Page 1 Maintenance 2005 Service Gasoline Vehicles Manual No. 102680402 Edition Code 0205A00000...
Page 3 Club Car distributor/dealer representative or by a Club Car factory- trained technician. It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl- edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep- resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s continuing commitment to customer support.
Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. 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 General Warnings ..........................SECTION 2 – VEHICLE SPECIFICATIONS SECTION 3 – GENERAL INFORMATION Serial Number Identification ......................Safety Committee ..........................Storage ............................. Preparing the Gasoline Vehicle for Extended Off-Season Storage ..........Returning the Stored Gasoline Vehicle to Service ................ SECTION 4 –...
Page 6 Rear Body – Two-Passenger Vehicles .................... Universal Accessory Mounting ..................... Backrest and Structural Accessory Module (SAM) ..............4-10 Rear Body Components (Two-Passenger) .................. 4-10 Rear Body – Four-Passenger Vehicles .................... 4-12 Seat Backs ........................... 4-12 Seat Support ..........................4-13 Foot Deck ............................. 4-14 Rear Body Components (Four-Passenger) ..................
Page 7 Steering Wheel ..........................Steering Wheel Removal ......................Steering Wheel Installation ......................Steering Column ..........................Steering Column Removal ......................Steering Column Installation ......................Rack and Pinion ..........................Rack and Pinion Removal ......................Rack and Pinion Disassembly ...................... Rack and Pinion Assembly ......................Rack and Pinion Installation ......................
Page 8 SECTION 9 – REAR SUSPENSION General Information ......................... Shock Absorbers ..........................Shock Absorber Removal and Inspection ..................Shock Absorber Installation ......................Leaf Springs (Two-Passenger Vehicles) ..................Leaf Spring Removal (Two-Passenger Vehicles) ................. Leaf Spring Installation (Two-Passenger Vehicles) ..............Leaf Springs (Four-Passenger Vehicles) ..................Leaf Spring Removal (Four-Passenger Vehicles) ................
Page 9 GCOR ............................... 12-15 Neutral Lockout Cam ........................12-18 Reverse Warning Buzzer ........................12-18 Reverse Buzzer Limit Switch ......................12-19 Low Oil Warning Light ........................12-20 Fuel Gauge ............................12-21 Fuel Level Sending Unit ........................12-23 Hour Meter ............................12-23 RPM Limiter ............................12-24 Ignition Coil ............................
Page 10 Engine Control Linkage ........................14-6 General Information ........................14-6 Governor Cable ..........................14-6 Accelerator Cable ......................... 14-6 Closed Throttle or Idle Adjustment ....................14-8 Engine RPM Adjustment ......................14-9 Choke and Air Intake System ......................14-9 General Information ........................14-9 Choke Button ..........................
Page 11 SECTION 16 – UNITIZED TRANSAXLE General Information .......................... 16-1 Lubrication ............................ 16-3 Axle Shaft ............................16-3 Axle Shaft and Oil Seal Removal ....................16-3 Axle Bearing ..........................16-4 Axle Shaft Installation ........................16-6 Unitized Transaxle Removal ......................16-7 Unitized Transaxle Installation ......................16-15 Forward/Reverse Shifter Cable ......................
Page 13: Section 1 - Safety
SECTION 1 – 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 CAU- TION.
Page 14 SAFETY General Warnings ý WARNING • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation.
Page 15 SAFETY General Warnings Remove negative (–) cable first. DISCONNECT BATTERY CABLES BEFORE WORKING ON VEHICLE Figure 1-1 Battery Cable Removal 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 1-3...
Page 17: Section 2 - Vehicle Specifications
SECTION 2 – VEHICLE SPECIFICATIONS Two-Passenger Four-Passenger SPECIFICATIONS Gasoline Vehicle Gasoline Vehicle POWER SOURCE Engine: 4-cycle OHV, 286 cc, 9.0 hp rated, single-cylinder, air-cooled, with pressure lubrication system • • Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel pump •...
Page 18: Specifications
VEHICLE SPECIFICATIONS Two-Passenger Four-Passenger SPECIFICATIONS Gasoline Vehicle Gasoline Vehicle LIQUID CAPACITIES 32 oz. 32 oz. Engine crankcase (without filter) (.95 liter) (.95 liter) 38 oz. 38 oz. Engine crankcase (with filter) (1.12 liters) (1.12 liters) 27 oz. 27 oz. Unitized transaxle (0.8 liter) (0.8 liter) 6.7 gallons (25.4...
Page 19: Section 3 - General Information
• See General Warnings, Section 1, Page 1-1. Important features unique to the different models covered in this manual are highlighted. Club Car, Inc. rec- ommends the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Page 20: Safety Committee
• Maintaining golf cars in a safe driving condition • How various rules are to be enforced. The safety committee should include all these items and such others as the committee feels necessary or appropriate. Warning signs available from Club Car are listed below. WARNING SIGN CCI P/N...
Page 21: Preparing The Gasoline Vehicle For Extended Off-Season Storage
GENERAL INFORMATION Storage CAUTION • Batteries in a low state of charge will freeze at low temperatures. PREPARING THE GASOLINE VEHICLE FOR EXTENDED OFF-SEASON STORAGE 1. 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 22: Returning The Stored Gasoline Vehicle To Service
GENERAL INFORMATION Storage Preparing the Gasoline Vehicle for Extended Off-Season Storage, Continued: 8. Thoroughly clean front body, rear body, seats, engine compartment, and underside of vehicle. 9. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling. RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1.
Page 23: Section 4 - Body And Trim
A garden hose at normal residential water pressure is adequate. Club Car does not recommend any type of pressure washing or steam cleaning. Such a process (especially if the vehicle has a Surlyn rear body that is removed) will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure.
Page 24: Front And Rear Body Repair
BODY AND TRIM Front and Rear Body Repair CAUTION • To prevent damage to the vehicle when removing difficult stains or heavy soiling, remove the seat bottom from the vehicle first. FRONT AND REAR BODY REPAIR See General Warnings, Section 1, Page 1-1. STRESS LINES OR STREAKS Repeatedly flexing the Surlyn body can cause white stress lines or streaks in the finish.
Page 25 BODY AND TRIM Front and Rear Body Repair TYPICAL 4 PLACES TYPICAL 5 PLACES TYPICAL 5 PLACES Figure 4-1 Front Body 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4-3...
Page 26: Front Body
BODY AND TRIM Front Body FRONT BODY See General Warnings, Section 1, Page 1-1. FRONT BODY REMOVAL 1. Remove the four screws (2) and pull the brow cap (1) from the brow and fascia assembly (4) (Figure 4-1, Page 4-3). 2.
Page 27 BODY AND TRIM Instrument Panel UNDERBODY FRONT SUSPENSION Figure 4-2 Front Bumper TYPICAL 2 PLACES TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 4-3 Instrument Panel 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4-5...
Page 28: Instrument Panel Installation
BODY AND TRIM Floor Mat and Retainers INSTRUMENT PANEL INSTALLATION 1. Position dash assembly (1) on vehicle. Make sure tabs on the forward edge engage to front underbody. Secure assembly in place with three screws (2) (Figure 4-3, Page 4-5). Tighten screws to 8.8 ft-lb (12 N·m).
Page 29: Floor Mat Retainer Removal
BODY AND TRIM Kick Plate and Choke Button FLOOR MAT RETAINER REMOVAL 1. Remove screws (2) from top of retainer (1) (Figure 4-4, Page 4-6). 2. Remove screw (4) from lower rear corner of retainer. This screw threads into a J-clip (5) that is attached to the rear underbody.
Page 30: Rear Body - Two-Passenger Vehicles
BODY AND TRIM Rear Body – Two-Passenger Vehicles TYPICAL 3 PLACES CHOKE CHOKE CONNECTION Figure 4-5 Kick Plate and Choke Button REAR BODY – TWO-PASSENGER VEHICLES See General Warnings, Section 1, Page 1-1. UNIVERSAL ACCESSORY MOUNTING The Structural Accessory Module (SAM) includes two threaded inserts on both the driver side and the pas- senger side (Figure 4-6, Page 4-8).
Page 31 BODY AND TRIM Rear Body – Two-Passenger Vehicles TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-7 Backrest and SAM 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4-9...
Page 32: Backrest And Structural Accessory Module (Sam)
BODY AND TRIM Rear Body – Two-Passenger Vehicles BACKREST AND STRUCTURAL ACCESSORY MODULE (SAM) SAM Removal 1. If the vehicle has a canopy, the rear upright supports must be removed from the SAM. 2. Remove four bolts (4) to release the SAM (3) from the vehicle (Figure 4-7, Page 4-9). SAM Installation 1.
Page 33 BODY AND TRIM Rear Body – Two-Passenger Vehicles TWO-PASSENGER VEHICLES ONLY TYPICAL 4 PLACES TYPICAL BODY 4 PLACES CLIPS TWO-PASSENGER VEHICLES ONLY TWO-PASSENGER VEHICLES ONLY Figure 4-8 Rear Body Components 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4-11...
Page 34: Rear Body - Four-Passenger Vehicles
BODY AND TRIM Rear Body – Four-Passenger Vehicles Rear Beauty Panel Installation 1. Install rear beauty panel (12) on vehicle. Make sure body clips on the rear of the beauty panel engage the mating slot in the rear underbody (4). Secure beauty panel in place with four screws (13). Tighten screws to 3.7 ft-lb (5 N·m) (Figure 4-8, Page 4-11).
