Club Car TURF 1 2000 Maintenance And Service Manual
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Club Car TURF 1 2000 Maintenance And Service Manual

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2000
MAINTENANCE
S E R V I C E
MANUAL
TURF 1, TURF 2, TURF 6,
CARRYALL 1, CARRYALL 2,
CARRYALL 2 PLUS AND
CARRYALL 6 VEHICLES
MANUAL NUMBER 102067502
EDITION CODE 0500C0312B

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  • Page 1 2000 MAINTENANCE S E R V I C E MANUAL TURF 1, TURF 2, TURF 6, CARRYALL 1, CARRYALL 2, CARRYALL 2 PLUS AND CARRYALL 6 VEHICLES MANUAL NUMBER 102067502 EDITION CODE 0500C0312B...
  • Page 3 If it appears that a service question is not answered in this manual, you may write to us at: Club Car, Inc.; P.O. Box 204658; Augusta, GA 30917; Attention: Technical Services, or contact a Club Car Technical Service Representative at (706) 863-3000, ext.
  • Page 4 SPECIFICATIONS OR MODIFICATIONS 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.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 – SAFETY General Warning ..........................SECTION 2 – VEHICLE SPECIFICATIONS General Information ........................... Vehicle Capacities ..........................SECTION 3 – GENERAL INFORMATION Model Identification ..........................Pre-Operation Checklist ........................Performance Inspection ......................... Controls and Indicators ........................Key Switch ............................. Forward/Reverse Control .......................
  • Page 6 SECTION 4 – BODY AND TRIM Cleaning the Vehicle .......................... Seat ..............................Front Body Repair ..........................Stress Lines or Streaks ........................Minor Impact Damage/Deformations ..................... Minor Scratches and Surface Blemishes ..................Small Scratches That Cannot Be Buffed Out ................. Gouges, Punctures, Tears, Large Scratches, and Abrasions ............Front Body ............................
  • Page 7 Rear Floor Mat Installation – Turf 6 and Carryall 6 Only ............... 4-13 Bumper .............................. 4-13 Bumper Removal ........................... 4-13 Bumper Installation ........................4-13 SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment ........................Pedal Group Disassembly and Assembly ..................5-12 Brake Pedal Removal ........................
  • Page 8 SECTION 7 – STEERING AND FRONT SUSPENSION General Information ........................... Steering Wheel ........................... Steering Wheel Removal ....................... Steering Wheel Installation ......................Steering Column ..........................Steering Column Removal ......................Steering Column Disassembly ....................... Steering Column Assembly ......................Steering Column Installation ......................Steering Adjustment ...........................
  • Page 9 SECTION 8 – WHEELS AND TIRES General Information ........................... Wheels ............................... Wheel Removal ..........................Wheel Installation .......................... Tires ..............................Tire Removal ..........................Tire Repair ............................. Tire Installation ..........................SECTION 9 – REAR SUSPENSION General Information ........................... Shock Absorbers ..........................Inspecting and Removing Shock Absorbers .................. Installing Shock Absorbers ......................

  • Page 11: Section 1 - Safety

    SECTION 1 – SAFETY To ensure the safety of those servicing Club Car Turf and Carryall vehicles, and to protect the vehicles from possible damage resulting from improper service or maintenance, the procedures in this manual must be fol- lowed. It is important to note that throughout this manual there are statements contained within boxes labeled DANGER , WARNING , or CAUTION .
  • Page 12 • A CLUB CAR VEHICLE WILL NOT PROVIDE PROTECTION FROM LIGHTNING, FLYING OBJECTS, OR OTHER STORM RELATED HAZARDS. IF CAUGHT IN A STORM WHILE DRIVING A CLUB CAR VEHICLE EXIT THE VEHICLE AND SEEK SHELTER IN ACCORDANCE WITH APPLICABLE SAFETY GUIDELINES FOR YOUR LOCATION.
  • Page 13 SAFETY General Warning WARNING GASOLINE VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE: - DISCONNECT BATTERY CABLES, NEGATIVE (–) FIRST (FIGURE 1-1, PAGE 1-3) . - DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG. • FRAME GROUND - DO NOT ALLOW TOOLS OR OTHER METAL OBJECTS TO CONTACT FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING.

  • Page 15: Section 2 - Vehicle Specifications

    SECTION 2 – VEHICLE SPECIFICATIONS GENERAL INFORMATION Club Car, Inc. reserves the right to change specifications and design of either the gasoline or electric vehicle at any time without notice and without obligation to make these changes on units previously sold.
  • Page 16 VEHICLE SPECIFICATIONS General Information Turf 1 Turf 2 Carryall 2 Turf 6 SPECIFICATIONS Carryall 1 Carryall 2 Plus Carryall 6 PowerDrive PowerDrive Key-Start (CA 6) PowerDrive STEERING/SUSPENSION/BRAKES Pedal-Start Pedal-Start Key-Start System 48 System 48 Pedal-Start (T urf 6) System 48 (continued) Gasoline Gasoline...

  • Page 17: Vehicle Capacities

    VEHICLE SPECIFICATIONS Vehicle Capacities Turf 1 Turf 2 Carryall 2 Turf 6 SPECIFICATIONS Carryall 1 Carryall 2 Plus Carryall 6 PowerDrive PowerDrive Key-Start (CA 6) PowerDrive Pedal-Start Pedal-Start Key-Start DIMENSIONS/WEIGHT (continued) System 48 System 48 Pedal-Start (T urf 6) System 48 Gasoline Gasoline Gasoline...

