Page 1 2018 Café Express Maintenance and Service Manual Gasoline Vehicle with Subaru EX40 Engine Manual Number 105344222 Edition Code 0617A00000...
Page 3 To find your local authorized Club Car dealer, visit www.clubcardealer.com, call 1-800-ClubCar (258–2227), or scan this Quick Response (QR) code to be taken to the Club Car dealer locator. Refer to Figure 1. Download a QR code reader such as RedLaser or Barcode Scanner to your cell phone or tablet.
Page 4 Deionizer Filter Replacement Cartridge (non-SPWS) CC PN AM10975 NOTE: This manual represents the most current information at the time of publication. Club Car is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.
Page 5: Table Of Contents
CONTENTS SECTION 1 — Safety............................1-1 Safety Details ..............................1-1 Personal Safety ............................1-1 Machine Safety............................1-1 Information..............................1-1 General Warnings............................1-1 Disabling the Vehicle..........................1-3 Disconnecting the Battery-Gasoline Vehicles ....................1-3 Connecting the Battery-Gasoline Vehicles ....................1-3 Recycling Lead-Acid Batteries ........................1-4 International safety symbols on batteries .....................
Page 6 SECTION 5 — Accelerator and Brake Pedal Group ..................... 5-1 Brake Pedal and Park Brake .......................... 5-1 Brake Pedal Removal (Gas and Electric Vehicles) ..................5-1 Brake Pedal Installation (Gas and Electric Vehicles)..................5-1 Park Brake Removal ..........................5-4 Park Brake Installation ..........................5-4 Accelerator Pedal ............................
Page 7 Delta A-Plate Removal..........................7-20 Delta A-Plate Installation .......................... 7-20 Shock Absorber Removal......................... 7-20 Shock Absorber Installation ........................7-20 Front Wheel Bearings and Hubs ........................7-21 Front Wheel Free Play Inspection ......................7-21 Front Hub and Wheel Bearings Removal....................7-21 Front Hub and Wheel Bearings Installation ....................7-22 SECTION 8 —...
Page 8 Bearing Removal ............................. 12-6 Field Coil Assembly ..........................12-6 Visual Inspection of Armature ........................12-6 Commutator Cleaning and Inspection ....................... 12-7 Armature Ground Test..........................12-8 Visual Inspection of Field Coils ......................... 12-9 Starter/Generator Rework ........................12-9 Starter/Generator Assembly ........................12-9 Starter/Generator Installation........................12-12 Belt Tension Adjustment for EFI Engines ....................12-13 Voltage Regulator ............................12-15...
Page 9 Battery ...............................12-33 General Information ..........................12-33 Testing the Battery ..........................12-33 Preventive Maintenance..........................12-33 Self-Discharge............................12-34 Vibration Damage ...........................12-34 Battery Removal .............................12-35 Charging the Battery ..........................12-35 Battery Installation ..........................12-35 Battery Storage ............................12-36 Charging a Dead Battery.........................12-36 Ground Cables ............................12-36 SECTION 13 — Engine (Subaru EX40)......................13-1 General Information .............................
Page 10 Fuel Line Removal..........................14-16 Fuel Line Installation ..........................14-17 Fuel Pump Module............................14-18 General Information ..........................14-18 Fuel Pump Module Removal ........................14-18 Fuel Pump Module Installation.........................14-18 Fuel Tank ..............................14-21 General Information ..........................14-21 Fuel Tank Removal ..........................14-21 Fuel Tank Disposal ..........................14-22 Fuel Tank Storage ..........................14-22 Fuel Tank Installation ..........................14-22 Fuel Filter..............................14-23 General Information ..........................14-23...
Page 11 Transaxle Removal ............................17-9 Transaxle Installation ..........................17-13 Shifter Cable ..............................17-13 Shifter Cable Removal ..........................17-13 Shifter Cable Installation .........................17-14 Shifter Cable Adjustment.........................17-14 SECTION 18 — Refreshment Unit ........................18-1 General Information ............................. 18-1 Refreshment Center Compartments......................18-1 Cleaning ..............................18-1 Interior Aluminum Surfaces ........................18-1 Exterior Aluminum Surfaces ........................
Page 13: Section 1 - Safety
SAFETY DETAILS Safety To ensure the safety of those servicing Club Car vehicles, and to protect the vehicles from possible damage 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 labeled DANGER, WARNING, or CAUTION.
Page 14 • The 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 15: Disabling The Vehicle
SAFETY General Warnings WARNING • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring. DISABLING THE VEHICLE Engage park brake to lock wheels. Turn the key switch OFF and remove the key. Place the Forward/Reverse control in the NEUTRAL position.
Page 16: Recycling Lead-Acid Batteries
Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries. 1403...
Page 17: International Safety Symbols On Batteries
SAFETY General Warnings INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries. 1. Shield eyes. 3. No smoking, no open flames, no sparks. 5. Battery acid hazard. 2.
Page 18 General Warnings SAFETY Pagination Page Page 1-6 2018 Café Express Maintenance and Service Manual...
Page 19 SPECIFICATIONS CAFE EXPRESS POWER SOURCE GASOLINE Engine: 4 cycle, OHC, 404 cc, 14.0 Horsepower (10.4 kW) rated engine @ 3600 RPM (per SAE J 1940), ●...
Page 20: Section 2 - Vehicle Specifications
CAFE EXPRESS POWER SOURCE GASOLINE Rear wheel tread 39.5 in (100.3 cm) Weight: Standard gasoline vehicle with Cafe Express unit (dry fuel tank) 1147 lb (520.2 kg) Curb weight: 1175 lb (532.9 kg) Maximum forward speed 12 to 14 mph (19 to 23 km/h) Outside clearance circle (diameter) 248.5 in (631.19 cm)
Page 21: Section 3 - General Information
• See General Warnings on page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 22: Storage
Storage GENERAL INFORMATION 2843 Figure 3-1 Serial Number Decal STORAGE See General Warnings on page 1-1. DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. •...
Page 23: Preparing The Gasoline Vehicle For Extended Storage
GENERAL INFORMATION Storage PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE Unload the vehicle so that tires are supporting only the weight of the vehicle. Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician.
Page 24 Storage GENERAL INFORMATION Pagination Page Page 3-4 2018 Café Express Maintenance and Service Manual...
Page 25: Section 4 - Body And Trim
SECTION 4 — BODY AND TRIM DANGER Body and Trim • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. CLEANING THE VEHICLE See General Warnings on page 1-1. CAUTION • Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali materials on body panels or seats.
Page 26: Front Body Repair
Front Body Repair BODY AND TRIM CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat from the vehicle first. FRONT BODY REPAIR See General Warnings on page 1-1. LIGHT SCRATCHES Clean entire area to be repaired with clean, clear water. Using 1200 grit sandpaper, water-sand entire area of scratch until original scratch is no longer visible, either with finishing sander or wet sanding block.
Page 27: Front Body
BODY AND TRIM Front Body COLOR CC P/N Dark Gray 105117705 Black 105117706 105117707 Bright Blue 105117708 TITN Silver 105117709 Light Gray 105117710 FRONT BODY See General Warnings on page 1-1. HEAVY DUTY BUMPER REMOVAL Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Loosen and remove screws (1), washers (3), and locknuts (2) that attach heavy duty (HD) bumper mounting bracket (4) to HD bumper weldment (5) (Figure 4-1, Page 4-4).
Page 28 Front Body BODY AND TRIM 2986 Figure 4-1 Heavy Duty Bumper Page 4-4 2018 Café Express Maintenance and Service Manual...
Page 29: Cowl Removal
BODY AND TRIM Front Body COWL REMOVAL Park vehicle and chock tires. Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. The cowl is secured by tabs located behind the front fenders (2), and under the lip of the dash (1) (Figure 4-2, Page 4-6).
Page 30: Grille Removal
Front Body BODY AND TRIM 2846 Figure 4-2 Front Cowl GRILLE REMOVAL Park vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove HD bumper (if equipped). See Heavy Duty Bumper Removal, Section 4, Page 4-3. Remove cowl.
Page 31: Grille Installation
BODY AND TRIM Front Body GRILLE INSTALLATION Connect the charger receptacle or connector (quick connect). Install, but do not tighten upper M6 screws. (Do not tighten screws until plastic bumper is installed). Lower grille holes are shared with the front bumper, ensure lower bumper screws are attached first then install grille.
Page 32 Front Body BODY AND TRIM 2844 Figure 4-3 Front Grille, Bumper, and Side Fenders Page 4-8 2018 Café Express Maintenance and Service Manual...
Page 33: Front Bumper And Side Fender Removal
BODY AND TRIM Front Body FRONT BUMPER AND SIDE FENDER REMOVAL Park the vehicle, chock tires. Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove HD bumper, (if equipped). See Heavy Duty Bumper Removal on page 4-3. Remove cowl.
Page 34: Instrument Panel Removal
Front Body BODY AND TRIM INSTRUMENT PANEL REMOVAL Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove front cowl. See Cowl Removal, Section 4, Page 4-5. From the inside of the dash, press upper snap tabs (1) of the instrument panel inward to release from dash. Then push the instrument panel near the bottom (2) to pop out the lower body clips (be careful not to pry the lower clips off).
Page 35: Dash Removal
BODY AND TRIM Front Body DASH REMOVAL Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove cowl. See Cowl Removal on page 4-5. Remove steering wheel. See Steering Wheel Removal, Section 7, Page 7-1. Disconnect instrument panel wiring. Remove the bolts, and washers (5, 6, 7, 8, and 9) from the top, sides and bottom of the dash (10).
Page 36 Front Body BODY AND TRIM 2863 Figure 4-5 Dash Assembly Page 4-12 2018 Café Express Maintenance and Service Manual...
Page 37: Tilt Bed
BODY AND TRIM Tilt Bed TILT BED See General Warnings on page 1-1. TILT BED REMOVAL NOTE: This procedure requires two people. WARNING • Remove all cargo before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised.
Page 38 Tilt Bed BODY AND TRIM 2980 Figure 4-6 Tilt Bed Mounting Page 4-14 2018 Café Express Maintenance and Service Manual...
Page 39: Bed Latch Assembly Removal
BODY AND TRIM Tilt Bed BED LATCH ASSEMBLY REMOVAL NOTE: This procedure requires the aid of an assistant. Park the vehicle and chock the tires. Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Raise bed and secure prop rod (9) in prop rod track (2) (Figure 4-6, Page 4-14). See following WARNING. WARNING •...