Page 35: Seat Support
BODY AND TRIM Rear Body – Four-Passenger Vehicles Seat Back Installation Secure seat back (8 or 11) to seat support with screws (9 or 13). Tighten screws to 71 in-lb (8 N·m) (Figure 4-11, Page 4-15). SEAT SUPPORT Seat Support Removal 1.
Page 36: Foot Deck
BODY AND TRIM Rear Body – Four-Passenger Vehicles TYPICAL 10 PLACES TYPICAL 6 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES Figure 4-10 Foot Deck (Four-Passenger Vehicles) FOOT DECK Foot Deck Removal 3. Remove screws (8 and 11) securing the rear hip restraints (6) and remove the hip restraints from the vehicle (Figure 4-9, Page 4-13).
Page 37: Rear Body Components (Four-Passenger)
BODY AND TRIM Rear Body – Four-Passenger Vehicles TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-11 Seats (Four-Passenger Vehicles) REAR BODY COMPONENTS (FOUR-PASSENGER) Rear Beauty Panel Removal 1. Remove seat support. See Seat Support Removal on page 4-13. 2.
Page 38: Canopy - Two-Passenger
BODY AND TRIM Canopy – Two-Passenger Rear Beauty Panel Installation 1. Install rear beauty panel (12) on vehicle. Make sure body clips on the rear of the beauty panel engage the mating slot in the rear underbody. Secure beauty panel in place with four screws (13). Tighten screws to 3.7 ft-lb (5 N·m) (Figure 4-8, Page 4-11).
Page 39 BODY AND TRIM Canopy – Two-Passenger Figure 4-12 Precedent Two-Passenger Canopy 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4-17...
Page 40: Two-Passenger Canopy Installation
BODY AND TRIM Canopy – Two-Passenger TWO-PASSENGER CANOPY INSTALLATION 1. Install the front canopy supports. 1.1. Ensure the front supports are properly oriented to the correct side of the vehicle as shown (Figure 4-12, Page 4-17). The lower profile of each support follows the profile of the vehicle. If the supports are placed on the wrong side of the vehicle, they will not follow the vehicle’s profile.
Page 41 BODY AND TRIM Canopy – Two-Passenger TYPICAL 4 PLACES TYPICAL 4 PLACES REF. TYPICAL TYPICAL 2 PLACES 2 PLACES REF. TYPICAL 4 PLACES TYPICAL 2 PLACES REF. SEATS REMOVED FOR CLARITY TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 4-13 Precedent Four-Passenger Canopy 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 4-19...
Page 42: Canopy - Four-Passenger
BODY AND TRIM Canopy – Four-Passenger CANOPY – FOUR-PASSENGER See General Warnings, Section 1, Page 1-1. CAUTION • To prevent damage to the canopy, do not remove the canopy supports (1 and 6) from the vehicle without first removing the canopy (9) (Figure 4-13, Page 4-19). FOUR-PASSENGER CANOPY REMOVAL 1.
Page 43: Section 5 - Accelerator And Brake Pedal Group
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. PEDAL GROUP See General Warnings, Section 1, Page 1-1. PEDAL GROUP REMOVAL 1.
Page 44 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group TYPICAL 2 PLACES TYPICAL 2 PLACES ACCELERATOR CABLE ATTACHMENT/REMOVAL Figure 5-2 Pedal Group Page 5-2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 45: Gcor
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Pedal Group Removal, Continued: 7. Loosen turnbuckle (6) until the threaded rod from the pedal group is free of the turnbuckle. 8. Loosen two nuts (8 and 9) on the accelerator cable and lift the cable from its mounting bracket. 9.
Page 46: Pawl Assembly
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group PAWL ASSEMBLY The pawl assembly (6) serves to lock the brakes when the PARK pedal is pressed. The pawl assembly also releases the brakes when either the STOP or GO pedal is pressed (Figure 5-4, Page 5-5). The pawl assem- bly is serviced as a unit.
Page 47 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group OPPOSITE SIDE VIEW Typical 3 places Figure 5-4 Pedal Group 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 5-5...
Page 48: Pedal Group Installation
ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Figure 5-5 Accelerator Spring Clip Figure 5-6 Accelerator Spring Upper Crosspin Figure 5-7 Accelerator Spring Pin Removal PEDAL GROUP INSTALLATION 1. Place the GCOR on the pedal group and secure with two screws (1) (Figure 5-3, Page 5-3). Tighten the screws to 23 in-lb (2.6 N·m).
Page 49 ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group EQUALIZER TURNBUCKLE Figure 5-8 Brake Pedal Adjustment 6. Adjust brake cable equalizer. See Brake Cable Equalizer Adjustment, Section 6, Page 6-8. 7. Position accelerator cable in its bracket. Ensure there is a nut (1) on each side of the mounting tabs (Figure 5-9, Page 5-7).
Page 51: Section 6 - Wheel Brake Assemblies
SECTION 6 – WHEEL BRAKE ASSEMBLIES ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. • Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake mechanisms are handled.
Page 52 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 7. Remove brake drums and badly worn brake shoes. 7.1. On the back of each brake cluster assembly, locate the heads of two brake shoe retainer pins. It may be necessary to remove sealant material around the head of each pin. BRAKE CABLES BRAKE...
Page 53 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal TYPICAL 4 PLACES TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 6-4 Self-adjusting Wheel Brake Assembly 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 6-3...
Page 54 WHEEL BRAKE ASSEMBLIES Brake Shoe Removal Brake Shoe Removal, Continued: 9. Using needle nose pliers, turn the clip retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-5, Page 6-4). ý CAUTION • The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed.
Page 55: Brake Assembly Cleaning
WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning BRAKE ASSEMBLY CLEANING See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. 1. Carefully clean the brake backing plate and all of its mechanical components. 2. Remove the rubber boot from backing plate and wipe with a clean damp cloth. 3.
Page 56: Brake Shoe Installation
WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 17T STAMPING ON TRAILING SHOE Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe BRAKE SHOE INSTALLATION See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. 1.
Page 57 WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 4. While maintaining spring attachment on both shoes, position tips of leading shoe in the mounting slots and then push shoe into place. Hold shoe in position and install retaining clip (Figure 6-15, Page 6-7). 5.
Page 58: Brake Cable Equalizer Adjustment
WHEEL BRAKE ASSEMBLIES Brake Cable Equalizer Adjustment Brake Shoe Installation, Continued: 7.2. Using 90° internal snap ring pliers (0.090 tip) (CCI P/N 1012560), attach the internal retaining ring into the axle tube hub so that it seats against the axle bearing assembly and into the machined slot in the inside wall of the axle tube hub (Figure 6-3, Page 6-2).
Page 59: Brake Cluster Removal And Installation
WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation JAM NUT (1 OF 2) EQUALIZER TURNBUCKLE Figure 6-18 Brake Equalizer Adjustment BRAKE CLUSTER REMOVAL AND INSTALLATION See General Warnings, Section 1, Page 1-1. See also Warning on Page 6-1. Brake Cluster Removal 1.
Page 60: Brake Cluster Installation
WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation Brake Cluster Removal, Continued: 9. Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle (Figure 6-4, Page 6-3). 10. Remove brake assembly from transaxle. BRAKE CLUSTER INSTALLATION 1.
Page 61 WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation CLIPS Figure 6-19 Loosen Brake Cables 6. Rotate the bolt (5) and equalizer bracket (4) to the upright position then slip the cable heads out of the bracket. 7. Remove nut (1) from the bolt (2) that secures front of the leaf spring (Figure 6-21, Page 6-11). Do not remove bolt (2).
Page 62 WHEEL BRAKE ASSEMBLIES Brake Cable Removal and Installation Brake Cable Installation NOTE: The driver-side and passenger-side brake cables are not interchangeable. Make sure the correct cable is used on the correct side. 1. Insert the end of the new brake cable through the hole in the frame (Figure 6-19, Page 6-11). Push on the cable housing so the clips on the housing ends secure the housing in the hole.
Page 63: Section 7 - Steering And Front Suspension
SECTION 7 – STEERING AND FRONT SUSPENSION ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, 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 64: Steering Wheel Installation
STEERING AND FRONT SUSPENSION Steering Column Steering Wheel Removal, Continued: 7. Remove the steering wheel bolt (6) and the steering wheel (7) from the steering column (9) (Figure 7-3, Page 7-3). APPEARANCE OF SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN Figure 7-1 Steering Wheel Puller Figure 7-2 Steering Wheel Puller STEERING WHEEL INSTALLATION...
Page 65 STEERING AND FRONT SUSPENSION Steering Column APPEARANCE OF SCORECARD HOLDER MAY BE DIFFERENT THAN THAT SHOWN TYPICAL 2 PLACES NOT REQUIRED FOR SOME SCORECARD HOLDERS TYPICAL 4 PLACES Figure 7-3 Steering Column 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7-3...
Page 66: Steering Column Installation
STEERING AND FRONT SUSPENSION Rack and Pinion Steering Column Removal, Continued: 4. Loosen the bolt (11) that attaches the steering column universal joint to the stud on the steering gear (Figure 7-3, Page 7-3). 5. Remove the four bolts (10) that attach the steering column to the frame. 6.
Page 67: Rack And Pinion Disassembly
STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-4 Rack and Pinion Removal 4. Remove the three bolts (5) from the steering rack and pinion assembly mounting bracket. 5. Remove the bolt (6) from the universal joint, then remove the rack and pinion assembly and universal joint from the vehicle.