  • Page 19: Section 3 - General Information

    Figure 3-2 Serial Number Decal Behind Dash PRE-OPERATION CHECKLIST All Club Car vehicles are thoroughly inspected and adjusted by both the factory and the Club Car dealer. However, before accepting any new Club Car vehicle(s), the responsible individual should become familiar with the controls and operation, and carefully inspect each vehicle to be satisfied that it is in proper working...

  • Page 20: Performance Inspection

    FORWARD position, depress accelerator pedal. As pedal is depressed, the engine or motor should start and the vehicle should accelerate smoothly to full speed. When pedal is released it should return to the original position and the engine or motor should stop. Club Car vehicles operate at reduced speed when in REVERSE.

  • Page 21: Controls And Indicators

    GENERAL INFORMATION Controls and Indicators operate at 17-18 mph (27-29 km/h) on a level surface. All Club Car vehicles operate at reduced speed when in REVERSE. • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle’s ride and performance.

  • Page 22: Forward/Reverse Control

    F (FORWARD), to operate the vehicle in the forward direction, or towards the passenger, R (REVERSE), to operate the vehicle in reverse. Club Car vehicles operate at a reduced speed when in reverse. The reverse buzzer will sound as a warning when the forward/reverse handle is in the REVERSE position.

  • Page 23: Accelerator Pedal

    GENERAL INFORMATION Controls and Indicators ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 3-6, Page 3-5). The operation of the accelerator pedal differs from that of an automobile: • Pedal-Start Vehicle: When the key switch is ON, and the Forward/Reverse handle is in either FOR- WARD or REVERSE, depressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected (FORWARD or REVERSE).

  • Page 24: Neutral Lockout

    GENERAL INFORMATION Controls and Indicators Figure 3-7 Brake Pedal Figure 3-8 Park Brake NEUTRAL LOCKOUT Gasoline Vehicles Only For the convenience of the trained technician, there is a neutral lockout cam (yellow knob) located on the back of the Forward/Reverse handle, inside the engine compartment. If the neutral lockout cam is pulled out approximately 3/8 inch (10 mm) and then rotated one-half turn until it snaps into place, the cam will be in the SERVICE position (Figure 3-9, Page 3-6).

  • Page 25: Choke

    GENERAL INFORMATION Controls and Indicators tion, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position. NOTE • BE SURE TO RETURN THE CAM TO THE OPERATE POSITION AFTER SERVICING THE VEHICLE OR THE ENGINE WILL NOT RUN WITH THE FORWARD/REVERSE HANDLE IN EITHER THE FORWARD OR REVERSE POSITIONS.

  • Page 26: Oil Light

    If the oil warning light goes on and off, the vehicle may be driven, but oil should be checked at the first opportunity. If the oil level is correct and the light stays on, have a Club Car factory trained technician check the vehicle.

  • Page 27: Driving Instructions

    16 hours (see PowerDrive Battery Charger Owner’s Manual) and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and batteries should be checked by a Club Car distributor/dealer. • The warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (DC plug is still connected) if AC power to the charger is interrupted.

  • Page 28: Starting The Vehicle

    GENERAL INFORMATION Driving Instructions WARNING • TO AVOID POSSIBLE INJURY TO AN INATTENTIVE PASSENGER AND (OR) DAMAGE TO THE VEHICLE, AVOID SUDDEN STARTS, SUDDEN STOPS AND ABRUPT TURNS. • DO NOT USE THE VEHICLE ON PUBLIC ROADS. IT IS NOT DESIGNED OR INTENDED FOR STREET USE AND SHOULD NOT BE LICENSED FOR USE ON PUBLIC ROADS.

  • Page 29: Stopping The Vehicle

    GENERAL INFORMATION Bed Latch NOTE • PEDAL-START VEHICLE: IF THE VEHICLE IS SHIFTED INTO NEUTRAL, POWER WILL BE CUT OFF AND THE VEHICLE WILL STOP RUNNING. • KEY-START VEHICLE: IF THE ACCELERATOR PEDAL IS DEPRESSED WHILE THE FORWARD/ REVERSE HANDLE IS IN NEUTRAL, OR IF YOU TRY TO SHIFT FROM FORWARD TO REVERSE WHILE THE ACCELERATOR PEDAL IS DEPRESSED, THE ENGINE WILL SHUT OFF.

  • Page 30: Loading And Unloading

    GENERAL INFORMATION Loading and Unloading PROP PROP ROD TRACK Figure 3-16 Prop Rod The Turf 1, Turf 2, Carryall 1, Carryall 2, and Carryall 2 Plus are equipped with a bed latch on the driver side of the vehicle as standard equipment (Figure 3-14, Page 3-11). To lift the bed, pull the latch handle toward the rear of the vehicle and lift the bed (Figure 3-15, Page 3-11).

  • Page 31: Towing With The Vehicle

    Because towing a vehicle or trailer can have adverse effects on vehicle handling, be especially cautious when towing with a Club Car vehicle. Total vehicle capacity, including the tow vehicle load rating and the gross trailer weight of the vehicle or trailer should not exceed the weight specified in the preceding WARN- ING.

  • Page 32: Storage - Gasoline Vehicle

    • FOR USE ON PUBLIC ROADS, THE TRAILER MUST MEET ALL FEDERAL, STATE, AND LOCAL REQUIREMENTS SUCH AS TAILLIGHTS, BRAKE LIGHTS, ETC. • NEVER TOW A CLUB CAR VEHICLE BEHIND A PASSENGER VEHICLE OR TRUCK ON A PUBLIC ROAD UNLESS IT IS ON AN APPROVED TRAILER.

