 ELECTRICAL SYSTEM COMPONENTS STARTER G
154. nchronizer ring as shown Fig 7 E ure 10 43 The input gear should seat in the synchronizer ring 8 Install the thrust washer 53 and then the spring Belleville washer 39 The spring washer should be oriented with the raised center toward the end of the shaft Figure 10 43 Page 53 9 Press a new bearing 54 onto the shaft until it seats Figure 10 43 Make sure the input gear turns freely A CAUTION APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY APPLYING PRES SURE ANYWHERE ELSE WILL DAMAGE THE BEARING SYNCHRONIZER INSERTS OVERLAP SNAP RINGS WITH GROOVED END OF SYNCHRONIZER SIDE VIEW CLUTCH HUB POINTING DOWN TOWARD LONG END OF SHAFT INSTALL IT ONTO THE SYNCHRONIZER SLEEVE d Hy GROOVE ON END OF CLUTCH HUB 4 SS SYNCHRONIZER 7 Cay aye Se CLUTCH HUB NOTCHED Y SYNCHRONIZER SURFACES us Te m SLEEVE OF SYNCHRO Bir INSERTS FACE TOP VIEW LONG END OUT OF SHAFT SNAP RINGS TOP AND BOTTOM FIGURE 10 59 FIGURE 10 60 SYNCHRONIZER RING SLIDE SYNCHRONIZER RING ONTO CLUTCH HUB WITH THE SMOOTH COLLAR OF RING TOWARD CLUTCH HUB SYNCHRONIZER CLUTCH HUB FIGURE 10 61 10 On the other end of the input shaft install the thrust washer 41 and the synchronizer ring 45 The smooth collar of the synchronizer ring should be oriented toward the clutch hub and the notches in it should mate with the synchronizer inserts as shown Figure 10 43 Page 53 11 Install
155. nd greater on regulator mounting screw 8 Figure 12 49 4 Install jam nut 2 only on vehicles prior to serial number 9710 563353 and tighten to 6 ft lbs 8 N m of torque Install the nylon lock hex nut 1 and tighten to 6 ft Ibs 8 N m of torque Figure 12 49 5 Install snap on electrical component box cover Be sure to firmly press down all corners Install screw 6 Connect battery cables positive cable first 7 Place forward and reverse assembly in neutral position and place the neutral lock out cam in the ser vice position Start the engine and check regulator for proper functioning as described under voltage regulator testing See Test Procedure 10 Page 101 KEY SWITCH Removing the Key Switch 1 Disconnect battery cables as shown Figure 12 1 Page 82 2 Remove the plastic cap covering the screw on each side of the center dash 3 Loosen but do not remove the screw on each side of the center dash panel 4 Insert screwdriver at the top center of the dash between dash and cowl brace Gently pry center dash out slightly from under edge of cowl brace 5 Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down NOTE BENDING THE TOP RIGHT CORNER OF THE CENTER DASH INWARD WHILE REMOVING IT WILL PREVENT THE CONTACTS ON THE REAR OF THE KEY SWITCH FROM TOUCHING THE METAL FRAME AROUND
156. nect the terminal to the frame of the vehicle Connect the red battery cable to the postive post of the battery then attach the black cable to the negative post of the battery Turn the key switch ON The oil light should illuminate If it does not check continuity of the yellow wire that runs from the key switch to the oil light If there is no continuity replace the wire Then test the key switch See Test Procedure 2 If the yellow wire and the key switch test okay then replace the oil light Test Procedure 22 Key Switch Engine Kill Circuit 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Remove the center dash assembly See Removing the Key Switch Page 115 Check that wires are connected correctly and are tight If they are not rewire or tighten as necessary Insert the key and turn the switch to ON Place the red probe of the multimeter on the No 2 terminal and the black probe on the No 1 terminal of the key switch The reading should be continuity If the reading is incorrect replace the key switch Figure 12 34 Test Procedure 23 Neutral Lock out Cam Check to be sure the lobes on the cam are depressing the neutral lock out limit switch lever as the for ward and reverse lever is being shifted The limit switch should make an audible click as it is depressed If it does not check for wear o
157. ned within the flyweight brackets of the gear as shown Figure 10 71 Page 62 and then push them onto the shaft until the gear snaps into the groove on the shaft 5 Position the interior washer on the pivot arm then install the pivot arm and washer into the left driver side casing as shown Figure 10 72 Page 63 Then install the exterior washer and cotter pin on the pivot arm outside the casing as shown Figure 10 72 Page 63 6 Install the shifter shaft into the left driver side casing as shown Figure 10 73 Page 63 Then install the washer and retaining ring on the shifter shaft outside of the casing Figure 10 73 7 Install the gear assemblies into the left driver side casing 7 1 Stand the left side casing on the mounting plate then install the differential gear case assembly as shown Figure 10 74 Page 64 Do not seat the assembly in the bore but insert it just far enough that it will not fall out 7 2 Install the idler shaft assembly into the casing as shown Do not seat the assembly in the bore but insert far enough that it will not fall out No gears mesh at this time Figure 10 75 Page 64 7 8 Place a drop of Cyanoacrylate adhesive Super Glue in each of the oil guide slots in the casing Then install the guide with the baffle toward the casing wall as shown Figure 10 76 Page 64 Make sure that the two tabs on the guide are positioned in the slots in the casing Page 61 Unitized Transaxle Assembly Cont
158. ng on the floor 12 Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle Figure 10 28 13 Place blocks under the engine mounting plate so that they will completely support the engine and keep it level to the floor Figure 10 29 Page 46 See NOTE below NOTE PLACE THE BLOCKS SO THAT THEY WILL SUPPORT THE ENGINE WHEN THE UNITIZED TRANSAXLE IS DETACHED AND MOVED AWAY FROM IT IN THE FOLLOWING STEPS A REMOVE BOLTS THEN ROTATE SHACKLES UP AND AWAY FROM SPRING USE A 9 16 SOCKET TO REMOVE SPRING RETAINER BOLTS FIGURE 10 23 FIGURE 10 24 Page 44 RAISE REAR OF VEHICLE UNTIL DRIVE TRAIN CAN BE ROLLED OUT WITH JACKSTANDS IN PLACE REMOVE JACKSTAND FLOORJACK FIGURE 10 25 FIGURE 10 26 SNUBBER BRACKET LOWER SNUBBER TO THE GROUND VEHICLE BODY AND FRAME REMAIN STATIONARY ON JACKSTANDS WHILE ROLL ENTIRE DRIVETRAIN IS ROLLED DRIVETRAIN Genera N OUT FROM UNDER cn 7 VEHICLE BODY FIGURE 10 27 FIGURE 10 28 14 Remove the drive belt 14 1 Grasp the belt midway between the drive clutch and driven clutch and pull up forcefully on the belt to force the driven clutch sheeves apart Then roll the belt counterclockwise while pulling it off of the driven clutch Figure 10 30 Page 46 15 Use a 1 2 wrench to remove the driven clutch retaining bolt and then remove the driven clutch from the unitized transaxle Figure