Page 40 Tilt Bed BODY AND TRIM 2982 Figure 4-7 Bed Latch Assembly Page 4-16 2018 Café Express Maintenance and Service Manual...
Page 41: Rear Fenders And Tailskirt
BODY AND TRIM Rear Fenders and Tailskirt REAR FENDERS AND TAILSKIRT See General Warnings on page 1-1. REAR FENDER AND TAILSKIRT REMOVAL Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the park brake.
Page 42 Rear Fenders and Tailskirt BODY AND TRIM 2984 Figure 4-8 Rear Fender and Tailskirt Page 4-18 2018 Café Express Maintenance and Service Manual...
Page 43: Electric Bed Lift
BODY AND TRIM Electric Bed Lift ELECTRIC BED LIFT 2983 Figure 4-9 Electric Bed Lift 2018 Café Express Maintenance and Service Manual Page 4-19...
Page 44: Electric Bed Lift Removal
Electric Bed Lift BODY AND TRIM ELECTRIC BED LIFT REMOVAL NOTE: For vehicles equipped with an electric bed lift. This procedure requires the aid of an assistant. Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Raise the bed. Disconnect actuator wires.
Page 45: Floor Mat
BODY AND TRIM Floor Mat 2985 Figure 4-10 Electric Bed Mounting FLOOR MAT See General Warnings on page 1-1. FLOOR MAT REMOVAL Remove the brake and accelerator pedals. See Accelerator and Brake Pedal Group, Section 5, Page 5-1. Remove the top edge of the floor mat from the overlapping flange under the dash. Lift the mat from the vehicle.
Page 46 Floor Mat BODY AND TRIM Pagination Page Page 4-22 2018 Café Express Maintenance and Service Manual...
Page 47: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 — ACCELERATOR AND BRAKE PEDAL GROUP DANGER Accelerator and Brake Pedal Group • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. BRAKE PEDAL AND PARK BRAKE BRAKE PEDAL REMOVAL (GAS AND ELECTRIC VEHICLES) Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s).
Page 48 Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP 3207 Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting Page 5-2 2018 Café Express Maintenance and Service Manual...
Page 49 ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake 2999 Figure 5-2 Brake Pedal Weldment Through Floor Position and attach brake pedal assembly, mounting blocks (3 and 8), and washers (10) to vehicle frame as shown. Tighten the bolts (11) and nuts to 95 in·lb (10.7 N·m). Figure 5-1, Page 5-2. Tighten the nut (2) on the equalizer rod (1) so that brake pedal free-play is from 1/4 inch to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3).
Page 50: Park Brake Removal
Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP PARK BRAKE REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands.
Page 51: Accelerator Pedal
ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal Install the two bushings (30) in the park brake pedal and position the park brake pedal on the shaft on the brake pedal assembly weldment (10). Then attach the ends of the torsion spring to the park brake pedal and to the brake pedal weldment as shown (Figure 5-5, Page 5-4).
Page 52: Accelerator Pedal Installation - Gasoline Vehicles
Accelerator Pedal ACCELERATOR AND BRAKE PEDAL GROUP 3000 Figure 5-6 Accelerator Pedal – Gasoline Vehicles ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the four bolts (22), flat washers (19), and lock nuts (18).
Page 53: Pedal Group Adjustment
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment Install the bolt (4), two washers (5), and a new lock nut (7) through the lower hole in the pedal and through the pivot rod. Finger-tighten nut at this time. Install the ball stud (8) through the pivot rod. Install the bearing (9) and spring retainer (11) onto the ball stud. Secure these parts with the nut (10).
Page 54 Pedal Group Adjustment ACCELERATOR AND BRAKE PEDAL GROUP Figure 5-8 Loosen Rear Brake Equalizer Rod Nuts 2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on the pedal. Next, adjust the brake stop bumper (22) up or down (Figure 5-9, Page 5-8). Adjusting the bumper upward decreases distance between pedal and floorboard.
Page 55 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment 3.2. Tighten the nut (2) on the equalizer rod (1) so that the brake pedal free play is 1/4 to 1/2 inch (6 mm to 13 mm) (Figure 5-3, Page 5-3). 3.3. Tighten the jam nut (3) while holding the adjustment nut (2) in the correct position.
Page 56 Pedal Group Adjustment ACCELERATOR AND BRAKE PEDAL GROUP 1. Locked Position 2. Ratchet (B) Tooth Length 3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B). Figure 5-12 Accelerator Pedal Height Measurement Figure 5-13 Ratchet/Pawl Tooth Engagement 4.5.
Page 57 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment 1. Accelerator Pedal Adjustment Tool (CC P/N 101871001) 2. Rubber Strap Figure 5-16 Accelerator Pedal Height Adjustment Adjust the accelerator rod. See following DANGER. DANGER • Before servicing, turn the key switch to the OFF position and place the Forward/Reverse handle in the NEUTRAL position.
Page 58 Pedal Group Adjustment ACCELERATOR AND BRAKE PEDAL GROUP 14° Top View of the Electrical Component Box 1344 Figure 5-17 Accelerator Cable CAUTION • After accelerator rod adjustment, make sure that approximately the same number of threads are exposed at each end of the accelerator rod. •...
Page 59: Section 6 - Wheel Brake Assemblies
SECTION 6 — WHEEL BRAKE ASSEMBLIES DANGER Wheel Brake Assemblies • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. Asbestos Dust Warning • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
Page 60 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES BRAKE DRUM TWO BRAKE SHOE RETAINER PIN HEADS AXLE TUBE 1/2 INCH X 5/8 INCH COLD CHISEL 2814 2834a Figure 6-1 Loosen Equalizer Nut Figure 6-2 Shoe Retainer Pins 4.2. Insert a 1/2 inch x 5/8 inch cold chisel (1) under the head (2) of each pin and shear them off as illustrated (Figure 6-2, Page 6-2).
Page 61: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 2824 2825 Figure 6-3 Rotate Clip Retainer Figure 6-4 Remove Shoes BRAKE ASSEMBLY CLEANING See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. Carefully clean the brake backing plate and all mechanical components. Remove the rubber boot from backing plate and wipe with a clean damp cloth.
Page 62 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning ® BR2-Plus or equivalent) on each of the six raised bosses on brake backing plate (Figure 6-7, Page 6-4). See preceding WARNING.
Page 63: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation BRAKE SHOE INSTALLATION See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. NOTE: Components of the front wheel brake assembly are identical to the rear wheel manually-adjusted brake assembly. The front brake assembly is rotated 90° (when compared to the rear brake assembly) so the adjusting bolt on each assembly is oriented to the rear of the vehicle rather than at the top of the assembly (Figure 6-23, Page 6-14).
Page 64: Brake Adjustment
Brake Adjustment WHEEL BRAKE ASSEMBLIES 2808 2800 Figure 6-13 Insert Shoes Figure 6-14 Position Shoes CAUTION • Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to installing the axle shaft. For electric vehicles: Install the axle shaft.
Page 65 Figure 6-18 Front Brake Adjustment Bolt Use a torque wrench and a 7 mm 8–point socket or Club Car brake adjustment tool (CC P/N 1013582) to turn the brake adjustment bolt (5) on each brake clockwise until it is tightened to 15 ft·lb (20.3 N·m) then back off 5 clicks.
Page 66 Brake Adjustment WHEEL BRAKE ASSEMBLIES 2806 Figure 6-19 Front Manually Adjusted Brake Assembly Page 6-8 2018 Café Express Maintenance and Service Manual...
Page 67: Brake Cable Equalization
WHEEL BRAKE ASSEMBLIES Brake Adjustment TYPICAL 4 PLACES TYPICAL 4 PLACES 2903 Figure 6-20 Rear Manually-Adjusted Brake Assembly BRAKE CABLE EQUALIZATION Set park brake in the third tooth of the ratchet. Place a wedge between the park brake pedal and brake pedal to prevent the park brake from disengaging while equalizing the brake cables (Figure 6-21, Page 6-10).
Page 68: Final Brake Cluster Adjustment
Brake Adjustment WHEEL BRAKE ASSEMBLIES 2809 Figure 6-21 Set Park Brake and Insert Wedge Equalize the brake cables. 2.1. Tighten the nylon lock nut (6) on the front equalizer rod (2) to 35 in·lb (4 N·m) (Figure 6-16, Page 6-7). 2.2.
Page 69: Brake Cluster Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation Test drive vehicle. Be sure the brakes function properly. When brake pedal is fully pressed under moderate pressure, it should not go more than halfway to floor, and the vehicle should come to a smooth, straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop, check pedal group adjustment, and readjust cable tension and brakes.
Page 70 Brake Cluster Removal and Installation WHEEL BRAKE ASSEMBLIES TYPICAL 4 PLACES 2810 Figure 6-22 Front Spindle Assembly Page 6-12 2018 Café Express Maintenance and Service Manual...
Page 71: Rear Brake Cluster Removal
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation REAR BRAKE CLUSTER REMOVAL Place chocks at the front wheels, loosen the lug nuts on the rear wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. Release park brake and loosen equalizer retaining nuts (1 and 5) on equalizer rod (2) to slightly loosen brake cable (Figure 6-15, Page 6-7).
Page 72: Front Brake Cables
Front Brake Cables WHEEL BRAKE ASSEMBLIES FRONT BRAKE CABLES See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1. 3189 Figure 6-23 Front Brake Cables and Equalizer Page 6-14 2018 Café Express Maintenance and Service Manual...
Page 73: Front Brake Cable Removal
WHEEL BRAKE ASSEMBLIES Front Brake Cables FRONT BRAKE CABLE REMOVAL Remove bow-tie pin (9) and clevis pin (6) from brake lever arm on front brake cluster (Figure 6-23, Page 6-14). Remove E-clip (7) from brake cable housing at the front spindle bracket and remove cable (8 or 18) from spindle. Remove bow-tie pin (9), clevis pin (6), and E-clip (7) from brake cable (8 or 18) at equalizer (2).
Page 74: Rear Brake Cables
Rear Brake Cables WHEEL BRAKE ASSEMBLIES REAR BRAKE CABLES REAR BRAKE CABLE REMOVAL Chock wheels to keep vehicle from unintentionally moving. Release park brake if latched and loosen equalizer retaining nuts (13 and 14) on equalizer rod (2) to slightly loosen brake cables (7) (Figure 6-25, Page 6-17).
Page 75 WHEEL BRAKE ASSEMBLIES Rear Brake Cables 3191 Figure 6-25 Rear Brake Cables and Equalizer 2018 Café Express Maintenance and Service Manual Page 6-17...