Page 68 STEERING AND FRONT SUSPENSION Rack and Pinion Figure 7-5 Steering Gear Page 7-6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 69 STEERING AND FRONT SUSPENSION Rack and Pinion Rack and Pinion Disassembly, Continued: 10. If the ball bearing (4) (Figure 7-5, Page 7-6) has been damaged, remove the C-type stop ring (16) (Figure 7-7, Page 7-7) and press the bearing off (Figure 7-9, Page 7-7). 11.
Page 70: Rack And Pinion Assembly
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION ASSEMBLY 1. Apply a liberal amount of EP grease to the teeth of the rack (18), then slide the rack through the bushing (7) and housing (17) (Figure 7-5, Page 7-6). CAUT ION •...
Page 71: Rack And Pinion Installation
STEERING AND FRONT SUSPENSION Rack and Pinion RACK AND PINION INSTALLATION 1. To minimize corrosion, apply a light coat of anti-seize lubricating compound to the splined portion of the steering column universal joint. 2. Align the flat portion of the shaft (13) spline with the bolt hole in the upper universal joint and then slide the shaft into the universal joint.
Page 72: Front Suspension
STEERING AND FRONT SUSPENSION Front Suspension FRONT SUSPENSION See General Warnings, Section 1, Page 1-1. LUBRICATION Two grease fittings are provided (one in each spindle housing). Lubricate these fittings at the recommended interval with the proper lubricant. See Periodic Lubrication Schedule, Section 10, Page 10-4. CAUTION •...
Page 73 STEERING AND FRONT SUSPENSION Front Suspension 7 MM DEEP WELL SOCKET Figure 7-14 Check Camber Figure 7-15 Adjust Camber Toe-in Adjustment 1. On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead.
Page 74: Front Suspension Components
STEERING AND FRONT SUSPENSION Front Suspension Components Toe-in Adjustment, Continued: 5. Subtract the measurement on the front of the tires from the measurement on the rear of the tires. The difference is the toe-in. Proper toe-in is 5/16 inch (7.8 mm). 6.
Page 75: Leaf Spring Removal
STEERING AND FRONT SUSPENSION Front Suspension Components LEAF SPRING REMOVAL 1. Loosen lug nuts on both front wheels and raise front of vehicle with a chain hoist or floor jack. Place jack stands under the aluminum rails of the vehicle frame just aft of the front suspension. Lower the vehicle onto the jack stands.
Page 76: Control Arm Removal
STEERING AND FRONT SUSPENSION Front Suspension Components Kingpin and Steering Spindle Installation, Continued: 5. Attach the tie rod ends (12) to the spindle tabs, then install and tighten the nuts (14) to 70 ft-lb (95 N·m). Install the retaining pins (15) (Figure 7-18, Page 7-15). 6.
Page 77 STEERING AND FRONT SUSPENSION Front Suspension Components Figure 7-18 Upper Front Suspension Assembly 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 7-15...
Page 78 STEERING AND FRONT SUSPENSION Front Suspension Components CLEVIS Figure 7-19 Lower Front Suspension Assembly Page 7-16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 79: Control Arm Installation
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs CONTROL ARM INSTALLATION 1. Install the control arm in reverse order of removal. Tighten the control arm bolts (11 and 19) to 20 ft-lb (27 N·m) (Figure 7-18, Page 7-15). Tighten three rack and pinion mounting bolts (17) to 22 ft-lb (30 N·m).
Page 80: Hub Installation
STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs HUB INSTALLATION 1. Clean and apply a light coat of anti-seize lubricant to the spindle shaft (3). 2. Slide the hub assembly (9) onto the spindle shaft (Figure 7-19, Page 7-16). 3.
Page 81: Section 8 - Wheels And Tires
SECTION 8 – WHEELS AND TIRES ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care. •...
Page 82: Tires
WHEELS AND TIRES Tires TIRES See General Warnings, Section 1, Page 1-1. TIRE REMOVAL NOTE: Tire must be removed or installed from the valve stem side of the rim. 1. Remove the tire and wheel assembly from the vehicle as instructed above. 2.
Page 83: Tire Repair
Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit avail- able at your local Club Car dealer. 2. When the cause of the air leak has been determined, remove tire from the rim and repair as required. See Tire Removal on page 8-2.
Page 84 WHEELS AND TIRES Tires Tire Installation, Continued: 7. Quickly remove the air nozzle and install the valve core. 8. Adjust air pressure in tire to recommended pressure. See Section 2 – Vehicle Specifications. 9. Immerse the wheel and tire assembly in water to make sure there are no leaks. Figure 8-2 Inflate Tire Page 8-4 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 85: Section 9 - Rear Suspension
SECTION 9 – REAR SUSPENSION ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION The rear suspension of the Precedent vehicle is completely independent. It consists of two leaf springs con- trolled by two shock absorbers mounted between the springs and the vehicle frame.
Page 86 REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) BRAKE CABLE HANGER MOUNTING TYPICAL ON EACH SIDE OF VEHICLE TYPICAL 2 PLACES Figure 9-1 Rear Suspension Assembly and Mounting (Two-Passenger Vehicles) Page 9-2 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 87 REAR SUSPENSION Leaf Springs (Two-Passenger Vehicles) Leaf Spring Removal (Two-Passenger Vehicles), Continued: ý 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 88: Leaf Spring Installation (Two-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) LEAF SPRING INSTALLATION (TWO-PASSENGER VEHICLES) 1. To install the springs, reverse the removal procedure. See following CAUTION. ý CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.
Page 89 REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) BRAKE CABLE HANGER MOUNTING REF. TYPICAL ON EACH SIDE OF VEHICLE REF. TYPICAL 2 PLACES REAR OF VEHICLE REF. Figure 9-4 Rear Suspension Assembly and Mounting (Four-Passenger Vehicles) 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 9-5...
Page 90: Leaf Spring Installation (Four-Passenger Vehicles)
REAR SUSPENSION Leaf Springs (Four-Passenger Vehicles) LEAF SPRING INSTALLATION (FOUR-PASSENGER VEHICLES) 1. To install the springs, reverse the removal procedure. See following CAUTION. ý CAUTION • When positioning the spring on the transaxle, be sure to insert the locating bolt on the spring in the locating hole in the transaxle saddle.
Page 91: Section 10 - Periodic Maintenance
Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. PRE-OPERATION AND DAILY SAFETY CHECKLIST Use the following checklist as a guide to inspect the vehicle.
Page 92: Performance Inspection
Use the following checklist as a guide to inspect the vehicle and check daily for proper operation. Any prob- lems should be corrected by a Club Car distributor/dealer or a trained technician. • Forward/Reverse shifter: Check for proper operation. See Controls and Indicators in the vehicle owner’s manual.
Page 93 PERIODIC MAINTENANCE Periodic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE Monthly service by owner Check engine oil level; change if or trained technician necessary. Properly dispose of used oil. See Periodic Lubrication Schedule on page 10-4. Engine Check engine cooling air intake; clean if necessary.
Page 94: Periodic Lubrication Schedule
PERIODIC MAINTENANCE Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE See General Warnings, Section 1, Page 1-1. PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT POINTS Semiannually by owner or trained technician Shifter cable pivots Dry Moly Lube (CCI P/N 1012151) (every 50 hours of operation or every 100 rounds for golf cars)
Page 95: Engine Oil
PERIODIC MAINTENANCE Engine Oil ENGINE OIL See General Warnings, Section 1, Page 1-1. Even though the low oil warning light on the dash should illuminate if the engine oil level becomes low, the engine oil level should be checked monthly. The vehicle should be on a level surface when checking oil. ENGINE OIL LEVEL CHECK 1.
Page 96: Oil Viscosity
PERIODIC MAINTENANCE Fueling Instructions OIL VISCOSITY Choose the viscosity according to the temperature as indicated by the oil viscosity chart (Figure 10-3). See follow- ing NOTE. ° ° ° ° ° ° ° -20 C -10 C 10 C SAE 40 SAE 30 SAE 10W-30/SAE 10W-40 SAE 5W-20...
Page 97: Battery
PERIODIC MAINTENANCE Battery 1. Turn the key switch to the OFF position. 2. Lift and remove seat bottom. 3. The fuel tank is located on the driver side of the vehicle (Figure 10-2, Page 10-5). Remove fuel cap and fill the fuel tank with fresh unleaded fuel only. See preceding CAUTION and NOTE. 4.
Page 99: Section 11 - Troubleshooting And Electrical System
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION This section contains the information required to correctly troubleshoot the vehicle. A troubleshooting guide is provided for general troubleshooting.
Page 100 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine starts but does not run Spark plug is fouled or in poor condition Section 13 – FE290 Engine smoothly. Spark plug wire is damaged or loose Section 13 –...
Page 101 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Loss of engine power, continued Air filter is dirty or clogged Section 14 – Fuel System Governor is improperly adjusted Section 14 – Fuel System Throttle linkage out of adjustment Section 14 –...
Page 102 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Starter fails to operate, continued Test Procedure 7 – Neutral Lockout Limit Neutral lockout limit switch failed Switch on page 11-20 Loose or broken wire in starter/generator Starter/Generator, Section 12, circuit Page 12-1...
Page 103 TROUBLESHOOTING AND ELECTRICAL SYSTEM Troubleshooting Guide TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSES REFER TO Engine won’t stop running. Kill circuit wire is disconnected from the Test Procedure 12 – Disconnected Kill ignition coil Wire on page 11-23 Section 11 – Troubleshooting and Key switch failure Electrical System, Test Procedures 4, 5A Carburetor is too lean;...