159. of the vehicle and line up the scribed match marks on the pivot rod and ratchet Rotate the pivot rod back and forth slightly to align the splines and slide the ratchet onto the splines 10 Install the nylon lock nut 25 on the pivot rod Tighten the nut to 16 20 ft lbs 22 27 N m 11 Install the accelerator rod assembly 19 20 and 21 Figure 6 11 Page 21 12 Adjust the accelerator pedal height See NOTE below NOTE THE PROCEDURE FOR ADJUSTING THE ACCELERATOR PEDAL HEIGHT IS ON PAGE 17 13 Adjust the accelerator rod See NOTE below THE PROCEDURE FOR ADJUSTING THE ACCELERATOR ROD ON GASOLINE VEHICLES IS ON PAGE 19 ACCELERATOR ROD ADJUSTMENT FOR V GLIDE 36 VOLT VEHICLES AND FOR POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBERS 9711 564736 AND LATER IS ON PAGE 20 REMOVING THE ACCELERATOR PEDAL ASSEMBLY DS PowerDrive System 48 and DS PowerDrive Plus Vehicles Prior to Serial Number 9711 564736 1 Make sure the key switch is off and that the Forward and Reverse Switch is in neutral then disconnect the batteries as shown Figure 22 6 Page 22 5 in the Maintenance amp Service Manual See CAU TION below A CAUTION DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES PER INSTRUCTIONS IN WARNING ON PAGE 15 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube of the veh
160. omatic ground speed sensing internally geared in the unit ized transaxle Ignition Transistor electronic ignition with electronic RPM limiter Unitized Transaxle Fully synchronized forward and reverse with neutral 11 8 1 forward 17 1 1 reverse Transaxle Double reduction helical gear with 12 28 1 direct drive axle Electrical System 12 volt 460 cold cranking amp battery and 35 amp charging capacity Electrical System 48 volts DC reduced speed reverse Electrical System 36 volts DC reduced speed reverse Batteries High capacity deep cycle Trojan PowerDrive 8 volt 117 min capacity Batteries High capacity deep cycle Trojan 6 volt 115 min capacity Charger Automatic 17 amp PowerDrive UL and CSA listed Charger Automatic 21 amp Accu Power UL and CSA listed Torque Converter Automatic variable speed dry type STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Suspension Front and rear tapered mono leaf springs with dual hydrau lic shocks Brakes Dual rear wheel self adjusting brakes with cast iron drums and single brake pedal with automatic release park brake BODY CHASSIS Frame Chassis Twin l Beam welded aluminum Front and Rear Body Armorflex amp Body Finish Protective coat over molded in color Tires 18 00 x 8 50 8 00 tubeless 4 ply rated SEATING CAPACITY FUEL CAPACITY Standard Se
161. on 9 in the 1995 1996 DS Maintenance and Service Manual are superseded by Section 10 in this supplement SECTION 18 REAR SUSPENSION GASOLINE VEHICLE This section supersedes Section 18 in the 1995 1996 Maintenance and Service Manual GENERAL INFORMATION The rear suspension of the DS gasoline vehicle is completely independent It consists of two mono leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame The engine is mounted on a plate that is bolted to the transaxle A snubber mounted on the front of the engine mounting plate and contained by brackets on the vehicle frame controls engine mounting plate motion A WARNING ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING VEHICLE WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES TURN KEY SWITCH OFF PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI TION AND REMOVE KEY PRIOR TO SERVICING DO NOT WEAR LOOSE CLOTHING REMOVE JEWELRY SUCH AS RINGS WATCHES CHAINS ETC BEFORE SERVICING VEHICLE ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON NECTIONS MOVING PARTS DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING HOT
162. ost hole in the pedal Install the bolt 4 two washers 5 and nut 7 through the lower hole in the pedal and through the pivot rod Tighten the nut with fingers only at this time Install the actuator lever 17 Figure 6 19 Page 24 on the pivot rod and position the pedal and actuator lever on the rod so that about one half of the total length of the pivot rod is protruding out of the actuator lever 3 Place the plastic washer 18 on the end of the accelerator pivot rod and align the pivot rod and washer with the hole in the potentiometer housing 21 then insert the pivot rod through the potentiometer vehicle frame and pivot rod support until the end of the pivot rod is flush with the outside surface of the pivot rod support 22 Figure 6 19 Page 24 Page 31 Pedal Group Disassembly and Assembly Continued 4 Rotate the potentiometer lever 27 clockwise until lever fork is at the two o clock position Figure 6 25 The lever must be at approximately two o clock in order for it to mate with the alignment pin on the actu ator lever 5 Rotate the actuator lever until its alignment pin is aligned with the slot in the potentiometer lever fork Figure 6 25 then slide the actuator lever toward the potentiometer housing See CAUTION below A CAUTION DO NOT BEND THE LIMIT SWITCH LEVER THE CAM ON THE ACTUATOR LEVER SHOULD BE AT THE TWELVE O CLOCK POSITION WHEN THE ACTUATOR LEVER IS IN POSITION TO MATE WITH THE POTENTIOMETER
163. oz 8 liters Transaxle electric vehicle 22 oz 67 liters Gasoline Tank 7 gallons 26 5 liters Tire Pressure 12 14 psi 83 96 kPa 18 20 psi 124 138 kPa A WARNING F ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE THE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH Page 9 1 9 PERIODIC SERVICE GASOLINE VEHICLES DES A WARNING EB F ANY PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE DO NOT OPERATE VEHICLE UNTIL REPAIRS ARE MADE FAILURE TO MAKE NECESSARY REPAIRS COULD RESULT IN FIRE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH ALL SERVICE REPAIRS AND ADJUSTMENTS MUST BE MADE PER INSTRUCTIONS IN THIS MANUAL PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Check for proper operation See Performance Accelerator Pedal Rod Inspection Page 3 2 in the Maintenance amp Service Manual Adjust as necessary Check for proper operation See Performance Inspec Accelerator Governor Linkage and Cables tion Page 3 2 in the Maintenance amp Service Manual Adjust as necessary Check for proper operation See Performance Inspec Brake System tion Page 3 2 in the Maintenance amp Service Manual Adjust as necessary Choke Check for proper operation See Section 14 Engine Check for proper op
164. p and then rotating the panel out and up There is sufficient slack in the wiring to allow for this 7 Disconnect the wires from the reverse warning buzzer Do not allow wires to touch Figure 12 53 8 Remove the two mounting screws 3 that secure the buzzer to the center dash Figure 12 53 Testing the Reverse Warning Buzzer See Test Procedure 19 Page 105 Installing the Reverse Warning Buzzer Figure 12 53 1 Install the two screws through the buzzer bracket tabs and tighten to a torque of 3 4 in Ibs 0 35 0 45 N m 2 Connect black wire from key switch to the negative terminal on the buzzer Connect the red white wire from the wire harness to the positive terminal on the buzzer 4 Reverse removal procedures to reinstall the center dash in the vehicle Be sure that the key switch ter minals cannot touch the frame and that the panel is properly seated and snapped in place REVERSE BUZZER LIMIT SWITCH Removing the Reverse Buzzer Limit Switch Figure 12 51 Page 123 1 Remove seat from the rear body e Page 124 2 Disconnect the battery wires as shown Figure 12 1 Page 82 3 Disconnect the orange and red white wires from the reverse buzzer limit switch 4 located on the back of the forward and reverse assembly 4 Remove the two nuts 2 and washers 6 from the neutral lock out limit switch 5 and slide the neutral lock out limit switch off the screws Do not disconnect the wires 5 Remove the two spac
