Club Car Cafe Express Maintenance And Service Manual 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 - Wheels and Tires ........................................................................................................................ 8-1
General Information ....................................................................................................................................... 8-1
Wheels ......................................................................................................................................................... 8-1
Wheel Removal ......................................................................................................................................... 8-1
Wheel Installation ...................................................................................................................................... 8-1
Tires ............................................................................................................................................................. 8-2
Tire Removal............................................................................................................................................. 8-2
Tire Repair ................................................................................................................................................ 8-2
Tire Installation .......................................................................................................................................... 8-3
SECTION 9 - Rear Suspension ........................................................................................................................ 9-1
General Information ....................................................................................................................................... 9-1
Shock Absorbers ........................................................................................................................................... 9-1
Shock Absorber Inspection and Removal ................................................................................................... 9-1
Shock Absorber Installation ........................................................................................................................ 9-1
Multi-Leaf Springs.......................................................................................................................................... 9-2
Multi-Leaf Spring Removal ......................................................................................................................... 9-2
Multi-Leaf Spring Installation ...................................................................................................................... 9-3
SECTION 10 - Periodic Maintenance .............................................................................................................. 10-1
General Information ..................................................................................................................................... 10-1
Pre-Operation and Daily Safety Checklist ...................................................................................................... 10-1
Performance Inspection ........................................................................................................................... 10-2
Maintenance ............................................................................................................................................... 10-2
Periodic Service Schedule............................................................................................................................ 10-3
Periodic Lubrication Schedule ...................................................................................................................... 10-5
SECTION 11 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle .................................................11-1
General Information ......................................................................................................................................11-1
Accessories..............................................................................................................................................11-1
Low Oil Warning Light ...............................................................................................................................11-1
Ground Locations .....................................................................................................................................11-1
Features of the Electronic Fuel Injection (EFI) System ................................................................................11-2
Troubleshooting Guide ..................................................................................................................................11-2
ECU Error Codes (Displayed by the Low Oil Warning Light) ........................................................................11-2
Gasoline Powertrain .................................................................................................................................11-4
Wiring Diagrams ...........................................................................................................................................11-8
Electrical System ........................................................................................................................................ 11-13
Test Procedures ......................................................................................................................................... 11-14
Testing Basics ........................................................................................................................................ 11-14
SECTION 12 - Electrical Components: Pedal-Start Gas Vehicle ....................................................................... 12-1
Starter/Generator......................................................................................................................................... 12-1
Starter/Generator Removal ...................................................................................................................... 12-1
Disassembly of the Starter/Generator to Service the Brushes ..................................................................... 12-1
Brush Inspection and Replacement........................................................................................................... 12-2
Brush Spring Inspection and Replacement ................................................................................................ 12-2
Starter/Generator Assembly ..................................................................................................................... 12-3
Disassembly of the Starter/Generator to Service the Armature/Commutator ................................................ 12-4
Bearing Cleaning and Inspection .............................................................................................................. 12-5
2018 Café Express Maintenance and Service Manual Page v