Headlight Switch - Club Car FE350 2005 Maintenance Service Supplement

12
ELECTRICAL COMPONENTS
Voltage Limiter Removal
1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 10, Page 10-1.
2. Remove the center dash panel. See Key Switch Removal on page 12-13.
3. Disconnect wires from the voltage limiter (1) (Figure 12-35, Page 12-31).
4. Remove the mounting hardware (2) from the voltage limiter and remove it from the vehicle.
Voltage Limiter Installation
1. Mount the voltage limiter to the frame using the mounting hardware. Tighten to 25 in-lb (2.8 N·m)
(Figure 12-35, Page 12-31).
2. Connect the black 16-gauge wire from the harness to the negative (–) terminal on the voltage limiter.
Connect the black wire from the ground terminal block to the positive (+) terminal on the voltage limiter.
3. Install 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, 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.

HEADLIGHT SWITCH

See General Warning, Section 10, Page 10-1.
Testing the Light Switch
See Test Procedure 32, Section 11, Page 11-43.
Headlight Switch Removal
1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 10, Page 10-1.
2. Loosen the set screw locking the light switch knob (1) to the shaft (Figure 12-36, Page 12-31).
3. Remove the center dash panel. See Key Switch Removal on page 12-13.
4. Disconnect the wires from the light switch.
5. Remove the outer nut (2) from the switch (Figure 12-36, Page 12-31).
6. Remove the light switch (3) from the center dash.
Headlight Switch installation
1. Connect the wires to the light switch. See Wiring Diagrams, Section 11, Page 11-6.
2. Thread the check nut (4) onto the switch until an equal number of threads show on both sides. Insert the
switch through the center dash and install the nut on the outside of the dash. Tighten the nut to 14 in-lb
(1.6 N·m) (Figure 12-36, Page 12-31).
3. Push the light switch shaft in. Screw the knob onto the end of the shaft until the knob touches the outer
nut. Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to
the ground. Tighten the set screw to lock the knob to the shaft.
4. Install 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.
Page 12-32 2005 FE350 Gasoline Vehicle Maintenance and Service Supplement
Headlight Switch