  • Page 33: Return Stored Vehicle To Service

    3.3. Disconnect fuel vent line from fuel tank vent nipple. 3.4. Plug the fuel tank vent nipple so it is air tight. Club Car recommends using a slip-on vinyl cap. 4. To protect the engine, remove the spark plug and pour 1/2 ounce of SAE 10 weight oil into the engine through the spark plug hole.

  • Page 34: Storage - Electric Vehicle

    GENERAL INFORMATION Storage – Electric Vehicle valve is fully open. A partially closed fuel valve (Figure 3-20, Page 3-16) combined with the use of the choke can result in a fouled spark plug and engine failure. 1.2. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the SERVICE position (Figure 3-9, Page 3-6).

  • Page 35: Return Stored Vehicle To Service

    (do not allow this solution to enter the batteries). Let the terminals dry and coat them with Battery Terminal Protector (Club Car Part No. 1014305). 4. Store in a cool, dry place. This will minimize battery self-discharge.

  • Page 37: Cleaning The Vehicle

    SECTION 4 – BODY AND TRIM WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN GENERAL BODY AND PAINT REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL.

  • Page 38: Seat

    BODY AND TRIM Seat SEAT To preserve seat appearance clean regularly with mild soap or detergent applied with a sponge or soft cloth. Use a soft bristle brush to clean areas that are especially soiled. Use the following guidelines: Light Soiling – A solution of 10% liquid soap and warm water applied with a soft, damp cloth is recom- mended.

  • Page 39: Small Scratches That Cannot Be Buffed Out

    AND ABRASIONS ON PAGE 4-3. 3. Using the brush provided with the touch-up paint (available from Club Car Service Parts, see color chart below), apply paint to the scratch. Multiple layers of paint may be required to fill the scratch.

  • Page 40: Front Body Installation

    BODY AND TRIM Front Body 3. Remove carriage bolts (15), locknuts (17) and washers (16) from front body trim. Remove screws (14) from top of front body (Figure 4-1, Page 4-4). 4. Loosen (do not remove) screws (18) holding front body trim against front body (Figure 4-1, Page 4-4). 5.

  • Page 41: Tilt Bed - Turf 1, 2, Carryall 1, 2 And 2 Plus

    BODY AND TRIM Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus NOTE • IF INSTALLING A NEW FRONT BODY, TWO 5/16 INCH HOLES MUST BE DRILLED AFTER THE BODY HAS BEEN PLACED ON THE VEHICLE. USE THE BODY TRIM (13) AS A GUIDE FOR DRILLING THE HOLES (FIGURE 4-1, PAGE 4-4).
  • Page 42 BODY AND TRIM Tilt Bed – Turf 1, 2, Carryall 1, 2 and 2 Plus TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-2 Tilt Bed - Turf 1, 2, Carryall 1, 2 and 2 Plus Page 4-6 2000 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 43: Tilt Bed Installation

    BODY AND TRIM Flat Bed – Turf 6 and Carryall 6 TILT BED INSTALLATION 1. Hold bed at a slight angle (front of bed lower than rear of bed) to vehicle and place front edge of bed onto vehicle frame. Bed latches (5) should be engaged with latch plates (1) (Figure 4-2, Page 4-6). 2.
  • Page 44 BODY AND TRIM Flat Bed Trim – Turf 6 and Carryall 6 5. Remove two 5/16 x 1 hex head bolts (4) and locknuts (6) from each of the two handles on rear edge of bed. Remove the two handles (7) and rear trim strip (3) (Figure 4-4, Page 4-9). 6.
  • Page 45 BODY AND TRIM Flat Bed Trim – Turf 6 and Carryall 6 TYPICAL 3 TYPICAL 2 PLACES PLACES TYPICAL 4 PLACES TYPICAL 8 TYPICAL 16 PLACES PLACES TYPICAL 2 PLACES AT BODY TYPICAL 2 PLACES AT DOOR Figure 4-4 Flat Bed Trim, Access Door and Side Door - Turf 6 and Carryall 6 2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 4-9...

  • Page 46: Flat Bed Trim Installation

    BODY AND TRIM Access Door – Turf 6 and Carryall 6 FLAT BED TRIM INSTALLATION 1. Install trim in the reverse order of removal. 2. Tighten bolts (4) to 8 ft-lb. (10.8 N·m) (Figure 4-4, Page 4-9). 3. Install bolts, flatwashers and locknuts that secure bed to vehicle frame. Tighten bolts to 75 in-lb (8 N·m). ACCESS DOOR –...

  • Page 47: Rear Fender Installation

    BODY AND TRIM Trailer Hitch – (Optional on Some Models) Turf 6 and Carryall 6 Only: 3.1. Remove pan head screws (16) connecting reverse buzzer (17) to rear fender (6) and disconnect the two wires from the reverse buzzer (Figure 4-6, Page 4-12). All Vehicles: 4.

  • Page 48: Trailer Hitch Installation

    BODY AND TRIM Trailer Hitch – (Optional on Some Models) 3. Where the hitch (7) is mounted to hitch brace (8), remove the nut (12), lock washer (11), washer (10) and bolt (9). 4. Remove hitch (7) from vehicle. TRAILER HITCH INSTALLATION 1.

  • Page 49: Tailskirt

    BODY AND TRIM Tailskirt TAILSKIRT TAILSKIRT REMOVAL 1. Remove two thread-forming screws (5) from tailskirt (4) and lift tailskirt from vehicle frame (Figure 4-5, Page 4-11 or Figure 4-6, Page 4-12). TAILSKIRT INSTALLATION 1. Insert upper edge of tailskirt (4) under, and in front of, back edge of rear body (Figure 4-5, Page 4-11 or Figure 4-6, Page 4-12).

