2009-2011 DS Service Manual PDF

2009-2011 DS Golf Car
Maintenance and Service

Manual
Gasoline and Electric Vehicles
Manual Number 103472703

Edition Code 0409C0312B
FOREWORD
Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation.
This manual provides detailed information for the maintenance and repair of the electric Precedent vehicles, and
should be thoroughly reviewed prior to servicing the vehicle. The procedures provided herein must be properly
implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
This manual was written for the trained technician who already possesses knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the
vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be performed
by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained technician.
It is the policy of Club Car, LLC to assist its distributors and dealers in continually updating their service knowledge
and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical representatives,
periodic service bulletins, maintenance and service manuals, and other service publications also represent Club Car’s
continuing commitment to customer support.
Club Car offers a full line of training and continuing education classes for technicians who want to learn more about
our products. For more information, contact your local dealer or Club Car’s Technical Services department for a
list of upcoming classes.
This manual covers all aspects of typical vehicle service; however, unique situations sometimes occur when servicing a
vehicle. If it appears that a service question is not answered in this manual, please contact your nearest authorized
Club Car dealer or distributor for assistance. You may also write to us at: Club Car, LLC, P.O. Box 204658; Augusta,
GA 30917–4658 USA, Attention: Technical Services.
WARNING
• Read See Section 1 – Safety. before attempting any service on the vehicle.
• Before servicing vehicle, read complete section(s) and any referenced information that may be
relevant to the service or repair to be performed.
NOTE: This manual represents the most current information at the time of publication. Club Car, LLC is continually
working to further improve its vehicles and other products. These improvements may affect servicing
procedures. Any modification and/or significant change in specifications or procedures will be forwarded to all
Club Car dealers and will, when applicable, appear in future editions of this manual.
Club Car, LLC reserves the right to change specifications and designs at any time without notice and without
the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this manual. See the limited warranty found in the vehicle
owner’s manual or write to Club Car, LLC, P.O. BOX 204658, Augusta, Georgia 30917-4658 USA, Attention:
Warranty Department.
Copyright © 2009, 2010, 2012 Club Car, LLC

Club Car, Carryall, and ArmorFlex
are registered trademarks of Club Car, LLC
This manual effective August 4, 2008
2009-2011 DS Golf Car Maintenance and Service Manual Page i

CONTENTS
SECTION 1 – SAFETY ...................................................................................................................................... 1-1
General Warnings.......................................................................................................................................... 1-1

Disabling the Vehicle.................................................................................................................................. 1-3
Disconnecting the Battery – Gasoline Vehicles ............................................................................................ 1-3
Connecting the Battery – Gasoline Vehicles ................................................................................................ 1-3
Disconnecting the Batteries – Electric Vehicles ............................................................................................ 1-5
Connecting the Batteries – Electric Vehicles ................................................................................................ 1-5
SECTION 2 – VEHICLE SPECIFICATIONS ........................................................................................................ 2-1
SECTION 3 – GENERAL INFORMATION ........................................................................................................... 3-1
Serial Number Identification............................................................................................................................ 3-1

Safety Committee .......................................................................................................................................... 3-2
Storage – Electric Vehicles ............................................................................................................................. 3-2
Preparing the Electric Vehicle for Extended Storage..................................................................................... 3-3
Returning the Stored Electric Vehicle to Service .......................................................................................... 3-4
Storage – Gasoline Vehicles........................................................................................................................... 3-5
Preparing the Gasoline Vehicle for Extended Storage .................................................................................. 3-5
Returning the Stored Gasoline Vehicle to Service ........................................................................................ 3-6
SECTION 4 – BODY AND TRIM......................................................................................................................... 4-1
Cleaning the Vehicle ...................................................................................................................................... 4-1

Seat Cleaning............................................................................................................................................ 4-1
Front and Rear Body Repair........................................................................................................................... 4-2
Stress Lines or Streaks .............................................................................................................................. 4-2
Minor Impact Damage/Deformations ........................................................................................................... 4-2
Minor Scratches and Surface Blemishes ..................................................................................................... 4-2
Small Scratches That Cannot Be Buffed Out ............................................................................................... 4-3
Gouges, Punctures, Tears, Large Scratches, and Abrasions......................................................................... 4-3
Touch-up Paint Color Chart ....................................................................................................................... 4-3
Canopy ......................................................................................................................................................... 4-4
Canopy Removal ....................................................................................................................................... 4-4
Canopy Installation .................................................................................................................................... 4-4
Front Body .................................................................................................................................................... 4-6
Front Body Removal .................................................................................................................................. 4-6
Front Body Installation ............................................................................................................................... 4-6
Rear Body..................................................................................................................................................... 4-8
Rear Body Removal................................................................................................................................... 4-8
Rear Body Installation .............................................................................................................................. 4-10
Floor Mat .....................................................................................................................................................4-11
Floor Mat Removal ...................................................................................................................................4-11
Floor Mat Installation.................................................................................................................................4-11
SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ............................................................................ 5-1
Brake Pedal and Park Brake .......................................................................................................................... 5-1

Brake Pedal Removal ................................................................................................................................ 5-1
Brake Pedal Installation ............................................................................................................................. 5-1
Park Brake Removal .................................................................................................................................. 5-4
Park Brake Installation ............................................................................................................................... 5-4
Accelerator Pedal – Gasoline Vehicles ............................................................................................................ 5-5
Accelerator Pedal Removal – Gasoline Vehicles .......................................................................................... 5-5
Accelerator Pedal Installation – Gasoline Vehicles ....................................................................................... 5-6
Accelerator Pedal – Electric Vehicles .............................................................................................................. 5-7
Accelerator Pedal Removal – Electric Vehicles ............................................................................................ 5-7
Accelerator Pedal Installation – Electric Vehicles ....................................................................................... 5-10
2009-2011 DS Golf Car Maintenance and Service Manual Page iii

Pedal Group Adjustment – Gasoline Vehicles ................................................................................................ 5-10
Pedal Group Adjustment – Electric Vehicles .................................................................................................. 5-15
SECTION 6 – WHEEL BRAKE ASSEMBLIES .................................................................................................... 6-1
General Information ....................................................................................................................................... 6-1

Brake Shoe Removal ..................................................................................................................................... 6-1
Brake Assembly Cleaning .............................................................................................................................. 6-4
Brake Shoe Installation .................................................................................................................................. 6-6
Brake Adjustment .......................................................................................................................................... 6-8
Brake Cluster Removal and Installation ........................................................................................................... 6-9
Brake Cluster Removal .............................................................................................................................. 6-9
Brake Cluster Installation ........................................................................................................................... 6-9
Brake Cable Removal and Installation........................................................................................................... 6-10
Brake Cable Removal .............................................................................................................................. 6-10
Brake Cable Installation ........................................................................................................................... 6-10
SECTION 7 – STEERING AND FRONT SUSPENSION ....................................................................................... 7-1

Steering Wheel.............................................................................................................................................. 7-1
Steering Wheel Removal............................................................................................................................ 7-1
Steering Wheel Installation ......................................................................................................................... 7-2
Steering Column............................................................................................................................................ 7-2
Steering Column Removal.......................................................................................................................... 7-2
Steering Column Disassembly .................................................................................................................... 7-4
Steering Column Assembly ........................................................................................................................ 7-4
Steering Column Installation....................................................................................................................... 7-4
Steering Adjustment ...................................................................................................................................... 7-5
Rack and Pinion ............................................................................................................................................ 7-6
Rack and Pinion Inspection ........................................................................................................................ 7-7
Rack and Pinion Removal – Conventional Ball Joints ................................................................................... 7-7
Rack and Pinion Removal – Maintenance-Free Ball Joints ........................................................................... 7-7
Rack and Pinion Disassembly .................................................................................................................... 7-8
Rack and Pinion Assembly ....................................................................................................................... 7-10
Rack and Pinion Installation – Conventional Ball Joints .............................................................................. 7-13
Rack and Pinion Installation – Maintenance-Free Ball Joints....................................................................... 7-13
Tie Rod and Drag Link ................................................................................................................................. 7-14
Tie Rod and Drag Link Removal – Conventional Ball Joints ........................................................................ 7-14
Tie Rod and Drag Link Installation – Conventional Ball Joints ..................................................................... 7-14
Tie Rod and Drag Link Removal – Maintenance-Free Ball Joints ................................................................ 7-15
Tie Rod and Drag Link Installation – Maintenance-Free Ball Joints.............................................................. 7-15
Front Suspension ........................................................................................................................................ 7-16
Lubrication .............................................................................................................................................. 7-16
Wheel Alignment ..................................................................................................................................... 7-16
Front Suspension Components..................................................................................................................... 7-18
Leaf Spring Removal ............................................................................................................................... 7-18
Leaf Spring Installation............................................................................................................................. 7-18
Kingpin and Steering Spindle Removal – Conventional Ball Joints .............................................................. 7-18
Kingpin and Steering Spindle Installation – Conventional Ball Joints ........................................................... 7-20
Kingpin and Steering Spindle Removal – Maintenance-Free Ball Joints....................................................... 7-21
Kingpin and Steering Spindle Installation – Maintenance-Free Ball Joints.................................................... 7-23
Delta A-Plate Removal............................................................................................................................. 7-24
Delta A-Plate Installation .......................................................................................................................... 7-24
Shock Absorber Removal......................................................................................................................... 7-24
Shock Absorber Installation ...................................................................................................................... 7-24
Front Wheel Bearings and Hubs ................................................................................................................... 7-25
Front Wheel Free Play Inspection ............................................................................................................. 7-25
Front Hub Removal.................................................................................................................................. 7-25
Front Hub Installation............................................................................................................................... 7-25
SECTION 8 – WHEELS AND TIRES .................................................................................................................. 8-1
Page iv 2009-2011 DS Golf Car Maintenance and Service Manual

Wheels ......................................................................................................................................................... 8-1
Wheel Removal ......................................................................................................................................... 8-1
Wheel Installation ...................................................................................................................................... 8-1
Tires ............................................................................................................................................................. 8-2
Tire Removal............................................................................................................................................. 8-2
Tire Repair ................................................................................................................................................ 8-2
Tire Installation .......................................................................................................................................... 8-3
SECTION 9 – REAR SUSPENSION ................................................................................................................... 9-1

Shock Absorbers ........................................................................................................................................... 9-1
Shock Absorber Removal and Inspection .................................................................................................... 9-1
Shock Absorber Installation ........................................................................................................................ 9-1
Leaf Springs.................................................................................................................................................. 9-3
Leaf Spring Removal ................................................................................................................................. 9-3
Leaf Spring Installation............................................................................................................................... 9-4
SECTION 10 – PERIODIC MAINTENANCE ...................................................................................................... 10-1
General Information ..................................................................................................................................... 10-1

Pre-Operation and Daily Safety Checklist ...................................................................................................... 10-1
Performance Inspection ........................................................................................................................... 10-2
Periodic Service Schedules .......................................................................................................................... 10-3
Periodic Lubrication Schedules..................................................................................................................... 10-6
Engine Oil – Gasoline Vehicles ..................................................................................................................... 10-8
Engine Oil Level Check ............................................................................................................................ 10-8
Engine Oil And Filter Change ................................................................................................................... 10-8
Spark Plugs................................................................................................................................................10-10
Gearcase Lubrication.................................................................................................................................. 10-11
Air Filter Replacement................................................................................................................................. 10-11
Fueling Instructions – Gasoline Vehicles ...................................................................................................... 10-11
Battery .......................................................................................................................................................10-12
SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE290 PEDAL-START GAS

VEHICLE .........................................................................................................................................................11-1
General Information ......................................................................................................................................11-1

Troubleshooting Guide ..................................................................................................................................11-1
Wiring Diagram – Gasoline Vehicle ................................................................................................................11-6
Electrical System ..........................................................................................................................................11-8
Test Procedures ...........................................................................................................................................11-8
SECTION 12 – ELECTRICAL COMPONENTS: FE290 PEDAL-START GAS VEHICLE ...................................... 12-1
Starter/Generator (Model 114–01–4005B) ..................................................................................................... 12-1

Starter/Generator Removal ...................................................................................................................... 12-1
Disassembly of the Starter/Generator to Service the Brushes ..................................................................... 12-2
Brush Inspection and Replacement........................................................................................................... 12-3
Brush Spring Inspection and Replacement ................................................................................................ 12-3
Starter/Generator Assembly ..................................................................................................................... 12-4
Disassembly of the Starter/Generator to Service the Armature/Commutator ................................................ 12-5
Bearing Cleaning and Inspection .............................................................................................................. 12-5
Bearing Removal ..................................................................................................................................... 12-6
Field Coil Removal................................................................................................................................... 12-6
Visual Inspection of Armature ................................................................................................................... 12-7
Commutator Cleaning and Inspection ....................................................................................................... 12-7
Armature Ground Test.............................................................................................................................. 12-8
Visual Inspection of Field Coils ................................................................................................................. 12-9
Starter/Generator Rework ........................................................................................................................ 12-9
Starter/Generator Assembly ..................................................................................................................... 12-9
Starter/Generator Installation...................................................................................................................12-10
Belt Tension Adjustment..........................................................................................................................12-12
Voltage Regulator .......................................................................................................................................12-12
2009-2011 DS Golf Car Maintenance and Service Manual Page v

Voltage Regulator Removal .....................................................................................................................12-12
Voltage Regulator Installation ..................................................................................................................12-13
Key Switch .................................................................................................................................................12-13
Key Switch Removal ...............................................................................................................................12-13
Key Switch Installation ............................................................................................................................12-15
Solenoid.....................................................................................................................................................12-15
Solenoid Removal ..................................................................................................................................12-15
Solenoid Installation................................................................................................................................12-16
Fuse ..........................................................................................................................................................12-16
Fuse Removal ........................................................................................................................................12-16
Fuse Installation .....................................................................................................................................12-16
Accelerator Pedal Limit Switch ....................................................................................................................12-17
Accelerator Pedal Limit Switch Removal ..................................................................................................12-17
Accelerator Pedal Limit Switch Installation................................................................................................12-17
Kill Limit Switch ..........................................................................................................................................12-18
Kill Limit Switch Removal ........................................................................................................................12-18
Kill Limit Switch Installation .....................................................................................................................12-18
Neutral Lockout Limit Switch .......................................................................................................................12-19
Neutral Lockout Limit Switch Removal .....................................................................................................12-19
Neutral Lockout Limit Switch Installation...................................................................................................12-19
Neutral Lockout Cam ..................................................................................................................................12-20
Testing the Neutral Lockout Cam .............................................................................................................12-20
Neutral Lockout Cam Removal ................................................................................................................12-20
Neutral Lockout Cam Installation .............................................................................................................12-21
Reverse Warning Buzzer.............................................................................................................................12-21
Reverse Warning Buzzer Removal ..........................................................................................................12-21
Reverse Warning Buzzer Installation........................................................................................................12-21
Reverse Buzzer Limit Switch .......................................................................................................................12-22
Reverse Buzzer Limit Switch Removal .....................................................................................................12-22
Reverse Buzzer Limit Switch Installation ..................................................................................................12-22
Low Oil Warning Light .................................................................................................................................12-23
Low Oil Warning Light Removal ...............................................................................................................12-23
Low Oil Warning Light Installation ............................................................................................................12-23
Fuel Gauge/Hour Meter ..............................................................................................................................12-24
General Information ................................................................................................................................12-24
Fuel Gauge/Hour Meter Removal ............................................................................................................12-24
Fuel Gauge/Hour Meter Installation..........................................................................................................12-25
Fuel Level Sending Unit ..............................................................................................................................12-25
RPM Limiter ...............................................................................................................................................12-25
RPM Limiter Removal .............................................................................................................................12-25
RPM Limiter Installation ..........................................................................................................................12-26
Ignition Coil ................................................................................................................................................12-27
Ignition Coil Removal ..............................................................................................................................12-27
Ignition Coil Installation ...........................................................................................................................12-28
Oil Level Sensor .........................................................................................................................................12-30
Oil Level Sensor Removal .......................................................................................................................12-30
Oil Level Sensor Installation ....................................................................................................................12-30
Headlights..................................................................................................................................................12-30
Headlight Bulb Removal..........................................................................................................................12-30
Headlight Bulb Installation .......................................................................................................................12-31
Voltage Limiter ...........................................................................................................................................12-31
Voltage Limiter Removal .........................................................................................................................12-31
Voltage Limiter Installation.......................................................................................................................12-32
Headlight Switch.........................................................................................................................................12-32
Headlight Switch Removal.......................................................................................................................12-32
Headlight Switch installation ....................................................................................................................12-33
Battery .......................................................................................................................................................12-33
Testing the Battery ..................................................................................................................................12-34
Preventive Maintenance..........................................................................................................................12-34
Self-Discharge........................................................................................................................................12-34
Water Level ............................................................................................................................................12-35
Vibration Damage ...................................................................................................................................12-35
Mineral Content ......................................................................................................................................12-35
Page vi 2009-2011 DS Golf Car Maintenance and Service Manual

Battery Removal .....................................................................................................................................12-36
Charging the Battery ...............................................................................................................................12-36
Battery Installation ..................................................................................................................................12-36
Battery Storage ......................................................................................................................................12-37
Charging a Dead Battery.........................................................................................................................12-37
Ground Cables ...........................................................................................................................................12-37
SECTION 13 – ENGINE ................................................................................................................................... 13-1

Before Servicing ...................................................................................................................................... 13-1
Engine Rotation....................................................................................................................................... 13-1
Spark Plug .............................................................................................................................................. 13-1
Cylinder Head ............................................................................................................................................. 13-3
General Information ................................................................................................................................. 13-3
Breather Valve (Reed Valve)..................................................................................................................... 13-3
Crankcase................................................................................................................................................... 13-3
Engine Removal ...................................................................................................................................... 13-3
Crankcase Cover Removal....................................................................................................................... 13-4
Oil Level Sensor ...................................................................................................................................... 13-5
Crankcase Cover Installation .................................................................................................................... 13-6
Ignition Coil and Flywheel............................................................................................................................. 13-7
Ignition Coil and Flywheel Removal .......................................................................................................... 13-7
Flywheel Installation ................................................................................................................................ 13-8
Ignition Coil Inspection and Repair............................................................................................................ 13-9
Ignition Coil Installation ............................................................................................................................ 13-9
Crankcase Cover Installation .................................................................................................................... 13-9
Engine Installation ....................................................................................................................................... 13-9
Torque Specifications..................................................................................................................................13-10
Adjustments and Settings............................................................................................................................ 13-11
SECTION 14 – FUEL SYSTEM ........................................................................................................................ 14-1

Carburetor................................................................................................................................................... 14-1
Main Jet Elevation/Size Chart................................................................................................................... 14-3
Changing the Main Jet ............................................................................................................................. 14-3
Engine Control Linkage ................................................................................................................................ 14-6
General Information ................................................................................................................................. 14-6
Accelerator Rod....................................................................................................................................... 14-6
Governor Cable ....................................................................................................................................... 14-8
Accelerator Cable ...................................................................................................................................14-10
Closed Throttle or Idle Adjustment ...........................................................................................................14-10
Engine RPM Adjustment ......................................................................................................................... 14-11
Choke and Air Intake System ......................................................................................................................14-12
Choke Button Removal ...........................................................................................................................14-12
Choke Button Installation ........................................................................................................................14-12
Air Box Removal.....................................................................................................................................14-12
Air Box Installation ..................................................................................................................................14-12
Intake Duct Removal...............................................................................................................................14-12
Intake Duct Installation............................................................................................................................14-13
Air Filter .................................................................................................................................................14-15
Fuel Filters .................................................................................................................................................14-16
Fuel Filter Removal.................................................................................................................................14-16
Fuel Filter Installation..............................................................................................................................14-16
Fuel Pump .................................................................................................................................................14-18
Fuel Pump Removal ...............................................................................................................................14-18
Fuel Pump Disassembly (Metal Pump Only) .............................................................................................14-18
Fuel Pump Cleaning and Inspection (Metal Pump Only) ............................................................................14-19
Fuel Pump Assembly (Metal Pump Only) .................................................................................................14-19
Fuel Pump Installation.............................................................................................................................14-20
Fuel Tank ...................................................................................................................................................14-21
2009-2011 DS Golf Car Maintenance and Service Manual Page vii

Fuel Tank Removal .................................................................................................................................14-21
Fuel Tank Disposal .................................................................................................................................14-22
Fuel Tank Storage ..................................................................................................................................14-22
Fuel Tank Installation ..............................................................................................................................14-23
Fuel Lines ..................................................................................................................................................14-24
Fuel Shut-Off Valve.....................................................................................................................................14-25
Fueling Instructions.....................................................................................................................................14-25
SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES ............................................................................ 15-1
Muffler ........................................................................................................................................................ 15-1

Muffler Removal ...................................................................................................................................... 15-1
Muffler Installation.................................................................................................................................... 15-1
SECTION 16 – UNITIZED TRANSAXLE ........................................................................................................... 16-1