Page 76 Rear Brake Cables WHEEL BRAKE ASSEMBLIES Pagination Page Page 6-18 2018 Café Express Maintenance and Service Manual...
Page 77: Section 7 - Steering And Front Suspension
SECTION 7 — STEERING AND FRONT SUSPENSION DANGER Steering and Front Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering wheel.
Page 78: Steering Wheel Installation
Steering Wheel STEERING AND FRONT SUSPENSION 2862 1500-18300-10253 Figure 7-1 Steering Wheel Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or anti-seize compound to steering shaft splines and taper before installing the steering wheel.
Page 79: Steering Column
STEERING AND FRONT SUSPENSION Steering Column STEERING COLUMN See General Warnings on page 1-1. 2609 Figure 7-3 Steering Column 2018 Café Express Maintenance and Service Manual Page 7-3...
Page 80: Steering Column Removal
Steering Column STEERING AND FRONT SUSPENSION STEERING COLUMN REMOVAL Remove the steering wheel as previously instructed. Remove cowl. See Cowl Removal, Section 4, Page 4-5. Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-3, Page 7-3). Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5), (Figure 7-3, Page 7-3).
Page 81: Steering Column Installation
STEERING AND FRONT SUSPENSION Steering Column (CC P/N 1014259) (CC P/N 1014264) 2 to 2 1/8 inches (CC P/N 1014264) (5.1 to 5.4 cm) 1. Step 1 1. Step 1 2. Step 2 2. Step 2 3. Step 3 3. Step 3 1500-18200-10255 1500-18200-10256 Figure 7-4 Steering Shaft –...
Page 82: Steering Adjustment
Steering Adjustment STEERING AND FRONT SUSPENSION STEERING ADJUSTMENT See General Warnings on page 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 7-8). 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 83: Rack And Pinion
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION See General Warnings on page 1-1. CAUTION • Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear components. See Rack and Pinion Inspection on page 7-7. The manufacturer recommends inspecting the rack and pinion and replacing if damaged.
Page 84: Rack And Pinion Disassembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1838 Figure 7-6 Adjust Steering Alignment RACK AND PINION DISASSEMBLY CAUTION • The ball joint (23) (Figure 7-10, Page 7-10) has left-hand threads. Remove ball joint from the spindle and inspect it for excessive wear. Remove the drag link (28) (Figure 7-10, Page 7-10).
Page 85 STEERING AND FRONT SUSPENSION Rack and Pinion 1. Press Ram 2. Pinion Gear 3. Bearing 1500-18400-10259 1500-18400-10260 Figure 7-7 Remove Pinion from Housing Figure 7-8 Remove Bearing from Pinion If necessary, remove the dust seal (12). See following NOTE. NOTE: If the dust seal (12) is removed, replace with a new one. Use snap ring pliers to remove the internal snap ring (11) (Figure 7-10, Page 7-10).
Page 86: Rack And Pinion Assembly
Rack and Pinion STEERING AND FRONT SUSPENSION 1839 Figure 7-10 Steering Gear – Maintenance-Free Ball Joints RACK AND PINION ASSEMBLY Install a new tab washer (4) and an inner ball joint (3) (Figure 7-9, Page 7-9). Install the ball joint onto the rack by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack from damage.
Page 87 STEERING AND FRONT SUSPENSION Rack and Pinion Apply a light coating of EP grease to the teeth of the rack (17), then slide the rack through the bushing (5) and housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-10, Page 7-10). CAUTION •...
Page 88 Rack and Pinion STEERING AND FRONT SUSPENSION 1500-18400-10265 Figure 7-13 Rack and Pinion Resistance Install the internal snap ring (11) (Figure 7-10, Page 7-10). Using an appropriate size deep well socket (1) to apply pressure evenly, press in a new dust seal (2) (Figure 7-11, Page 7-11).
Page 89: Rack And Pinion Installation - Maintenance-Free Ball Joints
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION – MAINTENANCE-FREE BALL JOINTS Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31), and nuts (32). Do not tighten the mounting bolts (Figure 7-10, Page 7-10). For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the splined end of the steering column shaft.
Page 90: Tie Rod And Drag Link
Tie Rod and Drag Link STEERING AND FRONT SUSPENSION TIE ROD AND DRAG LINK See General Warnings on page 1-1. TIE ROD AND DRAG LINK REMOVAL – MAINTENANCE-FREE BALL JOINTS Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-18, Page 7-18) and loosen jam nuts (27 and 29) on the drag link (Figure 7-10, Page 7-10).
Page 91: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings on page 1-1. LUBRICATION Two grease fittings (one in each spindle housing) are provided. Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedule, Section 10, Page 10-5. WHEEL ALIGNMENT Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
Page 92 Front Suspension STEERING AND FRONT SUSPENSION Tighten the hex nut (8) on the adjustment eccentric (7) to 23 ft·lb (31 N·m) (Figure 7-19, Page 7-19). See also Figure 7-15, Page 7-15. Toe-in Adjustment On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do not turn the steering wheel again during this procedure.
Page 93: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components FRONT SUSPENSION COMPONENTS See General Warnings on page 1-1. LEAF SPRING REMOVAL Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove both front wheels.
Page 94 Front Suspension Components STEERING AND FRONT SUSPENSION 2610 Figure 7-18 Front Suspension – Upper Portion Page 7-18 2018 Café Express Maintenance and Service Manual...
Page 95 STEERING AND FRONT SUSPENSION Front Suspension Components 2611 Figure 7-19 Front Suspension – Lower Portion 2018 Café Express Maintenance and Service Manual Page 7-19...
Page 96: Kingpin And Steering Spindle Installation - Maintenance-Free Ball Joints
Front Suspension Components STEERING AND FRONT SUSPENSION KINGPIN AND STEERING SPINDLE INSTALLATION – MAINTENANCE-FREE BALL JOINTS Inspect all parts and replace them as necessary. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-19, Page 7-19).
Page 97: Front Wheel Bearings And Hubs
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs FRONT WHEEL BEARINGS AND HUBS See General Warnings on page 1-1. FRONT WHEEL FREE PLAY INSPECTION Raise the front of the vehicle. Using your hands, attempt to rock the wheel and hub assembly back and forth on the spindle. If there is any observable movement of the wheel and hub on the spindle, remove dust cap (1) and cotter pin (2) and then tighten the spindle nut (3) until the bearing (5) fully seats in the bearing race (7) (Figure 7-20, Page 7-21).
Page 98: Front Hub And Wheel Bearings Installation
Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION FRONT HUB AND WHEEL BEARINGS INSTALLATION Pack the wheel bearings (5) and hub cavities, and lubricate cups (7) with wheel bearing grease or chassis lube. Make sure the grease is forced between the rollers (Figure 7-20, Page 7-21). If bearing cups (7) were removed, press new ones in squarely against stops in the hub (Figure 7-20, Page 7-21).
Page 99: Section 8 - Wheels And Tires
• See General Warnings on page 1-1. GENERAL INFORMATION NOTE: Use only Club Car approved tires when replacing tires. Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. • Keep tires properly inflated. See Vehicle Specifications on page 2-1.
Page 100: Tires
Tires WHEELS AND TIRES TIRES See General Warnings on page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. Remove the tire and wheel assembly from the vehicle as instructed above. See Wheel Removal on page 8-1. Remove the valve cap and valve core and allow air to escape from the tire.
Page 101: Tire Installation
WHEELS AND TIRES Tires NOTE: An air leak could be due to a punctured casing, faulty valve core, improperly seated valve stem, or improperly seated tire bead. Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available at auto supply stores.
Page 102 Tires WHEELS AND TIRES Figure 8-2 Inflate Tire Page 8-4 2018 Café Express Maintenance and Service Manual...
Page 103: Section 9 - Rear Suspension
SECTION 9 — REAR SUSPENSION DANGER Rear Suspension • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.
Page 104: Multi-Leaf Springs
Multi-Leaf Springs REAR SUSPENSION NOTE: Tighten 3/8 hex nut at shock absorber until shock absorber cushions are approximately the same diameter as the retainers. Do not over tighten. On the upper and lower shock absorber mounting stems, tighten the nut (1) until the rubber bushing (3) expands to the size of the cup washer (4).
Page 105: Multi-Leaf Spring Installation
REAR SUSPENSION Multi-Leaf Springs 2600-30000-10369 1400-18100-10243 Figure 9-2 Support Vehicle on Jack Stands Figure 9-3 Disconnect Brake Cable MULTI-LEAF SPRING INSTALLATION NOTE: Tighten bolt (11) after clamp from brake cable has been positioned between nut and frame component. Install the bushings and spacers in the spring eyes. See following CAUTION. CAUTION •...
Page 106 Multi-Leaf Springs REAR SUSPENSION 2987 Figure 9-4 Rear Suspension Assembly and Mounting Page 9-4 2018 Café Express Maintenance and Service Manual...
Page 107: Section 10 - Periodic Maintenance
• Tires: Check for proper tire pressure upon delivery and on a daily basis when the vehicle is in service. See Vehicle Specifications on page 2-1. • Loading: Before driving the vehicle, ensure that the load weight is evenly distributed in the Cafe Express refreshment center.
Page 108: Performance Inspection
Use the following checklist, in conjunction with the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician.
Page 109: Periodic Service Schedule
PERIODIC MAINTENANCE Periodic Service Schedule 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 can result in fire, property damage, serious personal injury, or death. •...
Page 110 Periodic Service Schedule PERIODIC MAINTENANCE PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE See Pre-Operation and Daily Safety Pre-Operation and Daily Safety Checklist Checklist on page 10-1. Daily service by owner Performance Inspection See Performance Inspection on page 10-2. Check air pressure and adjust if necessary. Tires See Vehicle Specifications on page 2-1.
Page 111: Periodic Lubrication Schedule
PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Brake pedal shaft bearings Dry Moly Lube (CC PN 1012151) Brake linkage and pivots Dry Moly Lube (CC PN 1012151) Semiannually by owner or trained technician (or every 50 Accelerator pivot rod supports and Dry Moly Lube (CC PN 1012151)
Page 112 Periodic Lubrication Schedule PERIODIC MAINTENANCE Pagination Page Page 10-6 2018 Café Express Maintenance and Service Manual...
Page 113: Section 11 - Troubleshooting And Electrical System: Pedal-Start Gas Vehicle
SECTION 11 — TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE DANGER Troubleshooting and Electrical System: Pedal-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION WARNING • To prevent damage to the ECU, never mix the black and gray connectors that attach to it. The black connector is tethered to the ECU mounting plate to help avoid installing it in the gray port.