  • Page 51: Section 5 - Accelerator And Brake Pedal Group

    SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THE VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR. • FOLLOW THE PROCEDURES EXACTLY AS STATED IN THIS MANUAL, AND HEED ALL DANGER, WARNING, AND CAUTION STATEMENTS LISTED IN THIS MANUAL AS WELL AS THOSE AFFIXED TO THE VEHICLE.

  • Page 52: Pedal Group Adjustment

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment WARNING ELECTRIC VEHICLES ONLY: • TO AVOID UNINTENTIONALLY STARTING THE VEHICLE, DISCONNECT BATTERIES AS SHOWN (FIGURE 1-2 OR 1-3, SECTION 1, PAGE 1-3). • AFTER DISCONNECTING BATTERIES, DISCHARGE THE CONTROLLER AS FOLLOWS: - TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD/REVERSE HANDLE IN THE REVERSE POSITION.
  • Page 53 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment CORRECT PEDAL POSITION IS 5-3/4 ±1/4 INCH (14.6 ±.6 CM) FROM FLOORMAT TO BACK OF BRAKE PEDAL Figure 5-2 Adjust Brake Pedal Height Figure 5-3 Measure Brake Pedal Height 2. ADJUST BRAKE PEDAL FREE PLAY NOTE •...
  • Page 54 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Adjust Park Brake Ratchet/Pawl Gap and Pawl Engagement, Continued: CUTAWAY SIDE VIEW ADJUST RETAINING NUT (7) UNTIL .060 inch THERE IS A .060 INCH GAP BETWEEN RACHET (A) AND PAWL (B) USE FEELER GAUGE BOTTOM VIEW TO CHECK GAP Figure 5-5 Adjust Park Brake Ratchet/Pawl Gap...
  • Page 55 4.1. Loosen the nut and bolt (Figure 5-9, Page 5-5) 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 closest to the floorboard, next depress the accelerator pedal until the end of the tool rests against the floorboard (pedal height should be 5-5/...
  • Page 56 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Adjust the Accelerator Rod, Continued: DANGER • TO PREVENT ACCIDENTALLY STARTING THE VEHICLE, DISCONNECT THE BATTERY(IES) AS INSTRUCTED IN WARNING ON PAGES 5-1 AND 5-2. THIS WILL PREVENT THE POSSIBILITY OF THE VEHICLE RUNNING OVER YOU WHEN YOU ARE ADJUSTING THE ACCELERATOR ROD.
  • Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Adjust the Accelerator Rod – Gasoline Vehicles, Continued: 5.5. If 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. 5.6.
  • Page 58 6. ADJUST THE ACTUATOR LEVER • Adjust the Actuator Lever – Turf 2, Carryall 2 and 6 Electric Vehicles: 6.1. Connect Calibration Test Module (CTM) (Club Car Part No. 1018871-01) (Figure 5-12, Page 5-8) to vehicle. 6.1.1. Disconnect three-pin connector to potentiometer from wire harness as shown (Figure 5-15, Page 5-10).
  • Page 59 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Figure 5-14 Accelerator Pedal – Electric Turf 1, Carryall 1 and all Gasoline Vehicles 2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 5-9...
  • Page 60 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment TYPICAL 4 PLACES TYPICAL 2 PLACES Figure 5-15 Accelerator Pedal – Turf 2, Carryall 2 and 6 Electric Vehicles Page 5-10 2000 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 61 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Adjust the Actuator Lever, Continued: 4-5/8 INCHES READS MICRO BREAK POINT REPOSITION ACCELERATOR PEDAL ADJUSTMENT TOOL SO THAT "MICRO BREAK POINT" IS TOWARD FLOORBOARD. DEPRESS THE USE A RUBBER STRAP ACCELERATOR PEDAL UNTIL A TO HOLD PEDAL IN PEDAL HEIGHT OF 4-5/8 INCHES DEPRESSED POSITION...

  • Page 62: Pedal Group Disassembly And Assembly

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Adjust the Actuator Lever, Continued: 6.10. With the actuator lever in position, tighten the actuator lever bolt to 75 in-lb (8.5 N·m) This step sequence ensures that the solenoid will not engage with the accelerator pedal in the UP position. 6.11.

  • Page 63: Brake Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly or are damaged, they must be replaced with new ones before installing pedal assembly (Figure 5-23, Page 5-15 or Figure 5-24, Page 5-16). 3.2. Remove shoulder bolts (16) and nuts (15) then disconnect the rod(s) (14 and 36) from the pedal shaft (Figure 5-23, Page 5-15 or Figure 5-24, Page 5-16).

  • Page 64: Park Brake Removal

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly NOTE • BRAKE PEDAL FREE-PLAY IS THE DISTANCE THE BRAKE PEDAL CAN BE DEPRESSED BEFORE THE BRAKE ACTUATOR ARM (AT THE BRAKE CLUSTER) MOVES. Turn hex nuts until there is a 1/4 inch to 1/2 inch (6.3 to 12.7 mm) free play in brake pedal while depressing the brake...
  • Page 65 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly 3. Install the bushings (30) in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment (10) (Figure 5-26, Page 5-17). Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown (Figure 5-27, Page 5-17).
  • Page 66 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly TYPICAL 2 PLACES Figure 5-24 Brake and Park Brake Pedal Assembly and Mounting – Four-Wheel Brake Vehicles Page 5-16 2000 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 67: Accelerator Pedal Removal

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Park Brake Installation, Continued: Figure 5-25 Brake Pedal Weldment Through Floor Figure 5-26 Park Brake Assembly HOOK ONE END OF SPRING (20) ON PARK BRAKE WELDMENT SHAFT LIFT OTHER END OF SPRING (20) UP AND OVER BRAKE WELDMENT BY PRYING DOWN ON SHAFT WITH SMALL SCREWDRIVER Figure 5-27 Attach Torsion Spring...