Page 104 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams WIRING DIAGRAMS NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES #18 ORANGE 3-PIN CONNECTORS #16 BLK/WHITE #18 BLK LEFT #18 BRN #16 BRN TAIL LIGHT #18 RED #18 YELLOW #18 BLK #16 BLK/WHITE RIGHT #16 BRN #18 BRN...
Page 105 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams #18 ORANGE #16 ORANGE FUEL LEVEL #16 BLACK SENSOR FRAME GROUND #18 YELLOW OIL LEVEL SENSOR #16WHT/BLK ENGINE KILL HOOK UP SINGLE POSITION CONNECTOR #10 BLACK ENGINE GROUND FORWARD/REVERSE LIMIT SWITCHES #16 BLACK #16 GREEN #16 WHITE BATTERY SONIC...
Page 106 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams NOTE: SOME WIRING / COMPONENTS SHOWN ARE OPTIONAL ACCESSORIES USED WHEN THERE ARE LIGHTS BUT NO TURN SIGNAL. NORMALLY OPEN MOMENTARY PUSH BUTTON FOR HORN 9-POSITION #16 ORANGE CONNECTOR #16 BLUE/WHITE #16 WHITE #16 YELLOW SONIC #16 BROWN/WHITE WELD...
Page 107 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams HEADLIGHT ASSEMBLY HORN #16 BLACK #18 ORANGE DIODE #16 BLACK/WHT #12 BLACK SONIC WELD #16 BLACK VOLTAGE LIMITER SONIC WELD #16 BROWN/WHT #16 ORANGE #16 GREEN LIGHT SWITCH #16 RED SONIC #16 BLUE/WHITE WELD 9-PIN CONNECTOR.
Page 108 TROUBLESHOOTING AND ELECTRICAL SYSTEM Wiring Diagrams FUEL GAUGE SWITCH SONIC WELD 9-POSITION CONNECTOR. CONNECTS TO MAIN HARNESS. SEE FIGURES 11-1 AND 11-2. #18 BLUE OIL LIGHT #18 YELLOW/WHT #18 YELLOW #16 BLK SONIC WELD REVERSE BUZZER #18 BLACK Figure 11-5 Precedent Gasoline Vehicle Instrument Panel Wiring Diagram Page 11-10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 109: Test Procedures
TROUBLESHOOTING AND ELECTRICAL SYSTEM Electrical System ELECTRICAL SYSTEM The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of nine circuits that are easily identified: • Starter Circuit • Generator Circuit •...
Page 110 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Index of Test Procedures, Continued: 18. Engine Kill Wire 19. Reverse Buzzer Limit Switch 20. Reverse Buzzer 21. Oil Level Sensor 22. Low Oil Warning Light 23. Neutral Lockout Cam 24. Battery Test (Under Load) 25.
Page 111 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Performing the Hydrometer Test 1. Be sure that the battery has sufficient water to cover the plates by approximately 1/2 inch (12.7 mm) and is fully charged prior to beginning the test. If water must be added, recharge the battery before perform- ing the hydrometer test (Figure 11-6, Page 11-13).
Page 112 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined by referring to the following table: SPECIFIC APPROXIMATE GRAVITY(TEMPERATURE STATE OF CHARGE CORRECTED) 1.250-1.280 100% 1.220-1.240 1.190-1.210 1.160-1.180 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch- up charge or it may be a weak cell.
Page 113 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 2 – FUSE See General Warnings, Section 1, Page 1-1. The fuse (red 10 amp) is located in the wiring harness (Figure 11-8, Page 11-15). 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-1.
Page 114 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures ENGINE GROUND RETAINING NUT GROUND WIRE TERMINAL Figure 11-9 Starter/Generator Ground Cable Test Figure 11-10 Engine Ground Cable Test 4. Check the battery ground cable. 4.1. Four 10-gauge black wires are crimped together and connected to the negative (–) battery post. One of these wires is connected via a single position in-line connector to the frame.
Page 115 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 4 – KEY SWITCH (STARTER CIRCUIT) See General Warnings, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-1. 2.
Page 116 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 4. Make sure the battery is disconnected. With the key switch in the OFF position, the Forward/Reverse handle in NEUTRAL, and the accelerator pedal in the UP position, the reading should be no continuity. With the accelerator pedal pressed, the reading should be continuity.
Page 117 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3. Set a multimeter to 200 ohms. Place the red (+) probe on one of the small posts of the solenoid and place the black (–) probe on the other small post. The reading should be 14 to16 ohms. If the reading is not within limits, replace the solenoid.
Page 118 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 6 – Solenoid, Continued: 9. Disconnect the 10-gauge black cables from the negative (–) post of the battery before reconnecting the wires to the solenoid. TEST PROCEDURE 7 – NEUTRAL LOCKOUT LIMIT SWITCH See General Warnings, Section 1, Page 1-1.
Page 119 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 3. Disconnect the wires from all the terminals on the starter/generator. Then place the black (–) probe of a multimeter, set to 200 ohms, on the starter/generator housing (scratch through the paint to ensure a good ground).
Page 120 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 9 – WIRE CONTINUITY See General Warnings, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-1. 2. To test a wire for continuity, disconnect either end from the electrical component it is attached to. 3.
Page 121 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 11 – VOLTAGE REGULATOR See General Warnings, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. 1. Place the neutral lockout cam in the MAINTENANCE position, put the Forward/Reverse handle in the NEUTRAL position, and chock the wheels.
Page 122 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 12 – Disconnected Kill Wire, Continued: 2. Disconnect the engine kill white/black wire at the bullet connector located next to the RPM limiter (Figure 11-22, Page 11-24). 3. With the neutral lockout cam in the MAINTENANCE position, turn the key switch to the ON position. In a well ventilated area, depress the accelerator to start the engine.
Page 123 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures IGNITION GAP TEST TOOL SPARK PLUG WIRE SPARK PLUG FRAME Figure 11-23 Ignition Spark Test 3. If the spark gap tester tool indicates a strong blue spark, it is possible the spark plug has failed internally. Check the spark plug gap.
Page 124 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 14 – RPM LIMITER See General Warnings, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2. 2. Disconnect both of the bullet terminals (Figure 11-24, Page 11-25). 3.
Page 125 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 2.1. Disconnect both of the bullet terminals at the RPM limiter (Figure 11-24, Page 11-25). Place the red (+) probe of the meter on the male bullet terminal of the wire connecting to the ignition coil under the fan housing, and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-25, Page 11-26).
Page 126 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 4. Test the spark plug cap separately from the secondary coil. 4.1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (3) (Figure 11-27, Page 11-27). 4.2.
Page 127 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures Test Procedure 15B – Ignition Coil – Bench Test 1. Remove the coil from the engine. See Ignition Coil Removal, Section 12, Page 12-25. 2. Using a multimeter set to 20k ohms, measure the primary coil resistance. 2.1.
Page 128 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 4.2. Remove the cap from the wire by turning the cap counterclockwise three or four revolutions while gently pulling it off the wire (Figure 11-28, Page 11-27). 4.3. Using a multimeter set to 20k ohms, place the red (+) probe of the multimeter into the end of the spark plug cap that normally connects to the spark plug and place the black (–) probe into the end of the cap with the internal screw (Figure 11-29, Page 11-28).
Page 129 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures ý DANGER • Do not operate vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 4. If the reading does not change after six minutes, then replace the hour meter. TEST PROCEDURE 17 –...
Page 130 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 19 – REVERSE BUZZER LIMIT SWITCH See General Warnings, Section 1, Page 1-1. NOTE: Keep the battery connected while performing this test procedure. The reverse buzzer limit switch is located on the Forward/Reverse shifter; red/white and orange wires are connected to it.
Page 131 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 22 – LOW OIL WARNING LIGHT See General Warnings, Section 1, Page 1-1. 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2. 2.
Page 132 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures TEST PROCEDURE 25 – FUEL LEVEL SENDING UNIT See General Warnings, Section 1, Page 1-1. ý 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 133 TROUBLESHOOTING AND ELECTRICAL SYSTEM Test Procedures 5. If the readings are within the specifications listed above, the fuel level sending unit is working properly. If the readings are incorrect, the fuel level sending unit has failed and the fuel tank must be replaced. See Fuel Tank Removal, Section 14, Page 14-18.
Page 135: Section 12 - Electrical Components
SECTION 12 – ELECTRICAL COMPONENTS ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. STARTER/GENERATOR See General Warnings, Section 1, Page 1-1. Testing the Starter/Generator See Test Procedure 8 – Starter/Generator (Starter Function) on page 11-20 and Test Procedure 10 – Starter/Generator (Generator Function) on page 11-22.
Page 136 ELECTRICAL COMPONENTS Starter/Generator Starter/Generator Removal, Continued: 4. Mark and disconnect the wires from the starter/generator (1). Loosen the two pivot nuts (7) and bolts (5) (Figure 12-1, Page 12-1). 5. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and remove the belt (4) from the pulley (10).