Page 114: Features Of The Electronic Fuel Injection (Efi) System
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE • Top of Fuel Tank: The fuel tank is grounded to the chassis through the main wire harness. FEATURES OF THE ELECTRONIC FUEL INJECTION (EFI) SYSTEM • Open-loop system (i.e. oxygen sensor not used) •...
Page 115 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide Error Codes – ECU BLINK CODE CODE DESCRIPTION CORRECTIVE ACTION Check battery voltage. Charge/replace battery Low Battery Voltage as necessary. Check connector at ECU & Throttle module. MAP Sensor: Open or Shorted Connection If connection is made and no corrosion is present, replace ECU and Throttle Module.
Page 116: Gasoline Powertrain
TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE GASOLINE POWERTRAIN TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Spark plug is partially fouled or in poor Clean or replace condition Spark plug is damaged or loose Replace or tighten Incorrect spark plug gap Adjust gap Spark plug wire is damaged or loose Replace or reconnect...
Page 117 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Fuel tank is empty Section 14 — Fuel System: Gasoline Vehicles Fuel line or filter clogged Section 14 — Fuel System: Gasoline Vehicles Fouled spark plug Section 13 —...
Page 118 TROUBLESHOOTING AND ELECTRICAL Troubleshooting Guide SYSTEM: PEDAL-START GAS VEHICLE TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Incorrect plug Section 13 — Engine (Subaru EX40) Spark plug wire is damaged Section 13 — Engine (Subaru EX40) Unsuitable fuel, or incorrect (rich) fuel mixture Section 14 —...
Page 119 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION Transmission shifter linkage is binding or is Section 17 — Transaxle (ED65): Gasoline out of adjustment Vehicles Insufficient (low) level of lubricant or wrong Section 17 —...
Page 120: Wiring Diagrams
TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE WIRING DIAGRAMS WD1050077_DGM_D-L Figure 11-1 Wiring Diagram for Pedal-Start Gasoline Vehicle Page 11-8 2018 Café Express Maintenance and Service Manual...
Page 121 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WD1050077_DGM_D-R Figure 11-2 Wiring Diagram for Pedal-Start Gasoline Vehicle – Continued 2018 Café Express Maintenance and Service Manual Page 11-9...
Page 122 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE WD1050951_DGM_A Figure 11-3 Wiring Diagram – Instrument Panel and FNR Shifter Page 11-10 2018 Café Express Maintenance and Service Manual...
Page 123 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Wiring Diagrams WD1050081_DGM_D Figure 11-4 Wiring Diagram – EFI and Engine 2018 Café Express Maintenance and Service Manual Page 11-11...
Page 124 TROUBLESHOOTING AND ELECTRICAL Wiring Diagrams SYSTEM: PEDAL-START GAS VEHICLE 3022 Figure 11-5 Sonic Weld and Diode Locations (Approximate) – CA500/550/Cafe Express Page 11-12 2018 Café Express Maintenance and Service Manual...
Page 125: Electrical System
TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of the following circuits that are easily identified: • Starter Circuit •...
Page 126: Test Procedures
TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURES Using the following procedures, the entire electrical system can be tested without major disassembly of the vehicle. WARNING • If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury, or death.
Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 2 – Fuses 3 – Ground Cables 4 – EFI System (ECU and Sensors) 5 – Key Switch (Start Circuit) 6 – Key Switch (Engine Kill Circuit) 7 – Accelerator Pedal Limit Switch – Pedal-Start Vehicles Only 8 –...
Page 128 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 1 – Battery See General Warnings on page 1-1. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near a battery.
Page 129 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE 70 °F (20 °C and above) 9.6 V 60 °F (16 °C) 9.5 V 50 °F (10 °C) 9.4 V 40 °F (4 °C) 9.3 V 30 °F (-1 °C) 9.1 V 20 °F (-7 °C)
Page 130 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 2 – Fuses See General Warnings on page 1-1. WARNING • Failure to use properly rated fuse can result in a fire hazard. NOTE: These vehicles predominately use a combination of ATC-style and ATM-style blade fuses. A single ABC-style glass fuse is used for the Guardian/Visage 4-pin connector that is labeled “V3 circuit”...
Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 5-amp ATM Fuse Only: With the key switch in the ON position: 4.1. Probe the two, small metal contacts on the top of the fuse (Figure 11-6, Page 11-18). 4.2. Each contact should show battery voltage. 4.3.
Page 132 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 3 – Ground Cables See General Warnings on page 1-1. NOTE: This is a continuity test for the main ground wire(s) of the vehicle. An additional ground wire is located on top of the fuel tank.
Page 133 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 4 – EFI System (ECU and Sensors) See General Warnings on page 1-1. WARNING • This procedure involves testing voltage, resistance and continuity. If necessary, see Testing Basics on page 11-14. 2018 Café...
Page 134 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Resistance: ECU Gray Pin 1 (Black/White) and ECU Approx.
Page 135 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures 18-PIN CONNECTOR (GRAY AND BLACK): A. ECU SIDE OF CONNECTOR B. WIRE ENTRY SIDE OF CONNECTOR CONNECTOR FUNCTION TEST TYPE & PROBE BETWEEN LOCATIONS TEST RESULT CONDITION I.D. COLOR Meter should beep Key OFF Black Ignition OFF Input...
Page 136 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 5 – Key Switch (Start Circuit) See General Warnings on page 1-1. NOTE: This is a voltage test. The key switch provides power and KEY INPUT to the ECU. If necessary, see Testing Basics on page 11-14.
Page 137 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 6 – Key Switch (Engine Kill Circuit) See General Warnings on page 1-1. NOTE: This is a continuity test. If necessary, see Testing Basics on page 11-14. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove the instrument panel.
Page 138 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 8 – Solenoid See General Warnings on page 1-1. NOTE: This is a resistance and voltage test. WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18 Ga. White Wire 5.
Page 139 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 9 – Maintenance/Operate Switch – Pedal-Start Vehicles See General Warnings on page 1-1. NOTE: This is a continuity test. The Maintenance/Operate Switch is also known as the Neutral Lockout Switch. If necessary, see Testing Basics on page 11-14.
Page 140 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 10 – Neutral Lockout Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. This switch is located on the transaxle. A black/white wire, a gray wire, and a red wire are connected to this limit switch with a 3-pin connector.
Page 141 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 11 – Starter/Generator (Generator Function) See General Warnings on page 1-1. NOTE: This is a voltage test. If necessary, see Testing Basics on page 11-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 142 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE • When disconnecting wires from starter/generator terminals, use a second wrench on the lower nut of the terminal post to hold post steady. • Scrape a small amount of paint from starter/generator housing (ground) and use this location when testing motor terminals to electrical ground.
Page 143 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 13 – Voltage Regulator See General Warnings on page 1-1. NOTE: This is a voltage test. Keep the battery connected while performing this test procedure. If necessary, see Testing Basics on page 11-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 144 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 14 – Kill Limit Switch – Pedal-Start Vehicles Only See General Warnings on page 1-1. NOTE: This is a continuity test. The kill limit switch is the lower of the two limit switches located in the electrical component box. There is a white/black wire and a blue wire connected to this limit switch.
Page 145 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 15 – Ignition Spark See General Warnings on page 1-1. NOTE: Keep the battery connected while performing this test procedure. If necessary, see Testing Basics on page 11-14. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position.
Page 146 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 16 – Ignition Coil See General Warnings on page 1-1. NOTE: This is a resistance test. The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some ignition coils can fail to operate at normal (warmer) operating temperatures.
Page 147 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 17 – Reverse Buzzer and Reverse Buzzer Limit Switch See General Warnings on page 1-1. NOTE: Reverse Buzzer: This is a voltage test. Reverse Buzzer Limit Switch: This is a continuity test. A reverse buzzer is mounted on the back side of the instrument panel.
Page 148 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 19 – Oil Level Sensor See General Warnings on page 1-1. NOTE: Keep the battery connected while performing this test procedure. This procedure requires the oil to be drained from the engine. If necessary, see Testing Basics on page 11-14.
Page 149 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 21 – Fuel Pump See General Warnings on page 1-1. WARNING • To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while performing this test procedure.
Page 150 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE Probe between pin (1) and pin (2) terminals in module (Figure 11-18, Page 11-37). 4.1. The reading should be approximately 2 to 5 ohms. If the reading indicates no resistance, the fuel pump has failed and the fuel pump module must be replaced.
Page 151 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 23 – Fuel Gauge See General Warnings on page 1-1. NOTE: This is a voltage test. 1. Black 2. Red/White 4. Purple 6. Black 7. White Figure 11-19 Fuel Gauge/Hour Meter If necessary, see Testing Basics on page 11-14.
Page 152 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE WAVETEK WAVETEK 1000 1000 2000 2000 200k 200k 200nA 200nA 1000 --- FUSED 750V 1000 --- FUSED 750V 1. 20 VDC Setting 2. Purple 3. Black 4. White 5. Red/White 1. 20 VDC Setting 2. Purple Figure 11-20 Fuel Gauge Voltage Test - Terminal 2 Figure 11-21 Fuel Gauge Voltage Test - Terminal 4 TEST PROCEDURE 24 –...
Page 153 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 25 – Light Switch See General Warnings on page 1-1. NOTE: The headlight circuit is protected by the 20-amp fuse. Check the fuse before this procedure is performed. See Test Procedure 2 – Fuses on page 11-18. This is a voltage test.
Page 154 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE TEST PROCEDURE 27 – Voltage Limiter See General Warnings on page 1-1. NOTE: This is a diode test. The voltage limiter is a diode. Diodes are designed to conduct current in one direction only. See following NOTE. NOTE: If the voltage limiter conducts current in both directions, the diode has failed closed.
Page 155 TROUBLESHOOTING AND ELECTRICAL SYSTEM: PEDAL-START GAS VEHICLE Test Procedures TEST PROCEDURE 28 – 4-Pin Connector (for Connected Car Device) See General Warnings on page 1-1. NOTE: This is a voltage and continuity test. The Connected Car Device 4-pin connector is used for Guardian/Visage and is labeled “V3 circuit” on the main wire harness.
Page 156 TROUBLESHOOTING AND ELECTRICAL Test Procedures SYSTEM: PEDAL-START GAS VEHICLE Pagination Page Page 11-44 2018 Café Express Maintenance and Service Manual...