  • Page 68: Accelerator Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Accelerator Pedal Removal, Continued: WARNING • LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES, UNLOAD THE CARGO BED, AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE (CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LB.

  • Page 69: Accelerator Pedal Removal

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly 5. Tighten the four bolts (22) (Figure 5-14, Page 5-9) attaching the pivot rod supports to the frame to 75 in-lb (8.5 N·m). 6. Install the ball stud (8) through the pivot rod. Using needle-nose pliers, install the pivot support bearing (9) and the spring retainer (11) onto the ball stud.

  • Page 70: Accelerator Pedal Installation

    ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly WARNING • LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES, UNLOAD THE CARGO BED, AND CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE (CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LB.
  • Page 71 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly 5. Rotate the actuator lever until its alignment pin is aligned with the slot in the potentiometer lever fork (Figure 5-29, Page 5-21), then slide the actuator lever toward the potentiometer housing. See follow- ing CAUTION.
  • Page 72 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Disassembly and Assembly Accelerator Pedal Installation, Continued: Turf 2, Carryall 2 and 6 Electric Vehicles 13. Install the nut (7) (Figure 5-15, Page 5-10) on the accelerator pivot rod and tighten it to 18 ft-lb (24 N·m). See following NOTE.

  • Page 73: Section 6 - Wheel Brake Assemblies

    SECTION 6 – WHEEL BRAKE ASSEMBLIES WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL.

  • Page 74: General Information

    WHEEL BRAKE ASSEMBLIES General Information GENERAL INFORMATION The Club Car utility vehicles covered in this manual are equipped with two-wheel, self-adjusting brakes, two-wheel manually adjusted brakes, or four-wheel, manually adjusted brakes. See Section 2 – Specifications. TYPICAL 4 TYPICAL 4...

  • Page 75: Brake Shoe Removal

    5, skip step number 6. 5. Remove the axle. 5.1. Using 90° snap ring pliers (Club Car Part No. 1012560), remove axle retaining ring (1) (Figure 6- 3, Page 6-3). 5.2. Pull the axle shaft (2) from the axle tube (Figure 6-3, Page 6-3).

  • Page 76: Brake Assembly Cleaning (Self-Adjusting Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning (Self-Adjusting Brakes) Brake Shoe Removal, Continued: BRAKE DRUM TWO BRAKE SHOE RETAINER PIN HEADS AXLE TUBE 1/2 INCH X 5/8 INCH COLD CHISEL Figure 6-4 Shoe Retainer Pins 6. Using needle nose pliers, rotate the clip retainer pin (1) 90° to remove the shoe retainer clip (2) on each shoe (Figure 6-5, Page 6-4).
  • Page 77 2. Remove the rubber boot from backing plate and wipe with a clean damp cloth. 3. Lubricate the slide (1) and slide plate (2) with dry moly lubricant (Club Car Part No. 1012151) on both sides of the backing plate. After lubricating, work the slide back and forth to ensure it slides smoothly and easily (Figure 6-8, Page 6-5).

  • Page 78: Brake Shoe Installation (Self-Adjusting Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Self-Adjusting Brakes) Brake Assembly Cleaning (Self-Adjusting Brakes), Continued: 17T STAMPING ON TRAILING SHOE Use a brush to apply a Turn adjusting liberal amount of lithium NLGI #2 wheel so that the grease to the areas indicated. shoe slot is vertical.
  • Page 79 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Self-Adjusting Brakes) 2. Install the shoe retainer clip. Compress clip while turning retainer pin into position (Figure 6-13, Page 6-6). 3. Attach the springs onto the trailing shoe already installed. Then hold the leading shoe next to the trail- ing shoe, correctly oriented, and attach the springs to it (Figure 6-14, Page 6-6).

  • Page 80: Brake Adjustment (Self-Adjusting Brakes)

    2. Remove rubber boot from backing plate and wipe with a clean, damp cloth. 3. Lubricate slide (1) and slide plate (2) with dry moly lubricant (Club Car Part No. 1012151) on both sides of the backing plate. After lubricating, work slide back and forth to ensure it slides smoothly and easily (Figure 6-18, Page 6-8).

  • Page 81: Brake Shoe Installation (Manually Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually Adjusted Brakes) WARNING • APPLY GREASE CAREFULLY WHEN PERFORMING THE FOLLOWING STEPS. DO NOT ALLOW ANY GREASE TO GET ONTO THE FRICTION SURFACES OF THE BRAKE SHOE PADS. FAILURE TO HEED THIS WARNING COULD CAUSE DIMINISHED BRAKE PERFORMANCE, POSSIBLY RESULTING IN PROPERTY DAMAGE OR SEVERE PERSONAL INJURY.
  • Page 82 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation (Manually Adjusted Brakes) Brake Shoe Installation (Manually Adjusted Brakes), Continued: WARNING • WHEN INSTALLING BRAKE SHOES, THE SHOES MUST BE ORIENTED WITH TIPS STAMPED J10 INSERTED INTO THE MOUNTING BLOCK SLOTS RATHER THAN INTO THE BRAKE ACTUATOR SLOTS (FIGURE 6-22, PAGE 6-10).