Shifter Lever............................................................................................................................................ 16-1
Neutral Lockout ....................................................................................................................................... 16-1
Governor System..................................................................................................................................... 16-2
Unitized Transaxle Service ....................................................................................................................... 16-2
Tools Required For This Section ............................................................................................................... 16-3
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....................................................................................................................16-20
Forward/Reverse Shifter Cable Removal..................................................................................................16-20
Forward/Reverse Shifter Cable Installation ...............................................................................................16-20
Forward/Reverse Shifter Cable Adjustment ..............................................................................................16-21
SECTION 17 – TORQUE CONVERTER: GASOLINE VEHICLE......................................................................... 17-1

Troubleshooting........................................................................................................................................... 17-1
Drive Belt .................................................................................................................................................... 17-2
Drive Belt Removal .................................................................................................................................. 17-3
Drive Belt Installation ............................................................................................................................... 17-3
Drive Clutch ................................................................................................................................................ 17-4
Drive Clutch Removal .............................................................................................................................. 17-4
Drive Clutch Cleaning and Inspection........................................................................................................ 17-5
Drive Clutch Disassembly......................................................................................................................... 17-7
Inspection of Drive Clutch Parts................................................................................................................ 17-9
Drive Clutch Assembly ............................................................................................................................17-10
Drive Clutch Installation .......................................................................................................................... 17-11
Driven Clutch .............................................................................................................................................17-12
Driven Clutch Removal ...........................................................................................................................17-12
Driven Clutch Disassembly......................................................................................................................17-12
Driven Clutch Inspection .........................................................................................................................17-13
Driven Clutch Assembly ..........................................................................................................................17-13
Driven Clutch Installation.........................................................................................................................17-16
SECTION 18 – IQ SYSTEM TROUBLESHOOTING........................................................................................... 18-1

Wiring Diagram – Electric Vehicle ................................................................................................................. 18-2
Troubleshooting........................................................................................................................................... 18-5
Troubleshooting the Vehicle with the IQDM ............................................................................................... 18-5
Troubleshooting Guide 1 .......................................................................................................................... 18-6
Troubleshooting Guide 2 .......................................................................................................................... 18-9
Test Procedures ......................................................................................................................................... 18-11
Page viii 2009-2011 DS Golf Car Maintenance and Service Manual

Battery Warning Light..................................................................................................................................18-34
Communication Display Module (CDM) ........................................................................................................18-35
Using the CDM to Retrieve Data from the Onboard Computer ...................................................................18-36
CDM Troubleshooting Guide .......................................................................................................................18-37
SECTION 19 – IQ DISPLAY MODULE (IQDM) AND IQDM-P DIAGNOSTICS: IQ SYSTEM ................................ 19-1
Plugging the Handset into the Vehicle ........................................................................................................... 19-1

Introductory Display ..................................................................................................................................... 19-2
Menu Navigation ......................................................................................................................................... 19-2
Program (IQDM-P only) ........................................................................................................................... 19-3
Monitor ................................................................................................................................................... 19-3
Faults ..................................................................................................................................................... 19-4
Functions ................................................................................................................................................ 19-4
Information.............................................................................................................................................. 19-4
Programmer Setup .................................................................................................................................. 19-4
Monitor Menu .............................................................................................................................................. 19-4
Throttle ................................................................................................................................................... 19-4
Batt Voltage............................................................................................................................................. 19-5
Heatsink.................................................................................................................................................. 19-5
Arm Current ............................................................................................................................................ 19-5
Field Current ........................................................................................................................................... 19-5
Arm PWM ............................................................................................................................................... 19-5
Field PWM .............................................................................................................................................. 19-5
Speed Pulses .......................................................................................................................................... 19-5
Foot Input ............................................................................................................................................... 19-5
Forward Input .......................................................................................................................................... 19-6
Reverse Input.......................................................................................................................................... 19-6
Main Cont ............................................................................................................................................... 19-6
Key Input ................................................................................................................................................ 19-6
Password Tries (IQDM-P only) ................................................................................................................. 19-6
10.3 Transaxle......................................................................................................................................... 19-6
20+ Speed .............................................................................................................................................. 19-6
Faults Menu ................................................................................................................................................ 19-7
System Faults ......................................................................................................................................... 19-7
HW Failsafe ............................................................................................................................................ 19-9
KEY SWITCH SRO (Static Return to Off) .................................................................................................. 19-9
Throttle Fault 1 .......................................................................................................................................19-10
Speed sensor .........................................................................................................................................19-10
Main Welded ..........................................................................................................................................19-10
Main Driver On .......................................................................................................................................19-10
Main Driver Off .......................................................................................................................................19-10
High Speed Walkaway ............................................................................................................................19-10
Main Coil FAULT.....................................................................................................................................19-10
Field Missing .......................................................................................................................................... 19-11
HPD ...................................................................................................................................................... 19-11
Proc/Wiring ............................................................................................................................................ 19-11
Overvoltage............................................................................................................................................ 19-11
Low Battery Voltage ................................................................................................................................ 19-11
Thermal Cutback .................................................................................................................................... 19-11
Motor Stall.............................................................................................................................................. 19-11
Main Dropout ......................................................................................................................................... 19-11
Open Armature.......................................................................................................................................19-12
Incorrect Password (IQDM-P only)...........................................................................................................19-12
Max Password Tries (IQDM-P only) .........................................................................................................19-12
Fault History...........................................................................................................................................19-12
Clearing Fault History .............................................................................................................................19-12
Functions Menu..........................................................................................................................................19-13
Get Settings From Controller ...................................................................................................................19-13
Write Settings to Controller......................................................................................................................19-14
Reset All Settings ...................................................................................................................................19-15
Information.................................................................................................................................................19-16
Model Number........................................................................................................................................19-16
Serial Number ........................................................................................................................................19-16
2009-2011 DS Golf Car Maintenance and Service Manual Page ix

MFG Date ..............................................................................................................................................19-16
Software Version ....................................................................................................................................19-16
Programmer Setup .....................................................................................................................................19-17
Program.................................................................................................................................................19-17
Faults ....................................................................................................................................................19-17
Information.............................................................................................................................................19-17
IQDM and IQDM-P Handset Troubleshooting ...............................................................................................19-18
Test Procedures .........................................................................................................................................19-19
SECTION 20 – ELECTRICAL COMPONENTS.................................................................................................. 20-1
Key Switch .................................................................................................................................................. 20-1

Testing the Key Switch ............................................................................................................................. 20-1
Key Switch Removal ................................................................................................................................ 20-1
Key Switch Installation ............................................................................................................................. 20-2
Forward/Reverse Rocker Switch................................................................................................................... 20-3
Testing the Forward/Reverse Rocker Switch.............................................................................................. 20-3
Forward/Reverse Rocker Switch Removal................................................................................................. 20-3
Forward/Reverse Rocker Switch Installation .............................................................................................. 20-3
Tow/Run Switch........................................................................................................................................... 20-4
Testing the Tow/Run Switch...................................................................................................................... 20-4
Tow/Run Switch Removal......................................................................................................................... 20-4
Tow/Run Switch Installation ...................................................................................................................... 20-4
Motor Controller Output Regulator (MCOR) ................................................................................................... 20-5
Testing the MCOR ................................................................................................................................... 20-5
MCOR Removal ...................................................................................................................................... 20-5
MCOR Installation ................................................................................................................................... 20-6
Reverse Buzzer........................................................................................................................................... 20-7
Reverse Buzzer Removal......................................................................................................................... 20-7
Reverse Buzzer Installation ...................................................................................................................... 20-7
Solenoid...................................................................................................................................................... 20-7
Testing the Solenoid ................................................................................................................................ 20-7
Solenoid Removal ................................................................................................................................... 20-7
Solenoid Installation................................................................................................................................. 20-8
Onboard Computer (OBC)............................................................................................................................ 20-8
Testing the Onboard Computer ................................................................................................................. 20-8
Onboard Computer Removal .................................................................................................................... 20-8
Onboard Computer Installation ................................................................................................................. 20-9
Speed Controller ........................................................................................................................................20-10
Testing the Speed Controller ...................................................................................................................20-10
Speed Controller Removal ......................................................................................................................20-10
Speed Controller Installation.................................................................................................................... 20-11
Charger Receptacle ....................................................................................................................................20-12
Charger Receptacle Inspection................................................................................................................20-12
Charger Receptacle Removal..................................................................................................................20-12
Charger Receptacle Installation ...............................................................................................................20-12
Receptacle Fuse Link .............................................................................................................................20-13
Battery Warning Light..................................................................................................................................20-14
Testing the Battery Warning Light.............................................................................................................20-14
Battery Warning Light Removal ...............................................................................................................20-14
Battery Warning Light Installation.............................................................................................................20-14
Pin 9 Diode ................................................................................................................................................20-14
Testing the Pin 9 Diode ...........................................................................................................................20-14
Pin 9 Diode Removal ..............................................................................................................................20-14
IQ Main Dropout Harness Installation .......................................................................................................20-15
Ferrite Beads – CE Mark Vehicles ...............................................................................................................20-16
DC/DC Converter .......................................................................................................................................20-16
DC/DC Converter Removal .....................................................................................................................20-16
DC/DC Converter Installation...................................................................................................................20-17
SECTION 21 – BATTERIES ............................................................................................................................. 21-1

Battery Troubleshooting Chart ...................................................................................................................... 21-2
Page x 2009-2011 DS Golf Car Maintenance and Service Manual

Battery Testing – 12 Volt............................................................................................................................... 21-3
Battery Charger Test ................................................................................................................................ 21-3
On-Charge Voltage Test ........................................................................................................................... 21-3
Hydrometer Test ...................................................................................................................................... 21-3
Discharge Test ........................................................................................................................................ 21-5
Battery Troubleshooting Examples............................................................................................................ 21-6
Battery Testing – 8 Volt ................................................................................................................................ 21-7
Battery Charger Test ................................................................................................................................ 21-7
On-Charge Voltage Test ........................................................................................................................... 21-8
Hydrometer Test ...................................................................................................................................... 21-8
Discharge Test .......................................................................................................................................21-10
Battery Troubleshooting Examples........................................................................................................... 21-11
Battery Replacement ..................................................................................................................................21-12
Battery Care...............................................................................................................................................21-13
Water Quality .........................................................................................................................................21-13
Battery Care – Vehicles Equipped with the Single-Point Watering System ..................................................21-14
Battery Care – Vehicles Without the Single-Point Watering System............................................................21-15
Self-Discharge........................................................................................................................................21-16
Electrolyte Level .....................................................................................................................................21-16
Vibration Damage ...................................................................................................................................21-17
Single Point Watering System (SPWS).........................................................................................................21-17
Initial Maintenance of the SPWS..............................................................................................................21-17
Watering Batteries with the SPWS ...........................................................................................................21-18
Battery Charger ..........................................................................................................................................21-19
Charging Batteries ..................................................................................................................................21-20
Plug and Receptacle...............................................................................................................................21-21
Charger Shuts Off After 16 Hours ............................................................................................................21-21
Deep-Discharge .....................................................................................................................................21-21
Early Excessive Discharging ...................................................................................................................21-22
Incoming AC Service ..............................................................................................................................21-22
Fleet Rotation.........................................................................................................................................21-22
Numbering Vehicles and Chargers...........................................................................................................21-22
Battery Storage ..........................................................................................................................................21-22
Charging a Battery Pack that has Low Voltage .............................................................................................21-23
SECTION 22 – BATTERY CHARGER .............................................................................................................. 22-1
SECTION 23 – MOTOR (MODELS EJ4-4001 AND EJ8-4001A)......................................................................... 23-1

Motor Identification ...................................................................................................................................... 23-1
External Motor Testing ................................................................................................................................. 23-2
Motor .......................................................................................................................................................... 23-4
Motor Removal ........................................................................................................................................ 23-4
Motor Disassembly .................................................................................................................................. 23-5
Motor Component Testing and Inspection...................................................................................................... 23-8
Armature Inspection and Testing............................................................................................................... 23-8
Motor Frame and Field Windings Inspection .............................................................................................23-10
Motor Brush, Spring, and Terminal Insulator Inspection .............................................................................23-10
Reconditioning the Motor ............................................................................................................................23-13
Motor Specifications ...............................................................................................................................23-13
Motor Assembly..........................................................................................................................................23-13
Motor Installation ........................................................................................................................................23-15
SECTION 24 – TRANSAXLE (TYPE G) ............................................................................................................ 24-1
Lubrication .................................................................................................................................................. 24-1

Axle Bearing and Shaft ................................................................................................................................ 24-1
Axle Shaft ............................................................................................................................................... 24-1
Axle Bearing............................................................................................................................................ 24-4
Transaxle .................................................................................................................................................... 24-5
Transaxle Removal .................................................................................................................................. 24-5
Transaxle Disassembly, Inspection, and Assembly......................................................................................... 24-7
2009-2011 DS Golf Car Maintenance and Service Manual Page xi

Transaxle Disassembly and Inspection...................................................................................................... 24-7
Transaxle Assembly................................................................................................................................. 24-9
Transaxle Installation ..................................................................................................................................24-10
SECTION 25 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P): IQ SYSTEM................................................. 25-1
Plugging the Handset into the Vehicle ........................................................................................................... 25-1

Program Menu ............................................................................................................................................ 25-2
Speed Setting.......................................................................................................................................... 25-3
Fast Accel ............................................................................................................................................... 25-3
Pedal Up Mode........................................................................................................................................ 25-3
Speed Cal ............................................................................................................................................... 25-3
Code A, Code B, and Code C................................................................................................................... 25-3
Slow Pedal Up......................................................................................................................................... 25-4
KSI SRO Enable...................................................................................................................................... 25-4
M2 Max Speed ........................................................................................................................................ 25-4
SECTION i – INDEX
Page xii 2009-2011 DS Golf Car Maintenance and Service Manual

SECTION 1 – SAFETY 1
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 CAUTION.
These special statements relate to specific safety issues, and must be read, understood, and heeded before
proceeding with procedures. There are statements labeled NOTE, which provide other essential service or
maintenance information.
DANGER
• A DANGER indicates an immediate hazard that will result in severe personal injury or death.
WARNING
• A WARNING indicates an immediate hazard that could result in severe personal injury or death.
CAUTION
• A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in
minor personal injury.
CAUTION
• A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could
result in property damage.
GENERAL WARNINGS
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. Other
specific safety statements appear throughout this manual and on the vehicle.
DANGER
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service
area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and
rubber gloves when working on or near batteries.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing.
Antidotes:
– External: Flush with water. Call a physician immediately.

– Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
– Eyes: Flush with water for 15 minutes. Call a physician immediately.
DANGER CONTINUED ON NEXT PAGE
2009-2011 DS Golf Car Maintenance and Service Manual Page 1-1

1 General Warnings SAFETY
DANGER
• Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Service only in a well-ventilated area.
• Do not operate gasoline vehicle in an enclosed area without proper ventilation. The engine produces
carbon monoxide, which is an odorless, deadly poison.
WARNING
• Only trained technicians should service or repair the vehicle or battery charger. 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.
• Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and
CAUTION statements in this manual as well as those on the vehicle and battery charger.
• Prior to leaving the vehicle unattended or servicing the vehicle, set the park brake, turn the key switch
OFF, remove the key, and place the Forward/Reverse switch in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
Gasoline vehicles only:
• To avoid unintentionally starting a gasoline vehicle, disconnect the battery and spark plug wire. See
Disconnecting the Battery – Gasoline Vehicles on page 1-3.
• Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery
cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or
any other metal component.
Electric vehicles only:
• Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. Failure to
heed this warning could result in a battery explosion or severe personal injury.
• To avoid unintentionally starting an electric vehicle, disconnect the batteries and discharge the
controller. See Disconnecting the Batteries – Electric Vehicles on page 1-5.
All vehicles:
• Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. Wear a
full face shield and rubber gloves when working on or near batteries.
• 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. Use approved jack stands of proper weight capacity to support the vehicle and chock
the wheels that remain on the floor. When not performing a test or service procedure that requires
movement of the wheels, lock the brakes.
• Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle
performance, severe personal injury, or death.
• Any modification or change to the vehicle that affects the stability or handling of the vehicle, or
increases maximum vehicle speed beyond factory specifications, could result in severe personal
injury or death.
• Check the vehicle owner’s manual for proper location of all vehicle safety and operation decals and
make sure they are in place and are easy to read.
WARNING CONTINUED ON NEXT PAGE
Page 1-2 2009-2011 DS Golf Car Maintenance and Service Manual

SAFETY General Warnings 1
WARNING
• Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle or battery charger.
• Use insulated tools when working near batteries or electrical connections. Use extreme caution to
avoid shorting of components or wiring.
• Moving parts! Do not attempt to service the vehicle while it is running.
• Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could
result in severe burns.
• If wires are removed or replaced, make sure wiring and wire harness are properly routed and secured.
Failure to properly route and secure wiring could result in vehicle malfunction, property damage,
personal injury, or death.
• For vehicles with cargo beds, remove all cargo before raising the bed or servicing the vehicle. If the
vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised. Do not
close bed until all persons are clear of cargo bed area. Keep hands clear of all crush areas. Do not
drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning could result in
severe personal injury or death.
• Do not leave children unattended on vehicle.
DISABLING THE VEHICLE
1. Set the park brake.

2. Turn the key switch OFF and remove the key.
3. Place the Forward/Reverse control in the NEUTRAL position.
4. In addition, chock the wheels if servicing or repairing the vehicle.
DISCONNECTING THE BATTERY – GASOLINE VEHICLES
1. Disable the vehicle. See Disabling the Vehicle on page 1-3.

2. Disconnect the battery cables, negative (–) cable first, as shown (Figure 1-3).
3. Disconnect the spark plug wire(s) from the spark plug(s).
CONNECTING THE BATTERY – GASOLINE VEHICLES
1. Connect the battery cables, positive (+) cable first.

2. Tighten battery terminals to 80 in-lb (9 N·m).
3. Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to minimize corrosion.
4. Connect the spark plug wire(s) to the spark plug(s).

1 General Warnings SAFETY
3
(+)
2 1
(–)
3
4
(Viewed from driver side of vehicle)

1. Place TOW/RUN Switch in TOW before disconnecting or
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.
2
Figure 1-1 Battery Cable Removal – 4x12-Volt Battery
Configuration
RUN
TOW 3
WAR
NIN
G
(+)
1
3
4
2
(–)
1
2
2 1
5
6
(Viewed from driver side of vehicle) (Viewed from passenger side of vehicle)
1. Place TOW/RUN Switch in TOW before disconnecting or connecting 1. Remove negative battery cable.
battery cables. 2. Remove positive battery cable.
2. Remove negative battery cable. Connect battery cables in reverse order.
3. Remove positive battery cable.
Connect battery cables in reverse order.
1436 1
Figure 1-2 Battery Cable Removal – 6x8-Volt Battery Figure 1-3 Battery Cable Removal – Gasoline Vehicle
Configuration

SAFETY General Warnings 1
DISCONNECTING THE BATTERIES – ELECTRIC VEHICLES
1. Disable the vehicle. See Disabling the Vehicle on page 1-3.

2. Place Tow/Run switch in the TOW position before disconnecting or connecting the batteries. Failure to heed
this warning could result in a battery explosion or severe personal injury.
3. Disconnect the batteries, negative (–) cable first, as shown (Figure 1-1) or (Figure 1-2).
4. After disconnecting the batteries, wait 90 seconds for the controller capacitors to discharge.
CONNECTING THE BATTERIES – ELECTRIC VEHICLES
1. Ensure the Tow/Run switch is in the TOW position.

3. Tighten battery terminals to 110 in-lb (12.4 N·m).
4. Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305) to minimize corrosion.