Page 137: Starter/Generator
ELECTRICAL COMPONENTS Starter/Generator STARTER/GENERATOR BRUSH BRUSH HOLDER WEAR LINE Figure 12-4 Inspect Brushes Brush Spring Inspection and Replacement 1. Visually inspect springs. Replace all four springs if any spring is discolored from heat (straw or bluish in color). 2. Install the four brushes (27) into their holders and insert the four brush springs (28) (Figure 12-3, Page 12-2).
Page 138 ELECTRICAL COMPONENTS Starter/Generator Starter/Generator Assembly 1. Connect the brush wires to the holders using four lock washers (26) and four screws (25), making sure the crossover leads are connected also. Tighten the screws to 31 in-lb (3.5 N·m) (Figure 12-3, Page 12-2).
Page 139 ELECTRICAL COMPONENTS Starter/Generator Figure 12-7 Armature and Output End Cover Assembly Bearing Cleaning and Inspection 1. 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 12-8, Page 12-5). 2.
Page 140 ELECTRICAL COMPONENTS Starter/Generator Bearing Removal 1. Place the wedge attachment tool (CCI 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 (CCI P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Page 141 ELECTRICAL COMPONENTS Starter/Generator • Flared armature windings • Worn, burned, or glazed commutator • Loose or raised commutator bars • Bruised or damaged armature core laminations • Worn armature bearing or shaft • Dirty or oily commutator POLE PIECE SCREW RETAINING NUT POLE SET INSULATOR...
Page 142 ELECTRICAL COMPONENTS Starter/Generator Measure each position in two places 90 apart. Figure 12-11 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 143 ELECTRICAL COMPONENTS Starter/Generator 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 144 ELECTRICAL COMPONENTS Starter/Generator Starter/Generator Assembly, Continued: CAUTION • To prevent damage to the retainer, use care while pressing new bearing onto the output end of the shaft. • Press against the inner race of the new bearing until it is fully seated. 6.
Page 145 6. Position a pry bar (13) between the top of the starter/generator mounting bracket (2) and the underside of the starter/generator by passing the pry bar under the exhaust header. See following NOTE. NOTE: As an alternative to using a pry bar, a belt tensioning tool is available from Club Car (CCI P/N 102570401).
Page 146: Voltage Regulator
ELECTRICAL COMPONENTS Voltage Regulator VOLTAGE REGULATOR See General Warnings, Section 1, Page 1-1. Testing the Voltage Regulator See Test Procedure 11, Section 11, Page 11-23. Voltage Regulator Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2.
Page 147: Key Switch
ELECTRICAL COMPONENTS Key Switch KEY SWITCH See General Warnings, Section 1, Page 1-1. Testing the Key Switch See Test Procedure 17, Section 11, Page 11-31. See Test Procedure 4, Section 11, Page 11-17. Key Switch Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2.
Page 148: Solenoid
ELECTRICAL COMPONENTS Solenoid Key Switch Installation 1. Reverse removal procedures to install key switch in the instrument panel. Connect wires to key switch. See Figure 11-5, Section 11, Page 11-10. 2. Install the instrument panel. 2.1. Connect the electrical connector (3) (Figure 12-16, Page 12-13). 2.2.
Page 149: Fuse
ELECTRICAL COMPONENTS Fuse FUSE See General Warnings, Section 1, Page 1-1. Testing the Fuse See Test Procedure 2, Section 11, Page 11-15. Fuse Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2. 2.
Page 150 ELECTRICAL COMPONENTS GCOR GCOR GCOR Figure 12-17 GCOR GCOR Installation 1. Position the GCOR on the pedal group. 2. Secure the GCOR with two screws (1) (Figure 12-17, Page 12-16). Tighten screws to 23 in-lb (2.6 N·m). 3. Install pedal group. See Pedal Group Installation, Section 5, Page 5-6. Accelerator Pedal Limit Switch See General Warnings, Section 1, Page 1-1.
Page 151 ELECTRICAL COMPONENTS GCOR Neutral Lockout Limit Switch Installation 1. Install the neutral lockout limit switch (5) with two washers (6) and two nuts (2) (Figure 12-18, Page 12-17). Tighten to 5 in-lb (0.6 N·m). Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate.
Page 152: Neutral Lockout Cam
ELECTRICAL COMPONENTS Neutral Lockout Cam NEUTRAL LOCKOUT CAM See General Warnings, Section 1, Page 1-1. If the cam lobes have worn to the point where they will no longer activate the neutral lockout limit switch, the cam must be replaced. Testing the Neutral Lockout Cam See Test Procedure 23, Section 11, Page 11-33.
Page 153: Reverse Buzzer Limit Switch
ELECTRICAL COMPONENTS Reverse Buzzer Limit Switch REVERSE BUZZER VIEWED FROM UNDERSIDE OF INSTRUMENT PANEL RED/ WHITE BLACK Figure 12-20 Reverse Buzzer Reverse Warning Buzzer Installation 1. Install the screws (3) through the buzzer bracket tabs and tighten to 3.5 in-lb (0.40 N·m) (Figure 12-20, Page 12-19).
Page 154: Low Oil Warning Light
ELECTRICAL COMPONENTS Low Oil Warning Light Reverse Buzzer Limit Switch Removal, Continued: 2. Disconnect the wires from the reverse buzzer limit switch (4) located on the back of the Forward/Reverse assembly (Figure 12-18, Page 12-17). 3. Remove the nuts (2) and washers (6) from the neutral lockout limit switch (5) and slide the neutral lockout limit switch off of the screws.
Page 155: Fuel Gauge
ELECTRICAL COMPONENTS Fuel Gauge YELLOW YELLOW/ WHITE Figure 12-21 Low Oil Warning Light Low Oil Warning Light Installation 1. Push a new unit into hole in instrument panel until plastic tabs engage (Figure 12-21, Page 12-21). 2. Connect yellow and yellow/white wires from the wire harness to the low oil warning light. 3.
Page 156 ELECTRICAL COMPONENTS Fuel Gauge Fuel Gauge Removal, Continued: 4. Remove the two hex nuts (3) and lock washers (4) from the threaded studs on the back of the gauge. Remove the mounting bracket (5) from the back side of the fuel gauge (2) and remove the fuel gauge from the instrument panel.
Page 157: Fuel Level Sending Unit
ELECTRICAL COMPONENTS Fuel Level Sending Unit FUEL LEVEL SENDING UNIT See General Warnings, Section 1, Page 1-1. The fuel level sending unit is an integral part of the fuel tank and should never be removed. Thoroughly test the fuel level sending unit before replacing the fuel tank. Testing the Fuel Level Sending Unit See Test Procedure 25, Section 11, Page 11-34.
Page 158: Rpm Limiter
ELECTRICAL COMPONENTS RPM Limiter RPM LIMITER See General Warnings, Section 1, Page 1-1. Testing the RPM Limiter See Test Procedure 14, Section 11, Page 11-26. RPM Limiter Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2.
Page 159: Ignition Coil
ELECTRICAL COMPONENTS Ignition Coil IGNITION COIL See General Warnings, Section 1, Page 1-1. Testing Ignition Coil See Section 11, Test Procedure 13, Page 11-24, Test Procedure 14, Page 11-26, and Test Procedure 15, Page 11-26. Ignition Coil Removal 1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warnings, Section 1, Page 1-2.
Page 160 ELECTRICAL COMPONENTS Ignition Coil Ignition Coil Removal, Continued: 10. Disconnect the 18-gauge black wire (12) from the spade terminal on the ignition coil (11) and remove the coil by removing two bolts (10) (Figure 12-28, Page 12-26). Figure 12-27 Fan Housing and Shroud Installation Figure 12-28 Coil Removal Ignition Coil Installation NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet...
Page 161 ELECTRICAL COMPONENTS Ignition Coil 10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012-inch (0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet. Tighten the two mounting bolts (6) to 30 in-lb (3.4 N·m) (Figure 12-30, Page 12-27).
Page 162: Oil Level Sensor
Club Car recommends a group 70, side-post battery (CCI P/N 1012328), with a 650 cranking amp rating at 32 °F (0 °C) (500 CCA at 0 °F (-17.8 °C)) and a reserve capacity of at least 105 minutes. The group 70 clas- sification indicates battery size: 8-1/4 inches W x 6-1/2 inches D x 7-1/4 inches H (21.0 cm W x 16.5cm D x...
Page 163 ELECTRICAL COMPONENTS Battery Testing the Battery See Test Procedure 1, Section 11, Page 11-12. Preventive Maintenance To keep the battery in good operating condition, follow these steps on a regular basis. 1. Any corrosion build-up on or around the battery should be removed immediately. Post connections should be clean and tight.
Page 164 ELECTRICAL COMPONENTS Battery Vibration Damage The battery hold-down clamp should always be tight enough to keep the battery from bouncing. Battery life may be severely shortened if the clamp is too loose. Excessive vibration shortens the life of the battery. It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts.
Page 165 ELECTRICAL COMPONENTS Battery 2. Attach the positive (+) charger cable to the positive (+) battery post. 3. Attach the negative (–) charger cable to the negative (–) battery post. 4. The battery may be charged with a slow charge (3-10 amps) or a fast charge (20-30 amps). Charge until the specific gravity reaches 1.250.
Page 166: Ground Cables
ELECTRICAL COMPONENTS Ground Cables Battery Storage, Continued: 6. The frequency of recharging required depends on the temperature of the storage area, but it is recom- mended that the battery be monitored for state of charge every month. Also, if the storage area is unheated in a cold climate and recharging is required, it is recommended that the area be heated to at least 60 °F (16 °C) prior to charging.
Page 167: Section 13 - Fe290 Engine
GENERAL INFORMATION See General Warnings, Section 1, Page 1-1. All Club Car gasoline vehicles are powered by 4-cycle, overhead valve, single cylinder, air-cooled engines. The 4-cycle engine has an oil reservoir (crankcase) similar to automobiles, trucks, aircraft, heavy equipment, machinery and other applications designed for reliable heavy-duty service. The engine has two major compo- nent assemblies: the cylinder assembly and the crankcase assembly.