  • Page 83: Rear Brake Cable Adjustment (Manually Adjusted Brakes)

    (Figure 6-28, Page 6-16, Detail A). 5. Using a 7 mm open-end wrench, 8-point socket or Club Car brake adjustment tool (Part Number 1013582), turn the brake adjustment bolt clockwise until it clicks audibly, then rotate the wheel and tire assembly by hand.

  • Page 84: Front Brake Cable Adjustment (Manually Adjusted Brakes)

    WHEEL BRAKE ASSEMBLIES Front Brake Cable Adjustment (Manually Adjusted Brakes) Rear Brake Cable Adjustment (Manually Adjusted Brakes), Continued: 6. Repeat step 5 until the wheel and tire assembly can no longer be rotated by hand. 7. To adjust the brake shoes, turn the adjustment bolt counterclockwise until it clicks, and then rotate the wheel and tire assembly by hand.

  • Page 85: Brake Cluster Removal And Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation 4. Using a 7 mm open-end wrench, 8-point socket, or Club Car brake adjustment tool (Part No. 1013582), turn the brake adjustment bolt clockwise until it clicks audibly, then rotate the tire by hand.
  • Page 86 WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 6-26 Rear Manually Adjusted Brake Assembly Page 6-14 2000 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 87 WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Figure 6-27 Front Manually Adjusted Brake Assembly 2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 6-15...

  • Page 88: Rear Brake Cluster Installation

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Rear Brake Cluster Removal, Continued: 5. Remove cotter pin (17) and clevis pin (16) from brake cable (Figure 6-26, Page 6-14 or Figure 6-1, Page 6-2). 6. Remove 4 bolts (20) and cone locknuts (19) that mount the brake assembly to the transaxle (Figure 6- 26, Page 6-14 or Figure 6-1, Page 6-2).

  • Page 89: Front Brake Cluster Removal

    WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation FRONT BRAKE CLUSTER REMOVAL 1. Place chocks at rear wheels, loosen lug nuts on front wheels and lift the front of the vehicle with a chain hoist or floor jack. Place jack stands under the round tube crossmember of the frame to support vehicle. 2.

  • Page 90: Front Brake Cables

    WHEEL BRAKE ASSEMBLIES Front Brake Cables FRONT BRAKE CABLES Read WARNING on page 6-1. REMOVAL 1. Remove cotter pin (2) and clevis pin (3) from brake lever arm on front brake cluster (Figure 6-30, Page 6-18). 2. Remove E-clip (1) from brake cable housing at the front spindle bracket and remove cable from spindle (Figure 6-30, Page 6-18).

  • Page 91: Rear Brake Cables

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables 3. Route cable towards the rear of vehicle and over to the driver’s side I-beam and secure with wire ties so that the brake cable does not touch the brake equalizer (Figure 6-28, Page 6-16). FLOORBOARD REMOVED FOR CLARITY...

  • Page 92: Installation

    WHEEL BRAKE ASSEMBLIES Rear Brake Cables 3. Rotate brake cables upward and pull ends through holes in top of equalizer. Figure 6-32 Loosen Equalizer Nut 4. Disconnect brake cables at rear wheels. 4.1. Remove cotter pins (1) clevis pins (2) and E-clips (3) (Figure 6-33, Page 6-20). 4.2.

  • Page 93: General Information

    SECTION 7 – STEERING AND FRONT SUSPENSION 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 DANGER, WARNING AND CAUTION STATEMENTS IN THIS MANUAL.

  • Page 94: Steering Wheel

    3. Loosen the steering wheel nut (27) and back it off approximately 1/4 inch (6 mm). Do not remove the nut (Figure 7-4, Page 7-4). 4. Use the steering wheel puller (Club Car Part Number 102061201) to remove steering wheel. 4.1. Place the puller anvil (4) through the top opening of the steering wheel (Figure 7-1, Page 7-2).

  • Page 95: Steering Column

    STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN Read WARNING on page 7-1 STEERING COLUMN REMOVAL 1. Remove the steering wheel as previously instructed. 2. Remove the front body as instructed in Section 4 – Body and Trim. REMOVE PLASTIC CAP AND LOOSEN SCREW ON EACH SIDE OF DASH PANEL.
  • Page 96 STEERING AND FRONT SUSPENSION Steering Column Steering Column Removal, Continued: 5. Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-4, Page 7-4). 6. Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5) (Figure 7-4, Page 7-4).

  • Page 97: Steering Column Disassembly

    2. Press the bearing (17) all the way into the bearing seat (18) using a steering column bearing press tool (Club Car Part No. 1014264) or a metal tube approximately six inches (15.2 cm) long with a maximum outer diameter of 1-3/16 inches (3.3 cm) and a minimum inside diameter of 7/8 inch (2.2 cm). Be sure the bearing is installed in the bearing seat as shown (Figure 7-5, Page 7-6) so the wedge (16) will ride against the inner race of the bearing.

  • Page 98: Steering Column Installation

    STEERING AND FRONT SUSPENSION Steering Column Steering Column Assembly, Continued: 6. Press the seal (23) into the bearing seat (18) until it is flush with the top end of the seat (Figure 7-4, Page 7-4). When pressing the seal into the seat, set the steering tube on a bench so that all the pressure is exerted on the steering tube and not on the steering shaft.

  • Page 99: Steering Adjustment

    STEERING AND FRONT SUSPENSION Steering Adjustment STEERING ADJUSTMENT Read WARNING on page 7-1. 1. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2) and passenger side A-plate (3) (Figure 7-6, Page 7-7). The internal stop on the rack must reach its limit of travel against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right).