SECTION 2 – VEHICLE SPECIFICATIONS 2
IQ SYSTEM
SPECIFICATIONS GASOLINE
ELECTRIC
POWER SOURCE
Drive motor: Direct drive, 48 volts DC, shunt-wound, 3.2 hp •
Engine: 4-cycle OHV, 286 cc, 9.5 maximum hp @ 3600 RPM (per SAE J 1940/1349),
•
single-cylinder, air-cooled, with pressure lubrication system
Fuel system: Side-draft carburetor with float bowl, fixed jets, fuel filters, and impulse fuel
•
pump
Governor: Automatic ground-speed sensing, internally geared in unitized transaxle •
Ignition: Transistor electronic ignition with electronic RPM limiter •
Transaxle: Double reduction helical gear with 12.3:1 direct drive axle •
Unitized transaxle: Fully synchronized forward and reverse with neutral and reduced
•
speed reverse (11.8:1 forward, 17.1:1 reverse)
Torque converter: Automatic, variable-speed, dry type •
Electrical system: 48 volts DC, reduced speed reverse •
Electrical system: 12 volt, 500 cca at 0 °F (-17.8 °C), 650 at 32 °F (0 °C). 105-minute
•
reserve capacity and 35-amp charging capacity
Batteries: High capacity, deep cycle •
Charger: Automatic, 48-volt; UL and CSA listed •
STEERING/SUSPENSION/BRAKES
Steering: Self-adjusting rack and pinion • •
Suspension: Front and rear tapered mono-leaf springs with dual hydraulic shocks • •
Brakes: Dual rear wheel self-adjusting brakes with cast iron drums and single brake pedal
• •
with automatic-release park brake
BODY/CHASSIS
Frame/Chassis: Twin I-Beam welded aluminum • •
Front and rear body: ArmorFlex® • •
Body finish:Automotive-grade paint • •
Tires: 18 x 8.5 – 8 tubeless, 4 ply rated • •
DIMENSIONS/WEIGHT
Overall length 91.5 in. (232 cm)
Overall width 47.25 in. (120 cm)
Overall height (with canopy) 68.5 in. (174 cm)
Overall height (at steering wheel) 48 in. (122 cm)
Wheelbase 65.5 in. (166 cm)
Ground clearance 4.5 in. (11 cm)
Front wheel tread 34.5 in (88 cm)
Rear wheel tread 38.5 in. (98 cm)
TABLE CONTINUED ON NEXT PAGE

2 General Warnings VEHICLE SPECIFICATIONS
IQ SYSTEM
SPECIFICATIONS GASOLINE
ELECTRIC
Weight (vehicle with canopy, without batteries) 494 lb. (224 kg)
Weight (dry, without battery) 619 lb. (281 kg)
Forward speed 12-15 mph (19-24 km/h)
Curb clearance circle (diameter) 17 ft.-6 in. (533 cm)
Braking distance (at 12 mph (19 km/h)) 14 ft. (427 cm)
Standard seating capacity 2
LIQUID CAPACITIES
Transaxle 22 oz. (0.67 L)
Engine crankcase (without filter) 32 oz. (0.95 L)
Engine crankcase (with filter) 38 oz. (1.12 L)
Unitized transaxle 27 oz. (0.8 L)
Fuel tank 7 gallons (26.5 L)
TIRE PRESSURE
18-20 psi (1.24-1.38 12-14 psi (0.83-0.96

Front and rear
Bars) Bars)
NOISE AND VIBRATION
Drive-by noise level to operator 68 dBA 70.7dBA

Test method: EN 12053:2001 Uncertainty: 2 dBA Uncertainty: 2 dBA
Vibration at driver’s seat 0.7 m/s2 0.8 m/s2

Test method: EN 13059:2002 Uncertainty: 0.12 m/s2 Uncertainty: 0.020 m/s2

SECTION 3 – GENERAL INFORMATION 3
DANGER
• See General Warnings on page 1-1.
WARNING
Important features unique to the different models covered in this manual are highlighted. Club Car, LLC recommends
the owner/operator read and understand this manual and pay special attention to features specific to their vehicle(s).
Refer to the owner’s manual provided with the vehicle for information on the following topics:
• Pre-Operation and Daily Safety Checklist
• Controls and Indicators
• Driving Instructions
• Towing
• Transporting on a Trailer
• Subsequent Owner Registration
• Warranties
SERIAL NUMBER IDENTIFICATION
The serial number of the vehicle is printed on a bar code decal mounted on the frame directly above the accelerator
pedal (Example: AQ0601-123456) (Figure 3-1, Page 3-2). There is also a second serial number decal mounted on
the front body frame behind the center dash panel. The center dash panel must be removed to view this decal. See
following NOTE.
The two letters (1) at the beginning of the serial number indicate the vehicle model. The following four digits (2)
indicate the model year and production week during which the vehicle was built. The six digits (3) following the hyphen
represent the unique sequential number assigned to each vehicle built within a given model year. See following NOTE.
NOTE: Have the vehicle serial number available when ordering parts or making inquiries.
Build Code: The build code (4) is a five-digit number that appears on the vehicle serial number decal. The build code
exists to enable the user to identify the correct owner’s manual for a vehicle. This owner’s manual is valid for the build
code range indicated on the back cover of this owner’s manual.

3 Safety Committee GENERAL INFORMATION
1 2 3
4
SERIAL NUMBER
BC54679
PH0901-123456
ASSEMBLED IN USA
1400
Figure 3-1 Serial Number Decal
SAFETY COMMITTEE
If the golf car is to be rented or is part of a fleet, we strongly recommend that a safety committee be appointed. One of
the main concerns of this committee should be the safe operation of the golf cars.
This should include at a minimum:

• Where golf cars should be driven.
• Ensuring that proper warnings of driving hazards are displayed and visible.
• Who should and who should not drive golf cars.
• Instructing first time drivers.
• 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.
STORAGE – ELECTRIC VEHICLES
See General Warnings on page 1-1.
WARNING
• Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle or
switch in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle
or a fire hazard. Place Tow/Run switch in the TOW position.
• Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen
batteries can explode.

GENERAL INFORMATION Storage – Electric Vehicles 3
CAUTION
• Batteries in a low state of charge will freeze at low temperatures.
• To avoid exposing electrical components to moisture and subsequent damage, do not use any type of
pressure washing or steam cleaning equipment to wash the vehicle.
PREPARING THE ELECTRIC VEHICLE FOR EXTENDED STORAGE
1. Fully charge batteries. See Charging Batteries on page 21-20.

2. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking
soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water). Rinse solution off batteries. Do not
allow this solution to enter the batteries. Let the terminals dry and then coat them with Battery Terminal Protector
Spray (CC P/N 1014305).
3. Store vehicle in a cool, dry place. This will minimize battery self-discharge.
4. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
5. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-6.
6. Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle.
7. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling.
8. Keep batteries fully charged during storage.
8.1. Leave battery chargers plugged in during storage. The onboard computer (OBC) will automatically activate
the charger when necessary.
8.2. If the battery charger is left plugged in during extended storage, check the electrolyte level and charger
function monthly to ensure that proper operation is maintained. To check charger function, disconnect the
DC cord (stationary charger) from the vehicle or the AC cord (onboard charger) from the power source, wait
five seconds, then reconnect it. The charger is functioning properly if the ammeter indicates current.
NOTE: The OBC keeps track of the time spent in storage mode. When the OBC detects that the storage charge
cycles may have depleted the available electrolyte, it will stop the charger from further operation.
Disconnecting then reconnecting the DC cord (stationary charger) or AC cord (onboard charger) indicates the
electrolyte levels have been maintained and allows the OBC to resume operation.
While in storage, the Tow/Run switch should be in Tow. When in Tow mode, the amber battery warning light
will not illuminate. Do not attempt to use the battery light as an indication of battery state while in storage.
8.3. If AC power is off for 7 days or longer, the OBC will not function or charge the vehicle again until it has
been restarted. To restart the computer, make sure AC power has been restored, disconnect the DC
cord (stationary charger) from the vehicle or the AC cord (onboard charger) from the power source, wait
five seconds, then reconnect it.
CAUTION
• Be sure to check the batteries and charger monthly to maintain correct battery water level and to
ensure the charger is operating correctly during storage.
8.4. If the charger cannot remain plugged in, AC power will not be available during extended storage, or
electrolyte levels will not be maintained, then disconnect the batteries for storage (Figure 1-1, Page
1-4) or (Figure 1-2, Page 1-4).

3 Storage – Electric Vehicles GENERAL INFORMATION
RETURNING THE STORED ELECTRIC VEHICLE TO SERVICE
1. If necessary, connect batteries. See Connecting the Batteries – Electric Vehicles on page 1-5.
2. Fully charge batteries.
3. Adjust tires to recommended tire pressure. See Section 2 – Vehicle Specifications.
4. Perform the Pre-Operation and Daily Safety Checklist on page 10-1.

GENERAL INFORMATION Storage – Gasoline Vehicles 3
STORAGE – GASOLINE VEHICLES
DANGER
• Do not attempt to drain fuel when the engine is hot or while it is running.
• Be sure to clean up any spilled gasoline before operating the vehicle.
• Store fuel in an approved fuel container only. Store in a well-ventilated area away from sparks, open
flames, heaters, or heat sources.
• Keep fuel out of the reach of children.
• Do not siphon fuel from the vehicle.
WARNING
• Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle in
the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a
fire hazard.
• Turn the fuel shut-off valve to the closed (OFF) position (Figure 3-2, Page 3-6).
CAUTION
• Batteries in a low state of charge will freeze at low temperatures.
PREPARING THE GASOLINE VEHICLE FOR EXTENDED 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. Use an automotive-type 12-volt battery charger rated at 10 amps or less.
2. Drain carburetor and seal the fuel tank.
2.1. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the
MAINTENANCE position. Turn the fuel shut-off valve to the closed (OFF) position (Figure 3-2, Page 3-6)
and run the engine until fuel remaining in the carburetor and fuel lines is depleted and the engine stalls.
Return the neutral lockout cam to the OPERATE position.
2.2. Loosen, but do not remove, the carburetor drain screw and drain fuel remaining in bowl into a small, clean
container, then pour the fuel from the container into vehicle fuel tank. Tighten the carburetor drain screw.
2.3. Disconnect fuel vent line from fuel tank vent nipple.
2.4. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap.
3. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3.
4. Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with
a solution of baking soda and water (1 cup (237 mL) baking soda per 1 gallon (3.8 L) of
water). Rinse solution off batteries. Do not allow this solution to enter the batteries. Let the
terminals dry and then coat them with Battery Terminal Protector Spray (CC P/N 1014305).

3 Storage – Gasoline Vehicles GENERAL INFORMATION
1
2
1
3
2
1. Vent 2. Shut-off Valve 3. Vent Tubes
1. Fuel Shut-off Valve
2. Closed (OFF)
3. Open (ON)
NOTE: When selecting valve position, ensure that it is fully opened
or fully closed.
449 24
Figure 3-2 Fuel Shut-off Valve Figure 3-3 Fuel Tank, Vent, and Lines
5. To protect the engine, remove spark plug and pour 1/2 ounce (14.2 mL) of SAE 10 weight oil into the engine
through the spark plug hole. Rotate engine crankshaft by hand several times and then install the spark plug.
6. Adjust tires to recommended tire pressure. See Vehicle Specifications on page 2-1.
7. Perform semiannual periodic lubrication. See Periodic Lubrication Schedules on page 10-6.
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. Restore fuel system to operation (Figure 3-3, Page 3-6).

1.1. Remove plug from fuel tank vent.
1.2. Connect vent tube to fuel tank vent.
2. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-3.
3. Completely open the fuel shut-off valve (Figure 3-2, Page 3-6). Make sure the valve is fully open. A partially
closed fuel shut-off valve combined with the use of the choke can result in a fouled spark plug and engine failure.
4. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE
position. Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts. Turn the
engine off and return the neutral lockout cam to the OPERATE position. See following NOTE.
NOTE: Due to the oil added to the engine in preparation for storage, engine may smoke excessively for a short
time when it is run for the first time after storage.
5. Adjust tires to recommended tire pressure. See Vehicle Specifications on page 2-1.
6. Perform the Pre-Operation and Daily Safety Checklist on page 10-1.

SECTION 4 – BODY AND TRIM 4
DANGER
WARNING
CLEANING THE VEHICLE
CAUTION
• Do not use detergents or cleaning solvents that contain ammonia, aromatic solvents, or alkali
materials on body panels or seats.
• Do not allow battery acid to drip on body panels. Battery acid will cause permanent damage. Wash
spilled battery acid from body panels immediately.
Club Car DS vehicles are equipped with ArmorFlex® front and rear bodies. Use only commercially available automotive
cleaners with a sponge or soft cloth for normal cleaning. 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 an ArmorFlex rear body that is removed) will expose electrical components to moisture. Moisture entering
electrical components can result in water damage and subsequent component failure.
Use non-abrasive wax products. Battery acid, fertilizers, tars, asphalt, creosote, paint, or chewing gum should be
removed immediately to prevent possible stains. See following NOTE.
NOTE: Dispose of waste water properly.
SEAT CLEANING
To preserve seat appearance, clean regularly with mild soap or detergent applied with a sponge or soft cloth. Use a
soft bristle brush to clean areas that are especially soiled. Use the following guidelines:
Light Soiling: A solution of 10% liquid dish soap and warm water applied with a soft, damp cloth is recommended.
A soft bristle brush may be used if necessary. Wipe off any residue with a water dampened cloth.
Difficult Stains: Dampen a soft, white cloth with a solution of 10% household bleach (sodium hypochlorite) and
90% water. Rub gently to remove stain, then rinse with a water dampened cloth to remove bleach concentration.
More Difficult Stains: Perform previous procedure using full-strength bleach, or allow bleach to puddle on
affected area for approximately 30 minutes. Rinse with a water dampened cloth to remove any remaining bleach
concentration. See following CAUTION.

4 Front and Rear Body Repair BODY AND TRIM
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
STRESS LINES OR STREAKS
Repeatedly flexing the ArmorFlex body can cause white stress lines or streaks in the finish. To remove them:
1. Hold a heat gun 12 inches (30 cm) away from the affected area, with the gun on its lowest heat setting.
2. Slowly wave the heat gun back and forth over the affected area until the streak fades.
3. It may be necessary to move the gun closer to the body to fade the streak, but under no circumstance should the
gun be held closer than 6 inches (15 cm) to the body. See following CAUTION.
CAUTION
• Holding the heat gun too close to the body could melt the body or damage the finish.
MINOR IMPACT DAMAGE/DEFORMATIONS
Minor impact damage to an ArmorFlex body can be repaired using a procedure similar to the one used to remove
stress lines. To remove deformations resulting from minor impact damage:
1. Hold a heat gun 12 inches (30 cm) away from the affected area, with the gun on its lowest heat setting.
2. Periodically remove the heat gun and bend the body, using a push block, in the opposite direction of the
deformation.
3. Continue heating and bending the body until the original shape returns. Under no circumstance should the gun be
held closer than 6 inches (15 cm) to the body. See preceding CAUTION.
MINOR SCRATCHES AND SURFACE BLEMISHES
For minor scratches or blemishes in the body that do not penetrate the finish:
1. Thoroughly clean the affected area using a strong, non-abrasive detergent and hot water, then clean with
Ultra-Kleen® Solvent Cleaner to remove any oil-based contaminants.
2. Lightly buff imperfection with a clean soft cloth or buff pad. Do not use any kind of rubbing (abrasive) compound
on body assemblies.
3. Wax the entire body part to restore luster and weather protection.

BODY AND TRIM Front and Rear Body Repair 4
SMALL SCRATCHES THAT CANNOT BE BUFFED OUT
1. Thoroughly clean the affected area with alcohol and then dry thoroughly.
2. Using 240 grit or finer sandpaper, lightly sand the scratch to feather the edges. Finish sand the scratch with 320
grit or finer paper to remove gloss from the surface. Sand as little body surface as possible beyond the scratch.
See following CAUTION.
CAUTION
• Be careful not to sand completely through the finish to the body material.
3. Using the brush provided with the touch-up paint apply paint to the scratch. Multiple layers of paint may
be required to fill the scratch.
4. Allow paint to dry completely (approximately 10-20 minutes), then lightly buff the imperfection.
5. Wax the entire body part to restore luster and weather protection.
GOUGES, PUNCTURES, TEARS, LARGE SCRATCHES, AND ABRASIONS
Touch-up is not recommended. Replace the entire body part or have it repaired by a professional paint and body repair
shop with experience repairing TPO bodies.
TOUCH-UP PAINT COLOR CHART
COLOR CC P/N
Beige 101997201
White 101997202
Red 101997203
Gray 101997204
Dark Gray 101997205
Royal Blue (Pacific Blue) 101997206
Black 101997207
Dark Green 101997209
Classic Blue (Navy) 101997211
Burgundy 101997212

4 Canopy BODY AND TRIM
CANOPY
CANOPY REMOVAL
1. Remove the eight nuts (7) and eight washer-head screws (6) from the holes in each channel and brace of the
canopy as shown. Remove the canopy (11) from the windshield frame (3) and rear braces (4 and 5) (Figure 4-1,
Page 4-5).
2. Remove the nylon lock nuts (10) and four flat washers (9) from the bottom end of the driver and passenger side
rear braces (4 and 5). Remove the four hex-head cap screws (8) and four flat washers (9) and remove the rear
braces from the front side of the seat back supports.
3. Remove the two washer-head screws (1) securing the windshield frame (3) to the front body of the vehicle.
4. Remove the pads (12) from under the windshield frame mounting bracket on the front body.
CANOPY INSTALLATION
1. Place the pads (12) on the front body and under the windshield frame mounting brackets (Figure 4-1, Page 4-5).
Align the slots on the pads with the slots in the mounting brackets.
2. Secure the windshield frame (3) to the front body of the vehicle with two washer-head screws (1). Tighten
the screws to 45 in-lb (5.1 N-m).
3. Mount bottom end of the driver and passenger side rear braces (4 and 5) to the front side of the seat back
supports with four hex-head cap screws (8) and four flat washers (9). Secure with four flat washers (9) and four
nylon lock nuts (10). Tighten the hardware to 45 in-lb (5.1 N-m).
4. Place the canopy (11) onto the windshield frame (3) and braces (4 and 5). Insert the upper ends of the frame and
braces into the channels in the underside of the canopy. Insert eight washer-head screws (6) through the holes in
each channel and brace as shown. Secure the canopy with eight nuts (7). Tighten the screws to 45 in-lb (5.1 N-m).

BODY AND TRIM Canopy 4
11 4
6
7
3
5
8
9
9
12 10
1368
Figure 4-1 Canopy Assembly

4 Front Body BODY AND TRIM
FRONT BODY
FRONT BODY REMOVAL
1. Remove screws (3) and lock nuts (4) and pull front bumper (2) from vehicle frame (Figure 4-2, Page 4-7).
2. Remove blind rivets (5).
3. Remove the eight nuts (7) and eight washer-head screws (6) from the holes in each channel and brace of the
canopy as shown. Remove the canopy (11) from the windshield frame (3) and rear braces (4 and 5) (Figure 4-1,
Page 4-5).
4. Remove the two washer-head screws (1) securing the windshield frame (3) to the front body of the vehicle.
5. Remove the pads (12) from under the windshield frame mounting bracket on the front body.
6. Remove carriage bolts (10), lock nuts (17), and washers (11) from front body trim (Figure 4-2, Page 4-7).
7. Loosen (do not remove) screws (12) holding front body trim (9) against front body.
8. Remove the screws (16) securing the front body to the frame.
9. Pull front body (8) from under trim (9) and remove the body from the vehicle.
FRONT BODY INSTALLATION
1. Install front body (8) under trim (9), align holes and finger-tighten screws (16) holding front body against frame
(Figure 4-2, Page 4-7).
2. Install carriage bolts (10), washers (11), and lock nuts (17) onto front body trim. Tighten bolts to 11 ft-lb (14.9
N·m). Tighten screws (16) to 20 in-lb (2.3 N·m). See following NOTE.
NOTE: If installing a new front body, two 5/16 (8 mm) holes must be drilled after the body has been placed on the
vehicle. Use the body trim (9) as a guide for drilling the holes.
3. Tighten screws (12) holding front body trim against front body to 17 in-lb (1.9 N·m).
4. Remove the two finger-tightened screws (16) from step 1 that secure the front body to frame (Figure 4-2,
Page 4-7).
5. Place the pads (12) on the front body and under the windshield frame mounting brackets (Figure 4-1, Page 4-5).
Align the slots on the pads with the slots in the mounting brackets.
6. Secure the windshield frame (3) to the front body of the vehicle with the two washer-head screws (16) removed
in step 4. Tighten the screws to 45 in-lb (5.1 N-m).
7. Place the canopy (11) onto the windshield frame (3) and rear braces (4 and 5). Insert the upper ends of the frame
and braces into the channels in the underside of the canopy. Insert eight washer-head screws (6) through the
holes in each channel and brace as shown. Secure the canopy with eight nuts (7). Tighten the screws to
45 in-lb (5.1 N-m).
8. Install push type blind rivets (5) that secure lower part of front body to frame.
9. Install front bumper onto vehicle with screws (3) and lock nuts (4). Tighten to 65 in-lb (7.3 N·m).