Page 157: Section 12 - Electrical Components: Pedal-Start Gas Vehicle
SECTION 12 — ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE DANGER Electrical Components: Pedal-Start Gas Vehicle • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. STARTER/GENERATOR See General Warnings on page 1-1. TESTING THE STARTER/GENERATOR See Test Procedure 12 – Starter/Generator (Starter Function) on page 11-29. See Test Procedure 11 –...
Page 158: Brush Inspection And Replacement
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 12-2 Brush Covers and Brushes Figure 12-1 Commutator End Cover BRUSH INSPECTION AND REPLACEMENT Visually inspect brushes. Replace brushes that are cracked or severely chipped. Measure the length of each brush. Replace the brush set if a brush is less than 0.375 inch (9.5 mm) (Figure 12-3, Page 12-2).
Page 159: Starter/Generator Assembly
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator CAUTION • When checking brush spring tension, do not push springs beyond the point they would normally be if there were new brushes installed. Exerting excessive force or pushing brush springs beyond their normal maximum extension point will damage springs. Figure 12-4 Brush Spring Tension Test STARTER/GENERATOR ASSEMBLY Install the brushes (27) into the holders.
Page 160: Disassembly Of The Starter/Generator To Service The Armature/Commutator
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Figure 12-5 Pull Brushes Away From Center of the Commutator End Cover DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE ARMATURE/COMMUTATOR Remove the commutator end cover to prevent damage to the brushes and armature. See Commutator End Cover on page 12-2.
Page 161: Bearing Cleaning And Inspection
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 1342 Figure 12-6 Output End Cover Assembly, Armature and Housing BEARING CLEANING AND INSPECTION Using a clean cloth, wipe the carbon dust from the two bearings. Inspect bearings by spinning them by hand and checking for both axial (A) and radial (B) play (Figure 12-7, Page 12-5).
Page 162: Bearing Removal
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE BEARING REMOVAL Place the wedge attachment tool (P/N 1012812) between the bearing and the armature. Make sure the wedge attachment tool is supporting the inner race of the bearing. If a press is not available, secure a bearing puller (P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 163: Commutator Cleaning And Inspection
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator Figure 12-9 Field Coil Assembly COMMUTATOR CLEANING AND INSPECTION 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 commutator can be polished away with 400 grit (or finer) sandpaper.
Page 164: Armature Ground Test
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE 1. Measure each position in two places, 90 degrees apart Figure 12-10 Inspect Commutator ARMATURE GROUND TEST CAUTION • Do not submerge armature in solvent. NOTE: Before testing, wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars.
Page 165: Visual Inspection Of Field Coils
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator WAVETEK 1000 2000 200k 200nA 1000 --- FUSED 750V 1. 200 Ohms Setting 2. Commutator 3. Armature Shaft Figure 12-11 Armature Ground Test VISUAL INSPECTION OF FIELD COILS If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the starter/generator has overheated due to overloads or grounded or shorted coil windings.
Page 166 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE Press a new ball bearing (35) onto the output end of the armature (Figure 12-6, Page 12-5). Press a new ball bearing onto the commutator end of the armature shaft. See following CAUTION. CAUTION •...
Page 167 ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 90° 1. Jumper Wire 2. 1 inch (25.4 mm) Minimum Radius 3. Jumper Wire Not Allowed in this Area. 2687 Figure 12-12 A1 to F1 Terminal Jumper Wire Routing 2018 Café Express Maintenance and Service Manual Page 12-11...
Page 168: Starter/Generator Installation
ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE STARTER/GENERATOR INSTALLATION 2997 Figure 12-13 Starter/Generator Installation Install the green wire (1) from the F1 terminal to the A2 terminal on the starter/generator (Figure 12-14, Page 12-13). Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in·lb (5.4 N·m). Position the starter/generator over the mounting bracket so that the bolts will go through the starter/generator before going through the bracket.
Page 169: Belt Tension Adjustment For Efi Engines
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Starter/Generator 3033 Figure 12-14 Starter/Generator Wiring BELT TENSION ADJUSTMENT FOR EFI ENGINES NOTE: To prevent belt slipping while starting an EFI engine, follow procedure outlined below which is best performed by two people to expedite the process, but can be performed by a single individual if required. The amount a starter/generator belt is tensioned varies between a used and new belt.
Page 170 ELECTRICAL COMPONENTS: PEDAL-START Starter/Generator GAS VEHICLE – Use combination of above methods. Mark a location on belt to repeat tension measurement each time. Use paint pen or permanent marker of light color. For Existing Belts Only: Verify current belt tension using Universal Belt Tension Gauge (OTC 6673 ®...
Page 171: Voltage Regulator
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Voltage Regulator 7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 12-15, Page 12-13). NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal Belt Tension gauge between measurements.
Page 172: Voltage Regulator Installation
ELECTRICAL COMPONENTS: PEDAL-START Voltage Regulator GAS VEHICLE 1. Red wire to solenoid. 2. To kill limit switch. 3. To frame ground. 4. To bullet connector. 2973 Figure 12-18 Voltage Regulator VOLTAGE REGULATOR INSTALLATION Position the voltage regulator (9) in the electrical component box and install the mounting screw (8) (Figure 12-18, Page 12-16).
Page 173: Engine Control Unit (Ecu)
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Engine Control Unit (ECU) ENGINE CONTROL UNIT (ECU) CAUTION • The Engine Control Unit (ECU) and Throttle Body are to be purchased as one unit. They are matched pairs with matching serial numbers. Do not mix an ECU with another Throttle Body of a different serial number.
Page 174: Key Switch
ELECTRICAL COMPONENTS: PEDAL-START Key Switch GAS VEHICLE KEY SWITCH See General Warnings on page 1-1. TESTING THE KEY SWITCH See Test Procedure 5 – Key Switch (Start Circuit) on page 11-24. See Test Procedure 6 – Key Switch (Engine Kill Circuit) on page 11-25. KEY SWITCH REMOVAL Disconnect the batteries and spark plug.
Page 175: Maintenance/Operate Switch
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Maintenance/Operate Switch MAINTENANCE/OPERATE SWITCH TESTING THE MAINTENANCE/OPERATE SWITCH See Test Procedure 9 – Maintenance/Operate Switch – Pedal-Start Vehicles on page 11-27. MAINTENANCE/OPERATE SWITCH REMOVAL Disconnect the battery and spark plug wire(s).See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Using a 5/8 inch (16 mm) wrench, remove maintenance/operate boot/hex nut.
Page 176: Solenoid
ELECTRICAL COMPONENTS: PEDAL-START Solenoid GAS VEHICLE Connect the 3-wire connector to the neutral lockout limit switch lead. Connect battery and spark plug wire(s). See Connecting the Battery-Gasoline Vehicles on page 1-3. Test drive the vehicle in both forward and reverse for proper operation. SOLENOID See General Warnings on page 1-1.
Page 177: Fuse Removal
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Fuse TESTING THE FUSE See Test Procedure 2 – Fuses on page 11-18. FUSE REMOVAL Disconnect battery. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. ATC Fuse Only: Remove electrical component box cover cover. ATM Fuse Only: Remove fuse holder cover. Remove the fuse from the fuse block.
Page 178: Kill Limit Switch
ELECTRICAL COMPONENTS: PEDAL-START Kill Limit Switch GAS VEHICLE KILL LIMIT SWITCH See General Warnings on page 1-1. TESTING THE KILL LIMIT SWITCH See Test Procedure 14 – Kill Limit Switch – Pedal-Start Vehicles Only on page 11-32. KILL LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 179: Reverse Warning Buzzer
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Warning Buzzer 2948 Figure 12-20 Accelerator Starter and Kill Limit Switches REVERSE WARNING BUZZER See General Warnings on page 1-1. TESTING THE REVERSE WARNING BUZZER See Test Procedure 17 – Reverse Buzzer and Reverse Buzzer Limit Switch on page 11-35. REVERSE WARNING BUZZER REMOVAL Disconnect battery and spark plug wire(s).
Page 180 ELECTRICAL COMPONENTS: PEDAL-START Reverse Warning Buzzer GAS VEHICLE 3003 Figure 12-21 Instrument Panel Switches Page 12-24 2018 Café Express Maintenance and Service Manual...
Page 181: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Reverse Buzzer Limit Switch REVERSE BUZZER LIMIT SWITCH See General Warnings on page 1-1. TESTING THE REVERSE BUZZER LIMIT SWITCH See Test Procedure 17 – Reverse Buzzer and Reverse Buzzer Limit Switch on page 11-35. REVERSE BUZZER LIMIT SWITCH REMOVAL Disconnect battery and spark plug wire(s).
Page 182 ELECTRICAL COMPONENTS: PEDAL-START Reverse Buzzer Limit Switch GAS VEHICLE 3001 Figure 12-22 Forward/Reverse Assembly Switches Page 12-26 2018 Café Express Maintenance and Service Manual...
Page 183: Low Oil Warning Light
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Low Oil Warning Light LOW OIL WARNING LIGHT See General Warnings on page 1-1. TESTING THE LOW OIL WARNING LIGHT See Test Procedure 18 – Low Oil Warning Light (LED) on page 11-35. LOW OIL WARNING LIGHT REMOVAL Disconnect battery and spark plug wire(s).
Page 184: Fuel Gauge/Hour Meter Installation
ELECTRICAL COMPONENTS: PEDAL-START Fuel Level Sending Unit GAS VEHICLE Alternate pulling the lower and upper tabs away from the gauge housing to remove clip. Pull gauge/meter from the instrument panel. FUEL GAUGE/HOUR METER INSTALLATION Install a new fuel gauge/hour meter (6) into the hole in the instrument panel until the flange seats against the instrument panel (Figure 12-21, Page 12-24).
Page 185: Voltage Limiter Removal
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Voltage Limiter See Test Procedure 27 – Voltage Limiter on page 11-42. VOLTAGE LIMITER REMOVAL NOTE: Battery will charge reducing the voltage going to accessories. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels.
Page 186: Headlight Switch
ELECTRICAL COMPONENTS: PEDAL-START Headlight Switch GAS VEHICLE HEADLIGHT SWITCH See General Warnings on page 1-1. TESTING THE LIGHT SWITCH See Test Procedure 25 – Light Switch on page 11-41. HEADLIGHT SWITCH REMOVAL Remove the instrument panel. See Instrument Panel Removal, Section 4, Page 4-10. Disconnect the wires from the light switch (4 and 9) (Figure 12-21, Page 12-24).