  • Page 100: Rack And Pinion Disassembly

    STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Removal, Continued: 5. Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and universal joint from the vehicle (Figure 7-4, Page 7-4). Figure 7-7 Adjust Steering Alignment Figure 7-8 Ball Joint Tool RACK AND PINION DISASSEMBLY...

  • Page 101: Rack And Pinion Assembly

    14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly (Club Car Part No. 101878302) (Figure 7-12, Page 7-10). RACK AND PINION ASSEMBLY 1.
  • Page 102 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Assembly, Continued: TYPICAL 3 PLACES TYPICAL 3 PLACES Figure 7-12 Steering Gear CAUTION • IN STEP 4, DO NOT PRESS AGAINST THE OUTER RACE OF THE BEARING. 4. If the bearing (9) was removed, press on a new bearing, exerting all pressure on the inner race (grease the bearing before installing it).
  • Page 103 STEERING AND FRONT SUSPENSION Rack and Pinion 5. If the needle bearing (7) is damaged, the steering box assembly (Club Car Part No. 101878302) must be replaced (Figure 7-12, Page 7-10). 6. Install pinion (8) and bearing (9) assembly into the housing (6) (Figure 7-12, Page 7-10). Make sure the rack gear teeth will mesh with the gear teeth on the pinion.

  • Page 104: Rack And Pinion Installation

    STEERING AND FRONT SUSPENSION Tie Rod and Drag Link Rack and Pinion Assembly, Continued: 11.1. Reposition the rack and pinion in a vise. 11.2. Insert a 3/8 inch deep well socket into the steering column end of the universal joint (2) and tighten the bolt (1) to 15 ft-lb (20.3 N·m) (Figure 7-15, Page 7-11).

  • Page 105: Tie Rod And Drag Link Installation

    STEERING AND FRONT SUSPENSION Front Suspension 2. Remove the cotter pins (22) and ball joint retaining nuts (25 or 20) (Figure 7-12, Page 7-10 or Figure 7-21, Page 7-17). 3. Use a ball joint removal tool to remove ball joints (13 and 6) (Figure 7-21, Page 7-17) and (23) (Figure 7-12, Page 7-10) from the spindles.

  • Page 106: Wheel Alignment

    STEERING AND FRONT SUSPENSION Front Suspension WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels. There is also a drag link adjustment to equalize the turning radius in both directions. See Steer- ing Adjustment, Page 7-7.

  • Page 107: Front Suspension Components

    STEERING AND FRONT SUSPENSION Front Suspension Components PROPER CAMBER LOOSEN 4 BOLTS (30) Club Car ADJUSTMENT LOOSEN HEX NUT (8) ON ECCENTRIC ECCENTRIC EQUAL SPACE ADJUSTER (7) BETWEEN TIRES AND FRAMING SQUARES USE 7MM DEEP WELL IMPROPER SOCKET TO ADJUST...

  • Page 108: Leaf Spring Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components Leaf Spring Removal, Continued: 3. Remove the nuts (14) and bolts (25) from the bottom of each king pin (26) (Figure 7-22, Page 7-18). 4. Remove the four bolts (30), four nuts (32), four lock washers (31), and bottom spring plate (29) (Figure 7-22, Page 7-18).
  • Page 109 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-21 Two-Wheel Brake Vehicle – Upper Portion 2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-17...
  • Page 110 STEERING AND FRONT SUSPENSION Front Suspension Components TYPICAL 4 PLACES DRIVER TYPICAL SIDE ONLY 4 PLACES PASSENGER SIDE ONLY TYPICAL 4 PLACES Figure 7-22 Two-Wheel Brake Vehicle - Lower Portion Page 7-18 2000 Turf/Carryall Vehicle Maintenance and Service Manual...

  • Page 111: Kingpin And Steering Spindle Installation

    STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Removal, Continued: 8. Remove the wave washer (20) and inspect it (Figure 7-22, Page 7-18). If the washer is broken or has a wave bottom to wave crest height dimension of less than .040 inch (0.10 cm), it must be replaced. 9.
  • Page 112 STEERING AND FRONT SUSPENSION Front Suspension Components REFERENCE STEERING GEAR TYPICAL 4 PLACES TYPICAL 3 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 7-23 Four-Wheel Brake Vehicle - Upper Portion Page 7-20 2000 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 113 STEERING AND FRONT SUSPENSION Front Suspension Components REFERENCE STEERING GEAR ASSEMBLY TYPICAL 4 PLACES DRIVER SIDE ONLY PASSENGER SIDE ONLY TYPICAL 4 PLACES TYPICAL 4 PLACES Figure 7-24 Four-Wheel Brake - Lower Portion 2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 7-21...

  • Page 114: Shock Absorber Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Shock Absorber Removal, Continued: 2. Remove the nut (9) attaching the shock absorber to the A-Plate (Figure 7-21, Page 7-17). 3. Remove the nut (9) and bolt (8) attaching the shock absorber to the shock and gear support (Figure 7- 21, Page 7-17).

  • Page 115: Front Wheel Bearings And Hub Installation

    STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs Figure 7-25 Front Wheel Bearings and Hub FRONT WHEEL BEARINGS AND HUB INSTALLATION 1. Pack the wheel bearings (5) and hub cavities, and lubricate cups (7) with wheel bearing grease or chassis lube.

  • Page 117: Section 8 - Wheels And Tires

    SECTION 8 – WHEELS AND TIRES WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN ELECTRICAL AND MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNINGS STATED IN THIS MANUAL.

  • Page 118: Wheels

    WHEELS AND TIRES Wheels WHEELS Read WARNING on page 8-1. WHEEL REMOVAL 1. Slightly loosen the lug nuts on the wheel to be removed. 2. Raise the end of the vehicle from which the wheel is to be removed. Make sure the wheels are off the ground.