165. perly secure the battery in the vehicle frame Preventive Maintenance To keep the battery in good operating condition follow these steps on a regular basis 1 Any corrosion build up on or around the battery should be removed immediately Post connections should be clean and tight Any frayed or worn wires should be replaced After battery cables have been connected coat connectors with Battery Protector Spray Club Car Part No 1014305 to ward off future corrosion 2 The battery should be kept clean and dry to prevent self discharge Any dirt grime or acid spillage should be removed Wash the battery with a bristle brush using water and bicarbonate of soda baking soda 1 cup per gallon Rinse with water Do not allow solution to enter battery through the vent cap holes See Self Discharge below 3 Maintain proper water level See Water Level below and Figure 12 55 Page 129 4 Check battery periodically to see that it is in a full state of charge See Battery Charging Page 131 5 Keep battery hold down brackets tight See Vibration Damage Page 128 Self Discharge 1 Dirt and battery acid can provide a path for a small current draw that can slowly discharge the battery To prevent self discharge the battery should always be kept clean 2 Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a battery will discharge In hotter climates therefore the battery should be checke
166. pplied by the battery charger manufacturer 2 Attach the positive charger cable to the positive post on the battery 3 Attach the negative charger cable to the negative post on the battery 4 The battery may be charged with a slow charge 3 10 amps or a fast charge 20 30 amps Charge until the specific gravity reaches 1 250 See WARNING below A WARNING F THE BATTERY CASE FEELS HOT APPROXIMATELY 125 F OR MORE AND OR EMITS GASES AND OR FLUID BOILS FROM VENTS STOP CHARGING AT ONCE FAILURE TO STOP CHARGING BATTERY WHEN THESE CONDITIONS ARE PRESENT COULD RESULT IN AN EXPLOSION PERSONAL INJURY AND OR DAMAGE TO THE BATTERY DO NOT DISCONNECT THE D C LEADS FROM BATTERY WHEN THE CHARGER IS ON THE RESULTING ARCING BETWEEN THE D C LEADS AND BATTERY POST COULD CAUSE AN EXPLOSION F THE CHARGER MUST BE STOPPED DISCONNECT THE AC SUPPLY CORD FROM THE WALL OUTLET BEFORE DISCONNECTING THE D C LEADS FROM THE BATTERY ALLOW THE BATTERY TO COOL TO ROOM TEMPERATURE AND RESUME CHARGING BATTERY AT A LOWER AMP RATE Page 131 INSTALLING THE BATTERY A DANGER WEAR A FULL FACE SHIELD WHEN WORKING AROUND A BATTERY BECAUSE OF THE DAN GER OF AN EXPLODING BATTERY BATTERY EXPLOSIVE GASES KEEP SPARKS FLAMES CIGARETTES AWAY VENTILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE ALWAYS WEAR EYE PROTECTION WHEN WORKING ON OR NEAR BATTERY FOR ADDED PROTECTION COVER TOP OF THE BATTERY WHEN SERVICING THE
167. r brush springs 28 Figure 12 39 Using a spring scale test brush spring tension If the any spring has a tension less than 24 ounces replace all four springs Figure 12 40 See Caution above REPLACE SPRINGS WHICH APPLY A FORCE OF LESS THAN 24 OUNCES FIGURE 12 40 Assembly of the Starter Generator A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 1 Connect the brush wires to the holders using the four lockwashers 26 and four screws 25 making sure the crossover leads are connected also Apply 26 35 in Ibs 2 9 3 9 N m of torque to the screws Figure 12 39 2 To prevent contact between the brushes and commutator as the commutator is installed and possible damage to the brushes lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from sliding towards the center of the cover Figure 12 41 Page 110 Page 109 Assembly of the Starter Generator Continued 3 Install the commutator end cover 23 onto the armature shaft Align the locating pin with the pin hole in the cover Install the
168. r operation BLACK WIRE 7 BULLET TERMINAL BROWN WIRE FIGURE 12 29 Test Procedure 12 RPM Limiter Figure 12 29 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Disconnect the bullet terminal Using a multimeter set on ohms Q place the red probe on the brown ground wire and place the black probe on the black wire bullet connector The reading should be continuity If the reading is not correct replace the RPM Limiter This test will find 90 of bad RPM Limiters Some of them may bench test okay but fail under a load due to heat while operating Another method of testing is to replace the RPM Limiter and then run the engine If the engine runs properly keep the new RPM Limiter in the circuit Test Procedure 13 Ignition Coil and Igniter DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Using a multimeter set on ohms Q measure the primary coil resistance Place the black probe of the meter on the primary wire terminal connector 1 and place the red probe on the core 2 Fig ure 12 30 If the resistance is not within 0 6
169. rDrive Plus and Tranquility are registered trademarks of Club Car Inc This manual effective August 1 1996 THIS SUPPLEMENT REPRESENTS THE MOST CURRENT INFORMATION AT TIME OF PUBLI CATION CLUB CAR INC IS CONTINUALLY WORKING TO FURTHER IMPROVE OUR VEHI CLES AND OTHER PRODUCTS THESE IMPROVEMENTS MAY AFFECT SERVICING PROCEDURES ANY MODIFICATION AND OR SIGNIFICANT CHANGE IN SPECIFICATIONS OR PROCEDURES WILL BE FORWARDED TO ALL CLUB CAR DISTRIBUTORS AND DEALERS AND WILL WHEN APPLICABLE APPEAR IN FUTURE EDITIONS OF THE MANUAL DAMAGE TO A VEHICLE OR COMPONENT THEREOF NOT RESULTING FROM A DEFECT OR WHICH OCCURS DUE TO UNREASONABLE OR UNINTENDED USE OVERLOADING ABUSE OR NEGLECT INCLUDING FAILURE TO PROVIDE REASONABLE OR NECESSARY MAINTE NANCE AS INSTRUCTED IN THE VEHICLE OWNER S MANUAL ACCIDENT OR ALTERATION INCLUDING INCREASING VEHICLE SPEED BEYOND FACTORY SPECIFICATIONS OR MODIFI CATIONS WHICH AFFECT THE STABILITY OF THE VEHICLE OR THE OPERATION THEREOF WILL VOID THE WARRANTY CLUB CAR INC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS AND DESIGNS AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION OR LIABILITY WHATSOEVER THERE ARE NO WARRANTIES EXPRESSED OR IMPLIED IN THIS MANUAL SEE THE LIMITED WARRANTY FOUND IN THE VEHICLE OWNER S MANUAL OR WRITE TO CLUB CAR INC Practice Safety WARNING Moving Parts Safety signs like you see above may at first seem shocking but their impact is mild co