Page 187: Headlight Bulb Removal (Halogen)
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Headlights HEADLIGHT BULB REMOVAL (HALOGEN) Disconnect the batteries. See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Remove cowl. See Cowl Removal, Section 4, Page 4-5. Remove front fenders. See Front Bumper and Side Fender Removal, Section 4, Page 4-9. Rotate the bulb (4) (but do not touch) in a 90–degree angle and pull out of lens assembly (5).
Page 188 ELECTRICAL COMPONENTS: PEDAL-START Headlights GAS VEHICLE 2993 Figure 12-24 Headlight Assembly Page 12-32 2018 Café Express Maintenance and Service Manual...
Page 189: Battery
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery BATTERY See General Warnings on page 1-1. DANGER • Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working on or near batteries. • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area.
Page 190: Self-Discharge
ELECTRICAL COMPONENTS: PEDAL-START Battery GAS VEHICLE tightened to 41 in·lb (4.3 N·m), coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to prevent future corrosion. See preceding WARNINGS and following CAUTION. CAUTION • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so may cause them to overheat during operation and could result in a fire, property damage, or personal injury.
Page 191: Battery Removal
ELECTRICAL COMPONENTS: PEDAL-START GAS VEHICLE Battery BATTERY REMOVAL See General Warnings on page 1-1. Also see DANGER at beginning of Battery topic. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the wheels. Disconnect battery and spark plug wire(s).
Page 192: Battery Storage
ELECTRICAL COMPONENTS: PEDAL-START Ground Cables GAS VEHICLE BATTERY STORAGE See General Warnings on page 1-1. Also see DANGER at beginning of Battery topic. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 12-33. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The battery can be left in the vehicle.
Page 193: Section 13 - Engine (Subaru Ex40)
SECTION 13 — ENGINE (SUBARU EX40) DANGER Engine (Subaru EX40) • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION See General Warnings on page 1-1. This vehicle is powered by a Subaru EX40, high-compression, chain driven, overhead cam engine. The engine offers a heavy-duty construction featuring cast iron cylinder liner for longer life, dual ball bearing crankshaft support, low oil level sensor and heavy-duty air cleaner system, to name a few characteristics.
Page 194: Torque Specifications
General Information ENGINE (SUBARU EX40) TORQUE SPECIFICATIONS ITEM SIZE TORQUE Flywheel retaining nut 80 ft·lb (110 N·m) Crankcase cover to block bolts 250 in·lb (28.3 N·m) Step Step New head and bolts: New head and bolts: 159 in·lb (18 N·m) 336 in·lb (38 N·m) Cylinder head bolts Used head and bolts:...
Page 195 ENGINE (SUBARU EX40) General Information Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level).
Page 196 General Information ENGINE (SUBARU EX40) 1. Drain pan 2. Drain plug 2667 Figure 13-2 Engine Oil Drain Plug and Pan Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan. See following WARNING. WARNING •...
Page 197: Spark Plug
ENGINE (SUBARU EX40) General Information Figure 13-3 Oil Viscosity Chart Connect battery and spark plug wire. See Connecting the Battery-Gasoline Vehicles on page 1-3. With the Forward/Reverse handle in the NEUTRAL position and the Maintenance/Operate switch in the OPERATE position, start and run the engine for a few minutes. Observe the drain plug from under the vehicle and watch for oil leaks.
Page 198: Breather
General Information ENGINE (SUBARU EX40) Figure 13-4 Spark Plug Testing the Spark Plug Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should be blue and strong and able to jump a 5/16-in. (8 mm) gap. Setting the Spark Gap Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging.
Page 199: Valve Clearance Check And Adjustment
ENGINE (SUBARU EX40) General Information VALVE CLEARANCE CHECK AND ADJUSTMENT NOTE: Check and adjust clearance when the engine is cold. If equipped, remove air deflector from top of engine. Remove rocker cover. Turn the crankshaft until the piston is at top dead center of the compression stroke (Figure 13-5, Page 13-7). Using a feeler gauge (1), measure the clearance between the adjuster screw (3) and the top of the valve stem (Figure 13-6, Page 13-7).
Page 200: Engine Removal
Engine Removal ENGINE (SUBARU EX40) ENGINE REMOVAL See General Warnings on page 1-1. 3036a Figure 13-7 EX40 Engine and Mounting Brackets CAUTION • Before removal and disassembly, clean the engine. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Page 13-8 2018 Café...
Page 201 ENGINE (SUBARU EX40) Engine Removal For some vehicles, the engine (1) can be removed by lifting it up and out of the chassis. For other vehicles, it is easier to remove the entire powertrain assembly first. If removing powertrain, see Transaxle Removal on page 17-9.
Page 202: Engine Installation
Engine Installation ENGINE (SUBARU EX40) ENGINE INSTALLATION See General Warnings on page 1-1. If replacing engine (1), install starter/generator mounting weldment (10) on engine with screws (11), bolts (12), washers (13), and locknuts (14) (Figure 13-7, Page 13-8). Tighten locknuts (14) only finger-tight at this time. Install oil drain plug and tighten to 18 ft·lb (24.4 N·m).
Page 203: Flywheel Removal
ENGINE (SUBARU EX40) Flywheel 3037 Figure 13-8 Flywheel, Fan and Fan Housing – EX40 FLYWHEEL REMOVAL Remove screws (1) and fan housing (2) (Figure 13-8, Page 13-11). Hold flywheel (4) only, not fan (7), with strap wrench (5) and use a 24 mm socket to remove flywheel nut (8) and flat washer (9) by turning it counterclockwise (Figure 13-9, Page 13-12).
Page 204: Flywheel Installation
Oil Level Sensor ENGINE (SUBARU EX40) Figure 13-9 Flywheel Nut Removal Figure 13-10 Fan and Flywheel Installation FLYWHEEL INSTALLATION Wipe off any oil on tapered portions of crankshaft and flywheel (4) (Figure 13-8, Page 13-11). Insert woodruff key (10) into keyway of crankshaft. Then align groove in flywheel (4) to woodruff key (10) and push flywheel onto crankshaft until it seats.
Page 205: Oil Level Sensor Installation
ENGINE (SUBARU EX40) Oil Level Sensor Pull oil level sensor (5) out of engine. OIL LEVEL SENSOR INSTALLATION Lubricate oil level sensor o-ring with oil and carefully insert sensor (5) into engine until fully seated. Secure sensor (5) to engine with two bolts (4) and tighten to 80 in·lb (9 N·m) (Figure 13-11, Page 13-13). Connect oil level sensor wire (3) to wire harness.
Page 206: Ignition Coil
Ignition Coil ENGINE (SUBARU EX40) IGNITION COIL See General Warnings on page 1-1. TESTING THE IGNITION COIL See Test Procedure 15 – Ignition Spark on page 11-33 and Test Procedure 16 – Ignition Coil on page 11-34. IGNITION COIL REMOVAL Remove screws (1) and fan housing (2) (Figure 13-8, Page 13-11).
Page 207: Snubber
ENGINE (SUBARU EX40) Snubber SNUBBER See General Warnings on page 1-1. NOTE: The snubber is installed on the gasoline vehicle only. SNUBBER REMOVAL Support the powertrain with a floor jack under the engine pan (1) so that the snubber (2) is raised slightly and does not rest on the vehicle frame (Figure 13-14, Page 13-15).
Page 208 Snubber ENGINE (SUBARU EX40) Pagination Page Page 13-16 2018 Café Express Maintenance and Service Manual...
Page 209: Section 14 - Fuel System: Gasoline Vehicles
SECTION 14 — FUEL SYSTEM: GASOLINE VEHICLES DANGER Fuel System: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. • Fuel may be under pressure. Use extreme caution when disconnecting fuel line to prevent the spray of fuel onto hot engine.
Page 210: Relieving Fuel Pressure
Relieving Fuel Pressure FUEL SYSTEM: GASOLINE VEHICLES 1. ECU 2. Fuel Pump 3. Fuel Tank 4. Fuel Injector 5. MAP Sensor 6. Engine Temperature Sensor 7. CDI Ignition Unit 3040 Figure 14-1 EFI System Components RELIEVING FUEL PRESSURE In the event that servicing the EFI fuel system necessitates removal of the fuel delivery hose, extreme caution must be exercised.
Page 211: Throttle Body
FUEL SYSTEM: GASOLINE VEHICLES Throttle Body NOTE: To absorb any residual fuel the may be present in the fuel hose, place a rag or towel around the hose at the end being disconnected. THROTTLE BODY See General Warnings on page 1-1. Before suspecting the throttle body as the cause of poor engine performance, make sure the fuel and ignition systems are in proper operating condition.
Page 212: Throttle Body Installation
Throttle Body FUEL SYSTEM: GASOLINE VEHICLES 3041 Figure 14-2 Throttle Body – Exploded View THROTTLE BODY INSTALLATION See General Warnings on page 1-1. Install throttle body (1) and its related components onto threaded studs in order as shown (Figure 14-2, Page 14-4).
Page 213 FUEL SYSTEM: GASOLINE VEHICLES Throttle Body Connect governor cable to bracket (4). Connect breather hose (2) to air intake adapter (3). Connect air intake hose and secure with hose clamp. If removed, install fuel tank. See Fuel Tank Installation, Section 14, Page 14-22. If equipped, install air deflector on top of engine.
Page 214: Engine Control Linkages
Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES ENGINE CONTROL LINKAGES See General Warnings on page 1-1. DANGER • To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push rod, do the following: – Turn key switch OFF and remove key, place Forward/Reverse handle in the NEUTRAL position, and chock the wheels prior to servicing the vehicle.
Page 215: Ground Speed
FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages GROUND SPEED NOTE: If possible, the manufacturer recommends measuring ground speed when setting engine RPM. This vehicle should reach the forward ground speed specified in Section 2 – Vehicle Specifications. See How to Measure Ground Speed on page 14-13.
Page 216 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES CAUTION • Inspect the limit switches inside the electrical component box. If a limit switch lever is bent, replace the switch. 3113 3043 Figure 14-6 Accelerator Cable Cam Position – 7° (Top Figure 14-7 Governor Cable At Throttle Body View) Before tightening the jam nuts (3), set the park brake to the first latch and pawl position and check for proper activation of switches.
Page 217: Governor Cable
FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages GOVERNOR CABLE Governor Cable Removal Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. At engine: 3.1.
Page 218 Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES A = 0.055 in. ± 0.039 (1.4 mm ± 1) 3110 3111 Figure 14-8 Governor and Accelerator Cables At Governor Figure 14-9 Throttle Stop Screw Gap Page 14-10 2018 Café Express Maintenance and Service Manual...