  • Page 119: Tires

    WHEELS AND TIRES Tires TIRES Read WARNING on page 8-1. TIRE REMOVAL NOTE • TIRE MUST BE REMOVED OR INSTALLED FROM THE VALVE STEM SIDE OF THE RIM. 1. Remove the tire and wheel assembly from the vehicle as instructed. See “Wheel Removal” on page 8-2.
  • Page 120 WHEELS AND TIRES Tires Tire Installation, Continued: 1. Clean both tire beads to remove dirt or other foreign matter. 2. Where the tire beads seat, clean the rim with a wire brush. Wipe away any debris with a clean cloth. NOTE •...

  • Page 121: Section 9 - Rear Suspension

    SECTION 9 – REAR SUSPENSION WARNING • ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN MECHANICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL WARNING STATEMENTS IN THIS MANUAL. •...

  • Page 122: Shock Absorbers

    Read WARNING on page 9-1. NOTE • THERE ARE TWO DIFFERENT TYPES OF SUSPENSION SYSTEMS COMMON TO CLUB CAR VEHICLES. THE RECOMMENDED METHOD OF DETERMINING THE SUSPENSION TYPE IS TO LOOK FOR THE PRESENCE OF JOUNCE BUMPERS (20) (FIGURE 9-3, PAGE 9-4). VEHICLES WITHOUT JOUNCE BUMPERS UTILIZE A PAIR OF NEWLY DESIGNED LEAF SPRINGS.

  • Page 123: Removing The Multi-Leaf Springs

    REAR SUSPENSION Multi-Leaf Springs REMOVING THE MULTI-LEAF SPRINGS 1. Loosen the lug nuts on the wheel(s) to be removed. 2. Place chocks at the front wheels and lift rear of vehicle with a chain hoist or floor jack (Figure 9-2, Page 9-3).
  • Page 124 REAR SUSPENSION Multi-Leaf Springs TURF 1 & CARRYALL 1 GAS ONLY TYPICAL ON TYPICAL BOTH SIDES BOTH SIDES OF VEHICLE REAR BRAKE CABLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 9-3 Rear Suspension - Vehicles With Jounce Bumpers Page 9-4 2000 Turf/Carryall Vehicle Maintenance and Service Manual...
  • Page 125 REAR SUSPENSION Multi-Leaf Springs TYPICAL BOTH SIDES OF VEHICLE REAR BRAKE CABLE ELECTRIC VEHICLES ONLY TYPICAL 2 PLACES Figure 9-4 Rear Suspension - Vehicles Without Jounce Bumpers 2000 Turf/Carryall Vehicle Maintenance and Service Manual Page 9-5...

  • Page 126: Installing The Multi-Leaf Springs

    REAR SUSPENSION Multi-Leaf Springs Removing the Multi-Leaf Springs, Continued: 9. Remove bolt (15) and locknut (2) attaching the leaf spring (12) to the rear shackle (1) (Figure 9-3, Page 9-4 or Figure 9-4, Page 9-5). 10. Allow rear of leaf spring (12) to rest on the ground and remove the bolt (24) and locknut (25) attaching the front of the spring to the vehicle frame (Figure 9-3, Page 9-4 or Figure 9-4, Page 9-5).

  • Page 127: Snubber

    REAR SUSPENSION Snubber SNUBBER Read WARNING on Page 9-1. The snubber is installed on the gasoline vehicle only. SNUBBER REMOVAL 1. Support the drive train with a floor jack under the engine mounting plate so that the snubber is raised slightly and does not rest on the vehicle frame.

  • Page 128: Stabilizer Bar Installation

    REAR SUSPENSION Stabilizer Bar TYPICAL 8 PLACES TYPICAL 8 PLACES REFERENCE REAR SUSPENSION TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 9-6 Stabilizer Bar 3. Remove bolts (14) and locknuts (15) from the left and right stabilizer bar bushing support (12) and remove supports and stabilizer bar (1) from vehicle (Figure 9-6, Page 9-8).

  • Page 129: Jounce Bumpers

    REAR SUSPENSION Jounce Bumpers 5. Place lock washer (7), flat washer (4), spacer (2) and compression mount (3) onto bolt (6). Install bolt through mounting hole in stabilizer bar and place another compression mount (3) and flat washer (4) onto bolt (Figure 9-6, Page 9-8). 6.
  • Page 131 INDEX accelerator CAUTION pedal ..............3-5 definition of ............1-1 adjustment ............ 5-5 choke ..............3-7 installation ..........5-18 cleaning removal ............5-17 brake assembly (manually adjusted) ....6-8 performance inspection ........3-2 brake assembly (self-adjusting) ......6-4 seat ..............4-2 adjustment ............
  • Page 132 INDEX installation ............7-12 removal ..............7-7 inspection reverse buzzer accelerator performance inspection ........3-2 performance inspection ......... 3-2 brakes performance inspection ......... 3-2 governor safety ..............1-1 performance inspection ......... 3-2 serial number park brake vehicle ..............3-1 performance inspection ......... 3-2 shock absorbers performance inspection ........
  • Page 133 INDEX multi-leaf springs ..........9-2 shock absorbers ..........9-2 snubber ............. 9-7 stabilizer bar ............9-7 tailskirt removal and installation ........4-13 tie rod and drag link removal and installation ........7-12 tilt bed loading and unloading ........3-12 removal and installation ........4-5 tires pressure ............
  • Page 136 Golf Cars and Utility Vehicles Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...

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