Club Car Cafe Express Manuals

Manuals and User Guides for Club Car Cafe Express. We have 3 Club Car Cafe Express manuals available for free PDF download: Maintenance And Service Manual, Owner's Manual, Owner's Manual Supplement

Club Car Cafe Express Maintenance And Service Manual (284 pages)

Gasoline Vehicle with Subaru EX40 Engine

Brand: Club Car | Category: Golf Cars | Size: 29.6 MB

Table of Contents
5
SECTION 1 - Safety
13
- Safety Details
  13
  - Personal Safety
    13
  - Machine Safety
    13
  - Information
    13
- General Warnings
  13
SECTION 2 - Vehicle Specifications
20
- Vehicle Specifications
  20
SECTION 3 - General Information
21
- Model Identification
  21
- Storage
  22
  - Preparing the Gasoline Vehicle for Extended Storage
    23
  - Returning the Stored Gasoline Vehicle to Service
    23
SECTION 4 - Body and Trim
25
- Cleaning the Vehicle
  25
  - Seat Cleaning
    25
- Front Body Repair
  26
  - Light Scratches
    26
  - Abrasions and Haze
    26
  - Large Scratches and Abrasions
    26
  - Touch-Up Paint Color Chart
    26
- Front Body
  27
  - Heavy Duty Bumper Removal
    27
  - Heavy Duty Bumper Installation
    27
  - Cowl Removal
    29
  - Cowl Installation
    29
  - Grille Removal
    30
  - Grille Installation
    31
  - Front Bumper and Side Fender Removal
    33
  - Front Bumper and Side Fender Installation
    33
  - Instrument Panel Removal
    34
  - Instrument Panel Installation
    34
  - Dash Removal
    35
  - Dash Installation
    35
- Tilt Bed
  37
  - Tilt Bed Removal
    37
  - Tilt Bed Installation
    37
  - Bed Latch Assembly Removal
    39
  - Bed Latch Assembly Installation
    39
- Rear Fenders and Tailskirt
  41
  - Rear Fender and Tailskirt Removal
    41
  - Rear Fender and Tailskirt Installation
    41
- Electric Bed Lift
  43
  - Electric Bed Lift Removal
    44
  - Electric Bed Lift Installation
    44
- Floor Mat
  45
  - Floor Mat Removal
    45
  - Floor Mat Installation
    45
SECTION 5 - Accelerator and Brake Pedal Group
47
SECTION 6 - Wheel Brake Assemblies
59
- General Information
  59
- Brake Shoe Removal
  59
- Brake Assembly Cleaning
  61
- Brake Shoe Installation
  63
- Brake Adjustment
  64
  - Brake Cluster Adjustment
    64
  - Brake Cable Equalization
    67
  - Final Brake Cluster Adjustment
    68
  - Test Drive Vehicle
    68
- Brake Cluster Removal and Installation
  69
- Front Brake Cables
  72
  - Front Brake Cable Removal
    73
  - Front Brake Cable Installation
    73
- Rear Brake Cables
  74
  - Rear Brake Cable Removal
    74
  - Rear Brake Cable Installation
    74
SECTION 7 - Steering and Front Suspension
77
SECTION 8 - Wheels and Tires
99
- General Information
  99
- Wheels
  99
  - Wheel Removal
    99
  - Wheel Installation
    99
- Tires
  100
  - Tire Removal
    100
  - Tire Repair
    100
  - Tire Installation
    101
SECTION 9 - Rear Suspension
103
- General Information
  103
- Shock Absorbers
  103
  - Shock Absorber Inspection and Removal
    103
  - Shock Absorber Installation
    103
- Multi-Leaf Springs
  104
  - Multi-Leaf Spring Removal
    104
  - Multi-Leaf Spring Installation
    105
SECTION 10 - Periodic Maintenance
107
- General Information
  107
- Pre-Operation and Daily Safety Checklist
  107
  - Performance Inspection
    108
- Maintenance
  108
- Periodic Service Schedule
  109
- Periodic Lubrication Schedule
  111
SECTION 11 - Troubleshooting and Electrical System: Pedal-Start Gas Vehicle
113
- General Information
  113
  - Accessories
    113
  - Low Oil Warning Light
    113
  - Ground Locations
    113
  - Features of the Electronic Fuel Injection (EFI) System
    114
- Troubleshooting Guide
  114
  - ECU Error Codes (Displayed by the Low Oil Warning Light)
    114
  - Gasoline Powertrain
    116
- Wiring Diagrams
  120
- Electrical System
  125
- Test Procedures
  126
  - Testing Basics
    126
SECTION 12 - Electrical Components: Pedal-Start Gas Vehicle
157
- Starter/Generator
  157
- Bearing Removal
  162
- Field Coil Assembly
  162
- Visual Inspection of Armature
  162
- Commutator Cleaning and Inspection
  163
- Armature Ground Test
  164
- Visual Inspection of Field Coils
  165
- Starter/Generator Rework
  165
- Starter/Generator Assembly
  165
- Starter/Generator Installation
  168
- Belt Tension Adjustment for EFI Engines
  169
Voltage Regulator
171
- Voltage Regulator Removal
  171
- Voltage Regulator Installation
  172
Engine Control Unit (ECU)
173
- Engine Control Unit Removal
  173
- Engine Control Unit Installation
  173
Key Switch
174
- Key Switch Removal
  174
- Key Switch Installation
  174
Maintenance/Operate Switch
175
- Maintenance/Operate Switch Removal
  175
- Maintenance/Operate Switch Installation
  175
Neutral Lockout Limit Switch
175
- Neutral Lockout Limit Switch Removal
  175
- Neutral Lockout Limit Switch Installation
  175
Solenoid
176
- Solenoid Removal
  176
- Solenoid Installation
  176
Fuse
176
- Fuse Removal
  177
- Fuse Installation
  177
Kill Limit Switch
178
- Kill Limit Switch Removal
  178
- Kill Limit Switch Installation
  178
Reverse Warning Buzzer
179
- Reverse Warning Buzzer Removal
  179
- Reverse Warning Buzzer Installation
  179
Reverse Buzzer Limit Switch
181
- Reverse Buzzer Limit Switch Removal
  181
- Reverse Buzzer Limit Switch Installation
  181
Low Oil Warning Light
183
- Low Oil Warning Light Removal
  183
- Low Oil Warning Light Installation
