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Club Car Service Manual - Every Golf Cart Owner Should Have One.Club car repair manual free download
Club Car User Manuals Download | ManualsLib.Club car repair manual free download
A Club Car service manual is a great source of information for operating, servicing and fixing your golf cart. There are several different types of manuals for your Club Car.
Unlike a car manual that sits in your glove compartment, this golf cart manual just seems to get lost. Just download it to your computer for an easy reference. I saved and downloaded the manual for my year cart and I am happy to have it as a handy reference. A Club Car repair manual has to be purchased. Copyright laws prohibit anyone from making or distributing copies of this manual. They will have to order one — so you might as well do it yourself and have it shipped to you.
It is well worth the investment if you plan to do some of your own basic troubleshooting and repairs. For carts that are or newer you will find the serial number on the passenger side under the glove compartment. The first letter identifies the model and then the next two numbers represent the year the cart was made.
The serial number of each vehicle is printed on a bar code decal mounted either below the passenger side cup holder or above the accelerator or brake pedal Example: PH, as shown, or F The letters or letter at the beginning of the serial number 1 indicate the vehicle model, could be one or two letters. The following four digits 2 indicate the model year and production week during which the vehicle was built. The six digits following the hyphen 3 represent the unique sequential number assigned to each vehicle built within a given model year.
Club Car Service Manuals. Search for:. Previous Next. View Larger Image. Club Car Service Manual A Club Car service manual is a great source of information for operating, servicing and fixing your golf cart. To purchase your Club Car golf cart repair manual you will need to know: 1. Gas or Electric 2.
The year the golf cart was made You will find the year of your golf cart by checking the serial number. Where to Purchase You can purchase a Club Car manual from a couple of different on line websites.
Golf Car Catalog at and 2. Golf Cart Trader at 3. Amazon has a limited selection 4. About the Author: Chris Anderson. Chris Anderson has been in the golf cart and electric cart community for over 10 years and has worked with many retail and business to business companies in the industry.
He is also an avid photographer and windsurfer. Related Posts. August 3rd, 0 Comments. July 9th, 0 Comments. July 3rd, 0 Comments. June 29th, 0 Comments. Toggle Sliding Bar Area. Its perfect for grabbing the attention of your viewers. Choose between 1, 2, 3 or 4 columns, set the background color, widget divider color, activate transparency, a top border or fully disable it on desktop and mobile. We use cookies to ensure that we give you the best experience on our website.
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CLUB CAR GASOLINE SERVICE MANUAL Pdf Download | ManualsLib.Owner’s Manual
Check brake cables for damage; replace as required. Check brake pedal free play. Adjust as necessary See Section 6. Check for cracks, wear, and glazing, replace if neces- Semi-annual Service by sary. Trained Mechanic Only Adjust as necessary.
Check for proper operation See Section 6. Adjust as Park Brake necessary. Check for proper operation See Performance Inspec- tion, Page Clean, and adjust as necessary See Section 6. Brake System Check brake shoes, replace if necessary. Page 38 Page Water sand the body.
Clean and dry the body thoroughly. Apply a light coat of adhesion promoter Club Car Part No. Page 41 3. Apply a light coat of adhesion promoter to the damaged area and the surrounding surface. Spread the mixture over the damaged area with a putty knife or spreader, using ample pressure to eliminate air pockets Figure Page Seat 7. Apply a light coat of adhesion promoter and let it air dry for 30 minutes.
Paint the repaired area with matching spray paint available from Club Car. Hold the can about 12 to 14 inches cm from the repaired surface and coat with light, even strokes Figure Addi- tional coats may be required. Page 44 - Disconnect the three wires from the rear of the charger receptacle inside the battery compartment See Figure The receptacle does not have to be removed from the body. Remove the rear body as instructed on Pages through A and greater on electric vehicles, and Serial No.
Page 49 2. Using two wrenches, tighten the jam nuts on the brake equalizer rod Figure Disconnect the accelerator rod ball joint 11 at the accelerator pedal 1 Figure , Page Inspect the park brake pawl and latch for excessive wear, grooves, cracks, or chipping.
If either the pawl or latch is damaged, both must be replaced. Attach the equalizer rod 26 to the brake pedal weldment assembly 6 as shown Figure Position and attach the brake pedal assembly and mounting blocks 23 to the vehicle frame as shown.