170. reading Interpreting Results of the Hydrometer Test The approximate state of charge can be determined from the following table SPECIFIC GRAVITY AT 80 STATE OF CHARGE 1 250 1 280 1 220 1 240 1 190 1 210 1 160 1 180 25 If the difference between the cells is 020 or more the low cell should be suspected It may require a catch up charge or it may be a weak cell When the variations between cells reach 050 or more the battery should be replaced See Caution on page 129 VOLTAGE TEST See Testing the Battery Page 87 Load Test 1 Using a 160 ampere load tester connect the load tester to the battery posts 2 Read the battery voltage after the load tester has been on the battery for 15 seconds Compare the battery s voltage reading with the table below Make sure you have the correct ambient temperature IF TEMPERATURE IS MINIMUM VOLTAGE REQUIRED IS 70 F 20 C and above 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C 18 C REMOVING THE BATTERY 1 Remove the seat from the rear body 2 Disconnect the air hose that is clamped to the carburetor Remove the retention strap and lift the intake expansion chamber out of the vehicle Make sure the O ring is kept with the intake expansion chamber 3 Disconnect the battery wires as shown Figure 12 1 Page 82 4 Remove the two locknuts and washers and li
171. rvice Manual Club Car Part Number 1019051 01 SECTION 23B POWERDRIVE BATTERY CHARGER See Section 23B of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 24 MOTOR See Section 24 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 25 TRANSAXLE ELECTRIC VEHICLE For electric vehicles only see Section 9 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 Disregard information pertaining to gasoline vehicles SECTION 26 REAR SUSPENSION ELECTRIC VEHICLE See Section 25 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 Page 154 CLUB CAR Golf Cars Club Car Inc INGERSOLL RAND Box 204658 Augusta GA 30917 4658
172. s Reconnect the green white wire to the Forward and Reverse Limit Switch No 1 on standard PowerDrive System 48 vehicles or to the wiring har ness on PowerDrive Plus vehicles USE A 1 4 SOCKET OR A NUT DRIVER TO REMOVE TWO SCREWS 20 REMOVE POTENTIOMETER SLIGHTLY LOOSEN BOLT 9 WITH HOUSING COVER A 7 16 DEEP WELL SOCKET FIGURE 6 15 FIGURE 6 16 INSERT FLAT BLADE SCREWDRIVER THROUGH HOLE IN ACCLERATOR PIVOT ROD PLATE TO ADJUST POTENTIOMETER ADJUSTMENT SCREW ACCELERATOR PIVOT ROD PLATE LOOSEN THE POTENTIOMETER LOCK NUT WITH 5 16 WRENCH FIGURE 6 17 FIGURE 6 18 Page 23 Adjusting Actuator Lever on PowerDrive System 48 and PowerDrive Plus Vehicles Continued 4 12 Check potentiometer adjustment See 1995 1996 DS Maintenance and Service Manual Sec tion 20A Page 20 17 4 13 Install the potentiometer housing cover NOTE THE POTENTIOMETER IS PRESET AT THE FACTORY AND SHOULD NOT REQUIRE ADJUST MENT IF A PROBLEM IS SUSPECTED SEE SECTION 20A PAGE 20 17 IN THE MAINTENANCE AND SERVICE MANUAL ON POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBER 9704 667832 AND LATER TWO WASHERS ITEM 8 AND ITEM 16 ARE DELETED TYPICAL 4 PLACES POWERDRIVE SYSTEM 48 AND POWERDRIVE PLUS VEHICLES SERIAL NUMBERS PRIOR TO 9711 564736 TYPICAL 2 PLACES TO WIRE HARNESS FIGURE 6 19 Page 24 PEDAL GROUP DISASSEMBLY AND ASSEMBLY ALL VEHICLES Removing the Brak
173. s listed above Check for proper operation See Performance Inspec tion Page 3 2 in the Maintenance amp Service Manual Check brake pedal free play Adjust as necessary Brake System See Section 6 Check brake shoes replace if necessary Lubricate slide plates with graphite See Section 7 Semi annual Service by Drive Belt Check for cracks wear or glazing replace if neces Trained Mechanic Only sary Every 100 rounds or 50 hours of operation Electrical Wiring Check for cracked or worn insulation Check spark plug wire and boot for damage and Engine proper routing See Section 13 Check head and exhaust header pipe flange connec Exhaust System tion gasket for leaks Check muffler condition Front Wheel Alignment and Camber Check and adjust as required See Section 8 Periodic Service Schedule Continued on Next Page Page 11 PERIODIC SERVICE SCHEDULE GASOLINE VEHICLE REGULAR INTERVAL SERVICE Torque Converter Drive Belt Check for proper operation Inspect belt and replace as required See Section 16 Semi annual Service by Trained Mechanic Only Every 100 rounds or 50 hours of operation Starter Generator Belt Check for cracks wear and glazing replace if neces sary Check belt tension adjust as required Section 12 Continued General Vehicle Lubricate per Gas Vehicle Lubrication Chart Page 7 Check all daily
174. s the brake pedal slightly and then slide the park brake ratchet 26 Figure 6 11 Page 6 21 toward the end of the accelerator pivot rod Rotate the ratchet and remove it from the pivot rod 10 Remove the four bolts 24 washers 8 and nuts 16 that secure the accelerator pivot rod supports 23 to the frame Remove the pivot rod 6 and spacer 22 from the accelerator pivot rod supports 23 Figure 6 11 Page 21 11 Pull accelerator pedal 1 out of vehicle from the top side of the floorboard Figure 6 11 Page 21 INSTALLING THE ACCELERATOR PEDAL ASSEMBLY PowerDrive System 48 and PowerDrive Plus Electric Vehicles Serial Number 9711 564736 and Later and all 1997 DS V Glide 36 Volt and DS Gasoline Vehicles 1 Position the accelerator pivot rod supports 23 on the vehicle frame and install the four bolts 24 flat washers 8 and lock nuts 16 Tighten the nuts with fingers only at this time Figure 6 11 Page 21 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 Install the bolt 4 two washers 5 and nut 7 through the lower hole in the pedal and through the pivot rod Tighten the nut with fingers only at this time Figure 6 11 Page 21 3 Install the plastic spacer 22 on the pivot rod Figure 6 11 Page 6 21 4 nsert the pivot rod through the pivot rod supports on the vehicle frame 5 Tighten the four
175. screw 9 flat washer 8 See NOTE above and lock nut 11 that secure the spring retainer 12 to the pivot rod Figure 6 19 Page 24 and tighten to 45 55 in Ibs 5 6 2 N m A CAUTION MAKE SURE THAT THE HARDWARE IS INSTALLED WITH THE FLAT WASHER POSITIONED ON THE PASSENGER SIDE OF THE SPRING RETAINER 16 Install the hex head cap screw 4 two flat washers 5 and lock nut 7 that attach the accelerator pedal to the pivot rod Figure 6 19 Page 24 and tighten with fingers only at this time 17 Adjust the accelerator pedal height See NOTE below NOTE THE PROCEDURE FOR ADJUSTING THE ACCELERATOR PEDAL HEIGHT IS ON PAGE 17 18 Adjust the actuator lever See NOTE below NOTE THE PROCEDURE FOR ADJUSTING THE ACTUATOR LEVER IS ON PAGE 21 Page 33 1 9 SECTION 7 WHEEL BRAKE ASSEMBLIES E See Section 7 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 KN SECTION 8 STEERING AND FRONT SUSPENSION See Section 8 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 SECTION 9 WHEELS AND TIRES See Section 10 of the 1995 1996 Maintenance and Service Manual Club Car Part Number 1019051 01 Because of incorporation of the unitized transaxle in 1997 DS gasoline vehicles Section 10 in the 1995 1996 DS Maintenance and Service Manual becomes Section 9 in this supplement Page 34 SECTION 10 UNITIZED TRANSAXLE