  183
Fuel Gauge/Hour Meter
183
- General Information
  183
- Fuel Gauge/Hour Meter Removal
  183
- Fuel Gauge/Hour Meter Installation
  184
Fuel Level Sending Unit
184
Oil Level Sensor
184
- Oil Level Sensor Removal
  184
- Oil Level Sensor Installation
  184
Voltage Limiter
184
- Voltage Limiter Removal
  185
- Voltage Limiter Installation
  185
Headlight Switch
186
- Headlight Switch Removal
  186
- Headlight Switch Installation
  186
Headlights
186
- Headlight Bezel Removal
  186
- Headlight Bezel Installation
  186
- Headlight Bulb Removal (Halogen)
  187
- Headlight Bulb Installation (Halogen)
  187
- Headlight Bulb Removal (LED)
  187
- Headlight Bulb Installation (LED)
  187
- Battery
  189
  - General Information
    189
  - Testing the Battery
    189
  - Preventive Maintenance
    189
  - Self-Discharge
    190
  - Vibration Damage
    190
  - Battery Removal
    191
  - Charging the Battery
    191
  - Battery Installation
    191
  - Battery Storage
    192
  - Charging a Dead Battery
    192
- Ground Cables
  192
SECTION 13 - Engine (Subaru EX40)
193
- General Information
  193
  - Before Servicing
    193
  - Engine Rotation
    193
  - Torque Specifications
    194
  - Adjustments and Settings
    194
  - Engine Oil - Gasoline Vehicle
    194
  - Spark Plug
    197
  - Breather
    198
  - Valve Clearance Check and Adjustment
    199
- Engine Removal
  200
- Engine Installation
  202
- Flywheel
  202
  - Flywheel Removal
    203
  - Flywheel Installation
    204
- Oil Level Sensor
  204
  - Testing the Oil Level Sensor
    204
  - Oil Level Sensor Removal
    204
  - Oil Level Sensor Installation
    205
- Ignition Coil
  206
  - Testing the Ignition Coil
    206
  - Ignition Coil Removal
    206
  - Ignition Coil Installation
    206
- Snubber
  207
  - Snubber Removal
    207
  - Snubber Installation
    207
SECTION 14 - Fuel System: Gasoline Vehicles
209
- General Information
  209
  - EFI System Features/Specifications
    209
- Relieving Fuel Pressure
  210
  - To Relieve Fuel Pressure
    210
- Throttle Body
  211
  - Throttle Body Removal
    211
  - Throttle Body Installation
    212
- Engine Control Linkages
  214
  - General Information
    214
  - Ground Speed
    215
  - Accelerator Rod
    215
  - Governor Cable
    217
  - Accelerator Cable
    219
  - Closed Throttle or Idle Adjustment - Pedal-Start Vehicles
    220
  - How to Measure Ground Speed
    221
  - Engine RPM Adjustment
    221
- Air Intake System
  222
  - Air Filter
    223
  - Air Cleaner Removal
    223
  - Air Cleaner Installation
    223
- Fuel Line
  224
  - Fuel Line Removal
    224
  - Fuel Line Installation
    225
- Fuel Pump Module
  226
  - General Information
    226
  - Fuel Pump Module Removal
    226
  - Fuel Pump Module Installation
    226
- Fuel Tank
  229
  - General Information
    229
  - Fuel Tank Removal
    229
  - Fuel Tank Disposal
    230
  - Fuel Tank Storage
    230
  - Fuel Tank Installation
    230
- Fuel Filter
  231
  - General Information
    231
  - Fuel Filter Removal
    231
  - Fuel Filter Installation
    232
- Fueling Instructions - Gasoline Vehicle
  232
SECTION 15 - Exhaust System: Gasoline Vehicles
235
- Muffler
  235
  - Muffler Removal
    235
  - Muffler Installation
    235
SECTION 16 - Clutches: Gasoline Vehicles
237
- General Information
  237
- Troubleshooting
  238
- Drive Belt
  239
  - Drive Belt Removal
    239
  - Drive Belt Installation
    239
- Drive Clutch
  240
  - Drive Clutch Removal
    241
  - Drive Clutch Cleaning and Inspection
    242
  - Drive Clutch Disassembly
    243
  - Inspection of Drive Clutch Parts
    245
  - Drive Clutch Assembly
    246
  - Drive Clutch Installation
    247
- Driven Clutch
  248
  - Driven Clutch Removal
    249
  - Driven Clutch Disassembly
    249
  - Driven Clutch Inspection
    250
  - Driven Clutch Assembly
    250
  - Driven Clutch Installation
    252
SECTION 17 - Transaxle (ED65): Gasoline Vehicles
253
- General Information
  253
  - Shifter Lever
    253
  - Neutral Lockout
    253
  - Governor System
    254
  - Transaxle Service
    254
  - Lubrication
    254
  - Tools Required for this Section
    255
- Rear Hubs
  256
  - Rear Hub Removal
    256
  - Rear Hub Installation
    256
- Axle Tubes, Axle Shafts and Wheel Bearings
  258
  - Axle Tube and Axle Shaft Removal
    258
  - Axle Tube and Axle Shaft Installation
    259
  - Rear Wheel Bearing Removal
    259
  - Rear Wheel Bearing Installation
    259
  - Axle Shaft Oil Seal Removal
    259
  - Axle Shaft Oil Seal Installation
    260
- Transaxle Removal
  261
- Transaxle Installation
  265
- Shifter Cable
  265
  - Shifter Cable Removal
    265
  - Shifter Cable Installation
    266
  - Shifter Cable Adjustment
    266
SECTION 18 - Refreshment Unit
267
- General Information
  267
  - Refreshment Center Compartments
    267
- Cleaning
  267
  - Interior Aluminum Surfaces
    267
  - Exterior Aluminum Surfaces
    267
  - Drains
    268
  - Refreshment Center Doors
    268
  - Canopy Cover
    268
  - Windshield
    268
- Canopy
  268
  - Canopy Removal
    269
  - Canopy Installation
    270
  - Canopy Frame Removal
    270
  - Canopy Frame Installation
    270
- Unit Maintenance and Repairs
  271
  - Trash Drawer
    271
  - Slide Doors
    272
  - Coffee Doors
    273
  - Containers
    274
  - Cup Holder
    274
Index
275