Page 168 FE290 ENGINE General Information Remove all dirt from plug base in the cylinder head before removing plug. Use a 13/16-inch deep well socket wrench or 13/16-inch spark plug wrench to loosen the plug. Spark Plug Cleaning, Inspection and Repair Examine the plug (Figure 13-1, Page 13-2). The deposits on the plug base and electrode are an indication of the correct heat range and efficiency as well as a guide to the general condition of the engine, fuel and air mix- ture and ignition system.
Page 169: Cylinder Head
FE290 ENGINE Cylinder Head Spark Plug Installation NOTE: Before installing the plug, check the condition of the threads in the cylinder head. Soften deposits in cylinder head threads with penetrating oil and clean the threads with a tap if necessary. Use a high temperature, anti-seize lubricant on the threads of the spark plug to reduce friction when installing a new plug, and reduce “gauling”...
Page 170 FE290 ENGINE Crankcase 3. Remove drive clutch. See Drive Clutch Removal, Section 17, Page 17-4 and following NOTE. NOTE: The crankshaft has left-hand threads at the clutch mounting hole. 4. Remove muffler. See Muffler Removal, Section 15, Page 15-1. 5. Remove engine mounting hardware (items 1, 2, 5 and 6) (Figure 13-2, Page 13-4). 6.
Page 171: Crankcase Cover Removal
FE290 ENGINE Crankcase STARTER/ GENERATOR Figure 13-3 Oil Level Sensor Wire Figure 13-4 Crankcase Cover CRANKCASE COVER REMOVAL 1. Remove yellow jumper wire (11) from cord connector (12) (Figure 13-3, Page 13-5). 2. Remove nuts and clamps at two-ended bolts (1 and 2) (Figure 13-4, Page 13-5). 3.
Page 172: Crankcase Cover Installation
FE290 ENGINE Crankcase TYPICAL 3 PLACES TYPICAL 2 PLACES Figure 13-5 Oil Level Sensor Oil Level Sensor Installation 1. If the oil level sensor was removed from the bracket, install sensor (6) into bracket (5) and secure with three screws (7) (Figure 13-5, Page 13-6). Tighten to 17 in-lb (1.9 N·m). 2.
Page 173: Ignition Coil And Flywheel
FE290 ENGINE Ignition Coil and Flywheel Figure 13-6 Crankcase Cover Installation Figure 13-7 Fan and Flywheel Assembly IGNITION COIL AND FLYWHEEL See General Warnings, Section 1, Page 1-1. Ignition Coil and Flywheel Removal 1. Loosen three screws and remove the remaining four screws attaching the flywheel housing as shown, then remove the housing (Figure 13-8, Page 13-8).
Page 174 FE290 ENGINE Ignition Coil and Flywheel Loosen. Remove. Remove. Figure 13-8 Flywheel Housing Figure 13-9 Ignition Coil 0.012 INCH (0.304 mm) Figure 13-10 Flywheel Nut Removal Figure 13-11 Adjust Ignition Coil Air Gap Flywheel Installation See Flywheel Installation on page 13-9. Ignition Coil Inspection and Repair See Test Procedure 15, Section 11, Page 11-26.
Page 175: Flywheel Installation
FE290 ENGINE Flywheel Installation FLYWHEEL INSTALLATION 1. Insert the flywheel key into the keyway in the crankshaft. Then align the keyway in the flywheel to the key and push the flywheel and fan assembly onto the crankshaft until it seats. Install flat washer and nut finger tight.
Page 176 FE290 ENGINE Engine Installation Engine Installation, Continued: 7. Install oil drain plug in the crankcase and tighten to 20 ft-lb (27.1 N·m). Apply a light film of oil on the seal of a new oil filter and install the filter on the crankcase. Fill the crankcase to the proper level with the cor- rect type of oil.
Page 177: Torque Specifications
FE290 ENGINE Engine Installation TORQUE SPECIFICATIONS ITEM SIZE LIMITS Cylinder head bolts 220 in-lb (24 N·m) Valve clearance adjustment nuts 90 in-lb (10 N·m) Connecting rod bolts 180 in-lb (20 N·m) (coat threads with engine oil) Flywheel retaining nut 63 ft-lb (86 N·m) Crankcase cover to block bolts 250 in-lb (28.3 N·m) Starter/Generator...
Page 179: Section 14 - Fuel System
SECTION 14 – FUEL SYSTEM ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The car- buretor atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.
Page 180: Main Jet Elevation/Size Chart
FUEL SYSTEM Carburetor MAIN JET ELEVATION/SIZE CHART FE290 ENGINE ALTITUDE MAIN JET SIZE 0-3000 ft. (0-914.4 m) 3000-5000 ft. (914.4-1524 m) 5000-8000 ft. (1524-2438.4 m) 8000-10,000 ft. (2438.4-3048 m) 10,000 ft. and over (3048 m and over) CHANGING THE MAIN JET 1.
Page 181 FUEL SYSTEM Carburetor NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl is removed (Figure 14-2, Page 14-4). During normal operation, the fuel bowl retains the float pivot pin (6). Make sure that the float pivot pin does not fall out of the carburetor body after the fuel bowl is removed.
Page 182 FUEL SYSTEM Carburetor Changing the Main Jet, Continued: 6. Remove the main jet (8) from the carburetor body and discard it (Figure 14-2, Page 14-4). NOTE: Make sure the fuel nozzle (7) does not fall out of the carburetor body after removal of the main jet. This is best accomplished by positioning the carburetor upside down during main jet removal (Figure 14-2, Page 14-4).
Page 183 FUEL SYSTEM Carburetor CAUTION • Do not remove the valve/spring assembly from the float assembly. Doing so will damage the spring. NOTE: Inspect the main jet nozzle (7), and pilot jet (4) to ensure they are free from contamination. Replace any part that is clogged with contamination.
Page 184: Engine Control Linkage
FUEL SYSTEM Engine Control Linkage ENGINE CONTROL LINKAGE See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION For proper vehicle operation, it is important the accelerator pedal, governor linkage, and throttle adjustments are done correctly and in the proper sequence. See following CAUTION. CAUTION •...
Page 185 FUEL SYSTEM Engine Control Linkage GOVERNOR LEVER TYPICAL 2 PLACES TO PEDAL GROUP CARBURETOR Figure 14-3 Governor and Accelerator Cables 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14-7...
Page 186: Closed Throttle Or Idle Adjustment
FUEL SYSTEM Engine Control Linkage Accelerator Cable Installation 1. Insert the accelerator cable through the hole in the frame and feed it towards the pedal group. Connect the accelerator cable to the pedal group. See GCOR, Section 5, Page 5-3. 2.
Page 187: Engine Rpm Adjustment
FUEL SYSTEM Choke and Air Intake System ENGINE RPM ADJUSTMENT ý DANGER • Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. 1. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation and Adjustment on page 14-6.
Page 188 FUEL SYSTEM Choke and Air Intake System CHOKE AIR BOX CHOKE BUTTON WITH ON KICK PLATE HOSE TO FILTER INSIDE CARBURATOR AIR INTAKE CHOKE Figure 14-5 Air Intake and Choke Assembly Figure 14-6 Air Intake and Choke Assembly Page 14-10 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 189: Choke Button
FUEL SYSTEM Choke and Air Intake System CHOKE BUTTON The choke button actuates the choke mechanism via a rod that connects to the button and the choke (Figure 14-5, Page 14-10). Pressing in the button actuates the choke. A spring clip attaches the rod to the choke.
Page 190 • If air filter housing is extremely dirty, clean thoroughly. • Use only Club Car replacement air filters (CCI P/N 102558201) or equivalent. The use of other air filters could result in engine damage. If the air filter is too small, the cover will seat before the filter can seal, leaving space for dirt to pass into the engine on all sides of the element.
Page 191 FUEL SYSTEM Choke and Air Intake System 2 PLACES TO CRANKCASE Figure 14-8 Fuel and Vent Lines 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 14-13...
Page 192: Fuel Filter
FUEL SYSTEM Fuel Filter FUEL FILTER See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION Fuel is supplied to the fuel pump and carburetor through flexible lines. An in-line filter is installed between the fuel tank and the fuel pump (Figure 14-8, Page 14-13). The filter, fuel lines, and the fuel tank vent should be inspected periodically for leaks.
Page 193: Fuel Pump
FUEL PUMP DISASSEMBLY NOTE: A fuel pump rebuild kit is available from Club Car (CCI P/N 1014524). This kit includes all gaskets, diaphragms, and valves. 1. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-9, Page 14-16).
Page 194: Fuel Pump Cleaning And Inspection
FUEL SYSTEM Fuel Pump Fuel Pump Disassembly, Continued: 3. Note the orientations of the impulse gasket (27), the diaphragm (28), and the gasket (29), then remove them from the pump. See following CAUTION. ý CAUTION • Fuel pump gaskets and diaphragms must be installed in exactly the same positions and orientations they were in before disassembly, or the pump could leak.
Page 195: Fuel Pump Assembly
FUEL SYSTEM Fuel Pump FUEL PUMP ASSEMBLY 1. Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 14-9, Page 14-16). 2. Install the valve assembly in the pumping chamber (30). See following CAUTION. CAUTION • If the valve assembly is not installed exactly as shown (Figure 14-9, Page 14-16), the impulse fuel pump will not operate properly.
Page 196: Fuel Tank
FUEL SYSTEM Fuel Tank FUEL TANK See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION The vehicle is equipped with a high impact plastic, 6.7 gallon (25.4 liter) fuel tank. ý WARNING • If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal and disposal procedure.
Page 197: Fuel Tank Disposal
FUEL SYSTEM Fuel Tank ý WARNING • Make sure the key switch is off before disconnecting wiring. 9. Remove the vent tube (14) and fuel line (9) from the fuel tank (Figure 14-8, Page 14-13) 10. Remove two screws (3) holding the forward end of the fuel tank hold-down (2). Lift up on the forward end of the hold-down and release the rear end from the fuel bracket.
Page 198: Fuel Tank Installation
FUEL SYSTEM Fuel Tank FUEL TANK INSTALLATION 1. Place the fuel tank in the vehicle. 2. Secure the tank with the fuel tank hold-down (2) (Figure 14-8, Page 14-13). 2.1. Insert the tabs on the rear of the hold-down into the slots on the back of the fuel bucket. 2.2.