BODY AND TRIM Front Body 4
10
16 11
9 17
Club
Car
12
5 13
3
1362
Figure 4-2 Front Body Assembly

4 Rear Body BODY AND TRIM
REAR BODY
REAR BODY REMOVAL

NOTE: IQ System vehicles only: The rear bumper does not have to be removed to remove rear body.
Gasoline vehicles only: The choke button assembly does not have to be removed to remove rear body.
However, adjustment of the choke positioner may be necessary after the rear body is installed.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL and set the
park brake. Chock the wheels.
2. Remove the seat from the rear body.
3. Disconnect the battery cables and either discharge the controller or disconnect the spark plug wire(s). See
Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-5. See Disconnecting the Battery –
Gasoline Vehicles, Section 1, Page 1-3.
4. Remove bagwell protector by gently pulling the bagwell protector at each plastic barrel (2) (Figure 4-3, Page 4-8).
5. Remove the two screws (1), lock nuts and washers located under bagwell protector in bagwell floor.
6. Remove the two screws, nuts and washers located at the bottom edge of the seat support panel (in kick-plate just
above the floormat) (Figure 4-4, Page 4-8).
1
00000
00000
00000
1363 1364
Figure 4-3 Remove Screws Under Bagwell Protector Figure 4-4 Remove Kick-Plate Screws
7. Gasoline vehicles only: Remove the screw securing the Forward/Reverse handle and slide the handle from the
shaft.
8. IQ System vehicles only: Disconnect or remove charger receptacle (Figure 4-5, Page 4-9):
The charger receptacle must be disconnected, but does not have to be removed from the body:
8.1. Remove wire ties binding 10-gauge red wire (from charger receptacle to battery) to the vehicle frame.
Disconnect the 10-gauge red wire at the positive post of battery no. 1.
8.2. Remove the retaining nut and disconnect the 10-gauge black wire (from the onboard computer) from the
receptacle.
8.3. Unplug the fuse holder assembly to disconnect the gray sense lead from the receptacle

BODY AND TRIM Rear Body 4
1365
Figure 4-5 PowerDrive Charger Receptacle
9. Disconnect and remove Forward/Reverse switch:
9.1. IQ System vehicles: Disconnect the three-pin connector (13) from the Forward/Reverse switch (Figure
4-6, Page 4-9).
RUN
TOW
13
1366
Figure 4-6 IQ System Forward/Reverse Switch Connector
9.2. Gasoline vehicles: Remove four screws and nylon lock nuts securing the Forward/Reverse shifter to the
rear body. Pull the Forward/Reverse shifter (with wiring and cable assembly still connected) from body and
allow it to rest on vehicle frame I-beam.
9.3. Remove the shifter cable from the cable hanger under the driver-side seat hinge.
9.4. Remove two nylon lock nuts from fuel pump and remove fuel pump from seat support.
10. Remove the two screws securing the rear access panel.

4 Rear Body BODY AND TRIM
11. Remove two carriage bolts (2), nuts (4), and washers (3) attaching the rear legs (1) of the seat back support
assembly to the body (Figure 4-7, Page 4-10).
12. Remove four screws (8), flat washers (9), and spacers (10), attaching the front legs (5) of the seat back support
assembly to the body (Figure 4-7, Page 4-10).
13. Lift seat back assembly from vehicle. (Figure 4-7, Page 4-10).
14. Lift the rear body from the vehicle.
2
9 5
10 1
3
1 4
1367
Figure 4-7 Seat Back Support Front and Rear Leg Mounting
REAR BODY INSTALLATION
Install in reverse order of removal:
1. Tighten four screws (8), flat washers (9) and spacers (10), attaching the front legs (5) of the seat back support
assembly to the body to 20 in-lb (2.3 N·m) (Figure 4-7, Page 4-10).
2. Tighten the two bolts (2), nuts (4) and washers (3), attaching the rear legs (1) of the seat back support assembly
to the body to 11 ft-lb (14.9 N·m) (Figure 4-7, Page 4-10).
3. Tighten screws and lock nuts securing the Forward/Reverse switch or shifter to 33 in-lb (2.8 N·m).
4. Gasoline vehicles only: Install Forward/Reverse handle and tighten to 14 in-lb (1.6 N·m).
5. Tighten kick-plate screws, nuts and washers to 48 in-lb (5.4 N·m) (Figure 4-4, Page 4-8).
6. Tighten two screws (1), lock nuts and washers under rear body to 33 in-lb (2.8 N·m) (Figure 4-3, Page 4-8).
7. Gasoline vehicles only: Check the choke positioner for proper adjustment and adjust if necessary. Install fuel
pump. See Fuel Pump Installation on page 14-20.
8. IQ System vehicles only: Connect the three-pin connector (13) to the Forward/Reverse switch (Figure 4-6,
Page 4-9).
9. Connect the battery cables. See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. See
Connecting the Batteries – Electric Vehicles, Section 1, Page 1-5.

BODY AND TRIM Floor Mat 4
FLOOR MAT
FLOOR MAT REMOVAL
1. Remove the brake and accelerator pedals. See Accelerator and Brake Pedal Group, Section 5, Page 5-1.
2. Loosen two screws in the rear body kick-plate (Figure 4-4, Page 4-8) and pull the rear edge of the floormat from
between the rear body and the floor panel.
3. Remove the top edge of the floormat from the overlapping flange under the dash.
4. Lift the mat from the vehicle.
FLOOR MAT INSTALLATION
1. Reverse the removal procedure to install the floormat. Tighten kick-plate screws to 48 in-lb (5.4 N·m).
2. Install the brake and accelerator pedals. See Accelerator and Brake Pedal Group, Section 5, Page 5-1.

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP 5
DANGER
WARNING
BRAKE PEDAL AND PARK BRAKE
BRAKE PEDAL REMOVAL
2. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack. Place
jack stands under the front cross tube of the vehicle frame and lower the vehicle onto the jack stands. See
following WARNING.
WARNING
3. Remove the brake pedal assembly.

3.1. Disconnect the equalizer rod (14) from the pedal shaft by removing the clevis pin (16) and bow-tie pin
(15) (Figure 5-1, Page 5-2).
3.2. Remove the nuts (34), flat washers (27), bolts (28), and mounting blocks (26). If the mounting blocks (26)
show signs of excessive wear or are damaged, they must be replaced with new ones before installing
pedal assembly.
3.3. Remove the nut (25) and brake stop bumper (24) and lift pedal assembly (10) through the floorboard
BRAKE PEDAL INSTALLATION
1. From the top side of the floorboard, insert the brake pedal assembly (10) through the opening in the floor as
shown (Figure 5-2, Page 5-3) and install the brake pedal stop bumper (24) (Figure 5-1, Page 5-2) on the brake
pedal assembly, but do not tighten the jam nut (25) at this time.
2. Secure the equalizer rod (14) to the brake pedal assembly (10) with clevis pin (16) and bow-tie pin (15) as shown.

5 Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP
13
10
O P
ST 34
23
22 18
30 15
17 19
12
21 16
20 24
14
17
31 25 26
27
35 28
30 3
33 2
32 29
5 7
11
2
29
5 7
11
6
1400-18000-10201
Figure 5-1 Brake and Park Brake Pedal Assembly and Mounting

ACCELERATOR AND BRAKE PEDAL GROUP Brake Pedal and Park Brake 5
10
STOP
Figure 5-2 Brake Pedal Weldment Through Floor

3. Position and attach brake pedal assembly, mounting blocks (26), and washers (27) to vehicle frame as shown.
Tighten the bolts (28) and nuts to 95 in-lb (10.7 N·m).
4. Tighten the nut (2) on the equalizer rod (1) so that brake pedal free-play is 1/4 inch to 1/2 inch (6 mm to 13
mm) (Figure 5-3, Page 5-3). See following NOTE.
NOTE: Brake pedal free-play is the distance the brake pedal can be pressed before the brake actuator arm moves.
5. Tighten the jam nut (3) while holding the adjustment nut (2) in the correct position.
6. Adjust the pedal group. Refer to the appropriate adjustment procedure:
– For gasoline vehicles, see Pedal Group Adjustment – Gasoline Vehicles on page 5-10.
– For electric vehicles, see Pedal Group Adjustment – Electric Vehicles on page 5-15.
2 A
1
Dimension A: 1/4 inch to 1/2 inch (6.3 to 12.7 mm)

Note: Equalizer bracket may be inverted on some vehicles.
1369
Figure 5-3 Brake Pedal Free-Play Adjustment

5 Brake Pedal and Park Brake ACCELERATOR AND BRAKE PEDAL GROUP
PARK BRAKE REMOVAL
following WARNING.
WARNING
3. Remove the park brake assembly.

3.1. To remove the park brake rod and pawl assembly (17 through 20), remove the push nut (19) and disconnect
the ball joint sleeve (21) from the park brake pedal (1) (Figure 5-4, Page 5-4). See following NOTE.
NOTE: New push nuts (19) and (32) must be used when reassembling the park brake.
3.2. To remove the park brake pedal (1), remove the push retainer nut (32), disconnect the torsion spring (22)
and slide the pedal off of the shaft. See preceding NOTE.
3.3. Inspect all parts for wear and damage and replace as necessary.
A
23 20
22
30 C
1
10
18 19
21
B
35
30 17
32 12 A. Hook one end of spring (20) on park brake weldment.
B. Lift other end of spring (20) up and over brake weldment by prying
down on shaft with small screwdriver.
C. Shaft
Figure 5-4 Park Brake Assembly Figure 5-5 Torsion Spring Installation
PARK BRAKE INSTALLATION
1. From the bottom side of the floorboard, insert the park brake rod (17) through the brake pedal assembly opening.
Then install the park brake pawl (35) onto the shaft on the brake pedal assembly (10) and also insert the park
brake rod (17) into the park brake pawl (Figure 5-4, Page 5-4).
2. Install the push nut (19) on to the park brake pawl shaft.
3. Install the spacer (23) and torsion spring (22) on the park brake pedal shaft on the brake pedal assembly.

ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Gasoline Vehicles 5
4. Install the two bushings (30) in the park brake pedal and position the park brake pedal on the shaft on the brake
pedal assembly weldment (10). Then attach the ends of the torsion spring to the park brake pedal and to the
brake pedal weldment as shown (Figure 5-5, Page 5-4).
5. Install the push nut (32) on the park brake pedal shaft (Figure 5-4, Page 5-4).
6. Connect park brake rod (17) with ball joint (21) to the ball stud on the park brake pedal assembly.
7. Adjust park brake ratchet/pawl gap and pawl engagement. Refer to the appropriate adjustment procedure:
– For gasoline vehicles, see Pedal Group Adjustment – Gasoline Vehicles on page 5-10.
– For electric vehicles, see Pedal Group Adjustment – Electric Vehicles on page 5-15.
ACCELERATOR PEDAL – GASOLINE VEHICLES
ACCELERATOR PEDAL REMOVAL – GASOLINE VEHICLES
1. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section
1, Page 1-3.
following WARNING.
WARNING
3. Disconnect the accelerator rod assembly (17, 25, and 24) (Figure 5-6, Page 5-6) at the front and rear ball studs
and remove it from the vehicle.
4. Use a 9/16-inch socket and 9/16-inch wrench to remove the nut (7), two washers (5), and bolt (4) securing the
accelerator pedal (1) to the pivot rod (6).
5. Remove the nut (10) and ball stud (8) from the accelerator pivot rod assembly (6).
6. Slide the spring retainer (11) off of the accelerator pivot rod.
7. Inspect the pivot support bearing (9) for wear and replace if necessary.
8. Use a marker to mark the position of the park brake ratchet (23) on the accelerator pivot rod (6). See following
NOTE.
NOTE: Failure to mark position of the ratchet could cause it to be reinstalled improperly, resulting in improper
adjustment and possible failure of the park brake.
9. Remove the lock nut (26) from the accelerator pivot rod (Figure 5-6, Page 5-6).
10. Press the brake pedal slightly and slide the park brake ratchet (23) toward the end of the accelerator pivot rod.
Rotate the ratchet and remove it from the pivot rod.
11. Remove the pivot rod (6) and spacer (20) from the accelerator pivot rod supports (21).

5 Accelerator Pedal – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP
12. Inspect the accelerator pivot rod supports (21) for wear and damage and replace if necessary. If the pivot
rod supports do not require replacement, loosen, but do not remove, the four bolts (22) and lock nuts (18) to
make installation of the pivot rod easier.
13. Remove the accelerator pedal (1) from the vehicle.
14. Inspect all parts for wear and damage. Replace as necessary.
1 7
5 10
GO 6
11
12
13
14 15
9
5
4
8
24 16
25
17 17
25
24
18
19
21
20
22
26
21
23
Figure 5-6 Accelerator Pedal – Gasoline Vehicles
ACCELERATOR PEDAL INSTALLATION – GASOLINE VEHICLES
1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the
four bolts (22), flat washers (19), and lock nuts (18). Finger-tighten nuts at this time (Figure 5-6, Page 5-6).
2. Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6)
through the uppermost hole in the pedal.
3. Install the plastic spacer (20) on the pivot rod (6).

ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 5
4. Insert the pivot rod through the pivot rod supports on the vehicle frame.
5. Tighten the four bolts (22) attaching the pivot rod supports to the frame to 75 in-lb (8.5 N·m).
6. Install the bolt (4), two washers (5), and a new lock nut (7) through the lower hole in the pedal and through the
pivot rod. Finger-tighten nut at this time.
7. Install the ball stud (8) through the pivot rod. Install the bearing (9) and spring retainer (11) onto the ball stud.
Secure these parts with the nut (10). Tighten the nut to 50 in-lb (5.7 N·m).
8. Press 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).
Release the brake pedal and allow the ratchet to rotate until its tip is pointed downward (Figure 5-7, Page
5-7). The ratchet should now rotate freely on the rod.
Figure 5-7 Ratchet Installation

9. Rotate the ratchet clockwise until it touches the park brake pawl, then slide the ratchet onto the splines of the
pivot rod (it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines
accessible). The ratchet may have to be rotated counterclockwise slightly to align the splines.
10. Install the nylon lock nut (26) on the pivot rod and tighten the nut to 18 ft-lb (24 N·m) (Figure 5-6, Page 5-6).
11. Install the accelerator rod assembly (17, 25, and 24).
12. Adjust the accelerator pedal height and accelerator rod. See Pedal Group Adjustment – Gasoline Vehicles on
page 5-10.
ACCELERATOR PEDAL – ELECTRIC VEHICLES
ACCELERATOR PEDAL REMOVAL – ELECTRIC VEHICLES
1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles,
Section 1, Page 1-5.
following WARNING.

5 Accelerator Pedal – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP
WARNING
3. Remove the MCOR (2) and drive bar (3) as instructed (Figure 5-8, Page 5-9). See MCOR Removal, Section 20,
Page 20-5.
4. Use a 9/16-inch socket and 9/16-inch wrench to remove the nut (7), two washers (5), and bolt (4) securing the
accelerator pedal (1) to the pivot rod (6) (Figure 5-8, Page 5-9).
5. Remove the nut (10) and bolt (8) from the accelerator pivot rod assembly (6).
6. Slide the spring retainer (11) off of the accelerator pivot rod.
7. Inspect the pivot support bearing (9) for wear and replace if necessary.
8. Use a marker to mark the position of the park brake ratchet (24) on the accelerator pivot rod (6). See following
NOTE.
NOTE: Failure to mark position of the ratchet could cause it to be installed improperly, resulting in improper adjustment
and possible failure of the park brake.
9. Remove the lock nut (23) from the accelerator pivot rod.
10. Press the brake pedal slightly and slide the park brake ratchet (24) toward the end of the accelerator pivot rod.
Rotate the ratchet and remove it from the pivot rod.
11. Remove the pivot rod (6) and spacer (20) from the accelerator pivot rod supports (21) (Figure 5-8, Page 5-9).
12. Inspect the accelerator pivot rod supports (21) for wear and damage and replace as necessary. If the pivot
rod supports do not require replacement, loosen, but do not remove, the four bolts (22) and lock nuts (15) to
make installation of the pivot rod easier.
13. Remove the accelerator pedal (1) from the vehicle.
14. Inspect all parts for wear and damage. Replace as necessary.

ACCELERATOR AND BRAKE PEDAL GROUP Accelerator Pedal – Electric Vehicles 5
7
5
3
1
GO 6 10
5
4
9 11
15
16
21
20
22
23
21
24
Figure 5-8 Accelerator Pedal – Electric Vehicle

5 Pedal Group Adjustment – Gasoline Vehicles ACCELERATOR AND BRAKE PEDAL GROUP
ACCELERATOR PEDAL INSTALLATION – ELECTRIC VEHICLES
1. If the accelerator pivot rod supports were replaced, position the supports (21) on the vehicle frame and install the
four bolts (22), flat washers (16), and lock nuts (15) (Figure 5-8, Page 5-9). Finger-tighten nuts at this time.
2. Insert the lower end of the accelerator pedal (1) through the floorboard and install the accelerator pivot rod (6)
through the uppermost hole in the pedal.
3. Install plastic spacer (20) on pivot rod (6).
4. Insert the pivot rod through the pivot rod supports (21) on the vehicle frame.
5. Tighten the four bolts (22) attaching the pivot rod supports to the frame to 75 in-lb (8.5 N·m).
6. Insert the bolt (4), two washers (5), and a new lock nut (7) through the lower hole in the pedal and through the
pivot rod. Finger-tighten lock nut at this time.
7. Install the bolt (8) through the pivot rod (6) bearing (9) and spring retainer (11). Secure these parts with the nut
(10). Tighten the nut to 50 in-lb (5.5 N·m).
8. Press the brake pedal slightly, and with the park brake ratchet oriented so that the tip of the ratchet is pointed
toward the rear of the vehicle, slide the ratchet onto the pivot rod (do not slide the ratchet onto the pivot rod
splines). Release the brake pedal and allow the ratchet to rotate until its tip is pointed downward (Figure 5-7,
Page 5-7). The ratchet should now rotate freely on the rod.
9. Rotate the ratchet clockwise until it touches the park brake pawl, then slide the ratchet onto the splines of the
pivot rod (it may be necessary to push the pivot rod toward the driver side of the vehicle to make the splines
accessible). The ratchet may have to be rotated counterclockwise slightly to align the splines.
10. Install lock nut (23) on pivot rod (Figure 5-8, Page 5-9). Tighten to 18 ft-lb (24.5 N·m).
11. Install the MCOR (2) and drive bar (3) as instructed. See MCOR Installation, Section 20, Page 20-6.
12. Adjust the accelerator pedal height. See Pedal Group Adjustment – Electric Vehicles on page 5-15.
PEDAL GROUP ADJUSTMENT – GASOLINE VEHICLES
1, Page 1-3.
2. Adjust brake pedal height.
2.1. Chock wheels and release park brake. Lift rear of vehicle and place jack stands under the axle tubes
to support the vehicle.
2.2. To provide slack in the brake cables, loosen the equalizer retaining nuts (1) on the equalizer rod (2) (Figure
5-9, Page 5-11).

ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 5
1
2
4
3
Figure 5-9 Loosen Rear Brake Equalizer Rod Nuts

2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on
the pedal. Next, adjust the brake stop bumper (22) up or down (Figure 5-10, Page 5-11). Adjusting the
bumper upward decreases distance between pedal and floorboard. Adjusting the bumper downward
increases distance between pedal and floorboard. Proper brake pedal height is 6 inches (15.2 cm) (Figure
5-11, Page 5-11).
2.4. Tighten the jam nut (31) to 8 ft-lb (9.5 N·m) (Figure 5-10, Page 5-11).
12
9 10 11
7 8
00000
5 6
3 4
1 2
22
K
AP R P
TS O
31
00000
00000 00
Correct pedal position is 6 inches (15.2 cm)from floormat to back of

brake pedal.
Figure 5-10 Brake Pedal Height Adjustment Figure 5-11 Brake Pedal Height Measurement
3. Adjust brake pedal free play. See following NOTE.
NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the
brake cluster) moves.
3.1. Measure perpendicularly from the floorboard to the back of the brake pedal, then press the brake pedal
and measure the distance that the pedal moves before all of the slack is taken out of the brake cables

3.2. Tighten the nut (2) on the equalizer rod (1) so that the brake pedal free play is 1/4 to 1/2 inch (6.3 to 12.7
mm) (Figure 5-3, Page 5-3).
3.3. Tighten the jam nut (3) while holding the adjustment nut (2) in the correct position
4. Adjust park brake ratchet/pawl gap and pawl engagement.
4.1. Inspect the park brake pawl and ratchet for excessive wear, grooves, cracks, or chips. If either the pawl or
ratchet is damaged, both must be replaced.
4.2. Adjust retaining nut (7) on spring support rod until there is a 0.060 inch (1.5 mm) gap between the pawl
and the tips of the ratchet teeth. Use a feeler gauge to verify the gap (Figure 5-12, Page 5-12). The gap
should be consistent through range of pawl movement. If the gap is not consistent, loosen the four bolts (6)
securing the accelerator pivot rod supports and adjust the supports. If the gap becomes smaller as the park
brake pedal is pressed, move the pivot rod supports slightly rearward until the gap is consistent. If the gap
becomes larger as the park brake pedal is pressed, move the pivot rod supports slightly forward until gap
is consistent. See following NOTE.
NOTE: The accelerator rod must also be checked if the ratchet/pawl gap is adjusted. See step 6.
The accelerator rod must be disconnected before proceeding to the next step.
7
B 6
0.060 inch
(1.5 mm)
C D
C. Bottom View
D. Cutaway Side View
Figure 5-12 Park Brake Ratchet/Pawl Gap Adjustment

4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the
floorboard, then lock the park brake (Figure 5-13, Page 5-13).
4.4. With the park brake locked, make sure at least 75% of ratchet tooth length engages the pawl (Figure 5-14,
Page 5-13). Tooth engagement should be between the two lines marked on the pawl.

ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Gasoline Vehicles 5
10 2
9
7 8
6 1
4 5 A
3
1 2
GO
3
00000
K
P
00000
R
PA
OT
00000
S 1. Locked Position
2. Ratchet (B) Tooth Length
3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B).
00000 Figure 5-13 Accelerator Pedal Height Measurement

0 Figure 5-14 Ratchet/Pawl Tooth Engagement
4.5. With park brake still locked, measure the distance from the top of accelerator pedal to floorboard. If the
measurement has changed, ratchet tooth engagement is too deep and must be adjusted.
4.6. If ratchet/pawl engagement must be adjusted, disconnect the ball joint at the top of the brake rod and rotate
the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement.
Reconnect ball joint (Figure 5-15, Page 5-13).
4.7. If the accelerator push rod was disconnected from the accelerator pedal, reconnect it.
4.8. Check for proper brake operation prior to driving the vehicle.
1 2
1. 1/2-Inch Socket
2. 1/2-Inch Wrench
Figure 5-15 Brake Rod Adjustment Figure 5-16 Accelerator Pedal Height Adjustment
5. Adjust accelerator pedal height.
5.1. Loosen the nut and bolt (Figure 5-16, Page 5-13) securing the accelerator pedal to the pivot plate. Clamp
the accelerator pedal adjustment tool (CC P/N 101871001) to the accelerator pedal, with the end marked
accelerator pedal height closest to the floorboard. Press the accelerator pedal until the end of the tool rests
against the floorboard; pedal height should be 5-5/8 inches (14.3 cm). Use a rubber strap to hold pedal in
position against the floorboard and then tighten nut to 26 ft-lb (35.3 N·m) (Figure 5-17, Page 5-14).

PAR
K
PAR
K ST MICRO
BREAK
ST OP POINT
GO
OP G MICRO
BREAK
POINT
O
000 0
1
000 0
1. Accelerator Pedal Adjustment Tool (CC P/N 101871001)

2. Rubber Strap
000
Figure 5-17 Accelerator Pedal Height Adjustment

6. Adjust the accelerator rod. See following DANGER.
DANGER
• Before servicing, turn the key switch to the OFF position and place the Forward/Reverse handle in
the NEUTRAL position.
• To prevent accidentally starting the vehicle, disconnect the battery cables as instructed. See
Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. This will prevent the possibility of
the vehicle running over you when you are adjusting the accelerator rod.
6.1. Remove the electrical box screw and cover. See preceding DANGER.
6.2. Loosen the jam nuts (25) and disconnect the accelerator rod (17) at the accelerator pedal (Figure 5-6,
Page 5-6). Adjust the length of the rod to obtain an accelerator cable cam position of 14° as shown
(Figure 5-18, Page 5-14). See following CAUTION.
14°
Top View of the Electrical Component Box

1344
Figure 5-18 Accelerator Cable

ACCELERATOR AND BRAKE PEDAL GROUP Pedal Group Adjustment – Electric Vehicles 5
CAUTION
• After accelerator rod adjustment, make sure that approximately the same number of threads are
exposed at each end of the accelerator rod.
• If the lever on the limit switch in the electrical box is bent, replace the limit switch.
• When loosening jam nuts on the accelerator rod with one end disconnected, hold the disconnected
accelerator rod with locking pliers.
• When tightening jam nuts on the accelerator rod, hold the disconnected ball joint with locking pliers.
6.3. Reconnect the accelerator rod at the accelerator pedal.

6.4. Before tightening jam nuts on accelerator rod, set park brake to first ratchet and pawl position. Press
accelerator pedal and make sure the following events occur in the exact order shown:
EVENT APPROXIMATE PEDAL TRAVEL

Park brake release 2°-4°
Solenoid activation 4°-8°
Carburetor throttle actuation 8°-12°
6.5. 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.
6.6. Ensure that the events occur as described in the table above. See following NOTE.
NOTE: After the pedal group and accelerator rod are adjusted, the final governed engine RPM should be set. See
Engine RPM Adjustment, Section 14, Page 14-11.
6.7. Install the electrical box cover and screw.

7. Adjust the brakes. See Brake Adjustment, Section 6, Page 6-8.
PEDAL GROUP ADJUSTMENT – ELECTRIC VEHICLES
2. Adjust brake pedal height.
2.1. Chock wheels and release park brake. Lift rear of vehicle and place jack stands under the axle tubes
to support the vehicle.
2.2. To provide slack in the brake cables, loosen the equalizer retaining nuts (1) on the equalizer rod (2) (Figure
5-19, Page 5-16).

5 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP
1
2
4
3
Figure 5-19 Loosen Rear Brake Equalizer Rod Nuts

2.3. Loosen the brake stop jam nut (31), then relieve pedal pressure on the stop by pushing down slightly on
the pedal. Next, adjust the brake stop bumper (22) up or down (Figure 5-20, Page 5-16). Adjusting the
bumper upward decreases distance between pedal and floorboard. Adjusting the bumper downward
increases distance between pedal and floorboard. Proper brake pedal height is 6 inches (15.2 cm) (Figure
5-21, Page 5-16).
2.4. Tighten the jam nut (31) to 8 ft-lb (9.5 N·m) (Figure 5-20, Page 5-16).
12
9 10 11
7 8
00000
5 6
3 4
1 2
22
K
AP R P
TS O
31
00000
00000 00
Correct pedal position is 6 inches (15.2 cm)from floormat to back of

brake pedal.
Figure 5-20 Brake Pedal Height Adjustment Figure 5-21 Brake Pedal Height Measurement
3. Adjust brake pedal free play. See following NOTE.
NOTE: Brake pedal free play is the distance the brake pedal can be pressed before the brake actuator arm (at the
brake cluster) moves.
3.1. Measure perpendicularly from the floorboard to the back of the brake pedal, then press the brake pedal
and measure the distance that the pedal moves before all of the slack is taken out of the brake cables

3.2. Tighten the nut (2) on the equalizer rod (1) so that the brake pedal free play is 1/4 to 1/2 inch (6.3 to 12.7
mm) (Figure 5-3, Page 5-3).
3.3. Tighten the jam nut (3) while holding the adjustment nut (2) in the correct position.
4. Adjust park brake ratchet/pawl gap and pawl engagement.
4.1. Inspect the park brake pawl and ratchet for excessive wear, grooves, cracks, or chips. If either the pawl or
ratchet is damaged, both must be replaced.
4.2. Adjust retaining nut (7) on spring support rod until there is a 0.060 inch (1.5 mm) gap between the pawl
and the tips of the ratchet teeth. Use a feeler gauge to verify the gap (Figure 5-22, Page 5-17). The gap
should be consistent through range of pawl movement. If the gap is not consistent, loosen the four bolts (6)
securing the accelerator pivot rod supports and adjust the supports. If the gap becomes smaller as the
park brake pedal is pressed, move the pivot rod supports slightly rearward until the gap is consistent. If
the gap becomes larger as the park brake pedal is pressed, move the pivot rod supports slightly forward
until gap is consistent.
7
B 6
0.060 inch
(1.5 mm)
C D
C. Bottom View
D. Cutaway Side View
Figure 5-22 Park Brake Ratchet/Pawl Gap Adjustment

4.3. With the park brake unlocked, measure and note the distance from the top of the accelerator pedal to the
floorboard, then lock the park brake (Figure 5-23, Page 5-18).
4.4. With the park brake locked, make sure at least 75% of ratchet tooth length engages the pawl (Figure 5-24,
Page 5-18). Tooth engagement should be between the two lines marked on the pawl.

5 Pedal Group Adjustment – Electric Vehicles ACCELERATOR AND BRAKE PEDAL GROUP
10 2
9
7 8
6 1
4 5 A
3
1 2
GO
3
00000
K
P
00000
R
PA
TS O
00000
1. Locked Position
2. Ratchet (B) Tooth Length
3. Make sure pawl (A) engages at least 75% of ratchet tooth length (B).
00000 Figure 5-23 Accelerator Pedal Height Measurement

0 Figure 5-24 Ratchet/Pawl Tooth Engagement
4.5. With park brake still locked, measure the distance from the top of accelerator pedal to floorboard. If the
measurement has changed, ratchet tooth engagement is too deep and must be adjusted.
4.6. If ratchet/pawl engagement must be adjusted, disconnect the ball joint at the top of the brake rod and rotate
the ball joint sleeve clockwise to increase engagement or counterclockwise to decrease engagement.
Reconnect ball joint (Figure 5-25, Page 5-18).
4.7. Check for proper brake operation prior to driving the vehicle.
5. Adjust accelerator pedal height.
5.1. Loosen the nut and bolt (Figure 5-26, Page 5-18) securing the accelerator pedal to the pivot plate. Clamp
the accelerator pedal adjustment tool (CC P/N 101871001) to the accelerator pedal, with the end marked
accelerator pedal height closest to the floorboard. Press the accelerator pedal until the end of the tool rests
against the floorboard; pedal height should be 5-5/8 inches (14.3 cm). Use a rubber strap to hold pedal in
position against the floorboard and then tighten nut to 26 ft-lb (35.3 N·m) (Figure 5-27, Page 5-19).
1 2
1. 1/2-Inch Socket
2. 1/2-Inch Wrench
Figure 5-25 Brake Rod Adjustment Figure 5-26 Accelerator Pedal Height Adjustment

PAR
K
PAR
K ST MICRO
BREAK
ST OP POINT
GO
OP G MICRO
BREAK
P OINT
O
000 0
1
000 0
1. Accelerator Pedal Adjustment Tool (CC P/N 101871001)

2. Rubber Strap
000
Figure 5-27 Accelerator Pedal Height Adjustment

6. Adjust the brakes. See Brake Adjustment, Section 6, Page 6-8.

SECTION 6 – WHEEL BRAKE ASSEMBLIES 6
DANGER
WARNING
Asbestos Dust Warning
• Some aftermarket brake shoes contain asbestos fiber, and asbestos dust is created when these brake
mechanisms are handled. Wear approved eye and respiratory protection when disassembling and
cleaning brake mechanisms. Inhalation of asbestos could result in severe personal injury or death. Do
not use compressed air or aerosol sprays to clean the brake mechanism. Clean brake mechanism
using the negative pressure enclosure/hepa vacuum system or low pressure/wet cleaning method per
OSHA/29 CFR - 1910.1001.
GENERAL INFORMATION
DS Golf Cars are equipped with self-adjusting, mechanically-expanding shoe drum brakes on each rear wheel.
BRAKE SHOE REMOVAL
See General Warnings on page 1-1. See also Asbestos Dust Warning on page 6-1.
2. Place chocks at the front wheels. Loosen, but do not remove, lug nuts on rear wheels and lift the rear of the
vehicle with a chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. See
WARNING “Lift only one end...” in General Warnings on page 1-1.
3. Loosen the equalizer retaining nuts (1) on the equalizer rod (2) to loosen the brake cable (Figure 6-1, Page 6-2).
4. Remove the rear wheels and brake drums. If the brake drums were easily removed, proceed to step 6. See
following CAUTION and NOTE.
CAUTION
• Worn or damaged brake drums cannot be machined to refinish them. Replace as necessary.
NOTE: When servicing vehicles with severely worn brake shoes and when the drums cannot be removed by normal
methods, proceed to step 5 to minimize damage to the brake cluster and brake components.
5. Remove brake drums and badly worn brake shoes.

5.1. 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.

6 Brake Shoe Removal WHEEL BRAKE ASSEMBLIES
1
2
3
4
00
3
00
00
1
1400-18100-10209 1400-18100-10220
Figure 6-1 Loosen Brake Cables Figure 6-2 Shoe Retainer Pins
5.2. Insert a 1/2 inch x 5/8 inch cold chisel (1) under the head (2) of each pin and shear them off as illustrated
(Figure 6-2, Page 6-2). This will release the shoes from the backing plate, allowing them to pivot away
from the inside of the brake drum (3), which should then allow the brake drum to be pulled free. After
completing step 6, skip step 7. See following NOTE.
NOTE: Although step 6 allows easier access to the brake shoes, it is not imperative to do so in order to remove
the brake shoes.
6. Remove the axle.

6.1. Using 90° snap ring pliers (CC P/N 1012560), remove the axle retaining ring (1) (Figure 6-3, Page 6-2).
6.2. Pull the axle shaft (2) from the axle tube (Figure 6-3, Page 6-2).
1
0
2400-23600-10221
Figure 6-3 Remove Axle Retaining Ring

WHEEL BRAKE ASSEMBLIES Brake Shoe Removal 6
11 10
6
15 8
1 7
000
7 00000
6
00000
12
B
9
14
13
16
4
3 5 A 14
2
A. Electric Vehicle
B. Gasoline Vehicle
1332
Figure 6-4 Self-adjusting Wheel Brake Assembly
7. Using needle nose pliers, turn the clip retainer pin (1) 90° to remove the shoe retainer clip (2) (Figure 6-5, Page
6-4). See following CAUTION.
CAUTION
• The brake shoes are under pressure and can release suddenly when brake shoe retainers are removed.
8. Grasp both brake shoes and pull them, together with the springs, out of the brake assembly as shown (Figure
6-6, Page 6-4).
9. Remove adjuster wheel (1) with two washers (2 and 3) from the backing plate (Figure 6-7, Page 6-4).

6 Brake Assembly Cleaning WHEEL BRAKE ASSEMBLIES
2 00
00 00
00
1400-18100-10222 1400-17700-10225
Figure 6-5 Remove Shoe Retainer Clip Figure 6-6 Remove Brake Shoes
2
1
2
3
1. Slide
2. Slide Plate (If Equipped)
638 639
Figure 6-7 Remove Adjuster Wheel Figure 6-8 Lubricate Slide and Slide Plate
BRAKE ASSEMBLY CLEANING
NOTE: Later model vehicles are no longer equipped with the slide plate.
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. For vehicles equipped with a slide plate (2) (Figure 6-8, Page 6-4), lubricate the slide plate with dry moly
lubricant (P/N 1012151). For vehicles equipped without a slide plate (2), lubricate the backing plate, where the
slide operates, with dry moly lubricant (P/N 1012151).
4. Lubricate the slide (1) with dry moly lubricant (P/N 1012151). After lubricating, work slide back and forth against
backing plate to ensure that it slides smoothly and easily. Install rubber boot onto backing plate.

WHEEL BRAKE ASSEMBLIES Brake Assembly Cleaning 6
WARNING
• Apply grease carefully when performing the following steps. Do not allow any grease to get onto the
friction surfaces of the brake shoe pads or the brake drum. Failure to heed this warning could cause
diminished brake performance, possibly resulting in property damage or severe personal injury.
5. Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning® BR2-Plus or
equivalent) on each of the six raised bosses on the brake backing plate (Figure 6-9, Page 6-5). See preceding
WARNING.
6. Use a small brush to carefully apply a light coat of white lithium NLGI #2 grease (Dow Corning BR2-Plus or
equivalent) to each end of both brake shoes and into the slots in the brake shoe mounting block as shown
(Figure 6-10, Page 6-5). See preceding WARNING.
00 00
00 00
640 641
Figure 6-9 Apply Grease On Bosses Figure 6-10 Apply Grease To Brake Shoes and Slots
7. Use a small brush to carefully apply a light coat 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 6-11, Page 6-5). See preceding WARNING.
8. Install the adjuster wheel (1) and two washers (2 and 3) into the adjuster assembly (Figure 6-7, Page 6-4).
17T
00
642 643
Figure 6-11 Apply Grease To Brake Adjuster Figure 6-12 Install Adjuster Wheel, Trailing Shoe

6 Brake Shoe Installation WHEEL BRAKE ASSEMBLIES
BRAKE SHOE INSTALLATION
1. Turn the adjusting wheel screw so that the shoe slot is vertical, then position the trailing shoe in the slots in the
shoe mounting block and adjuster assembly (Figure 6-12, Page 6-5). See following NOTE.
NOTE: The trailing shoe has 17T stamped into the tip of the shoe flange (Figure 6-12, Page 6-5). The leading shoe is
stamped 17L. When installing the shoes, the stamping on both shoes should be oriented to the top of the
brake assembly. When installing the shoes on the passenger side of the vehicle, the side of the trailing shoe
flange marked 17T should be facing out and be visible. On the driver side, the 17L on the leading shoe should
be facing out and be visible.
When installed on the backing plate, the leading shoe (stamped 17L) is always oriented toward the rear of
the vehicle.
2. Install the shoe retainer clip, using pliers to compress the clip (1) while turning the retainer pin (2) into position
3. Attach the springs onto the trailing shoe already installed. Then hold the leading shoe next to the trailing shoe,
correctly oriented, and attach the springs to it (Figure 6-14, Page 6-6).
1 3
1
2
0
4
2
1. Bronze Spring 2. Silver Spring 3. Spring Coils 4. Note that the silver
spring is mounted with the coils to the side of the adjustment lever
spring (A).
644 645
Figure 6-13 Install Trailing Shoe Retainer Clip Figure 6-14 Attach Springs
4. While maintaining spring attachment on both shoes, position tips of leading shoe (1) 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. After the shoes are installed, move them together up and down and side to side to make sure that they will easily
slide approximately 1/4 to 3/8 inch (6.3 to 9.5 mm) without binding (Figure 6-16, Page 6-7).

WHEEL BRAKE ASSEMBLIES Brake Shoe Installation 6
1
A
00 0
00 00
00
B
00 00
646 647
Figure 6-15 Install Leading Shoe Figure 6-16 Check Shoe Positions
6. Place a flatblade screwdriver under the adjusting arm (1) and raise the arm off of the adjusting wheel (2). While
holding the arm (1) up, turn the wheel (2) upward until it stops (Figure 6-17, Page 6-7). Remove the screwdriver.
1 2
00
648
Figure 6-17 Set Adjusting Wheel
7. Install the rear axles into the transaxle. See following NOTE.
NOTE: There is a LEFT and RIGHT side axle. The splined portions on the axles that insert into the transaxle case are
two different lengths. The longest length spline is the LEFT, or driver side axle.
7.1. Insert the splined end of the axle shaft into the axle tube. Be careful not to damage the seal on the inside of
the axle tube hub. Advance the shaft through to the bearing on the shaft, and rotate it to align the shaft
splines with the splined bore of the differential gear. Continue advancing the shaft until the bearing on the
axle is firmly seated within the axle tube hub seat.
7.2. Using 90° internal snap ring pliers (0.090 tip) (CC 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).
7.3. Place a 1/4 to 3/8 - inch (6 - 10 mm) diameter rod against the retaining ring and tap lightly at four or five
locations to ensure it is properly seated. See following WARNING and CAUTION.

6 Brake Adjustment WHEEL BRAKE ASSEMBLIES
WARNING
• Be sure retaining ring is properly seated in groove. If ring is not properly installed, the axle assembly
will separate from the transaxle and damage the axle assembly and other components. Loss of vehicle
control could result in severe personal injury or death.
CAUTION
• Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from
the oil seal area.
8. Install the brake drum, and make sure that it is properly seated. See following NOTE.
NOTE: If drum installation is difficult, the brake shoes may need to be adjusted vertically in the mounting slots.
9. After the drum is installed, make sure the axle and drum turn freely and then install the wheel. See Wheel
Installation on page 8-1.
BRAKE ADJUSTMENT
1. When cleaning or repair on both wheels is complete, and with the brake cable still loose, lower the vehicle
to the floor.
2. Make the brake shoe and drum adjustment by pressing and releasing the brake pedal repeatedly until an audible
clicking can no longer be heard.
3. Adjust brake pedal free play.
3.1. For gasoline vehicles: See Pedal Group Adjustment – Gasoline Vehicles on page 5-10.
3.2. For electric vehicles: See Pedal Group Adjustment – Electric Vehicles on page 5-15.

WHEEL BRAKE ASSEMBLIES Brake Cluster Removal and Installation 6
BRAKE CLUSTER REMOVAL AND INSTALLATION
BRAKE CLUSTER REMOVAL
2. Place chocks at the front wheels and loosen the lug nuts on the rear wheels. Lift the rear of the vehicle with a
chain hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. See WARNING “Lift
only one end...” in General Warnings on page 1-1.
3. Loosen the brake cables, remove the rear wheel, remove the brake drum and axle shaft. See Brake Shoe
Removal on page 6-1.
4. Remove bow tie locking pin (13) and clevis pin (12) from brake cable (Figure 6-4, Page 6-3).
5. Remove four bolts (11) and lock nuts (10) that mount the brake assembly to the transaxle (Figure 6-4, Page 6-3).
6. Remove brake assembly from transaxle.
BRAKE CLUSTER INSTALLATION
1. Install in reverse order of disassembly. Use new bow tie locking pins when installing brake cables. See following
CAUTION.
CAUTION
• Before installing axle shaft, clean any residual oil from the exposed end of the axle tube and from
the oil seal area.
2. Be sure bolts (11) (CC P/N 1014153) and new lock nuts (10) (CC P/N 1013924) are used to mount the brake
assembly (Figure 6-4, Page 6-3).
3. Tighten nuts to 17 ft-lb (23.0 N·m). If torquing the bolt heads, torque to 30 ft-lb (40.6 N·m).
4. Install the axle shaft, brake drum and rear wheel. See Brake Shoe Installation on page 6-6.
5. Tighten lug nuts on rear wheels, using a crisscross pattern, to 55 ft-lb (74.6 N·m). See Wheel Installation
on page 8-1.
6. Adjust the brakes. See Brake Adjustment on page 6-8.

