Club Car Carryall 500 2016 Maintenance And Service Manual page 348

20
Starter/Generator
5. Tighten starter/generator mounting hardware (4 and 7) finger-tight (Figure 20-12, Page 20-11).
6. Install belt tension tool (P/N 102570401).
6.1. Carefully insert pry bar between starter/generator and bracket.
6.2. Carefully lift starter up until tension tool can be installed as shown over the slotted adjustment bracket
(Figure 20-15, Page 20-12). Note orientation of tension tool on the slotted adjustment bracket and how the
threaded J-bolt is inserted into the slot under the starter/generator mounting ear.
NOTE: In some cases, the threaded J-bolt of the belt tension tool does not have enough length to consistently fit
under the starter/generator mounting ear. Fit can be greatly improved by modifying the tension tool using
the following procedure.
– Remove nut and J-bolt from bracket.
– Grind or cut 3/8 to 1/2 inch (9.5 to 12.7 mm) from bracket as shown to increase the effective length of
the J-bolt (Figure 20-16, Page 20-14).
– Install J-bolt and nut into bracket.
6.3. Remove pry bar.
1
A
A. Remove 3/8 to 1/2 inch (9.5 to 12.7 mm)
1. Before 2. After
2726
Figure 20-19 Belt Tension Tool Modification (If Necessary)
7. Tension belt.
7.1. Tighten nut on belt tension tool 1/2 turn and check belt tension with gauge (Figure 20-14, Page 20-12).
NOTE: To prevent errors in measurement caused by residual tension, ensure to loosen, then reapply, the Universal
Belt Tension gauge between measurements.
7.2. Continue to tighten in 1/2 turn increments until proper belt tension is achieved.
– Proper tension for a used starter/generator belt is 75 to 85 lbf (334 to 378 N).
– Proper tension for a new starter/generator belt is 120 to 130 lbf (534 to 578 N).
8. Seat the belt.
8.1. Remove all other tools.
8.2. The belt tension tool can be temporarily left in place.
Page 20-16 2016 Carryall 500 and 700 Maintenance and Service Manual
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ELECTRICAL COMPONENTS: PEDAL-START
GAS VEHICLE