176. sembled by a qualified techni cian See Removal of the Starter Generator Page 107 Page 99 Test 6 Procedure 7 Continued Disconnect the yellow wire from the DF terminal and the green wire from the F1 terminal on the starter generator Using a multimeter set on ohms Q place the red probe on the DF terminal and the black probe on the F1 terminal The reading should be between 4 5 to 5 5 ohms If the reading is incorrect a possible grounded DF terminal and or grounded field coil may be the cause The starter generator will need to be removed from the vehicle and disassembled by a qualified technician See Removal of the Starter Generator Page 107 A A YELLOW WIRE a DCV orr DATA HOLD DATA HOLD AC DC 500V MAX AC DC 500V MAX a gt 250V MAX Am gt 250V MAX n S gt lt STARTER gt gt GENERATOR v GENERATOR x e FIGURE 12 25 FIGURE 12 26 Test Procedure 8 Wire Continuity 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels To test a wire for continuity disconnect either end from the electrical component it is attached to Set the multimeter to ohms Q and place the red probe on the terminal at one end of the wire Place the black probe on the other terminal end of the wire The re
177. side diameter is less than 1 535 inches 39 millimeters replace the armature and bearings Figure 12 46 Page 113 Armature Ground Test A CAUTION DO NOT SUBMERGE ARMATURE IN SOLVENT Using a multimeter set on ohms place the positive probe on the commutator bars and the negative probe on the armature core The reading should be no continuity If the reading is incorrect replace the armature and the two bearings Figure 12 47 See WARNING and NOTE below NOTE BEFORE TESTING WIPE THE ARMATURE WITH A CLEAN CLOTH AND REMOVE CARBON DUST AND METAL PARTICLES FROM BETWEEN COMMUTATOR BARS Visual Inspection of Field Coils If the insulation on the field coils appears blackened or charred the serviceability of the coils is ques tionable Burned or scorched coil insulation indicates the motor has overheated due to overloads or grounded or shorted coil windings Be sure the insulators are tight in the housing Reworking the Starter Generator Any rework must be performed by a qualified technician Starter Generator service specifications are listed in the following table ITEM SERVICE LIMIT Commutator diameter minimum 1 535 inches 39 millimeters Concentric with armature shaft within 002 inch 0 051 millimeter Limit depth of cut when machining commutator 007 inch 0 2 millimeter If undercut of segment insulator is less than 016 0 406 millimeter then it should be undercut to 0
178. st the floorboard and then tighten the nut to 12 15 ft lbs 16 20 N m Figure 6 9 Page 18 For gasoline vehicles proceed to Step 4 For V Glide 36 volt vehicles and for PowerDrive System 48 and PowerDrive Plus vehicles serial number 9711 564736 and later proceed to Page 20 For PowerDrive System 48 and PowerDrive Plus vehicles prior to serial number 9711 564736 proceed to Page 21 Page 17 LOCKED POSITION WITH PARK BRAKE UNLOCKED MEASURE FROM 7 FLOOR BOARD TO BACK i OF ACCELERATOR MAKE SURE PAWL A ENGAGES AT LEAST 75 OF RACHET TOOTH LENGTH B FIGURE 6 6 1 2 INCH SOCKET 1 2 INCH WRENCH ROTATE BALL JOINT 11 CLOCKWISE TO INCREASE PAWL RACHET ENGAGEMENT COUNTERCLOCKWISE TO DECREASE IT FIGURE 6 7 5 5 8 t 1 8 7 ACCELERATOR PEDAL ADJUSTMENT TOOL CLUB CAR PART NO 1018710 gt READS ACCELERATOR PEDAL X HEIGHT ON SIDE TOWARD FLOORBOARD USE A RUBBER STRAP TO HOLD PEDAL IN DEPRESSED POSITION FIGURE 6 9 4 ADJUST THE ACCELERATOR ROD See page 20 for V Glide 36 volt vehicles and for PowerDrive System 48 and PowerDrive Plus electric vehicles serial numbers 9711 564736 and later or page 21 for PowerDrive System 48 and PowerDrive Plus vehicles prior to serial number 9711 564736 Page 18 Adjust the Accelerator Rod Gasoline Vehicles Only DANGER BEFORE SERVICING TURN THE KEY SWITCH TO OFF AND PLACE THE FORWARD AND REVERSE LEVER IN TH
179. stallation 1 Connect the cable to the cam in the electrical box 2 Insert the cable housing into the mounting slot in the wall of the electrical box with approximately the same number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable housing Figure 14 9 Page 14 10 in the manual Tighten the nuts finger tight 3 Connect the spring 15 to the engine governor arm Figure 14 11 Page 141 4 Install the cable in the accelerator cable bracket and secure it with the E ring 7 Figure 14 11 5 Before tightening the cable housing retaining nuts make sure the governed speed adjustment is cor rect See Engine RPM Adjustment on Page 14 14 in the Maintenance and Service Manual 6 Install the electrical box cover See WARNINGS below A WARNING BECAUSE THE ENGINE MUST BE RUN TO CONDUCT TESTS AND MAKE ADJUSTMENTS THE FOLLOWING SAFETY PROCEDURES MUST BE STRICTLY FOLLOWED FAILURE TO DO SO COULD RESULT IN DAMAGE TO THE VEHICLE OR PERSONAL INJURY ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD FOLLOW THE CORRECT PROCEDURES AND HEED THE WARNINGS IN THIS AND ALL APPLICABLE PUBLICATIONS ALWAYS WEAR APPROVED EYE PROTECTION WHEN SERVICING THIS VEHICLE CHOCK BOTH THE FRONT AND REAR WHEELS TO PREVENT VEHICLE MOVEMENT HOT AVOID TOUCHING THE ENGINE AND EXHAUST WHEN WORKING ON THE VEHICLE A HOT ENGINE OR
180. step 11 2 for the left side axle tube 11 4 Install the right axle shaft 68 in the right axle tube 76 Figure 10 6 Page 39 Using snap ring pliers install the retaining ring as shown Figure 10 85 See WARNING below A WARNING BE SURE THAT THE RETAINING RING IS PROPERLY SEATED IN ITS GROOVE IF THE RING IS NOT PROPERLY INSTALLED THE AXLE ASSEMBLY WILL SEPARATE FROM THE TRANSAXLE AND DAMAGE THE AXLE ASSEMBLY AND OTHER COMPONENTS LOSS OF VEHICLE CON TROL COULD RESULT CAUSING SEVERE PERSONAL INJURY 11 5 Install the left axle shaft 67 in the left axle tube 75 Figure 10 6 Page 39 Using snap ring pli ers install the retaining ring as shown Figure 10 85 See WARNING above IN THE SEQUENCE SHOWN TORQUE TO 15 18 FT LBS 20 3 24 4 N m THE FIFTEEN CLEAN THE MATING SURFACE BOLTS THAT SECURE THE CASING TOGETHER OF THE RIGHT AXLE TUBE THEN APPLY A CONTINUOUS BEAD OF THREE BOND NO 1215 TO MATING SURFACE FIGURE 10 83 CLEAN MATING SURFACE ON WC N CASING BEFORE 4 0 x INSTALLING AXLE TN IN THE SEQUENCE SHOWN ABOVE TORQUE BOLTS WITH LOCK WASHERS TO 33 39 FT LBS FIGURE 10 84 FIGURE 10 85 Page 66 UNITIZED TRANSAXLE INSTALLATION 1 Install the brake assemblies wheels and leaf springs on the transaxle 2 Position the transaxle mounting plate on the two mounting studs at the rear of the engine and then G install the two mounting nuts Figure 10 86 Use a 14 mm wrench 3
181. t for troubleshooting problems with the starter and gen erator circuits ENGINE WILL NOT TURN OVER STARTER DOES NOT ROTATE SOLENOID DOES NOT CLICK SOLENOID DOES CLICK CHECK BATTERY SEE PAGE 126 CHECK FUSE TEST PROCEDURE 1 TAKE VOLTAGE READING TEST PROCEDURE 24 VOLTAGE ABOVE 8 VOLTS UNDER LOAD VOLTAGE LESS THAN 8 VOLTS NO VOLTAGE READING CHECK SOLENOID CHECK SOLENOID TEST PROCEDURE 5 CHECK STARTER GENERATOR SEE PAGE 107 CHECK BATTERY SEE PAGE 126 TEST PROCEDURE 5 CHECK WHITE WIRE CHECK STARTER ACCELERATOR LIMIT SWITCH TEST PROCEDURE 4 CHECK NEUTRAL LOCK OUT LIMIT SWITCH TEST PROCEDURE 6 CHECK KEY SWITCH TEST PROCEDURE 2 Page 88 CHECK GROUND STRAPS TEST PROCEDURE 3 CONTINUITY CHECK SOLENOID TEST PROCEDURE 5 TEST PROCEDURE 8 FIGURE 12 12 DANGER DO NOT OPERATE GASOLINE VEHICLE IN AN ENCLOSED AREA WITHOUT PROPER VENTI LATION ENGINE PRODUCES CARBON MONOXIDE WHICH IS AN ODORLESS DEADLY POI SON A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SA