Tighten the bolts and nuts to in. To remove the park brake rod and pawl assembly 9 through 13 and 32 , remove the push-on nut 11 and disconnect the ball joint sleeve 13 from the park brake pedal 1. Remove the accelerator rod by sliding back the ball joint sleeve and disconnecting the ball joint 11 from the ball joint stud 6 Figure , Page Page 62 3. Clamp the accelerator pedal adjustment tool Club Car Part No. Page 63 4. If the events above occur as they should, hold the ball joint at each end of the accelerator rod with pliers and tighten the accelerator rod jam nut against it 4.
Page 67 4. Rotate the actuator lever 17 on the pivot rod weldment 6 Figure , Page counter- clockwise until the red LED on the test module goes out limit switch clicks off. Then slowly rotate the actuator lever clockwise until the red LED is illuminated again limit switch clicks on.
Disconnect the Calibration Test Module from the vehicle and reconnect the three-wire connector from the potentiometer to the wire harness. Make sure the key switch is off and that the Forward and Reverse Switch is in neutral, then disconnect the battery or batteries as shown Figure , Page for gasoline vehicles, or Figure or , Page for electric vehicles. Page 71 23 Figure , Page See NOTE below. Page 72 Figure , Page Tighten the nut to ft. Install the accelerator rod assembly 19, 20, and 21 Figure , Page Make sure the key switch is off and that the Forward and Reverse Switch is in neutral, then disconnect the batteries as shown Figure , Page Page 75 8.
Slide the pivot rod toward the passenger side of the vehicle until approximately one-half of the length of the pivot rod splines is exposed Figure , Page Depress the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is pointed toward the rear of vehicle, slide the ratchet onto the pivot rod do not slide the ratchet onto the pivot rod splines. Page 76 Page Using snap ring pliers, remove the axle retaining ring 1 Figure , Page Use a brush to apply a liberal amount of white lithium NLGI 2 grease Dow Corning BR2-Plus or equivalent to the brake adjuster assembly, adjuster wheel shoe slots, and the shaft of the adjuster wheel as shown Figure , Page Page Brake Assembly 2.
Install the shoe retainer clips, using pliers to compress the clip while turning the clip retaining tab into position Figure Attach the springs onto the trailing shoe already installed. Then hold the leading shoe next to the trail- ing shoe, correctly oriented, and attach the springs to it Figure Page 84 5. Remove cotter pin 13 and clevis pin 12 from brake cable Figure , Page Remove 4 bolts 11 Club Car Part No. Page Steering Wheel 3. Do not remove it Figure Pull the steering wheel until it breaks free from the shaft splines Club Car recommends using a steer- ing wheel puller Figure Page 87 3.
Pull center dash out approximately one inch from the frame and then bend the top right corner of the center dash inward while pulling the top of the panel out and down. Page 88 Steering Column Disassembly, Continued: 8. Page 89 2. Press the bearing 17 all the way into the bearing seat 18 using a steering column bearing press tool Club Car Part No. Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper universal joint.
Remove the front body as instructed in Section 5. Remove the cotter pin 14 and ball joint retaining nut 15 Figure Using a ball joint removal tool, remove the ball joint 13 Figure from the spindle assembly See Figures and , Page Page 95 2. Install the washer 33 , a new tie rod lock washer 34 , and a new ball joint Tighten using two wrenches, one on the ball joint and one on the rack 9. Tighten the ball joint to ft.
Install the internal snap ring 29 Figure , Page Remove the dust seal 12 Figure with a cotter key puller See Figure , Page Install the rack guide 13 , pressure spring 14 , and screw Install the lock nut 15 on the screw and tighten it to 29 ft.
Page ETC. Thread the drag link rod 28 all the way onto the threaded stud of the inner ball joint assembly right hand threads Figure , Page Thread the ball joint 23 into the drag link rod 28 left hand threads to full thread depth Figure Remove the four bolts 30 , four nuts 32 , four lock washers 31 , and bottom spring plate 29 Figure Remove tapered leaf spring 6 Figure Check the condition of the bushings 27 and spacers 28 Figure Replace any that are worn or damaged.
