Solenoid; Testing The Solenoid; Solenoid Removal; Solenoid Installation - Club Car 2009 Electric Precedent Maintenance And Service Manual

ELECTRICAL COMPONENTS
WARNING
• Make sure that the vehicle operates in the reverse direction when the Forward/Reverse switch is in the
REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch
is in REVERSE.
• Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL
position.

SOLENOID

See General Warnings on page 1-1.
The solenoid is located on the rear side of the electronics module.

TESTING THE SOLENOID

See Test Procedure 3 – Solenoid Activating Coil on page 12-15 and Test Procedure 22 – Solenoid Continuity on
page 12-32.

SOLENOID REMOVAL

1. Disconnect the battery cables and discharge the controller as instructed. See WARNINGS "To avoid
unintentionally starting..." and "After disconnecting the batteries, wait 90 seconds..." in General
Warnings on page 1-1.
2. Remove the batteries from the vehicle to provide enough room to access the solenoid (5) (Figure 15-8, Page
15-11). See Battery Replacement on page 16-15.
3. Remove the bolt (11) that secures the electronics module to the battery bucket.
4. Pull electronics module forward and remove the four wires from solenoid.
5. Slide solenoid up to disengage the mounting tabs and remove from component mounting plate (14).

SOLENOID INSTALLATION

1. Mount solenoid (5) onto component mounting plate (14) (Figure 15-8, Page 15-11).
2. Connect the four wires to the appropriate solenoid terminals. See Wiring Diagrams on page 12-2 or 11-2.
Tighten the nuts that secure the yellow (4) and red (5) wires to 72 - 84 in-lb (8 - 9.5 N·m).
3. Return electronics module to its original location and secure with bolt (11). Tighten bolt to 40 in-lb (4.5 N·m).
4. Install the batteries and battery cables in their original locations. See Battery Replacement on page 16-15.
5. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first. Tighten
battery terminals to 110 in-lb (12.4 N·m) and coat terminals with Battery Terminal Protector Spray (CCI P/N
1014305) to minimize corrosion.
2009 Electric Precedent Maintenance and Service Manual
15
Solenoid
Page 15-13