182. t it should be replaced Faults seen during the visual inspection can aid in diagnosing the original cause of the failure Items to look for are listed below Burned charred or cracked insulation Improperly cured varnish Thrown solder Page 112 e Flared armature windings Worn burned or glazed commutator Loose or raised commutator bars Bruised or damaged armature core laminations Worn armature bearing or shaft Dirty or oily commutator POLE PIECE SCREW T POLE PIECE RETAINING NUT FIELD COIL TERMINAL FIELD COIL lt HOUSING FIGURE 12 45 MEASURE EACH POSITION IN 2 PLACES 90 APART FIGURE 12 46 Cleaning Inspection and Replacement of the Commutator 1 Clean the carbon dust dirt and oil from the commutator Visually inspect the commutator for worn burned or glazed areas Check for loose or raised commutator bars Slight roughness of the commuta tor can be polished away with 400 or finer sandpaper See Caution at the top of page 114 Page 113 Cleaning Inspection and Replacement of the Commutator Continued A CAUTION NEVER USE EMERY CLOTH ON THE COMMUTATOR PARTICLES OF EMERY ARE CONDUC TIVE AND MAY SHORT CIRCUIT THE COMMUTATOR BARS NEVER USE OIL OR LUBRICANTS ON THE COMMUTATOR OR BRUSHES 2 Using a micrometer measure the outside diameter at two points along the commutator If the commu tator out
183. tarter circuit Key switch failed Section 12 Gasoline Vehicle Electrical System Starter circuit Neutral lock out limit switch failed Section 12 Gasoline Vehicle Electrical System Neutral lock out circuit Loose or broken wire in starter generator circuit Section 12 Gasoline Vehicle Electrical System Starter generator Starter generator does not charge battery Loose or broken wire in the starter gen erator circuit Section 12 Gasoline Vehicle Electrical System Starter generator Generator field coil is shorted Section 12 Gasoline Vehicle Electrical System Starter generator Brushes are worn or commutator is dirty Section 12 Gasoline Vehicle Electrical System Starter generator Starter generator belt is loose or slipping Section 12 Gasoline Vehicle Electrical System Starter generator Voltage regulator failed Section 12 Gasoline Vehicle Electrical System Generator circuit Battery failed Section 12 Gasoline Vehicle Electrical System Transmission does not engage or disengage smoothly Transmission shifter linkage is binding or is out of adjustment Insufficient low level of lubricant or wrong type of lubricant in transaxle Section 10 Unitized Transaxle in this supplement Section 10 Unitized Transaxle in this supplement Internal gears are damaged or worn Section 10 Unitized Transaxle in this supplement
184. tarter limit switch 11 onto the two screws 16 Secure the switch in place using the two washers 10 and the two nuts 9 Torque to 5 in Ibs 0 6 N m A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED LIMIT SWITCHES COULD BE DAMAGED Depress and release the accelerator pedal to make sure that both switches are being actuated when the pedal is released Connect battery cables positive cable first 6 Install the seat on the rear body NEUTRAL LOCK OUT LIMIT SWITCH Removing the Neutral Lock out Limit Switch Figure 12 51 1 2 3 Remove seat from rear body Disconnect the battery wires as shown Figure 12 1 Page 82 Disconnect the green white and black wires from the neutral lock out limit switch 5 located on the back of the forward and reverse assembly Remove the two nuts 2 and washers 6 from the neutral lock out limit switch b and slide the neutral lock out limit switch off the screws Installing the Neutral Lock out Limit Switch Figure 12 51 1 Install the neutral lock out limit switch 5 and install the two washers 6 and the two nuts 2 Torque to 5 in Ibs 0 6 N m Place the forward and reverse lever in REVERSE position to make sure that both switches are actuated See WARNING at top of Page 123 Page 122 A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED LIMIT SWITCHES COULD BE DAMAGED 2 Connect
185. tery Page 87 Testing the Vehicle Battery Continued 4 Place the red probe of a multimeter set at Volts DC 20 volt range on the positive post and place the black probe on the negative post of the battery and take a voltage reading If it shows less than 12 4 volts or if the lowest specific gravity reading from Step 3 is less than 1 225 recharge the battery If battery voltage is greater than 12 4 volts and specific gravity is greater than 1 225 the prob lem is not with the battery If the battery does not reach 12 4 volts or if the specific gravity of a cell is still less than 1 225 after charging replace the battery See NOTE below NOTE A FULLY CHARGED BATTERY THAT IS IN GOOD CONDITION SHOULD HAVE A SPECIFIC GRAVITY OF AT LEAST 1 225 IN ALL CELLS AND THE DIFFERENCE IN THE SPECIFIC GRAV ITY OF ANY TWO CELLS SHOULD BE LESS THAN 50 POINTS OPEN CIRCUIT VOLTAGE SHOULD BE AT LEAST 12 4 VOLTS 5 Connect a 160 ampere load tester to the battery 6 After 15 seconds read the voltage and then disconnect the load tester from the battery If the voltage reading is below the required minimum See Load Test Page 130 replace the battery 7 f the battery is found to be good or if the electrical problem continues after the battery has been replaced with a good one test the electrical circuits TESTING THE STARTER CIRCUIT AND THE GENERATOR CIRUIT Use the chart below Figure 12 12 as a starting poin
186. the differential pin 88 Figure 10 6 Page 39 by pushing it through from one side See Fig ure 10 47 Page 55 Remove the two differential idler gears 89 and two idler gear thrust plates 85 Figure 10 6 Page 39 as the pin is driven through NOTE IT MAY BE NECESSARY TO DRIVE THE DIFFERENTIAL PIN OUT WITH HAMMER AND PUNCH 5 Remove the differential gear 91 from the carrier case Figure 10 6 Page 39 6 If the bearings 79 are to be removed place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing and carrier casing 84 and press the bearing off as shown Figure 10 48 Page 55 Repeat the process for the carrier cover 87 Figure 10 6 Page 39 A CAUTION DO NOT TIGHTEN THE BEARING PULLER WEDGE ATTACHMENT AGAINST THE SHAFT THE SHAFT COULD BE DAMAGED WHEN PRESSING THE BEARING OFF DISASSEMBLE THE SHIFTER FORK ASSEMBLY 1 Push the shift rod 33 out of the shift fork 34 Figure 10 43 Page 53 2 Shake the shift fork to remove the spring 35 and ball 36 Figure 10 43 Page 51 DISASSEMBLE THE SYNCHRONIZER GEAR ASSEMBLY A CAUTION MARK PARTS FOR IDENTIFICATION AS THEY ARE DISASSEMBLED PARTS MUST BE REAS SEMBLED IN THEIR ORIGINAL LOCATIONS AND ORIENTATIONS 1 Place a bearing puller wedge attachment Club Car Part No 1012812 between the bearing 38 and spur governor drive gear 40 Figure 10 43 Page 53 then press the bearing off the