Page 219: Accelerator Cable
FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages ACCELERATOR CABLE Accelerator Cable Removal Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL position, and chock the wheels. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. At transaxle: 3.1.
Page 220: Closed Throttle Or Idle Adjustment - Pedal-Start Vehicles
Engine Control Linkages FUEL SYSTEM: GASOLINE VEHICLES CLOSED THROTTLE OR IDLE ADJUSTMENT – PEDAL-START VEHICLES When the accelerator pedal is released, the engine will stop. Therefore, it is not possible to measure or set idling speed under normal vehicle operating conditions. Set throttle valve as follows: Loosen the throttle body idle screw so that it is not touching the throttle lever (Figure 14-11, Page 14-12).
Page 221: How To Measure Ground Speed
FUEL SYSTEM: GASOLINE VEHICLES Engine Control Linkages HOW TO MEASURE GROUND SPEED Best Method An easy way to check ground speed is by using a GPS device or smartphone application (app). If these are not available, use the alternate method below. Alternate Method (Calculated) Ground speed is easily determined by a known distance travelled, divided by the amount of time it took to travel that known distance (Rate = Distance/Time).
Page 222: Air Intake System
Air Intake System FUEL SYSTEM: GASOLINE VEHICLES AIR INTAKE SYSTEM See General Warnings on page 1-1. 3048 Figure 14-12 Air Intake System – CA 500/550/700/TRANSPORTER/Cafe Express Page 14-14 2018 Café Express Maintenance and Service Manual...
Page 223: Air Filter
• Engine damage will occur if the air cleaner cap is not properly secured. • If air cleaner is extremely dirty, remove air cleaner from vehicle and clean thoroughly. • Use only Club Car replacement air filters. The use of other air filters could result in engine damage and void the warranty.
Page 224: Fuel Line
NOTE: This EFI gasoline vehicle is equipped with SAEJ30R9 fuel hose rated for high-pressure systems. Always replace the fuel line on this vehicle with approved Club Car replacement part. Do not attempt to repair, patch or splice the fuel line.
Page 225: Fuel Line Installation
FUEL SYSTEM: GASOLINE VEHICLES Fuel Line 1. Push fuel line onto nipple until it locks into place. 2. Push in locking clip until fully seated. 1. Pull out locking clip. 2. Push in on release tab. 3. While pushing in on release tab, pull fuel line off nipple. 3050 3051 Figure 14-13 Fuel Line Connector –...
Page 226: Fuel Pump Module
Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES FUEL PUMP MODULE See General Warnings on page 1-1. GENERAL INFORMATION NOTE: The fuel pump and fuel level sending unit themselves are not replaceable. If necessary, the fuel pump module must be replaced as an assembly. The fuel pump module can be disassembled to replace the fuel filter.
Page 227 FUEL SYSTEM: GASOLINE VEHICLES Fuel Pump Module CAUTION • Ensure o-ring stays seated in place during fuel pump module installation. Install hold down ring (6) and ground wire (7) with hardware (5) and tighten in a crisscross pattern to 66 in·lb (7.5 N·m).
Page 228 Fuel Pump Module FUEL SYSTEM: GASOLINE VEHICLES 3052 Figure 14-15 Fuel System (Side-Fill) – Exploded View Page 14-20 2018 Café Express Maintenance and Service Manual...
Page 229: Fuel Tank
SAEJ30R9 1/4 in (6.3 mm) fuel vent hose (CC P/N 102865101) and 3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. FUEL TANK REMOVAL Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout switch in the MAINTENANCE position.
Page 230: Fuel Tank Disposal
3/16 in (4.78 mm) fuel vent hose (CC P/N 1015137). To remain in compliance with California and EPA regulations, replace any fuel vent hose on this vehicle with Club Car P/N's 102865101, 1015137, or equivalent. Place fuel tank (10) in vehicle.
Page 231: Fuel Filter
FUEL SYSTEM: GASOLINE VEHICLES Fuel Filter Connect fuel line (3) to fuel pump module (1). See Fuel Line Installation on page 14-17. See following DANGER. DANGER • Ensure line is connected properly to avoid a leak that can cause a fire. Connect wire harness plug (2) to fuel pump module (1).
Page 232: Fuel Filter Installation
Fueling Instructions – Gasoline Vehicle FUEL SYSTEM: GASOLINE VEHICLES FUEL FILTER INSTALLATION CAUTION • Fuel filter flex hoses are keyed to aid proper installation into fuel pump module. NOTE: The fuel filter is keyed to the fuel pump module to prevent incorrect assembly. The inlet and outlet flex hoses are keyed to the fuel filter ports to prevent incorrect assembly.
Page 233 FUEL SYSTEM: GASOLINE VEHICLES Fueling Instructions – Gasoline Vehicle CAUTION • Use unleaded gasoline only. • Whenever possible, avoid using oxygenated and blended fuels. • Do not use any fuel with an alcohol content that exceeds 10% by volume (such as E15 and E85). Ethanol is an alcohol that readily absorbs moisture, causing corrosion of fuel system components.
Page 234 Fueling Instructions – Gasoline Vehicle FUEL SYSTEM: GASOLINE VEHICLES Pagination Page Page 14-26 2018 Café Express Maintenance and Service Manual...
Page 235: Section 15 - Exhaust System: Gasoline Vehicles
SECTION 15 — EXHAUST SYSTEM: GASOLINE VEHICLES DANGER Exhaust System: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. MUFFLER MUFFLER REMOVAL Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. If equipped, remove air deflector from top of engine.
Page 236 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES 3112a Figure 15-1 Exhaust System Page 15-2 2018 Café Express Maintenance and Service Manual...
Page 237: Section 16 - Clutches: Gasoline Vehicles
SECTION 16 — CLUTCHES: GASOLINE VEHICLES DANGER Clutches: Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to the engine, is in the open position when the engine is at idle.
Page 238: Troubleshooting
Troubleshooting CLUTCHES: GASOLINE VEHICLES If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive clutch. Be sure to clean the plastic drive buttons (7) (Figure 16-3, Page 16-4). (CC P/N 101809101) (CC P/N 1014497) (CC P/N 1014508) (CC P/N 1014507)
Page 239: Drive Belt
CLUTCHES: GASOLINE VEHICLES Drive Belt DRIVE BELT See General Warnings on page 1-1. The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or glazed, replace the belt. As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will keep the vehicle’s maximum ground speed correct.
Page 240: Drive Clutch
Drive Clutch CLUTCHES: GASOLINE VEHICLES DRIVE CLUTCH See General Warnings on page 1-1. 1. Screw, 3/8-24 x 5.75, Patch 10. Retainer 2. Washer, Hard, M10 11. Ring, Spiral Backup 3. Washer, 3/8, Type A, Flat 12. Bushing, Split, Drive Clutch 4.
Page 241: Drive Clutch Removal
CLUTCHES: GASOLINE VEHICLES Drive Clutch 8. Drive Clutch Weight 17. Spacer, Idler, Drive 9. Thrust Washer 18. Sheave, Fixed, Drive 2960 Figure 16-3 Drive Clutch – Exploded View CAUTION • Be very careful when handling the clutches. A clutch that has been dropped will not be properly balanced.
Page 242: Drive Clutch Cleaning And Inspection
Drive Clutch CLUTCHES: GASOLINE VEHICLES WARNING • Lift only one end of the vehicle at a time. Use a suitable lifting device (chain hoist or hydraulic floor jack) with 1000 lb. (454 kg) minimum lifting capacity. Do not use lifting device to hold vehicle in raised position.
Page 243: Drive Clutch Disassembly
CLUTCHES: GASOLINE VEHICLES Drive Clutch DRIVE CLUTCH DISASSEMBLY CAUTION • The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive clutch hub and on the moveable sheave so they can be reassembled in the same positions (Figure 16-6, Page 16-7).
Page 244 Drive Clutch CLUTCHES: GASOLINE VEHICLES 3053 Figure 16-8 Drive Button Mounting Figure 16-9 Weight Position Remove the clutch weights: 5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 16-9, Page 16-8). 5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch. See following NOTE. NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary weight (3) (Figure 16-10, Page 16-9).
Page 245: Inspection Of Drive Clutch Parts
CLUTCHES: GASOLINE VEHICLES Drive Clutch Figure 16-10 Primary and Secondary Weights, Wave Washer and Pin Remove the retaining ring (6) from the shaft of the fixed sheave (18) and slide the moveable sheave (13) off the shaft (Figure 16-3, Page 16-4). See following NOTE. NOTE: If the moveable sheave is removed from the hub of the fixed sheave, the spiral back-up rings (11) must be replaced with new rings (Figure 16-3, Page 16-4).
Page 246: Drive Clutch Assembly
Drive Clutch CLUTCHES: GASOLINE VEHICLES Inspect the primary weights (8) and the hub casting for wear. If the primary weights show signs they are touching the casting, the tips of the weights have worn beyond specification and they must be replaced. Inspect the pins on the primary weights (8).
Page 247: Drive Clutch Installation
CLUTCHES: GASOLINE VEHICLES Drive Clutch NOTE: Make sure there is at least a (minimum) gap of 0.020 in. (0.51 mm) between each end of the mounting pin and the mounting bolt. Install three drive button take-up springs. 11.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 16-13, Page 16-11).
Page 248: Driven Clutch
Driven Clutch CLUTCHES: GASOLINE VEHICLES DRIVEN CLUTCH See General Warnings on page 1-1. 1. Screw, 5/16-18 X 3/4 Hex-Head with Patch 7. Screw, #8-32 X 3/4, Socket-Head Cap 2. Washer, Driven Clutch 8. Button, Drive 3. Ring, Retaining 9. Sheave, Movable, Driven 4.
Page 249: Driven Clutch Removal
CLUTCHES: GASOLINE VEHICLES Driven Clutch 5. Cam, Driven Clutch 11. Sheave, Fixed, Driven 6. Spring, Driven Clutch, 55 Degree 12. Key, 3/16 in. (4.7 mm) Square X 1.50 in. (38 mm) Long 2961 Figure 16-14 Driven Clutch – Exploded View DRIVEN CLUTCH REMOVAL Remove the drive belt as instructed.
Page 250: Driven Clutch Inspection
Driven Clutch CLUTCHES: GASOLINE VEHICLES Figure 16-15 Remove Retaining Ring Figure 16-16 Driven Clutch Disassembly DRIVEN CLUTCH INSPECTION Inspect the cam (5) for excessive wear (Figure 16-14, Page 16-12). Replace it if necessary. Inspect the drive buttons (8) for excessive wear. Replace if necessary. To remove the drive buttons (8), remove the socket-head cap screws (7) and then the buttons.