Page 199: Fuel Lines
FUEL SYSTEM Fuel Lines FUEL LINES See General Warnings, Section 1, Page 1-1. The fuel lines must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean. See following WARNING. ý WARNING • Make sure fuel lines are the correct length and are properly routed. Failure to heed this warning could result in a fire due to damaged fuel lines.
Page 200 FUEL SYSTEM Fuel Shut-Off Valve PARTIALLY CLOSED FULL OPEN (ON) POSITION POSITION VIEWED FROM SELECTOR VIEWED FROM SELECTOR SIDE OF VALVE SIDE OF VALVE Figure 14-13 Open Fuel Shut-off Valve Position Figure 14-14 Incorrect Fuel Shut-off Valve Position Page 14-22 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 201: Section 15 - Exhaust System
SECTION 15 – EXHAUST SYSTEM ý DANGER • See General Warnings, Section 1, Page 1-1. ý WARNING • See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION The exhaust system is designed to provide quiet vehicle operation. If the muffler should ever need to be removed for repairs or replacement, follow the instructions below.
Page 202 EXHAUST SYSTEM Muffler Muffler Installation, Continued: TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 15-1 Exhaust System 8. Connect the spark plug wire. 9. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16.3 N·m). See Figure 1-1, Section 1, Page 1-3. Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion 10.
Page 203: Section 16 - Unitized Transaxle
• See General Warnings, Section 1, Page 1-1. GENERAL INFORMATION All gasoline-powered Club Car vehicles manufactured since the beginning of the 1997 model year are equipped with heavy-duty, fully-synchronized Unitized Transaxles. The unitized transaxle utilizes fully-syn- chronized internal gearing to change vehicle direction. Because the unitized transaxle is used to reverse vehi- cle direction, the engine, drive clutch, belt, and driven clutch rotate in the same direction;...
Page 204 UNITIZED TRANSAXLE General Information Governor System The governor system regulates vehicle ground speed. It is mounted inside the unitized transaxle and is driven by transaxle gears. If any of the governor linkages are removed in order to service other components, read- justment of the governor linkage is required.
Page 205: Lubrication
UNITIZED TRANSAXLE Axle Shaft LUBRICATION There are two oil port plugs located on the right (driven clutch) side of the unitized transaxle (Figure 16-2, Page 16-2). When the vehicle is on a level surface, use the upper plug as a lubricant level indicator. Lubricant level should be even with the bottom of level indicator hole.
Page 206: Axle Bearing
UNITIZED TRANSAXLE Axle Shaft Axle Shaft and Oil Seal Removal, Continued: 7. Carefully pull the axle shaft (2) straight out of the axle tube (Figure 16-3, Page 16-3). 8. Position a 16-inch (40 cm) rolling head prybar (Figure 16-4, Page 16-3). under the inside lip of the seal and pull the oil seal out (Figure 16-5, Page 16-4).
Page 207 UNITIZED TRANSAXLE Axle Shaft REFERENCE PASSENGER SIDE CASE REFERENCE DRIVER SIDE CASE Figure 16-6 Differential Gear Case/Axle Tubes 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16-5...
Page 208: Axle Shaft Installation
UNITIZED TRANSAXLE Axle Shaft Axle Bearing Installation 1. Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE. 2. Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against axle shoulder (Figure 16-6, Page 16-5).
Page 209: Unitized Transaxle Removal
UNITIZED TRANSAXLE Unitized Transaxle Removal 5. Place a 1/4 to 3/8-inch (6-10 mm) diameter rod against the retaining ring and tap lightly at four to five locations to ensure it is properly seated. See following WARNING. ý WARNING • Be sure bearing retaining ring is properly seated in its groove. If ring is not properly installed, the axle assembly will separate from the transaxle and damage the axle assembly and other components.
Page 210 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: VENT TUBE Figure 16-9 Fuel Vent Tube Figure 16-10 Air Intake Hose 4.3. Disconnect impulse line from fuel pump (Figure 16-11, Page 16-8). 4.4. Loosen the hose clamp and then disconnect the fuel line from the carburetor. To prevent spilling fuel, the disconnected end of the line can be plugged with a 1/4-inch bolt (Figure 16-12, Page 16-8).
Page 211 UNITIZED TRANSAXLE Unitized Transaxle Removal ENGINE GROUND RETAINING NUT ACCELERATOR CABLE Figure 16-13 Throttle Cable Mounting Figure 16-14 Engine Ground Wire 4.7. Use a screwdriver or flat blade to snap the shifter cable rod end from the shifter arm on the unitized transaxle.
Page 212 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: STARTER GENERATOR YELLOW OIL SENDING UNIT JUMPER WIRE WHITE/BLACK WIRE BLACK WIRE Figure 16-17 Oil Level Sensor Jumper Wire Figure 16-18 Ignition Kill Wire 5. Disconnect the brake cables. Remove bow tie locking pins (1) and brake cable clevis pins (2) and using tool (CCI P/N 1025555) compress tangs on cable end and remove cable from bracket (3) (Figure 16-19, Page 16-10).
Page 213 UNITIZED TRANSAXLE Unitized Transaxle Removal Figure 16-20 Shock Absorbers Figure 16-21 Floor Jack 8. Raise vehicle just enough to relieve tension from leaf springs, then remove the bolts securing the leaf springs to the shackles (Figure 16-22, Page 16-11). 9. Remove the bolts securing the leaf springs to their front mounts (Figure 16-23, Page 16-11). Remove bolt, then rotate shackle up and away...
Page 214 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: JACK STAND JACK STAND Figure 16-24 Raise Vehicle Figure 16-25 Position Jack Stands 12. Pull the floor jack from beneath the vehicle and move it away. 13. Carefully lift the snubber out of the snubber bracket in the vehicle frame and lower it to the floor (Figure 16-26, Page 16-13).
Page 215 UNITIZED TRANSAXLE Unitized Transaxle Removal SNUBBER BRACKET Lower snubber to the ground. Lift snubber out of bracket. Roll entire powertrain out from under vehicle body. Figure 16-26 Snubber Figure 16-27 Remove Powertrain ENGINE APPROX. 6 INCH DRIVEN CLUTCH DRIVE CLUTCH WOODEN BLOCKS Figure 16-28 Position Powertrain Figure 16-29 Remove Drive Belt...
Page 216 UNITIZED TRANSAXLE Unitized Transaxle Removal Unitized Transaxle Removal, Continued: RETAINING BOLT Figure 16-30 Driven Clutch Figure 16-31 Governor Arm 19. Remove screws (1) securing the governor cable bracket to transaxle (Figure 16-32, Page 16-14). 20. Remove screws (1) securing the accelerator cable bracket to transaxle (Figure 16-33, Page 16-14). Figure 16-32 Governor Cable Bracket Figure 16-33 Accelerator Cable Bracket 21.
Page 217: Unitized Transaxle Installation
UNITIZED TRANSAXLE Unitized Transaxle Installation TRANSAXLE MOUNTING BOLT AND NUT (TYPICAL 4 PLACES) WOODEN BLOCKS TRANSAXLE MOUNTING NUT (TYPICAL 2 PLACES) Figure 16-34 Transaxle Mounting UNITIZED TRANSAXLE INSTALLATION See General Warnings, Section 1, Page 1-1. 1. Install the wheels. See Wheel Installation, Section 8, Page 8-1. 2.
Page 218 UNITIZED TRANSAXLE Unitized Transaxle Installation Figure 16-35 Transaxle Gear Casing and Brackets STUDS TRANSAXLE MOUNTING PLATE WOODEN BLOCKS MOUNTING NUT (TYPICAL 2 PLACES) Figure 16-36 Transaxle Mounting Figure 16-37 Accelerator Cable Bracket Page 16-16 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 219 UNITIZED TRANSAXLE Unitized Transaxle Installation Unitized Transaxle Installation, Continued: 8. Install the governor cable bracket on transaxle case. Tighten the mounting screws to 134 in-lb (15.1 N·m) (Figure 16-38, Page 16-17). 9. Install governor lever arm on governor shaft (Figure 16-39, Page 16-17). 9.1.
Page 220 UNITIZED TRANSAXLE Unitized Transaxle Installation 14. Position the floor jack under the rear bumper and raise the jack high enough to support the vehicle (Figure 16-42, Page 16-18). Make sure the vehicle is stable on the jack, then remove the jack stands. 15.
Page 221 UNITIZED TRANSAXLE Unitized Transaxle Installation WHITE/BLACK WIRE BLACK WIRE Figure 16-44 Shock Absorber Figure 16-45 Ignition Kill Wire 20. Connect the oil level sensor wire (18-gauge yellow) to the jumper wire (Figure 16-46, Page 16-19). 21. Connect the 6-gauge white wire to the F2 post, the 6-gauge black ground wire to the A2 post and tighten both wires to 48 in-lb (5.4 N·m).
Page 222 UNITIZED TRANSAXLE Unitized Transaxle Installation CLIP CABLE BOOT SHIFTER Figure 16-48 Connect Shifter Cable Figure 16-49 Engine Ground Wire 25. Insert the accelerator cable through the hole in the frame and connect the accelerator cable to the pedal group as described in GCOR, Section 5, Page 5-3 Position the accelerator cable in the mounting brack- ets in the vehicle base and adjust mounting nuts (1) to remove all slack in the wire portion of the cable.
Page 223 UNITIZED TRANSAXLE Unitized Transaxle Installation IMPULSE LINE Figure 16-52 Impulse Line Figure 16-53 Air Intake Hose 29. Connect carburetor vent tube to carburetor and secure with hose clamp (Figure 16-54, Page 16-21). Figure 16-54 Carburetor Tube 30. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m). 31.
Page 224: Forward/Reverse Shifter Cable
UNITIZED TRANSAXLE Forward/Reverse Shifter Cable 34. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16.3 N·m). See Figure 1-1, Section 1, Page 1-3. Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corrosion 35.
Page 225 UNITIZED TRANSAXLE Forward/Reverse Shifter Cable CLIP BOOT Figure 16-55 Forward/Reverse Cable 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 16-23...
Page 226: Forward/Reverse Shifter Cable Adjustment
UNITIZED TRANSAXLE Forward/Reverse Shifter Cable FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT With the shifter lever of the unitized transaxle in the NEUTRAL position (Figure 16-55, Page 16-23), the For- ward/Reverse handle (20) should be straight up. For minor adjustments, the lock nut (26) may be loosened and the ball joint socket (27) rotated to get the proper adjustment.