187. through the adjusting bracket 4 and then through the starter genera tor Install a lockwasher 9 and 5 16 nut 12 onto the end of the adjustment screw 11 Tighten to fin ger tight Figure 12 48 3 Install the belt 3 then tighten the mounting screws See Belt Adjustments on next page 4 Connect the yellow wire from the voltage regulator to the DF terminal on the starter generator Figure 12 2 Page 83 Install a flat washer lockwasher and nut onto the terminal Torque the nut to 26 35 in Ibs 3 0 4 0 N m 5 Install the white wire from the solenoid to the F2 terminal on the starter generator Install the black wire from the frame to the A2 terminal on the starter generator Install the green wire from the F1 to the A1 terminal on the starter generator Figure 12 2 Page 83 Install a flat washer lockwasher and nut onto each terminal Torque the nuts to 43 52 in Ibs 4 8 5 9 N m 6 Reinstall the access panel Figure 12 35 Page 106 7 Install the seat on the rear body Page 116 BELT ADJUSTMENTS ED Belt tension should be checked periodically If the starter generator slips when starter motor operates adjust belt to correct tension Belt Tension Adjustment 1 Remove the access panel from the rear body Figure 12 35 Page 106 2 Make sure the two pivoting screws 5 on the mounting bracket are finger tight The adjustment screw 11 and nut 12 are to be finger tight also Figure 12 48 FIGURE 12 48 3
188. tight If they are not rewire or tighten as neces sary Using a multimeter set on ohms Q place the red probe on the M terminal of the key switch and place the black probe on the M terminal With the key switch turned OFF the reading should be continuity With the key switch turned ON the reading should be no continuity If the readings are incor rect replace the key switch Place the red probe of the multimeter on the No 2 terminal of the key switch and place the black probe on the No 1 terminal Insert the key and turn the switch to ON The reading should be continuity With the key switch turned OFF the reading should be no continuity If the readings are incorrect replace the key switch Figure 12 19 Page 96 Test Procedure 3 Ground Straps 1 Place the neutral lock out cam in the SERVICE position put the forward and reverse lever in the NEU TRAL position and chock the wheels Set the multimeter to ohms Q Place the red probe on the A2 terminal of the starter generator and place the black probe on the frame of the vehicle The reading should be continuity If the read ing is incorrect clean and tighten wire connections If the connections are okay repair or replace the wire See Figure 12 57 Page 133 Place the red probe of the multimeter on the ground strap terminal end located on the oil filler bracket on the engine Place the black probe on the frame of the vehicle The readin
189. trolyte temperature of one of the center cells 4 Squeeze the rubber bulb of the hydrometer and insert into the cell Slowly release the bulb drawing electrolyte up into the glass tube of the hydrometer 5 When the float rises off the bottom adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube Remove the hydrometer from the cell and release the pressure from the bulb 6 Hold the hydrometer vertically insuring that the float is not contacting the sides of the barrel Hold the hydrometer at eye level and read the scale at the level of electrolyte Figure 12 56 7 Record the reading 8 Return the electrolyte to the cell from which it was taken 9 Repeat steps 2 8 on all cells Hydrometer Calibration BATTERY ie CAP PLATES HYDROMETER TEST WATER LEVEL HOLD THE HYDROMETER AT LEAST 1 2 AT EYE LEVEL READ THE ABOVE PLATES SCALE AT THE LEVEL OF OR TO LEVEL THE ELECTROLYTE INDICATOR FIGURE 12 55 FIGURE 12 56 Page 129 Hydrometer Calibration Continued Most hydrometers are calibrated to read correctly at 80 F The readings obtained as described above must be corrected for temperature For each 10 F above 80 F add 004 to the reading For each 10 F below 80 F subtract 004 from the
190. ttach the ends of the spring to the park brake pedal and to the brake pedal weldment as shown See Figure 6 23 5 Install the push nut 4 on the park brake pedal shaft Figure 6 22 Page 27 6 Connect park brake rod 9 ball joint to the ball stud on the park brake pedal assembly Figure 6 22 HOOK ONE TURN HEX NUTS UNTIL 4 BEING GU THERE IS A 1 4 TO 1 2 6 3 TO 12 7 MM FREE PLAY OF THE BRAKE PEDAL X00000 TE _ LIFT OTHER END OF SPRING 20 UP AND OVER BRAKE WELDMENT BY PRYING DOWN ON SHAFT WITH SMALL SCREWDRIVER FIGURE 6 23 FIGURE 6 24 REMOVING THE ACCELERATOR PEDAL ASSEMBLY PowerDrive System 48 and PowerDrive Plus Electric Vehicles Serial Number 9711 564736 and Later and all 1997 DS V Glide 36 Volt and DS Gasoline Vehicles For PowerDrive System 48 and PowerDrive Plus vehicles prior to serial number 9711 564736 see page 30 1 Make sure the key switch is off and that the Forward and Reverse Switch is in neutral then disconnect the battery ies DS V Glide PowerDrive System 48 and PowerDrive Plus vehicles disconnect the batteries as shown Figure 22 5 or 22 6 Page 22 5 in the Maintenance and Service Manual DS Gasoline powered vehicle disconnect both battery cables negative first 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube o
191. two M6 x 180mm screws 20 and tighten to 95 104 in Ibs 10 6 11 6 N m Fig ure 12 37 Page 108 Install the brushes into the holders Place 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 covers 29 in the openings in the commutator end cover 23 Figure 12 39 Page 108 Disassembly of the Starter Generator to Service the Armature Commutator 1 Remove two bolts 20 and washers 21 and 22 and pull commutator end cover 23 free of the starter housing 24 Figure 12 37 Page 108 See WARNING and NOTE below A WARNING WHEN MAKING ELECTRICAL TESTS OR REPAIRS ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION REMOVE THE KEY PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL DISCONNECT THE BATTERY AS SHOWN FIGURE 12 1 PAGE 82 FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED SEE THE SAFETY WARNINGS ON PAGE 81 NOTE IF THE BRUSHES ARE NOT REMOVED CONTACT BETWEEN THE BRUSHES AND COMMUTA TOR AS THE COMMUTATOR END COVER IS BEING REMOVED OR INSTALLED COULD POS SIBLY DAMAGE THE BRUSHES LIFT THE BRUSH SPRINGS OUT OF THE NOTCHES IN THE BRUSHES AND PULL THE BRUSHES BACK FROM THE CENTER OF THE COMMUTATOR END COVER THE SPRINGS WILL REST ON THE SIDES OF THE BRUSHES AND HELP PREVENT THEM FROM SLIDING TOWARDS THE CENTER OF THE COVER FIGURE 12 41 BRUSH BEING HELD IN LOCKED POSIT
192. ualizer rod so that brake pedal free play is 1 4 inch to 1 2 inch 6 35 mm to 12 7 mm Figure 6 24 Page 28 See NOTE below NOTE e BRAKE PEDAL FREE PLAY IS THE DISTANCE THE BRAKE PEDAL CAN BE DEPRESSED BEFORE THE BRAKE ACTUATOR ARM MOVES Removing the Park Brake Assembly 1 Make sure the key switch is off and that the Forward and Reverse Switch is in neutral then disconnect the battery or batteries as shown In the Maintenance and Service Manual see Figure 12 1 Page 12 2 for gasoline vehicles or Figure 22 5 or 22 6 Page 22 5 for electric vehicles See CAUTION below A CAUTION DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES PER INSTRUCTIONS ON PAGE 15 Page 26 2 Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack Place jackstands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands See WARNING below A WARNING LIFT ONLY ONE END OF A VEHICLE AT A TIME BEFORE LIFTING LOCK THE BRAKES AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR USE A SUITABLE LIFTING DEVICE CHAIN HOIST OR HYDRAULIC FLOOR JACK WITH 1000 LBS 454 KG MINIMUM LIFTING CAPACITY DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION ALWAYS USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE 3 Remove the park brake assembly 3 1 To remove the park brake rod and pawl assembly 9 through 13 an