6 Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES
BRAKE CABLE REMOVAL AND INSTALLATION
BRAKE CABLE REMOVAL
2. Place chocks at the front wheels.
3. Release the park brake if engaged and loosen equalizer retaining nuts (1) on equalizer rod (2) to slightly loosen
the brake cables (3) (Figure 6-1, Page 6-2).
4. Rotate the brake cable upward and pull cable end through hole in top of equalizer (4).
5. Remove E-clip securing front end of cable to frame crossmember and pull cable from crossmember.
6. Remove bow-tie pin (1) and the clevis pin (2) from the brake lever on each wheel and pull the clevis (4) away
from the lever (Figure 6-18, Page 6-10).
7. Remove E-clip (3) from cable at the cable support bracket (5). Remove cable from bracket.
8. Note routing of cable through hanger for installation of new cable. Pull cable from vehicle.
1
3
5
1400-18100-10243
Figure 6-18 Disconnect Cables at Rear Brakes
BRAKE CABLE INSTALLATION
1. Place the end of the new cable into the equalizer (4) (Figure 6-1, Page 6-2). Secure the cable to the vehicle
frame with new E-clip. Route cable through hanger in the same manner as before.
2. At the rear wheel brake, connect the cable to the brake actuator arm using new clevis pin (2) and new bow-tie pin
(1) (Figure 6-18, Page 6-10).
3. Place the cable in the cable support bracket (5) and secure with new E-clip (3).
4. Adjust the brakes. See Brake Adjustment on page 6-8.

SECTION 7 – STEERING AND FRONT SUSPENSION 7
DANGER
WARNING
GENERAL INFORMATION
Steering is controlled through a rack and pinion steering assembly that is connected by a steering column to a steering
wheel. No manual adjustment to the rack and pinion gear assembly is required. A spring loaded self-adjusting
mechanism is incorporated into the assembly.
STEERING WHEEL
STEERING WHEEL REMOVAL
2. Remove the two mounting screws (1) and plate (2) (Figure 7-1, Page 7-2).
3. Match mark the steering wheel (3) and steering column shaft (4) so when the steering wheel is removed it can
be placed back in exactly the same position on steering column shaft.
4. Loosen the steering wheel nut (5) and back it off approximately 1/4 inch (6 mm). Do not remove the nut.
5. Use the steering wheel puller (CC P/N 102061201) to remove steering wheel.
5.1. Place the puller anvil (6) through the top opening of the steering wheel (Figure 7-2, Page 7-2).
5.2. Insert the anvil feet through the two slots in the base plate (marked “B”) (7) as shown.
5.3. Rotate the anvil screw (8) clockwise until the base plate contacts the bottom of the steering wheel where it
attaches to the steering column.
5.4. Use a 1/2-inch drive air impact wrench to tighten the anvil screw (8) until the steering wheel breaks free
from the steering shaft.
5.5. Remove the steering wheel puller.
5.6. Remove the steering wheel nut (5) and the steering wheel (3) from the steering column (9) (Figure 7-1,
Page 7-2).

7 Steering Column STEERING AND FRONT SUSPENSION
3 5
B
8
6
7
4
1
1500-18300-10252 1500-18300-10253
Figure 7-1 Steering Wheel Removal Figure 7-2 Steering Wheel Puller
STEERING WHEEL INSTALLATION

NOTE: To minimize corrosion and to make future removal of the steering wheel easier, apply a small amount of oil or
anti-seize compound to steering shaft splines and taper before installing the steering wheel.
1. Install the steering wheel (3) on the splines of the steering shaft (4). Be sure to align the match marks placed on
the wheel and steering column shaft in step 3 above (Figure 7-1, Page 7-2).
2. Install the steering wheel nut (5) and tighten to 156 in-lb (17.6 N·m).
3. Install the plate (2) and screws (1) (Figure 7-1, Page 7-2). Tighten screws to 16 in-lb (1.8 N·m).
STEERING COLUMN
STEERING COLUMN REMOVAL
1. Remove the steering wheel as previously instructed.

2. Remove the front body. See Front Body Removal, Section 4, Page 4-6.

STEERING AND FRONT SUSPENSION Steering Column 7
34
28
32
31
33
20
21
27 18
19
25
16
17
12 14
22
15
17 30 000000
000000 0
0
13
000000 0
000000 0
16 000000
18 7
9 8 11
7
10
5
6
3
2
4
1
1500-18200-10254
Figure 7-3 Steering Column
3. Remove the center dash panel. See Key Switch Removal, Section 20, Page 20-1.
4. Remove the driver-side dash pocket.
4.1. If equipped, remove cup holder hardware and cup holder.
4.2. Remove the flange lock screw from the top of the dash pocket.

7 Steering Column STEERING AND FRONT SUSPENSION
4.3. Drill out the two pop rivets holding the dash pocket in place.
4.4. Slide dash pocket out of vehicle.
5. Remove the upper bolt (2) and lock washer (3) from the universal joint (Figure 7-3, Page 7-3).
6. Remove the nuts (9), bolts (8 and 10), and washers (7 and 11) from the steering column mount (4 and 5)
7. Remove the steering column from the vehicle.
STEERING COLUMN DISASSEMBLY
1. Remove bolts (6) and mounts (4 and 5) from steering column. Remove boot (12) (Figure 7-3, Page 7-3).
2. While supporting steering column (20) on a workbench, remove snap ring (13) from shaft. See following NOTE.
NOTE: Do not allow the steering shaft to slide out of the steering tube when removing the snap ring.
3. Remove the washer (14), spring (15), and wedge (16).

4. Turn the steering column over and slide the shaft out of the tube to expose the retaining ring (22). Use pliers to
twist the retaining ring (22) until it breaks off, then remove the wedge (16).
5. Remove the shaft (19) from the bottom of the tube (20).
6. Use steering shaft (19) to push bearing seat (18) out from the opposite end of the steering tube (20).
7. Insert a flat blade screwdriver between the bottom of the outer race of the bearing (17) and the bottom lip of the
bearing seat (18) and remove the bearing (17). See following NOTE.
NOTE: Use new retaining rings and bearings for reassembly.
STEERING COLUMN ASSEMBLY
1. Insert bearing seat (18) into both ends of steering tube (20). Place a block of wood on bearing seat and tap lightly
on block until bearing seat (18) is fully seated in steering tube (20) (Figure 7-4, Page 7-5).
2. Press the bearing (17) all the way into the bearing seat (18) using a steering column bearing press tool (CC P/N
1014264) or a metal tube approximately six inches (15.2 cm) long with a maximum outer diameter of 1-3/16
inches (3.3 cm) and a minimum inside diameter of 7/8 inch (2.2 cm). Be sure the bearing is installed in the bearing
seat as shown (Figure 7-4, Page 7-5) so the wedge (16) will ride against the inner race of the bearing.
3. Install the wedge (16), spring (15), washer (14), and snap ring (13) onto the bottom end of the steering shaft (19)
4. Insert the shaft (19) from the bottom of the steering tube (20) (Figure 7-3, Page 7-3).
5. Turn the assembly over and place the shaft (19) on a bench. Install the wedge (16) and retaining ring (22) onto
the top of the shaft. Be sure the prongs on the retaining ring face up and away from the wedge. Use a steering
column retaining ring tool (CC P/N 1014259) to seat the retaining ring to the proper depth. Support end of tube
while pressing. If you do not have the recommended tool, use the same tube as was used in step 2 to press the
retaining ring onto the top of the shaft. The retaining ring should be pressed onto the shaft until 2 to 2-1/8 inches
(5.1-5.4 cm) of the shaft extends from the top of the bearing seat in the steering tube (Figure 7-5, Page 7-5).
STEERING COLUMN INSTALLATION
1. Install boot (12). Reinstall mount (4 and 5) onto the end of the steering column. Tighten bolts (6) to 20 ft-lb (27
N·m) (Figure 7-3, Page 7-3).
2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize or lubricating compound to
both splined ends of the steering shaft.

STEERING AND FRONT SUSPENSION Steering Adjustment 7
19 (CCI P/N 1014259)
13
18
22
14
20 16
15 1
1
20 19
18 (CCI P/N 1014264) 2-2 1/8 inches
(CCI P/N 1014264) (5.1-5.4 cm)
16 18
17 17
2 16
2
3 3
1. Step 1 1. Step 1
2. Step 2 2. Step 2
3. Step 3 3. Step 3
1500-18200-10255 1500-18200-10256
Figure 7-4 Steering Shaft – Bottom End Figure 7-5 Steering Shaft – Top End
3. Position the steering column assembly in the vehicle while inserting the steering column shaft into the upper
universal joint (1). The flat portion of the steering shaft spline (19) must be aligned with the bolt hole in the
universal joint (1) before sliding the spline into the universal joint. While holding the steering column in place,
attach it to the frame using bolts (8), washers (7), and nuts (9) (Figure 7-3, Page 7-3). Thread the nuts onto the
bolts but do not tighten them.
4. Install washer (11) and screw (10). Tighten to 20 ft-lb (27 N·m) (Figure 7-3, Page 7-3).
5. Install the bolt (2) and lock washer (3) on the upper universal joint and finger-tighten.
6. Tighten the two nuts (9) and bolts (8) to 18 ft-lb (24.4 N·m) (Figure 7-3, Page 7-3).
7. Tighten the bolt (2) on the upper universal joint to 15 ft-lb (20 N·m) (Figure 7-3, Page 7-3).
8. Check the other two bolts of the universal joint (1) to ensure that they are properly tightened to 15 ft-lb (20
9. Reinstall dash pocket and related hardware.
10. Reinstall center dash panel in reverse order of disassembly. Make sure the key switch terminals do not touch the
frame and the center dash panel is properly seated and snapped into place.
11. Install front body and bumper. See Body and Trim, Section 4, Page 4-1.
STEERING ADJUSTMENT
1. Turn the steering wheel all the way to the right. Note the distance between the passenger side spindle stop (2)
and passenger side A-plate (3) (Figure 7-6, Page 7-8). The internal stop on the rack must reach its limit of travel
against rack and pinion housing at exactly the same time the spindle stops against the passenger side A-plate

7 Rack and Pinion STEERING AND FRONT SUSPENSION
(with vehicle wheels turned to the right). If simultaneous contact occurs, steering is in correct adjustment; proceed
to step 4. If simultaneous contact does not occur, proceed to step 2.
2. Loosen the nuts (27 and 29) and turn the drag link (28) (Figure 7-12, Page 7-10) to adjust the drag link rod.
Adjust the link rod with the steering wheel turned all the way to the right, so the passenger side spindle stop
lightly touches the passenger side A-plate. The internal stop on the rack must reach its limit of travel at the
same time the spindle stops against the passenger side A-plate (with vehicle wheels turned to the right). See
following CAUTION.
CAUTION
• The drag link has both left and right-hand threads. The end of the drag link toward the spindle has
left-hand threads, and the end toward the rack has right-hand threads. To prevent damage to threaded
parts, care should be taken when servicing the drag link.
3. When all adjustments have been completed, tighten the nuts (27 and 29) on the drag link assembly with an open
end wrench. Tighten nuts to 21 ft-lb (28.4 N·m) (Figure 7-12, Page 7-10).See following CAUTION.
CAUTION
• When tightening the nuts (27 and 29), make sure the drag link (28) does not turn (Figure 7-12, Page
7-10).
4. Straighten wheels and turn steering wheel from lock to lock. Wheels should turn smoothly and easily. If steering
wheel does not turn smoothly and easily, inspect steering assemblies as follows:
– ball joints (23) (Figure 7-12, Page 7-10) and (6 and 13) (Figure 7-21, Page 7-19)
– spindle bushings (3 and 4) (Figure 7-22, Page 7-20)
– wave washers (20) (Figure 7-22, Page 7-20)
– rack assembly (17) (Figure 7-12, Page 7-10)
5. Also inspect front suspension assemblies as follows:
– A-plates (1) (Figure 7-21, Page 7-19)
– urethane bushings (2) (Figure 7-21, Page 7-19)
– leaf springs (6) (Figure 7-22, Page 7-20)
6. Replace components as necessary.
RACK AND PINION
CAUTION
• Front impacts that bend tie rods and/or drag links can possibly damage internal steering gear
components. See Rack and Pinion Inspection on page 7-7. The manufacturer recommends inspecting
the rack and pinion and replacing if damaged.

STEERING AND FRONT SUSPENSION Rack and Pinion 7
RACK AND PINION INSPECTION
Look for obvious damage to the chassis, where the rack and pinion is mounted, and the rack and pinion housing.
Particularly check the housing for broken mounting points.
Compare the toe-in against the specification. See Toe-in Adjustment on page 7-17.
If obvious visible damage is found, such as a bent tie rod, check the steering gear for abnormal free-play, noise, binding
or clunking while it is under a load. With the steering system fully assembled and all four tires on the ground/floor,
turn the steering wheel from stop to stop. While turning, feel for any binding, clunking or tight/loose spots. Listen for
unusual noises. Replace the rack and pinion as an assembly if any is found.
In the event of an known impact and obvious visible damage is not found in the method described above, disconnect
the tie rods and/or drag links from the spindles. Turn the steering wheel from stop to stop. While turning, feel for any
binding or tight/loose spots. Listen for unusual noises. Replace the rack and pinion as an assembly if any is found.
RACK AND PINION REMOVAL – CONVENTIONAL BALL JOINTS
2. Remove the cotter pin (22) and ball joint retaining nut (25) (Figure 7-12, Page 7-10).
3. Using a ball joint removal tool (Figure 7-7, Page 7-7), remove the ball joint (23) (Figure 7-12, Page 7-10)
from the spindle assembly.
4. Remove the bolts (30), washers (31), and lock nuts (32) from the steering rack assembly mounting bracket
5. Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and universal
joint from the vehicle (Figure 7-3, Page 7-3).
2 3
1500-0-10257 1500-0-10258
Figure 7-6 Adjust Steering Alignment Figure 7-7 Ball Joint Tool
RACK AND PINION REMOVAL – MAINTENANCE-FREE BALL JOINTS
2. Remove the drag link ball joint retaining nut (25) (Figure 7-13, Page 7-11).
3. Remove the outer drag link ball joint (23) from the spindle assembly (33) and inspect for excessive wear and
seal damage.

4. Remove the bolts (30), washers (31), and lock nuts (32) from the steering rack assembly mounting bracket
5. Remove the bolt (2) and flat washer (3) on the upper universal joint, then remove the rack assembly and universal
joint from the vehicle (Figure 7-3, Page 7-3).
2 3
1838
Figure 7-8 Adjust Steering Alignment
RACK AND PINION DISASSEMBLY
CAUTION
• The ball joint (23) (Figure 7-12, Page 7-10) has left-hand threads.
1. Remove ball joint from the spindle and inspect it for excessive wear (Figure 7-7, Page 7-7).
2. Remove the drag link (28) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
3. Remove both bellows clamps (2) (plastic wire ties).
4. Remove the hex nut (29) and slide off the dust seal bellows (1).
5. Remove the retaining ring (21), then slide off dust seal bellows (20).
6. Remove the rack screw lock nut (15), rack guide screw (16), rack guide pressure spring (14), and the rack guide
(13) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
7. Remove the universal joint assembly from the pinion (8) by fully removing the bolt and then sliding off the
universal joint.

1. Press Ram 2. Pinion Gear 3. Bearing
1500-18400-10259 1500-18400-10260
Figure 7-9 Remove Pinion from Housing Figure 7-10 Remove Bearing from Pinion
8. If necessary, remove the dust seal (12). See following NOTE.
NOTE: If the dust seal (12) is removed, replace with a new one.
9. Use snap ring pliers to remove the internal snap ring (11) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
10. Install the universal joint onto the pinion and place a large open end wrench under the universal joint (Figure 7-9,
Page 7-9). Use the wrench as a lever to pull the pinion from the housing.
11. If the ball bearing (9) has been damaged, remove the external snap ring (10) (Figure 7-12, Page 7-10) (Figure
7-13, Page 7-11) and press the bearing off (Figure 7-10, Page 7-9).
12. Remove retaining ring (19) and stop washer (18), then remove rack (17) from housing (6) (Figure 7-12, Page
7-10) (Figure 7-13, Page 7-11).
13. If the inner ball joint (3) is excessively worn, remove the ball joint and tab washer (4) from the rack (Figure
7-11, Page 7-9).
13.1. Secure the rack in a vise using wood blocks (5) between the rack and the jaws of the vise to protect
the rack from damage (Figure 7-11, Page 7-9).
13.2.Loosen and remove the inner ball joint with a wrench.
3
4
1500-18400-10261
Figure 7-11 Secure Rack in Vise
14. Inspect the bushing (5) for excessive wear. If wear is excessive, replace the steering box assembly (CC P/N
101878302) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).

RACK AND PINION ASSEMBLY
1. Install a new tab washer (4) and an inner ball joint (3) (Figure 7-11, Page 7-9). Install the ball joint onto the rack
by securing the rack in a vise using wood blocks between the rack and the jaws of the vise to protect the rack
from damage. Tighten the ball joint to 60 ft-lb (81 N·m).
2. Bend the edges of the tab washer (4) up against the ball joint (3) (Figure 7-11, Page 7-9).
3. Apply a light coating of EP grease to the teeth of the rack (17), then slide the rack through the bushing (5) and
housing (6). Install the stop washer (18) and retaining ring (19) to the end of the rack (Figure 7-12, Page
7-10) (Figure 7-13, Page 7-11).
23 27
24
28
29
1
2
26 3
4
33
25 12
22
11
10
5 9
6 8
7
13
14
15 16
30
31
32
20
21
17
18
19
2
1500-18400-10262
Figure 7-12 Steering Gear – Conventional Ball Joints

23
27
28
29
1
2
3
4
33
25
12
11
10
5 9
6 8
7
13
14
15 16
30
31
32
20
21
17
18
19
2
1839
Figure 7-13 Steering Gear – Maintenance-Free Ball Joints
CAUTION
• In step 4, do not press against the outer race of the bearing.
4. If the bearing (9) was removed, press on a new bearing, exerting all pressure on the inner race (grease the
bearing before installing it). Then install the external snap ring (10) (Figure 7-12, Page 7-10) (Figure 7-13,
Page 7-11). See preceding CAUTION.

5. If the needle bearing (7) is damaged, the steering box assembly (CC P/N 101878302) must be replaced (Figure
7-12, Page 7-10) (Figure 7-13, Page 7-11).
6. Install pinion (8) and bearing (9) assembly into the housing (6) (Figure 7-12, Page 7-10) (Figure 7-13, Page
7-11). Make sure the rack gear teeth will mesh with the gear teeth on the pinion. The rack may need to be rotated
slightly while lightly tapping on the pinion-bearing assembly with a rubber mallet. See following CAUTION.
CAUTION
• Do not force the pinion-bearing assembly into the housing. The gear teeth or the small bearing
could be damaged.
15
16
1500-18400-10263 1500-18400-10264
Figure 7-14 Press In Dust Seal Figure 7-15 Rack and Pinion Adjustment
2
3
1
1500-18400-10265
Figure 7-16 Rack and Pinion Resistance
7. Install the internal snap ring (11) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
8. Using an appropriate size deep well socket (1) to apply pressure evenly, press in a new dust seal (2) (Figure
7-14, Page 7-12).
9. Apply a small amount of grease to the rack guide (13) where it comes into contact with the rack (17) (Figure
7-12, Page 7-10) (Figure 7-13, Page 7-11).
10. Place a few drops of Loctite® 222 to the threads of the screw (16) (Figure 7-12, Page 7-10) (Figure 7-13,
Page 7-11).

11. Install the rack guide (13), pressure spring (14), and screw (16). The screw should be threaded in until a rotational
torque of 10 in-lb (1.13 N·m) is achieved (Figure 7-12, Page 7-10).
11.1. Reposition the rack and pinion in a vise.
11.2. Insert a 3/8-inch deep well socket (3) into the steering column end of the universal joint (2) and tighten the
bolt (1) to 15 ft-lb (20.3 N·m) (Figure 7-16, Page 7-12).
11.3. Use a torque wrench connected to the 3/8-inch deep well socket (3) to measure the resistance of the rack
and pinion. Rotational resistance should measure 7 to 15 in-lb (0.8 to 1.7 N·m).
11.4. If measured resistance does not equal 7 to 15 in-lb, loosen the lock nut (15) and tighten the screw (16)
until it bottoms out, then back the screw off one quarter turn. Tighten the lock nut to 28 ft-lb (38 N·m)
(Figure 7-15, Page 7-12). See following NOTE.
NOTE: When tightening the lock nut (15) make sure the screw (16) does not change adjustment (Figure 7-15,
Page 7-12).
12. Install the dust seal bellows (20) and retaining ring (21) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
13. Install the dust seal bellows (1) and hex nut (29) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
14. Install the universal joint on the pinion. Tighten the bolt to 15 ft-lb (20 N·m).
15. Install new bellows clamps (wire ties) (2) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11).
16. Install the drag link (28) by fully threading the ground end into the inner ball joint (3). See following CAUTION.
CAUTION
• The ball joint (23) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11) has left-hand threads.
• The tie rod and drag link have right-hand threads on one end and left-hand threads on the other end.
Right-hand threads are identified by a groove in the tie rod or drag link.
17. Install the ball joint (23) (Figure 7-12, Page 7-10) (Figure 7-13, Page 7-11). See preceding CAUTION.
RACK AND PINION INSTALLATION – CONVENTIONAL BALL JOINTS
1. Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31),
and nuts (32). Do not tighten the mounting bolts (Figure 7-12, Page 7-10).
2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the
splined end of the steering column shaft.
3. Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft
into the upper universal joint. Install the bolt and lock washer on the upper universal joint and tighten it to
15 ft-lb (20 N·m).
4. Tighten the steering rack mounting bolts (30) to 22 ft-lb (29.8 N·m) (Figure 7-12, Page 7-10).
5. Adjust the steering. See Steering Adjustment on page 7-5.
RACK AND PINION INSTALLATION – MAINTENANCE-FREE BALL JOINTS
1. Position the steering gear box assembly on the shock and gear support and install the bolts (30), washers (31),
and nuts (32). Do not tighten the mounting bolts (Figure 7-13, Page 7-11).
2. For ease of assembly and to prevent corrosion, apply a light coat of anti-seize and lubricating compound to the
splined end of the steering column shaft.