Club Car Cafe Express Owner's Manual (56 pages)

Club Car Cafe Express Owner's manual

Brand: Club Car | Category: Scooter | Size: 3.65 MB

Table of Contents
5
Safety Decal Identification
6
Practice Safety
9
Proposition 65 - State of California
10
Safety Details
10
General Warnings
10
General Information
13
Model Identification
14
Controls and Indicators
14
Pre-Operation and Daily Safety Checklist
20
Vehicle Operation
21
Driving Instructions
23
Loading and Unloading
25
Vehicle Load Capacities
25
Refreshment Center
26
Towing with the Vehicle
27
Transporting on a Trailer
27
Storage
27
Maintenance
30
Periodic Service Schedule
30
Periodic Lubrication Schedule
32
Battery
33
Engine Oil - Gasoline Vehicle
34
Fueling Instructions - Gasoline Vehicle
37
Cleaning the Vehicle
38
Accessories
39
Subsequent Owner Registration
40
Vehicle Specifications
41
Warranties
43
EC Declaration of Conformity
50

Club Car Cafe Express Owner's Manual Supplement (20 pages)

Brand: Club Car | Category: Utility Vehicle | Size: 0.82 MB

Table of Contents
3
Safety Details
4
Safety Decals and Feature Identification
4
Vehicle Feature Identification - Cafe Express
5
Pre-Operation and Daily Safety Checklist
6
Controls and Indicators
6
Vehicle Operation
6
Tire Specifications
7
Prop Rod
7
Windshield
7
Refreshment Center
8
Maintenance
9
Periodic Service Schedule
9
Cleaning
9
Cafe Express Vehicle Specifications
10
Cafe Express Installation - General Information
11
Tools Required
12
Parts in this Kit
13
Upper Cabinet Installation
14
Windshield Frame Installation
14
Canopy Frame Installation
16
Canopy Cover Installation
17
Windshield Installation
18
Questions
18

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