Install the steering spindle on the king pin. Then install the thrust washer 19 , A-Plate clevis 16 , lock washer 18 , and nut Remove the wheel and tire. Remove the bolts 10 and 24 , A-Plate straps 14 , and nuts 5 Figure , Page Remove the lower shock absorber mounting nut 9 , then slide the shock absorber free of the Delta A- Plate Figure , Page Remove the seal 6 and the bearings 5 from the hub Figure Inspect the bearing cups 7.
If they are worn or pitted, remove the cups by inserting a drift punch from the opposite end of the hub and tapping lightly around them Figure Page Page The upper one, when the transaxle is in a horizontal position, is used as a lubricant level indicator. The lubricant level should be even with the bot- tom of the hole. Place a bearing puller wedge attachment Club Car Part No. Press the bearing 5 and collar 4 Figure , Page off together See Figure Page Removing The Transaxle 2.
Place a new seal 17 Figure in the axle tube with the seal lip facing away from the bearing. Use an axle seal tool Club Car Part No. Disconnect, at the starter, the braided ground wire from the starter to the frame.
Remove the rear wheels, then thread one lug nut onto a stud on each rear hub. This will keep the brake drums on the hubs. Carefully lift each end of the transaxle off of its positioning pin on the leaf spring and slide the trans- axle to the rear and out of the vehicle.
Drain the lubricant from the transaxle as instructed on Page Page 5. Use a bearing puller or arbor press to remove bearings 18 Figure , Page from the input pin- ion gear.
If the oil seal 10 Figure is damaged, replace it. Remove the idler gears and thrust washers 36 and 35 Figure , Page Page Apply grease to the lip of the new oil seal 10 Figure , Page and install the seal using a tran- saxle pinion seal tool Club Car Part No.
The lip of the oil seal should face to the inside of the transaxle housing. Use the chart below to determine whether shimming is required and, if so, how many shims Club Car Part No. Install the transmission and Forward and Reverse shifter cable bracket on the transaxle as instructed in Section 17, Page in this manual. Install the driven clutch as instructed in Section 16, Page in this manual.
Insert bolts through the spring shackles and bushings in the leaf spring eyes. Secure them with lock nuts. Connect the brake cables. Install the shock absorbers.
Tighten shock absorber retaining nuts until the rubber bushings expand to the same size as the cup washers. Slightly loosen the wheel rim mounting nuts on the wheel to be removed. Raise the end of the vehicle from which the wheel is to be removed. Make sure that the wheels are off of the ground. Remove the tire and wheel assembly from the vehicle as instructed above. Remove the valve cap and valve core and allow air to escape from the tire.
Where the tire beads seat, clean the wheel rim with a wire brush. Page The starter circuit consists of a twelve-volt battery, fuse, key switch, accelerator starter limit switch, neutral lock-out limit switch, solenoid, starter, and connecting wires. The battery is the source of power for the system. The fuse provides protection to the solenoid activating cir- cuit.
The light picks up power from the key switch when the key switch is turned to the ON position. When the oil level in the crankcase is low, the oil sending unit closes the circuit to the ground and illuminates the oil light. Page Testing the Vehicle Battery, Continued: 4. If it shows less than Page Use the chart on page Figure as a starting point for troubleshooting the neutral lock-out cir- cuit.
Page 1. Check that the wires are connected correctly and are tight. If they are not, rewire or tighten as neces- sary. Page Test Procedure 5 - Solenoid: 1. Remove the electrical component box cover. Page 2. Check for proper wiring and tight connections.
Place the black - probe on the normally open NO terminal of the limit switch. Without the lever depressed, the reading should be no continuity.
Page 4. Page Test Procedure 11, Continued: 1. Remove the plug wire from the spark plug. Remove the spark plug wire from the spark plug. Page Without the lever depressed, the reading should be no continuity. Depress the lever, and the reading should be continuity. If either reading is incorrect, replace the limit switch Figure Visually inspect springs. Replace all four springs if any spring is discolored from heat straw or bluish in color. Install the four brushes 27 into their holders and insert the four brush springs 28 Figure Using a spring scale, test brush spring tension.
Install the commutator end cover 23 onto the armature shaft. Align the locating pin with the pin hole in the cover. There are two types of generators. To separate armature 31 or 33 from output end cover 36 , remove nut 41 , lockwasher 40 , pulley 38 or 39 , shaft key 34 , spacer 37 , bearing retainer screws 43 and washers for vehicles prior to serial number , the gener- ators use washers and lockwashers with the bearing retaining screws Figure Page Make sure the wedge attachment tool is supporting the inner race of the bearing.