7 Tie Rod and Drag Link STEERING AND FRONT SUSPENSION
3. Align the flat portion of the steering shaft spline with the bolt hole in the universal joint and then slide the shaft
into the upper universal joint. Install the bolt and lock washer on the upper universal joint and tighten it to
15 ft-lb (20 N·m).
4. Tighten the steering rack mounting bolts (30) to 22 ft-lb (29.8 N·m) (Figure 7-13, Page 7-11).
5. Install the drag link ball joint (23) on the spindle arm riser (33) and secure with retaining nut (25). Tighten nut to
40 ft-lb (54 N·m).
6. Adjust the steering. See Steering Adjustment on page 7-5.
TIE ROD AND DRAG LINK
TIE ROD AND DRAG LINK REMOVAL – CONVENTIONAL BALL JOINTS
1. Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-21,
Page 7-19)and loosen jam nuts (27 and 29) on the drag link (Figure 7-12, Page 7-10).
2. Remove the cotter pins (22) and ball joint retaining nuts (20) (Figure 7-21, Page 7-19).
3. Use a ball joint removal tool to remove ball joints (13 and 6) (Figure 7-21, Page 7-19) and (23) (Figure 7-12,
Page 7-10) from the spindles.
4. Remove the ball joints from the tie rod (11) (Figure 7-21, Page 7-19).
5. Remove drag link (28) from inner ball joint assembly (3) and drag link ball joint (23) (Figure 7-12, Page 7-10).
TIE ROD AND DRAG LINK INSTALLATION – CONVENTIONAL BALL JOINTS
1. Thread ball joints (6 and 13) into tie rod (11) to a depth of 1/2-inch (12.5 mm) (Figure 7-21, Page 7-19). See
following WARNING and CAUTION.
WARNING
• The ball joints must be threaded into the rod at least 5/16 of an inch (8 mm). Failure to thread ball
joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being
operated, possibly resulting in loss of vehicle control and severe personal injury.
CAUTION
2. Install ball joint ends (6 and 13) into the left and right-hand spindle arms (23), then install the retaining nuts
(20) and cotter pins (22) (Figure 7-21, Page 7-19).
3. Thread the drag link rod (28) all the way onto the threaded stud of the inner ball joint assembly (3) (right-hand
threads) (Figure 7-12, Page 7-10).
4. Thread the ball joint (23) into the drag link rod (28) (left-hand threads) to full thread depth (Figure 7-12, Page
7-10).

STEERING AND FRONT SUSPENSION Tie Rod and Drag Link 7
5. Install the ball joint (23) on the spindle arm riser (33), then install the retaining nut and a new cotter pin (22)
(Figure 7-12, Page 7-10). Tighten nut to 18 ft-lb (2.0 N·m).
6. Adjust camber and toe-in. See Camber Adjustment on page 7-16 and Toe-in Adjustment on page 7-17.
7. Adjust steering. See Steering Adjustment on page 7-5.
TIE ROD AND DRAG LINK REMOVAL – MAINTENANCE-FREE BALL JOINTS
1. Using locking pliers to hold tie rod and drag link, loosen jam nuts (7 and 12) on tie rod ball joints (Figure 7-21,
Page 7-19)and loosen jam nuts (27 and 29) on the drag link (Figure 7-12, Page 7-10).
2. Remove the ball joint retaining nuts (20) (Figure 7-21, Page 7-19).
3. Remove ball joints (13 and 6) (Figure 7-21, Page 7-19) and (23) (Figure 7-12, Page 7-10) from the spindles.
4. Remove the ball joints from the tie rod (11) (Figure 7-21, Page 7-19).
5. Remove drag link (28) from inner ball joint assembly (3) and drag link ball joint (23) (Figure 7-12, Page 7-10).
TIE ROD AND DRAG LINK INSTALLATION – MAINTENANCE-FREE BALL JOINTS
1. Thread ball joints (6 and 13) into tie rod (11) to a depth of 1/2-inch (12.5 mm) (Figure 7-21, Page 7-19). See
following WARNING and CAUTION.
WARNING
• The ball joints must be threaded into the rod at least 5/16 of an inch (8 mm). Failure to thread ball
joints in deep enough may cause a ball joint to separate from the rod during adjustment or while being
operated, possibly resulting in loss of vehicle control and severe personal injury.
CAUTION
2. Attach the tie rod ball joints (6 and 13) to the spindle tabs (23), then install and tighten the nuts (20) to 40
ft-lb (54 N·m) (Figure 7-21, Page 7-19).
3. Thread the drag link rod (28) all the way onto the threaded stud of the inner ball joint assembly (3) (right-hand
threads) (Figure 7-12, Page 7-10).
4. Thread the ball joint (23) into the drag link rod (28) (left-hand threads) to full thread depth (Figure 7-12, Page
7-10).
5. Install the drag link ball joint (23) on the spindle arm riser (33) and secure with retaining nut (25) (Figure 7-12,
Page 7-10). Tighten nut to 40 ft-lb (54 N·m).
7. Adjust steering. See Steering Adjustment on page 7-5.

7 Front Suspension STEERING AND FRONT SUSPENSION
FRONT SUSPENSION
LUBRICATION
Two grease fittings (early 2010 to 2011 model year – one in each spindle housing) or five grease fittings (2009 to
early 2010 model year – one in each spindle housing, one in the ball joint on each end of the tie rod, and one in
the ball joint of the steering drag link) are provided. Lubricate these fittings at the recommended interval with the
proper lubricant. See Periodic Lubrication Schedules, Section 10, Page 10-6.
CAUTION
• To ensure proper lubrication of the front suspension and steering linkages, raise front of vehicle to
lubricate. See General Warnings on page 1-1.
WHEEL ALIGNMENT
Wheel alignment is limited to equalizing the camber angle of each front wheel and adjusting toe-in of the front wheels.
There is also a drag link adjustment to equalize the turning radius in both directions. See Steering Adjustment on
page 7-5. See following NOTE.
NOTE: Prior to making any front suspension adjustments, inspect components for wear and damage and repair or
replace as necessary.
Camber Adjustment
1. Check each front wheel with a framing square. At the floor (or ground), there should be an equal amount of space
between each tire and the framing square (Figure 7-17, Page 7-16).
2. Loosen, but do not remove, the four nuts (32) that secure the leaf spring (6) to the bottom spring plate (29)
(Figure 7-22, Page 7-20). See also Figure 7-18, Page 7-16.
32
1
A A 7
B A
1. Proper Camber Adjustment 2. Improper Camber Adjustment

1500-0-10266 1500-0-10267
Figure 7-17 Check Camber Figure 7-18 Adjust Camber

STEERING AND FRONT SUSPENSION Front Suspension 7
3. Loosen, but do not remove, the hex nut (8) on the adjustment eccentric (7) (Figure 7-22, Page 7-20) in the
center of the spring. See also Figure 7-18, Page 7-16.
4. Use a 7 mm deep well socket to rotate the eccentric (Figure 7-18, Page 7-16).
5. After adjusting camber, tighten the four spring retaining nuts (32) (Figure 7-22, Page 7-20) to 23 ft-lb (31 N·m).
Then roll the vehicle forward one full tire revolution and recheck the camber. Adjust as required. See also
Figure 7-17, Page 7-16.
6. Tighten the hex nut (8) on the adjustment eccentric (7) to 23 ft-lb (31 N·m) (Figure 7-22, Page 7-20). See
also Figure 7-18, Page 7-16.
Toe-in Adjustment
1. On a level surface, roll the vehicle forward, then stop. Make sure the front wheels are pointed straight ahead. Do
not turn the steering wheel again during this procedure.
2. On each front tire, mark (as closely as possible) the center of the tread face that is oriented toward the rear of the
vehicle. The marks should be even with the bottom surfaces of the vehicle frame I-beams.
3. Measure the distance between the marks on the rear-facing surfaces of the tires, and then roll the vehicle
forward one and a half wheel revolutions until the marks appear on the forward facing surfaces of the tires at
about the same height from the floor (Figure 7-19, Page 7-17).
Figure 7-19 Check Toe-In Figure 7-20 Adjust Toe-In

4. Measure the distance between the marks on the forward-facing surfaces of the tires. See following NOTE.
NOTE: The front measurement must be less than the rear measurement.
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 1/8 to 3/8 of an inch (3.2 to 9.5 mm).
6. If adjustment is necessary, loosen the jam nut on each tie rod ball joint and rotate the tie rod to increase or
decrease toe-in (Figure 7-20, Page 7-17). See following CAUTION.
CAUTION
• The tie rod has right-hand threads on one end and left-hand threads on the other end. Right-hand
threads are identified by a groove in the tie rod.
7. Tighten nuts (loosened in step 6) to 21 ft-lb (28 N·m) and recheck toe-in.
8. After toe-in adjustment is made and with wheels in the straight ahead position, the steering wheel should be at
the center of its travel. There should be equal travel to the left and right. See following NOTE.
NOTE: If the minimum turning radius is not the same for both left and right turns, adjust the steering. See Steering
Adjustment on page 7-5.

7 Front Suspension Components STEERING AND FRONT SUSPENSION
FRONT SUSPENSION COMPONENTS
LEAF SPRING REMOVAL
2. Remove both front wheels. See Wheel Removal, Section 8, Page 8-1.
3. Remove the nuts (14) and bolts (25) from the bottom of each king pin (26) (Figure 7-22, Page 7-20).
4. Remove the four bolts (30), four nuts (32), four lock washers (31), and bottom spring plate (29).
5. Remove tapered leaf spring (6).
6. Check the condition of the urethane bushings (27) and steel sleeves (28). Replace any that are worn or damaged.
LEAF SPRING INSTALLATION
1. Install urethane bushings (27) and steel sleeves (28) into leaf spring eyes (Figure 7-22, Page 7-20).
2. Install tapered leaf spring (6), bottom spring plate (29), four bolts (30), four lock washers (31), and four nuts (32).
Using a crisscross pattern sequence, tighten bolts to 23 ft-lb (31 N·m).
3. Install spring in king pins (26) with bolts (25) and nuts (14). Tighten to 23 ft-lb (31 N·m).
4. Install the wheels and lower the vehicle. See Wheel Installation, Section 8, Page 8-1.
KINGPIN AND STEERING SPINDLE REMOVAL – CONVENTIONAL BALL JOINTS
1. Remove the front hub. See Front Hub Removal on page 7-25.
2. Remove cotter pins (22) and nuts (20), then remove ball joints from the spindles (Figure 7-21, Page 7-19).
Remove drag link ball joint. See also Tie Rod and Drag Link Removal – Conventional Ball Joints on page
7-14.
3. Remove the lock nut (17) and conical washer (34) from the top of the kingpin (26) (Figure 7-22, Page 7-20).
4. Raise the upper clevis (16) from the kingpin.
5. Remove the flat washer (33) and thrust washer (19).
6. Slide the spindle off the kingpin (26).
7. Remove the wave washer (20) and inspect it. If the washer is broken or has a wave bottom to wave crest height
dimension of less than 0.040 inch (0.10 cm), it must be replaced.
8. Remove bolt (25) and nut (14) from bottom of kingpin (26) and remove kingpin.
9. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced.
10. Inspect the bushings (3 and 4). If the bushings are worn or damaged, remove them and press in new ones.
See following NOTE.
NOTE: If the bushings are replaced, ream new bushings to 0.750-0.752 (3/4 inch) (19.05-19.10 mm) in diameter. The
reamer should be long enough to ream both bushings from one direction.

STEERING AND FRONT SUSPENSION Front Suspension Components 7
13 18
12
9
5
8
11 10
9 7
6
2
19
14 15
5
10
4
2 2
3
14 2
5
2 1 24
4
2
16
17 5
23
20
22
1374
Figure 7-21 Front Suspension – Upper Portion

15
17
34
14 16
2 33
19
30
3
5
26 25 1 9
4
14
20
7
8 23
13
31 27
29
32 6
28
27
1375
Figure 7-22 Front Suspension – Lower Portion
KINGPIN AND STEERING SPINDLE INSTALLATION – CONVENTIONAL BALL JOINTS
1. Inspect all parts and replace them as necessary.

2. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-22, Page
7-20). Tighten the bolt to 23 ft-lb (31 N·m).

3. Install the wave washer (20).
4. Install the steering spindle on the kingpin. Then install the flat washer (33), thrust washer (19), upper plate clevis
(16), conical washer (34), and nut (17). Tighten the nut to 65 ft-lb (88 N·m).
5. Attach the ball joints (6 and 13) to the spindle arm, install and tighten the nut (20), and install the cotter pin
(22) (Figure 7-21, Page 7-19).
6. Install the drag link ball joint. See Tie Rod and Drag Link Installation – Conventional Ball Joints on page 7-14.
7. Install front hub and wheel. See Front Hub Installation on page 7-25.
KINGPIN AND STEERING SPINDLE REMOVAL – MAINTENANCE-FREE BALL JOINTS
1. Remove the front hub. See Front Hub Removal on page 7-25.
2. Remove nuts (20) and remove ball joints from spindles (Figure 7-23, Page 7-22). Remove drag link ball joint.
See also Tie Rod and Drag Link Removal – Maintenance-Free Ball Joints on page 7-15.
3. Remove the lock nut (17) and conical washer (34) from the top of the kingpin (26) (Figure 7-24, Page 7-23).
4. Raise the upper clevis (16) from the kingpin.
5. Remove the flat washer (33) and thrust washer (19).
6. Slide the spindle off the kingpin (26).
7. Remove the wave washer (20) and inspect it. If the washer is broken or has a wave bottom to wave crest height
dimension of less than 0.040 inch (0.10 cm), it must be replaced.
8. Remove bolt (25) and nut (14) from bottom of kingpin (26) and remove kingpin.
9. Inspect the kingpin and spindle. If either is worn or damaged, it must be replaced.
10. Inspect the bushings (3 and 4). If the bushings are worn or damaged, remove them and press in new ones.
See following NOTE.
NOTE: If the bushings are replaced, ream new bushings to 0.750-0.752 (3/4 inch) (19.05-19.10 mm) in diameter. The
reamer should be long enough to ream both bushings from one direction.

13
12 18
9
5
8
10
11 7
9 6
2
14 15
5
10
4
2 2
3
14 2
5
2 1 24
4
2
16
17 5
23
20
2448
Figure 7-23 Front Suspension – Upper Portion

15
17
34
14 16
2 33
19
30
3
5
26 25 1 9
4
14
20
7
8 23
13
31 27
29
32 6
28
27
2449
Figure 7-24 Front Suspension – Lower Portion
KINGPIN AND STEERING SPINDLE INSTALLATION – MAINTENANCE-FREE BALL JOINTS
1. Inspect all parts and replace them as necessary.

2. Install the kingpin (26) over the leaf spring eye. Insert the bolt (25) and install the nut (14) (Figure 7-24, Page
7-23). Tighten the bolt to 23 ft-lb (31 N·m).
3. Install the wave washer (20).
4. Install the steering spindle on the kingpin. Then install the thrust washer (19), flat washer (33), upper plate clevis
(16), conical washer (34), and nut (17). Tighten the nut to 65 ft-lb (88 N·m).
5. Attach the tie rod ball joints (6 and 13) to the spindle tabs, then install and tighten the nuts (20) to 40 ft-lb (54
6. Install the drag link ball joint. See Tie Rod and Drag Link Installation – Maintenance-Free Ball Joints on
page 7-15.
7. Install front hub and wheel. See Front Hub Installation on page 7-25.
DELTA A-PLATE REMOVAL
1. Remove front wheel(s). See Wheel Removal, Section 8, Page 8-1.

2. Remove bolts (10 and 24), A-Plate straps (14), and nuts (5) (Figure 7-21, Page 7-19).
3. Remove the lower shock absorber mounting nut (9), then slide the shock absorber free of the Delta A-Plate.
4. Remove the Delta A-Plate (1).
5. Inspect the bushings (2) and sleeves (3 and 4) in the Delta A-Plate and replace them if necessary.
DELTA A-PLATE INSTALLATION
1. Install the A-Plate in reverse order of removal. Tighten the A-Plate suspension bolts (10 and 24) to 20 ft-lb (27
2. Tighten shock absorber mounting nut (9) to 20 ft-lb (27.1 N·m).
3. Install the wheel(s). See Wheel Installation, Section 8, Page 8-1.
4. Adjust the wheel alignment. See Wheel Alignment on page 7-16.
SHOCK ABSORBER REMOVAL
1. Inspect the shock absorbers for fluid leakage at the point where the shaft enters the shock absorber body.
Leaking shock absorbers should be replaced.
2. Remove the nut (9) attaching the shock absorber to the A-Plate (Figure 7-21, Page 7-19).
3. Remove the nut (32) and bolt (8) attaching the shock absorber to the shock and gear support.
4. Remove the shock absorber.
SHOCK ABSORBER INSTALLATION

NOTE: When installing shock absorbers, make sure front shocks have identical part numbers and rear shocks
have identical part numbers.
1. Install the shock absorber by reversing the removal procedure.

2. Tighten the nuts to 20 ft-lb (27 N·m).

STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs 7
FRONT WHEEL BEARINGS AND HUBS
NOTE: The front wheel bearings are pressed into the spindle and are not serviceable. If excessive free-play is
detected the entire hub should be replaced.
FRONT WHEEL FREE PLAY INSPECTION
1. Raise the front of the vehicle.

2. Use your hands to attempt to rock the wheel and hub assembly back and forth on the spindle. Movement of
the wheel and hub on the spindle indicates that the hub bearing is worn; therefore, the hub assembly must be
replaced. See Front Hub Removal on page 7-25.
FRONT HUB REMOVAL
1. Remove the front wheels. See Wheel Removal on page 8-1.

2. Remove dust cap (12) and lock nut (11) (Figure 7-25, Page 7-26).
3. Slide the hub assembly (9) off of the spindle shaft (3).
4. Lightly sand spindle shaft to clean away any light rust.
5. Inspect the surface of the spindle shaft for surface damage. It should be clean and smooth. If severe pitting from
rust or corrosion has occurred, replace the spindle assembly. See Kingpin and Steering Spindle Removal –
Conventional Ball Joints on page 7-18.
FRONT 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 7-25, Page 7-26).
3. Install a new flanged lock nut (11) and tighten to 50 ft-lb (68 N·m).
4. Rotate the hub. The hub should rotate smoothly without binding, side play, or any indication of rough spots.
5. Repeat the procedure for the opposite wheel.
6. Install wheels and finger-tighten lug nuts.
7. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern. See Wheel Installation, Section
8, Page 8-1.

7 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION
9
3
11
678
Figure 7-25 Front Wheel Hub

SECTION 8 – WHEELS AND TIRES 8
DANGER
WARNING
GENERAL INFORMATION
Maximum tire life and good vehicle handling qualities are directly related to proper wheel and tire care.
• Keep tires properly inflated. See Section 2 – Vehicle Specifications.
• Keep lug nuts properly tightened.
• Keep the front end aligned and adjusted.
WARNING
• Tires affect vehicle handling. When selecting a replacement tire, use only original equipment or
comparable tires.
WHEELS
WHEEL REMOVAL
2. Slightly loosen the lug nuts on the wheel to be removed.
3. Raise the end of the vehicle from which the wheel is to be removed. Make sure that the wheels are off the
ground. See General Warnings on page 1-1.
4. Remove the lug nuts and remove the wheel.
WHEEL INSTALLATION
1. Install wheel(s) and tighten the lug nuts, using a crisscross pattern, until they are snug.
2. Lower the vehicle and finish tightening lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).

