Solenoid - Club Car 2005 FE290 Maintenance Service Supplement

12
ELECTRICAL COMPONENTS
A
Key Switch Removal, Continued:
2.5. 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.
3. Disconnect the wires from the key switch. Do not allow wires to touch.
4. Remove the key switch:
4.1. Remove the key switch cap with a small, flat-blade screwdriver.
4.2. Remove key switch from the dash by holding the key switch and turning the nut on the outside of
the dash with a 1-inch socket wrench. Remove the keyed washer with key switch.
Key Switch Installation
1. Reverse removal procedures to install key switch in the dash. Connect wires to key switch.
See Figure 11-1, Section 11, Page 11-6. Coat the connectors with Battery Terminal Protector Spray
(CCI P/N 1014305) to prevent corrosion. Be sure that key switch terminals cannot touch the frame and
that panel is properly seated and snapped in place.
2. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16 N·m).
See Figure 10-1, Section 10, Page 10-3. Coat terminals with Battery Terminal Protector Spray (CCI P/
N 1014305) to minimize corrosion.

SOLENOID

See General Warning, Section 10, Page 10-1.
Testing the Solenoid
See Test Procedure 6, Section 11, Page 11-13.
Solenoid Removal
1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 10, Page 10-1.
2. Remove electrical component box cover (Figure 12-26, Page 12-25).
3. Disconnect all the wires from the solenoid.
4. Remove the two screws securing the solenoid in place.
5. Remove the solenoid.
Solenoid Installation
1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box and
tighten to 14 in-lb (1.6 N·m).
2. Connect the 6-gauge white wire and the 16-gauge red wire from the voltage regulator on a large post on
the solenoid. See Figure 11-1, Section 11, Page 11-6.
3. Connect the 18-gauge white wire from the fuel/hour meter to the same large post.
4. Connect the 6-gauge red wire and the 10-gauge red wire from the fuse block on the other large post on
the solenoid. See Figure 11-1, Section 11, Page 11-6.
5. Connect the 18-gauge blue wire from the key switch to a small post on the solenoid.
6. Connect the 18-gauge orange wire from the accelerator pedal limit switch to the other small post on the
solenoid. See Figure 11-1, Section 11, Page 11-6.
7. Tighten the hex nuts on the large solenoid posts to 60 in-lb (6.8 N·m). Tighten the nuts on the small sole-
noid posts to 22 in-lb (2.5 N·m).
Page 12-14 2005 FE290 Gasoline Vehicle Maintenance and Service Supplement
Solenoid