If a press is not avail- able, secure a bearing puller Club Car Part No. Support the armature so that it will not drop when the bear- ing is removed Figure 2. Page Cleaning, Inspection, and Replacement of the Commutator 1.
Clean the carbon dust, dirt and oil from the commutator. Visually inspect the commutator for worn, burned or glazed areas. Check for loose or raised commutator bars.
Use the locating pin to align housing to the cover. To prevent contact between the brushes and commutator as the commutator cover is installed, and possible damage to the brushes, lift the brush springs out of the notches in the brushes and pull the brushes back from the center of the commutator end cover. Place the ten- sion tool 13 Club Car Part No. Reinstall the access panel Figure , Page Remove seat from body.
Disconnect battery wires as shown Figure , Page Remove electrical component box cover. Remove the fuse from the fuse block.
Installing the Fuse 1. Install the fuse. Use a 10 amp fuse only. Depress and release the accelerator pedal to make sure that both switches are being actuated when the pedal is released. Install the seat on the rear body.
Page Reverse Buzzer Limit Switch 6. Slide center dash panel up the steering column by snapping out the top and then rotating the panel out and up. Disconnect the wires from the reverse warning buzzer. Do not allow wires to touch Figure The battery on the DS gasoline car is a volt, low maintenance battery.
When changing a volt bat- tery in any Club Car gasoline-powered vehicle, the same size battery with adequate amperage ratings should be used as a replacement. Page Self-Discharge, Continued: 2. The higher the temperature, the quicker a battery will discharge. In hotter climates, therefore, the battery should be checked more often. When storing the battery, keep in a cool place See Battery Storage, Page Water Level Add water only after charging unless the water is below the level of the plates.
Page Inspect the hold-down bracket for rust, corrosion or damage. If both ends of the bracket cannot be fastened securely to the main frame, replace it with a new stainless steel battery hold-down, Club Car Part No. Page Performing the Hydrometer Test, Continued: 7. Record the reading. Return the electrolyte to the cell from which it was taken. Replace vent cap. Repeat steps on all cells.
Load Test 1. Using a ampere load tester, connect the load tester to the battery posts. Read the battery voltage after the load tester has been on the battery for 5 seconds. Page Removing the Battery, Continued: 1. Remove the seat from the rear body. Disconnect the air hose that is clamped to the carburetor. Remove the retention strap and lift the intake expansion chamber out of the vehicle.
Make sure the O-ring is kept with the intake expansion chamber. There are three ground straps on the DS Gasoline which ground the electrical system to the frame. 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. Page Dirt Clean the engine thoroughly before servicing it.
Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. Original equipment plug number is Club Car Part Number An acceptable replacement is a Champion N11YC. The spark gap is. Setting the Spark Gap 1. Remove carburetor 4 along with throttle spring 8 and throttle spring bracket 23 Figure Remove head gasket 3. The first letter identifies the model and then the next two numbers represent the year the cart was made.
Give Golf Cart Garage a call at Or you can check ebay. If you like to do your own golf cart repair, one repair done correctly that is will pay for the manual.
I use mine all the time and keep it in the garage right next to my Club Car. If you are interested in the free Golf Carts Etc. Newsletter you will find information and updates on:. Your e-mail information will never be shared with anyone else. Simply sign up here:. Check out our FREE monthly newsletter! Get the latest information on golf cart accessories, maintenance and more Owner's Manual. Club Car Service Manual A Club Car service manual is a great source of information for operating, servicing and fixing your golf cart.
To purchase your Club Car golf cart repair manual you will need to know: 1. Gas or Electric 2. The year the golf cart was made You will find the year of your golf cart by checking the serial number. Where to Purchase You can purchase a Club Car manual from a couple of different on line websites. Golf Car Catalog at and 2. Golf Cart Trader at 3. Amazon has a limited selection 4. About the Author: Chris Anderson.
Chris Anderson has been in the golf cart and electric cart community for over 10 years and has worked with many retail and business to business companies in the industry.
He is also an avid photographer and windsurfer. Related Posts. August 3rd, 0 Comments.
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