Page 227: Section 17 - Torque Converter
Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process. If these adjustments are within Club Car specifications and, when climbing a steep hill, the engine begins to lose RPM before the drive belt reaches the top of the driven clutch, there is a torque converter problem.
Page 228: Drive Belt
TORQUE CONVERTER Drive Belt Troubleshooting, Continued: 2. Inspect the driven clutch for dirt and dust buildup on its component parts. Clean the driven clutch with water to remove any dust or dirt, then drive the vehicle and check for proper operation. 3.
Page 229: Drive Belt Installation
TORQUE CONVERTER Drive Belt 2. Disconnect the spark plug wire from the spark plug. See WARNING “To avoid unintentionally start- ing...” in General Warnings, Section 1, Page 1-2. 3. Grasp the belt midway between the drive and driven clutches. Lift upward on the belt to force the sheaves of the DRIVEN clutch apart, then roll the belt off the DRIVEN clutch by rotating the clutch counterclock- wise (Figure 17-2, Page 17-3).
Page 230: Drive Clutch
2. Loosen the starter/generator mounting and adjusting hardware and then remove the starter belt. See WARNING “Moving parts! Do not...” in General Warnings, Section 1, Page 1-1. Use Club Car clutch holder VEHICLE BODY REMOVED FOR while tightening or loosening drive CLARITY clutch retaining bolt.
Page 231 TORQUE CONVERTER Drive Clutch 3. Remove the lower shock mounting hardware from both rear shocks (Figure 17-5, Page 17-5). 4. Place chocks at the front wheels and lift the rear of the vehicle just enough to relieve tension from leaf springs, then remove the bolts securing the leaf springs to the shackles (Figure 17-6, Page 17-5).
Page 232 TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES Figure 17-7 Drive Clutch Assembly Page 17-6 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 233: Drive Clutch Cleaning And Inspection
TORQUE CONVERTER Drive Clutch DRIVE CLUTCH CLEANING AND INSPECTION 1. Use a dry, lint-free cloth to clean clutch parts. CAUTION • Do not lubricate the drive clutch. Lubricants attract dirt and dust, which interfere with proper clutch operation. • Use only a dry cloth to lightly wipe the shaft of the fixed face assembly (7) (Figure 17-7, Page 17-6).
Page 234 TORQUE CONVERTER Drive Clutch Drive Clutch Disassembly, Continued: 3. Remove the thrust washer (11) from the moveable face (14) (Figure 17-7, Page 17-6). 4. Remove the drive buttons (Figure 17-10, Page 17-8). 4.1. Remove the screws, flat washers, drive button take-up springs, and drive buttons as shown (Figure 17-10, Page 17-8).
Page 235 TORQUE CONVERTER Drive Clutch SECONDARY WEIGHT WAVE WASHER PRIMARY WEIGHT SMALL PIN Figure 17-12 Install Pin and Washer Figure 17-13 Install Secondary Weight 6. Remove the retaining ring (3) from the shaft of the fixed face assembly (7) and slide the moveable face (14) off the shaft (Figure 17-7, Page 17-6).
Page 236: Inspection Of Drive Clutch Parts
TORQUE CONVERTER Drive Clutch INSPECTION OF DRIVE CLUTCH PARTS 1. Inspect the idler bearing (6) for smooth rotation or seal damage (Figure 17-7, Page 17-6). See follow- ing NOTE. NOTE: It is normal for a small amount of grease to be present at the edge of seal. 2.
Page 237 TORQUE CONVERTER Drive Clutch 8. Install a wave washer on each mounting pin. Make sure that the concave side of the washer faces the side of the primary weight with the small guide pin protruding from it (Figure 17-12, Page 17-9). 9.
Page 238: Drive Clutch Installation
TORQUE CONVERTER Drive Clutch TYPICAL 3 PLACES DRIVE BUTTON TAKE UP SPRING PROPERLY INSTALLED Figure 17-17 Correct Orientation of Drive Button Take-up Spring DRIVE CLUTCH INSTALLATION 1. Place the drive clutch assembly on the crankshaft taper. Position the mounting washer (with the green side facing out) on the bolt (17) and start the bolt into the crankshaft (Figure 17-7, Page 17-6).
Page 239: Driven Clutch
TORQUE CONVERTER Driven Clutch Figure 17-18 Leaf Spring and Shackles Figure 17-19 Shock Absorbers 6. Lower vehicle and remove the lifting device. 7. Install the drive belt as instructed. See Drive Belt Installation on page 17-3. 8. Connect battery cables, positive (+) cable first, and tighten hardware to 12 ft-lb (16.3 N·m). See Figure 1-1, Section 1, Page 1-3.
Page 240: Driven Clutch Disassembly
TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH DISASSEMBLY 1. Using external snap ring pliers, remove the retaining ring (4) (Figure 17-20, Page 17-14). See following WARNING. ý WARNING • Do not place fingers under the cam when removing the cam. The moveable face may spin when the cam buttons release from the cam ramps, resulting in severe personal injury.
Page 241 TORQUE CONVERTER Driven Clutch TYPICAL 3 PLACES Figure 17-22 Driven Clutch Assembly 2005 Precedent Gasoline Golf Car Maintenance and Service Manual Page 17-15...
Page 242: Driven Clutch Inspection
TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH INSPECTION 1. Inspect the cam (4) for excessive wear. Replace it if necessary (Figure 17-22, Page 17-15). 2. Inspect the drive buttons (6) for excessive wear. Replace if necessary. To remove the drive buttons, remove the socket-head cap screws and then the buttons.
Page 243 TORQUE CONVERTER Driven Clutch CAUTION • Do not use a metal hammer to tap the fixed face hub. A metal hammer will damage the shaft. CAM PRESS TOOL Figure 17-23 Cam Press Tool Figure 17-24 Cam Installation Tool 5.2. Field Assembly Process: NOTE: This process is for field assembly requirements where hydraulic and pneumatic press equipment is not available.
Page 244: Driven Clutch Installation
TORQUE CONVERTER Driven Clutch DRIVEN CLUTCH INSTALLATION 1. To install the driven clutch, reverse the removal procedure. Make sure that the washer (12) is mounted with the flat portion of the washer against the driven clutch (Figure 17-22, Page 17-15). Secure with a new bolt (11).
Page 245 INDEX removal ..............4-8 brake return spring ..........5-3 accelerator brakes cable adjustment ............6-8 installation ...........14-8 cable removal ............14-6 pedal installation ...........6-12 limit switch removal ............6-10 testing ...........11-17 cleaning assembly ..........6-5 accelerator return spring ........5-4 cluster access panel ..........4-12, 4-16 installation ...........6-10 air box removal ............6-9 removal ............14-11...
Page 246 INDEX cylinder head ............13-3 floor mat and retainers ........4-6 floor mat retainer installation ............4-7 DANGER removal .............. 4-7 definition of ............1-1 flywheel debris shields ............5-3 installation ............13-9 diagram, schematic ..........11-6 removal ............13-7 differential foot deck (four-passenger) see unitized transaxle...
Page 247 INDEX kick plate and choke button installation ............4-7 gcor ................5-3 kill circuit, engine governor testing ........11-18, 11-23, 11-31 governor system ..........16-2 governor cable installation and adjustment ......14-6 leaf spring removal ............14-6 see suspension, front and suspension, rear ground straps ...........12-32 low oil warning light .........11-11 testing ............11-15 installation ............12-21...
Page 248 INDEX periodic service schedule ......10-2, 10-4 removal ............4-13 serial number, vehicle ......... 3-1 service schedule see periodic service schedule rack and pinion ............. 7-4 see also periodic lubrication schedule assembly ............7-8 service tools disassembly ..........7-5, 7-7 torque converter kit .......... 17-1 installation ............
Page 249 INDEX installation ............7-4 engine kill circuit ......... 11-18, 11-23 removal ..............7-2 engine kill circuit wire ........11-31 steering wheel fuel gauge ............11-35 installation ............7-2 fuel level sending unit ........11-34 removal ..............7-1 fuse ..............11-15 storage ground straps ..........11-15 gasoline vehicle ..........3-2 ignition coil .............11-26 stress lines ignition test .............11-24 see repair, front and rear body...
Page 250 INDEX universal accessory mounting ......4-8 voltage regulator installation ............12-12 removal ............12-12 testing ............11-23 WARNING definition of ............1-1 wheel installation ............8-1 removal .............. 8-1 see also tire wheel liner installation ............4-12 removal ............4-12 wheel, steering see steering wheel wire...
Page 251: 2005 Precedent Gasoline Golf Car Maintenance And Service Manual
2. Ease of Finding Information 3. Clarity of Illustrations 4. Index Usability 5. Troubleshooting Chart Usability Comments/Suggestions Please fax a copy of this page to (706) 228-2662. Thank You! Club Car Technical Publication Department 2005 Precedent Gasoline Golf Car Maintenance and Service Manual...
Page 253 Club Car NOTES...
Page 254 Club Car NOTES...
Page 256 Club Car, Inc. www.clubcar.com Phone 1.706.863.3000 P.O. Box 204658 Augusta, GA 30917-4658 1.800.ClubCar Int’I +1 706.863.3000 1.706.863.5808...

Club Car 2005 precendent Maintenance And Service

Section 1 - Safety

Section 2 - Vehicle Specifications

Section 3 - General Information

Section 4 - Body and Trim

Section 5 - Accelerator and Brake Pedal Group

Section 6 - Wheel Brake Assemblies

Section 7 - Steering and Front Suspension

Section 8 - Wheels and Tires

Section 9 - Rear Suspension

Section 10 - Periodic Maintenance

Section 11 - Troubleshooting and Electrical System

Section 12 - Electrical Components

Section 13 - Fe290 Engine

Section 14 - Fuel System

Section 15 - Exhaust System

Section 16 - Unitized Transaxle

Section 17 - Torque Converter

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