Page 251 CLUTCHES: GASOLINE VEHICLES Driven Clutch 5.1.2. Hold the fixed sheave (3) and rotate the moveable sheave (1) one-third turn counterclockwise, then press the cam (2) onto the fixed sheave (Figure 16-17, Page 16-15). The match marks made before disassembly should now align. 5.1.3.
Page 252: Driven Clutch Installation
Driven Clutch CLUTCHES: GASOLINE VEHICLES 5.2.6. Hold the fixed sheave of the clutch (5) and rotate the moveable sheave of the clutch one-third turn counterclockwise (Figure 16-18, Page 16-15). The match marks made before disassembly should now align. 5.2.7. Use two wrenches and hold the bolt head (1) while tightening the cam press hub (6) to press the cam onto the keyed shaft.
Page 253: Section 17 - Transaxle (Ed65): Gasoline Vehicles
SECTION 17 — TRANSAXLE (ED65): GASOLINE VEHICLES DANGER Transaxle (ED65): Gasoline Vehicles • See General Warnings on page 1-1. WARNING • See General Warnings on page 1-1. GENERAL INFORMATION The vehicles addressed in this manual are equipped with heavy-duty transaxles. The transaxle utilizes internal gearing to change vehicle direction.
Page 254: Governor System
General Information TRANSAXLE (ED65): GASOLINE VEHICLES WARNING • With the switch in the MAINTENANCE position and the engine running, the vehicle may move suddenly if the Forward/Reverse handle is shifted or accidentally bumped. To prevent this, chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle.
Page 255: Tools Required For This Section
TRANSAXLE (ED65): GASOLINE VEHICLES General Information Use a funnel when filling the transaxle through the lubricant level indicator hole. Fill with 67.6 fl-oz (2 L) 80-90 WT. API class GL or 80-90 WT. AGMA class 5 EP gear lubricant (or until lubricant begins to run out of the level indicator hole).
Page 256: Rear Hubs
Rear Hubs TRANSAXLE (ED65): GASOLINE VEHICLES REAR HUBS REAR HUB REMOVAL Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 257 TRANSAXLE (ED65): GASOLINE VEHICLES Rear Hubs CAUTION • Do not allow anti-seize compound to contact the brake drum or shoes. Slide hub (6) onto axle shaft (Figure 17-3, Page 17-4). Install the large flat washer (5) onto the threaded portion of the axle. Install hub nut (4) and advance the nut to the large flat washer.
Page 258: Axle Tubes, Axle Shafts And Wheel Bearings
Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES AXLE TUBES, AXLE SHAFTS AND WHEEL BEARINGS Removal of the transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil seals. If the transaxle is to be removed from the vehicle, do not remove the wheels, axle shafts, or axle tubes first. Instructions for removing the transaxle from the vehicle begin on page 17-9.
Page 259: Axle Tube And Axle Shaft Installation
TRANSAXLE (ED65): GASOLINE VEHICLES Axle Tubes, Axle Shafts and Wheel Bearings AXLE TUBE AND AXLE SHAFT INSTALLATION Clean mating surfaces of axle tube (2) flange and transaxle gearcase (4). Also clean the threads of the five axle tube mounting holes in the gearcase. See following CAUTION. CAUTION •...
Page 260: Axle Shaft Oil Seal Installation
Axle Tubes, Axle Shafts and Wheel Bearings TRANSAXLE (ED65): GASOLINE VEHICLES Remove axle tube (2) from gearcase (4) (Figure 17-5, Page 17-6). See Axle Tube and Axle Shaft Removal on page 17-6. Pull oil seal (7) from gearcase (4). AXLE SHAFT OIL SEAL INSTALLATION Clean bore in gearcase (4) where new oil seal (7) will sit (Figure 17-5, Page 17-6).
Page 261: Transaxle Removal
TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Removal TRANSAXLE REMOVAL See General Warnings on page 1-1. Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in the NEUTRAL position. Disconnect battery and spark plug wire(s). See Disconnecting the Battery-Gasoline Vehicles on page 1-3. Place chocks at the front wheels and loosen lug nuts on both rear wheels.
Page 262 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES Figure 17-8 Disconnect Rear Shackles Figure 17-9 Disconnect Front of Leaf Spring Position floor jack under rear crossmember of chassis or trailer hitch mount (if equipped) (Figure 17-10, Page 17-10). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-1. Raise vehicle just enough to relieve weight on leaf springs, then remove bolts securing leaf springs to shackles (Figure 17-8, Page 17-10).
Page 263 TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Removal Roll powertrain out from under vehicle. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor (Figure 17-11, Page 17-11). See following NOTE. NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from the powertrain.
Page 264 Transaxle Removal TRANSAXLE (ED65): GASOLINE VEHICLES 3063 Figure 17-12 Transaxle Mounting Bolts Page 17-12 2018 Café Express Maintenance and Service Manual...
Page 265: Transaxle Installation
TRANSAXLE (ED65): GASOLINE VEHICLES Transaxle Installation TRANSAXLE INSTALLATION See General Warnings on page 1-1. Installation is reverse of removal procedure. When attaching transaxle to powertrain, initially install the eight bolts (1) finger-tight (Figure 17-12, Page 17-12). Then, tighten fasteners in the following order: 1.1.
Page 266: Shifter Cable Installation
Shifter Cable TRANSAXLE (ED65): GASOLINE VEHICLES Cut wire ties securing shifter cable to chassis. Make note of cable routing, then remove shifter cable from vehicle. 3064 3065 Figure 17-13 Shifter Cable at FNR Handle Figure 17-14 Shifter Cable at Transaxle SHIFTER CABLE INSTALLATION Install shifter cable (2), routing it exactly as it was originally, from instrument panel to transaxle.
Page 267: Section 18 - Refreshment Unit
The consumable ice compartments, located in the rear driver and passenger sides of the Cafe Express refreshment center should be used for consumable ice only. In order to prevent contamination of consumable ice, do not place food in these compartments. Consumable ice should not be stored in any other compartment of the Cafe Express refreshment center.
Page 268: Drains
Canopy REFRESHMENT UNIT CAUTION • Using abrasive cleaners on aluminum will damage or scratch the surface. Use a soft cloth with an industrial type aluminum cleaner/polish to clean the aluminum surfaces. • Do not use steel wool on refreshment center aluminum surfaces. DRAINS The drains should be flushed with a hose on a daily basis.
Page 269: Canopy Removal
REFRESHMENT UNIT Canopy 3069 Figure 18-1 Canopy – Café Express CANOPY REMOVAL Unhook retention cord loops from underside of canopy frame (1). Release the hook-and-loop strip at the rear of the canopy frame (1). Slip each end of canopy (3) off the frame (1) and remove canopy. See following NOTE. NOTE: The canopy (3) is attached to the frame in a manner similar to a “fitted”...
Page 270: Canopy Installation
Canopy REFRESHMENT UNIT CANOPY INSTALLATION NOTE: Canopy Orientation: The canopy (3) fits onto the frame one way. The rear has open corners and also has a hook-and-loop strip in the center. Place canopy (3) onto frame (2) and slip the front edge over the front of the frame. Pull canopy (3) tight towards the rear and secure over frame with the hook-and-loop strip.
Page 271: Unit Maintenance And Repairs
REFRESHMENT UNIT Unit Maintenance and Repairs UNIT MAINTENANCE AND REPAIRS See General Warnings on page 1-1. 3070 Figure 18-2 Lower Cabinet – Café Express TRASH DRAWER See General Warnings on page 1-1. Trash Drawer Removal Pull drawer (1) out as far as it will go and remove the trash can (2) (Figure 18-2, Page 18-5). Unlock drawer (1) from track slides (3).
Page 272: Slide Doors
Unit Maintenance and Repairs REFRESHMENT UNIT To remove the track slide (3), push up and hold the upper gray tab (5) near the rear of the track slide and pull slide straight out. Repeat for other side. Trash Drawer Installation Installation is reverse of removal.
Page 273: Coffee Doors
REFRESHMENT UNIT Unit Maintenance and Repairs 3071 Figure 18-3 Upper Cabinet – Café Express COFFEE DOORS See General Warnings on page 1-1. Coffee Door Removal NOTE: Coffee doors use flag hinges that separate easily. For temporary removal of the coffee doors (e.g. cleaning), simply open the door and lift straight up.
Page 274: Containers
Unit Maintenance and Repairs REFRESHMENT UNIT CONTAINERS See General Warnings on page 1-1. Container Removal NOTE: The hanger brackets used are a wedge-fit. Open vertical sliding doors (9) of upper cabinet for medium (15) and large (16) containers (Figure 18-3, Page 18-7).
Page 275: Index
Index Index shoe Index installation ............6-5 accelerator removal ............6-1 cable bumper installation .............14-11 installation ............4-9 removal ............14-11 removal ............... 4-9 pedal (gas) height adjustment..........5-10 installation ............5-6 removal ............5-5 pedal limit switch canopy..............18-2 testing ............11-25 cleaning.............
Page 276 INDEX installation ............16-3 adjustment............ 17-14 removal ............. 16-3 installation ............ 17-14 drive clutch removal ............17-13 assembly ............16-10 handle (lever)............. 17-1 cleaning and inspection ......16-6, 16-9 fuel disassembly............16-7 relieving pressure ..........14-2 installation ............16-11 fuel filter removal ............. 16-5 installation ............
Page 277 INDEX leaf spring headlight switch see suspension, front and suspension, rear ... 9-2 installation ............12-30 light switch removal ............12-30 testing ..............11-41 headlights low oil warning light see also lighting circuit........11-41 installation ............12-27 testing ..............11-41 removal ............12-27 hubs testing ..............11-35 hub, rear...
Page 278 INDEX assembly ............7-10 assembly ...........12-3, 12-9 disassembly............7-8 bearing installation ............7-13 cleaning ..........12-5–12-6 removal ............... 7-7 inspection..........12-5–12-6 rear suspension removal ............12-6 see suspension, rear ..........9-1 belt tension adjustment ........12-13 rear wheel bearing brush spring see wheel bearing ..........17-7 inspection............
Page 279 INDEX removal ............9-2 installation ............8-3 shock absorber pressure .............. 8-1 inspection and removal........9-1 removal ............... 8-2 installation ............9-1 repair..............8-2 tools see service tools ..........17-3 torque converter troubleshooting ..........16-1 transaxle test procedures, index of installation ............
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