193. until the vehicle runs smoothly Usually not more than one turn of the screw is necessary See Maintenance and Service Manual Page 14 4 for Figure 14 4 and chart PROCEDURE FOR CHANGING MAIN JET The governor guard 6 used previously and shown in the 1995 1996 Maintenance and Service Manual in Figure 14 6 on Page 14 6 is replaced on the 1997 engine by the new governor guard 6 shown in the illus tration at the top of page 138 Page 137 FIGURE 14 6 ACCELERATOR ROD Accelerator Rod Removal On page 14 9 in the 1995 1996 DS Maintenance and Service Manual under the sub heading above Figure 14 8 shows the previous accelerator pedal configuration as well as the current one The revised Figure 14 8 at the top of page 139 shows only the current pedal configuration Page 138 FIGURE 14 8 GOVERNOR CABLE The mounting of the governor and accelerator cables shown in the 1995 1996 Maintenance and Service Manual in Figure 14 11 on Page 14 12 was changed with incorporation of the unitized transaxle on 1997 vehicles The following instructions under the headings GOVERNOR CABLE and ACCELERATOR CABLE supersede those in the 1995 1996 Maintenance and Service Manual on pages 14 11 through 14 13 A WARNING ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL ELECTRICAL AND MECHANICAL REPAIR FOLLOW ALL PROCEDURES EXACTL
194. ure 6 19 Page 24 9 Remove the crescent retaining ring 16 See NOTE above from the accelerator pivot rod Figure 6 19 Page 24 10 Depress the brake pedal slightly and then slide the park brake ratchet 25 toward the end of the accel erator pivot rod Figure 6 19 Page 24 Rotate the ratchet towards the rear of the vehicle and remove it from the pivot rod 11 Hold the actuator lever 17 and accelerator pedal 1 in place and remove the accelerator pivot rod and plastic washer 18 Figure 6 19 Page 24 12 Pull the accelerator pedal 1 Figure 6 19 Page 24 out of the vehicle from the top side of the floor board 13 Remove the four hex head cap screws 23 flat washers 27 and lock nuts 11 attaching the acceler ator pivot rod support 22 and potentiometer assembly 21 to the vehicle frame Figure 6 19 Page 24 and remove the pivot rod support and the potentiometer assembly INSTALLING THE ACCELERATOR PEDAL ASSEMBLY DS PowerDrive System 48 Vehicles and DS PowerDrive Plus Vehicles Serial Num bers Prior to 9711 564736 1 Position the accelerator pivot rod support 22 and the potentiometer assembly 21 on the vehicle frame and install the four hex head cap screws 23 flat washers 27 and lock nuts 11 Tighten the nuts with fingers only at this time Figure 6 19 Page 24 2 Insert the lower end of the accelerator pedal 1 through the floorboard and install the accelerator pivot rod 6 through the upperm
195. ve post 9 Place the forward and reverse lever in NEUTRAL and place the neutral lock out cam in the SERVICE position Turn the key switch to the ON position With the accelerator in the up position the reading on the multimeter should be no continuity Depress the accelerator pedal and listen for the solenoid click There should be continuity If either reading is incorrect replace the solenoid With the forward and reverse lever still in NEUTRAL and the neutral lock out cam in the SERVICE position set the multimeter to DC volts DC V and place the red probe on the large post that does not have wires connected to it Place the black probe on the frame of the vehicle Turn key switch to ON position depress accelerator pedal and listen for solenoid click The meter should read full bat tery voltage If the reading is incorrect replace the solenoid Figure 12 23 Page 98 Disconnect the 6 gauge black wire from the negative post of the battery before reconnecting the wires to the solenoid Page 97 S Les MIN T AC DC 500V f 250V DATA HOLD A ACIDC 500V MAX gt 250V MAX n 0 n L 7 ELECTRICAL COMPONENT BOX FIGURE 12 22 FIGURE 12 23 Test Procedure 6 Cam Activated Neutral Lock out Limit Switch This switch is located on the forward and reverse switch assembly There
196. xle Assembly L 60 Unitized Transaxle Installation u U u a asss 67 Forward and Reverse Shifter Cable n 71 SECTION 11 TROUBLESHOOTING THE GASOLINE VEHICLE 75 Section 11 in this supplement supersedes Section 11 in the 1995 1996 DS Maintenance and Ser vice Manual Troubleshooting Guide sssessessssseseesseeeeen nennen nennen nnne nnns nnn dandani s dapan enne annt 75 SECTION 12 ELECTRICAL SYSTEM GASOLINE VEHICLE 81 Section 12 in this supplement supersedes Section 12 in the 1995 1996 DS Maintenance and Ser vice Manual General Information ea de eerte attt te etate dosis Un eerta 82 FE 290 Gasoline Vehicle Electrical Circuit nnne nnns 82 Circuit T sting i eret tm Pe Hr Gr det i Fe tre pe ne re e RE 87 Test Proced less cocto nn nien sau tutore E LETT 94 Electrical SystermmGomponentS 107 2c bale eet dente eet erdt edi edita 107 Voltage Regulator cete tete lanes nir essen ea ix o v oa eR E Ran adie 118 Key SWITCH e rene e FERE HO ER e eredi teris tpe epe Reid 119 ys ERR Tuy IEEE 119 USO kasihan EE ONN 120 Accelerator Starter Limit Switch ul u uy n Un Uu 121 Kall mee on Rel eee e eA
197. y A WARNING F THE FUSE IS BLOWN DETERMINE THE CAUSE OF THE FAILURE AND MAKE NECESSARY REPAIRS BEFORE INSTALLING A NEW FUSE USE 10 AMP FUSES ONLY IF A FUSE WITH A HIGHER AMP RATING IS USED DAMAGE TO THE VEHICLE ELECTRICAL SYSTEM MAY OCCUR 2 Install the snap on electrical box cover by firmly pressing down on all corners and install the screw Re connect the battery wires 3 Install the seat on the rear body Page 120 ACCELERATOR STARTER LIMIT SWITCH Removing the Accelerator Starter Limit Switch Figure 12 50 Remove seat from body EJ Disconnect battery wires as shown Figure 12 1 Page 82 Remove electrical component box cover 1 Disconnect the green wire and the orange wire from the accelerator starter limit switch 11 Remove the two nuts 9 and washers 10 that secure the accelerator limit switch in place 6 Remove the accelerator starter limit switch Qv S Qro ct Installing the Accelerator Starter Limit Switch Figure 12 50 1 Install the accelerator starter limit switch 11 onto the two screws 16 and secure the switch in place using the two washers 10 and the two nuts 9 Torque to 5 in Ibs 0 6 N m A WARNING DO NOT OVER TIGHTEN THE RETAINING NUTS IF THE NUTS ARE OVER TORQUED LIMIT SWITCHES COULD BE DAMAGED 2 Connect green wire to common COM terminal and the orange wire to the normally closed NC termi nal of the accelerator starter limit switch Figure 12

1997 DS Golf M&S Supplement

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1997 DS Golf M&amp;S Supplement

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1997 DS Golf M&S Supplement