8 Tires WHEELS AND TIRES
TIRES
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. Remove the valve cap and valve core and allow air to escape from the tire.
3. If possible, use a tire machine to remove the tire from the rim.
3.1. If a tire machine is not available, loosen both tire beads by applying pressure to the tire side walls and
pushing the tire bead away from the rim flange and into the rim well (Figure 8-1, Page 8-2, Detail A).
3.2. With the valve stem side of the wheel up, use a tire tool to carefully start the upper bead over the edge of
the wheel rim (Figure 8-1, Page 8-2, Detail B).
CAUTION
• To avoid damage to the tire, do not use excessive force when starting the bead over the edge of the rim.
4. When top bead is free of the rim, pull the bead from the bottom side of the rim up into the upper part of the rim
well. Insert the tire tool under the lower bead as shown (Figure 8-1, Page 8-2, Detail C) and carefully pry the
lower bead over the rim flange.
5. Once the lower bead is started over the rim flange, the tire can be removed from the rim by hand.
6
1
3
2
5
A B C
1. Upper Tire Beads 2. Lower Tire Beads 3. Rim Flange 4. Tire Beads Positioned In Rim Well 5. Valve Stem Side Up 6. Tire Tool
679
Figure 8-1 Tire Removal
TIRE REPAIR
1. Determine the location and cause of the air leak:

WHEELS AND TIRES Tires 8
1.1. Remove the wheel. See Wheel Removal on page 8-1. Inflate the tire to no more than 20 psi (1.38 Bars).
1.2. Immerse the tire in water and then mark the point where bubbles are formed by escaping air.
1.3. Determine the cause of the air leak. See following NOTE.
NOTE: An air leak could be due to a punctured casing, faulty valve core, improperly seated valve stem, or improperly
seated tire bead.
Small holes in the casing can be plugged using a standard automotive tubeless tire repair kit available
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
TIRE INSTALLATION
WARNING
• While mounting or inflating tire, keep hands, fingers, etc. from exposed areas between the tire bead
and rim.
1. Clean both tire beads to remove dirt or other foreign matter.

2. Where the tire beads seat, clean the wheel rim with a wire brush. Wipe away any debris with a clean cloth.
NOTE: Because tubeless tires require a perfect seal in order to seat, keeping the tire and rim clean is very important.
3. Apply a liberal amount of tire-mounting lubricant (soap and water solution) to both tire beads and rim flanges.
4. Install the tire on the rim from the valve stem side. If there is no tire machine available, use a rubber mallet
and tire iron.
5. Remove the valve core, and position tire so that both beads are on the rim flange narrow bead seats.
6. Place tire and wheel assembly against wall in upright position and push it against wall while inflating tire to 30-35
psi (2.07-2.42 Bars). The three-point contact (wall, floor, and hand) will help ensure that beads snap into place
and form a proper seal as tire is inflated (Figure 8-2, Page 8-4). See following WARNING.
WARNING
• Do not use a compressed air source with pressure over 100 psi (6.90 Bars). Due to low pressure
requirements of a small tire, over-inflation could be reached almost instantly with a high pressure air
supply. Over-inflation could cause tire to explode, possibly resulting in severe personal injury.
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.

8 Tires WHEELS AND TIRES
680
Figure 8-2 Inflate Tire

SECTION 9 – REAR SUSPENSION 9
DANGER
WARNING
GENERAL INFORMATION
The rear suspension and powertrain of the vehicle move independently from the vehicle frame. It consists of two leaf
springs controlled by two shock absorbers mounted between the springs and the vehicle frame.
SHOCK ABSORBERS
SHOCK ABSORBER REMOVAL AND INSPECTION
1. Check shock absorbers (7) for damage or fluid leakage at the point where the shaft enters the shock absorber
body. Replace damaged or leaking shock absorbers (Figure 9-1, Page 9-2).
2. To remove a shock absorber, remove the nut (5), cup washers (9) and rubber bushings (10) from the stem at
the top of the shock absorber.
3. Remove the nut (5), cup washers (9), and rubber bushings (10) from lower mounting stem.
4. Compress the shock absorber to remove it.
SHOCK ABSORBER INSTALLATION
1. To install, reverse the removal procedure.

2. On the upper and lower shock absorber mounting stems, tighten the nuts until the rubber bushing expands
to the size of the cup washer.

9 Shock Absorbers REAR SUSPENSION
A
B
17
17
15
2
11
4
3
15
4
7
4
3 1
12 15
16 9
4
14 10
8 3
9 4
A. Brake Cable Hanger Mounting – Gasoline Vehicle Only B. Brake Cable Hanger Mounting – Electric Vehicle Only
1308
Figure 9-1 Rear Suspension Assembly and Mounting

REAR SUSPENSION Leaf Springs 9
LEAF SPRINGS
LEAF SPRING REMOVAL
2. Loosen, but do not remove, lug nuts on tire and wheel assembly on the side from which the spring is to be
removed. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position
jack stands under the frame crossmember between the spring mount and the side stringer, just forward of each
rear wheel. Lower the vehicle to let the jack stands support the vehicle (Figure 9-2, Page 9-4). See following
WARNING.
WARNING
3. Place a floor jack under the transaxle differential casing to support (but not lift) the drivetrain. Raise it just enough
to relieve tension on the shock absorbers without compressing them.
4. Remove the tire and wheel assembly on the side from which the spring is to be removed.
5. Remove the bow-tie pin (1) and the clevis pin (2) at the brake lever and brake cable connection and pull the
clevis (4) away from the lever (Figure 9-3, Page 9-4). Remove the retaining clip (3) and pull the brake cable
from the shock mount bracket (5).
6. Remove the nut (5), cup washers (9), and rubber bushings (10) from the lower mounting stem of the shock
absorber (Figure 9-1, Page 9-2).
7. Remove the nuts (14) and the U-bolt (11) securing the spring to the transaxle. Remove the shock mount bracket
(16) and the U-bolt.
8. Remove the nut (2) and bolt (15) attaching the rear spring to the shackle (1).
9. Remove the nut (2) and bolt (15) attaching the front of the spring to the vehicle frame and remove the spring.
10. Inspect the bushings (4) and spacers (3) in the spring eyes and replace them if they are worn or damaged.

9 Leaf Springs REAR SUSPENSION
1
3
5
2600-30000-10369 1400-18100-10243
Figure 9-2 Support Vehicle on Jack Stands Figure 9-3 Disconnect Brake Cable
LEAF SPRING INSTALLATION
1. To install the springs, reverse the removal procedure. See following CAUTION.
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.
2. Tighten the nuts on the U-bolts to 25 ft-lb (34 N·m).

3. Tighten nylon lock nuts (2) on spring mounting bolts (15) to 15 ft-lb (20.3 N·m) (Figure 9-1, Page 9-2).

SECTION 10 – PERIODIC MAINTENANCE 10
GENERAL INFORMATION
To ensure trouble-free vehicle performance, it is very important to follow an established preventive maintenance
program. Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can
result from neglect. 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
Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new
vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to
ensure that it is in proper working condition before accepting delivery.
Use the following checklist as a guide to inspect the vehicle. This checklist should be used daily to ensure that the
vehicle is in proper working condition and in conjunction with the Performance Inspection on page 10-2 and the
Periodic Service Schedules on page 10-3. Any problems should be corrected by a Club Car distributor/dealer or a
trained technician.
• General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screws are tight.
On gasoline vehicles check all hose clamps for tight fit as well as the starter belt for tightness.
• Safety and information decals: Check to ensure that all safety and information decals are in place. See Safety
Decal and Feature Identification in the Owner’s Manual.
• Tires: Check for proper tire pressure. Visually inspect tires for wear, damage, and proper inflation on a daily basis.
See Vehicle Specifications on page 2-1.
• Battery(ies): Check electrolyte to ensure that it is at its proper level (Figure 12-34, Page 12-35) or (Figure 21-6,
Page 21-17). Check battery posts. Wires should be tight and free of corrosion. On electric vehicles, charge
batteries fully before first use of vehicle.
• Charger cord, plug, and receptacle (electric vehicles): Visually inspect for cracks, loose connections, and
frayed wiring.
• Engine (gasoline vehicles): Check for proper engine oil level. See Engine Oil – Gasoline Vehicles on page 10-8.
• Fuel (gasoline vehicles): Check fuel level. See Fueling Instructions – Gasoline Vehicles on page 10-11.
Check fuel tank, lines, cap, pump, fuel filters, and carburetor for fuel leakage.
• Exhaust system (gasoline vehicles): Check for leaks.
• Performance Inspection: Inspect as instructed. See Performance Inspection on page 10-2.
WARNING
• Be sure the plastic has been removed from the seat bottom before operating the vehicle. Failure to do
so may result in a fire, property damage, personal injury, or death.

10 Pre-Operation and Daily Safety Checklist PERIODIC MAINTENANCE
PERFORMANCE INSPECTION
After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions,
take the vehicle for a test drive.
Use the following checklist, in conjunction with the Daily Pre-Operation and Safety Checklist, as a guide to inspect the
vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a
trained technician.
All Vehicles
• Forward/Reverse control: Check for proper operation. See Controls and Indicators in the Owner’s Manual.
• Brakes: Be sure the brakes function properly. When brake pedal is fully pressed under moderate pressure, it
should not go more than halfway to the floor, and vehicle should come to a smooth, straight stop within 14 feet
(4.3 m). If the pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop within 14 feet
(4.3 m), have the brake system checked and adjusted as required. Brake adjustment must be maintained so that
the brake pedal cannot be pressed to the floor under any circumstance.
• Park brake: When latched, the park brake should lock the wheels and hold the vehicle stationary (on an incline of
20% or less). It should release when either the accelerator or brake pedal is pressed.
• Reverse buzzer: The reverse buzzer should sound as a warning when the Forward/Reverse handle or switch is in
the REVERSE position.
• Steering: The vehicle should be easy to steer and should not have any play in the steering wheel.
• General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle’s ride and performance.
Have a Club Car distributor/dealer or a trained technician investigate anything unusual.
Electric Vehicles
• Accelerator: With the key switch in the ON position and the Forward/Reverse switch in the FORWARD position, as
the accelerator pedal is pressed, the motor should start and the vehicle should accelerate smoothly to full speed.
When the pedal is released it should return to the original position and the motor should rotate freely or go into motor
braking mode. See Pedal Up Motor Braking below. All Club Car vehicles operate at reduced speed in reverse.
• Walk-Away Braking: With the vehicle parked on level ground and the park brake disengaged, place the Tow/Run
switch in the RUN position and attempt to push the vehicle. Motor braking should engage and cause resistance to
rolling (moving at no more than 1 to 3 mph) (1.5 to 4.8 km/h) with the Forward/Reverse switch in any position.
When walk-away braking is engaged, the reverse buzzer should emit a distinct pattern of beeps. See following
WARNING.
WARNING
• Walk-away braking will not limit vehicle speed to 1 mph (1.6 km/h) on very steep grades. Do not
operate vehicle on slopes exceeding 20% grades.
• Pedal Up Motor Braking (adjustable on IQ System vehicles): Accelerate the vehicle to full speed and then
release the accelerator pedal. Motor braking should quickly and smoothly slow the vehicle to approximately 11 mph
(17.7 km/h). Motor braking will disengage when vehicle slows to 11 mph (17.7 km/h). This feature is adjustable for
IQ System vehicles only. Contact your local Club Car dealer/distributor to inquire about this adjustable feature.
• Pedal Down Motor Braking: Accelerate down an incline with the accelerator pedal pressed. When the vehicle
reaches maximum programmed speed, motor braking should engage and limit the vehicle to its maximum
programmed speed. On very steep grades, the vehicle may slightly exceed its maximum programmed speed,
requiring use of the brake pedal.
Gasoline Vehicles
• Accelerator: With the key switch in the ON position and the Forward/Reverse switch in the FORWARD position, as
the accelerator pedal is pressed, the engine should start and the vehicle should accelerate smoothly to full speed.
When the pedal is released it should return to the original position and the engine should stop. All Club Car
vehicles operate at reduced speed in reverse.

PERIODIC MAINTENANCE Periodic Service Schedules 10
• Governor: Check maximum speed of the vehicle. The vehicle should operate at 12-15 mph (19-24 km/h) on a
level surface.
PERIODIC SERVICE SCHEDULES
WARNING
• Service, repairs, and adjustments must be made per instructions in the maintenance and service
manual.
• If any problems are found during scheduled inspection or service, do not operate the vehicle until
repairs are made. Failure to make necessary repairs could result in fire, property damage, severe
NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance
procedure should be performed more often than recommended in the periodic service and lubrication
schedules.
Both the Periodic Service Schedule and Periodic Lubrication Schedule must be followed to keep vehicle in
optimum operating condition.

10 Periodic Service Schedules PERIODIC MAINTENANCE
PERIODIC SERVICE SCHEDULE – ELECTRIC VEHICLES

REGULAR INTERVAL SERVICE
See Pre-Operation and Daily Safety
Pre-Operation and Daily Safety Checklist
Checklist on page 10-1.
Daily service by owner
Performance Inspection See Performance Inspection on page 10-2.
Batteries Charge batteries (after each daily use only).
Check electrolyte level. Add water if

Weekly service by owner Batteries
necessary. See page 21-17.
Wash battery tops and clean terminals with

Batteries
baking soda/water solution.
Monthly service by owner or trained Check air pressure and adjust if necessary.
Tires
technician See Vehicle Specifications on page 2-1.
Wash battery compartment and underside of

General vehicle
vehicle.
Check brake shoes; replace if necessary.
Lubricate brake slides per Lubrication

Schedule.
Brake system Check brake cables for damage; replace if
necessary.
Check brake cable equalizer adjustment;

Semiannual service by trained technician adjust if necessary.
only (every 50 hours of operation or 100
rounds of golf) Electrical wiring and connections Check for tightness and damage.
Check condition of contacts and wire

Forward/Reverse switch
connections. Make sure connections are tight.
Check and adjust as required. See Steering

Front wheel alignment and camber
and Front Suspension section.
Check for loose hardware, cracks and other

Motor controller output regulator (MCOR)
damage.
Annual service by trained technician only

If batteries are not performing as expected,
(every 100 hours of operation or 200 rounds Batteries
see Batteries section.
of golf)

PERIODIC MAINTENANCE Periodic Service Schedules 10
PERIODIC SERVICE SCHEDULE – GASOLINE VEHICLES

REGULAR INTERVAL SERVICE
See Pre-Operation and Daily Safety
Pre-Operation and Daily Safety Checklist
Daily service by owner Checklist on page 10-1.
Performance Inspection See Performance Inspection on page 10-2.
Check engine oil level; change if necessary.

See Periodic Lubrication Schedules on
page 10-6.
Engine Check engine cooling air intake; clean if
necessary. Visually inspect the unshrouded
Monthly service by owner or trained area around engine exhaust for grass and
technician debris, and clean if necessary.
Check air pressure and adjust as necessary.

Tires
See Vehicle Specifications on page 2-1.
Wash engine compartment and underside of

General vehicle
vehicle. Do not wash engine when hot.
Clean terminals and wash dirt from casing;

Battery check electrolyte level. See Battery, Section
12, Page 12-33.
Check and adjust if necessary. See Steering

Front wheel alignment and camber
and Front Suspension section.
Semiannual service by trained technician Electrical wiring and connections Check for tightness and damage.
only (every 50 hours of operation or every
Check brake shoes; replace if necessary.
100 rounds for golf cars)
Lubricate brake slides.
Brake system Check brake cables for damage; replace if

necessary.
Check brake cable equalizer adjustment;

adjust if necessary.
Check for leaks around gaskets, fill plugs, etc.

Engine Inspect, clean and regap spark plug; replace
if necessary.
Annual service by trained technician only Check air filter element; clean or replace if
(every 100 hours of operation or every 200 necessary.
rounds for golf cars) Engine air intake system
Check clamps for tightness; check hose for
cracks.
Check for loose hardware and tighten if

General vehicle
necessary.
Two year service by trained technician only

(every 200 hours of operation or every 400 Fuel filters Replace. Dispose of used filters properly.
rounds for golf cars)

10 Periodic Lubrication Schedules PERIODIC MAINTENANCE
PERIODIC LUBRICATION SCHEDULES
PERIODIC LUBRICATION SCHEDULE – ELECTRIC VEHICLES

LUBRICATION
REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT
POINTS
Brake pedal shaft bearings 1 Dry Moly Lube (CC P/N 1012151)
Brake linkage and pivots 2 Dry Moly Lube (CC P/N 1012151)
Accelerator pivot rod supports Dry Moly Lube (CC P/N 1012151)
Semiannually by owner or
trained technician (every 50 Charger receptacle WD-40
hours of operation or 100
rounds of golf) Brake slides Dry Moly Lube (CC P/N 1012151)
Front suspension (5 fittings 2009

and early 2010 model year)
Chassis Lube – EP NLGI Grade 2
(2 fittings starting mid-2010 model
year)
Annually by trained technician

only (every 100 hours of 22 oz. (0.67 L) SAE 30 WT. API Class SE,
Check/fill transaxle to plug level 7
operation or 200 rounds of SF, or SG Oil (or higher)
golf)
2 6
5 4
3 6
1 2
7
6
5
6
6
15
Figure 10-1 Lubrication Points – Electric Vehicles

PERIODIC MAINTENANCE Periodic Lubrication Schedules 10
PERIODIC LUBRICATION SCHEDULE – GASOLINE VEHICLES

LUBRICATION
REGULAR INTERVAL SERVICE RECOMMENDED LUBRICANT
POINTS
Brake pedal shaft bearings 1 Dry Moly Lube (CC P/N 1012151)
Brake linkage and pivots 2 Dry Moly Lube (CC P/N 1012151)
Semiannually by owner or Accelerator push rod pivots, mounts,

Dry Moly Lube (CC P/N 1012151)
trained technician (every 50 and shifter cable pivots
hours of operation or every Front suspension (5 fittings 2009
100 rounds of golf) and early 2010 model year)
Chassis Lube (EP NLGI Grade 2)
(2 fittings starting mid-2010 model
year)
Brake slides Dry Moly Lube (CC P/N 1012151)
Annually by trained technician

only (every 100 hours of Check/fill unitized transaxle to plug 27 oz. (0.8 L) 80-90 WT. API Class GL-3 or
operation or every 200 rounds level 80-90 WT. AGMA Class EP Gear Lube
of golf)
First change 100 hours –

additional change every
200 hours of operation (or 32 oz. (0.95 L) without filter; 38 oz. (1.12
Change engine oil and oil filter 7
every 400 rounds of golf), or L) with filter
annually, whichever comes
first.
2 4
5
3 4
1 2
3
3
3
1
3
7
6
4
5
4 4
16
Figure 10-2 Lubrication Points – Gasoline Vehicles

10 Engine Oil – Gasoline Vehicles PERIODIC MAINTENANCE
ENGINE OIL – GASOLINE VEHICLES
Even though the low oil warning light on the dash should illuminate if oil level becomes low, engine oil level should be
checked monthly. Vehicle should be on a level surface when checking oil. Do not overfill with oil.
ENGINE OIL LEVEL CHECK
1. Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (1) (Figure 10-3). See following
CAUTION.
CAUTION
• Do not remove dipstick while engine is running.
2. Check oil by fully inserting the dipstick into the oil filler tube (2) and immediately removing it.
3. If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low
and full levels (safe level) (3).
4. Insert the dipstick into the oil filler tube. See following NOTE.
NOTE: Properly recycle or dispose of used oil in accordance with local, state, and federal regulations.
1. Full level 2. Safe level 3. Low level
23
Figure 10-3 Engine Oil Level Check
ENGINE OIL AND FILTER CHANGE
Engine oil and oil filter should be changed after the first 100 hours of operation. After that, they should be changed
every 200 hours of operation or annually, whichever comes first.
1. Turn the key switch to the OFF position, then remove the key. Place the Forward/Reverse handle in the neutral
POSITION. Chock the front wheels.
2. Access the engine compartment.
3. Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles on page 1-3.
4. Position a pan designed for oil changes under the front drain plug (Figure 10-4).

PERIODIC MAINTENANCE Engine Oil – Gasoline Vehicles 10
1. Drain pan 2. Drain plug 3. Oil filter
25
Figure 10-4 Engine Oil Drain Plug and Pan
5. Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine
oil to drain into the pan. See following WARNING.
WARNING
• Do not attempt to change engine oil when the engine is hot or even warm. Engine oil can cause
skin burns.
• Wear safety glasses or approved eye protection when servicing the vehicle. Wear rubber gloves when
handling oil drain plug, oil filter, and oil drain pan.
6. Clean the oil drain plug threads with solvent to remove oil and oil residue. Make sure that the compression
washer remains on the drain plug.
7. Use a 14 mm socket or wrench and replace the front oil drain plug, turning it clockwise, and tighten to 18 ft-lb
(24.4 N·m).
8. Relocate the oil drain pan to a position under the engine oil filter (Figure 10-4).
9. Remove the engine oil filter (1), turning it counterclockwise, allowing the residual oil in the filter port and filter
to drain into the oil drain pan (2) (Figure 10-5). See following NOTE.
NOTE: An oil drip guard (3) can be used to prevent excess oil from dripping into the engine base plate. Use an empty
quart (one liter) container and cut the bottom off at an angle, then slide the open area of the container up and
under the oil filter prior to removing. Position the port of the plastic container so oil will be directed into the oil
pan. Or, make a drip guard by folding a piece of cardboard, thin metal, or plastic under the oil filter forming a
channel to direct the filter port oil into the drain pan.
Dispose of used oil according to the environmental laws and regulations for your area.

10 Spark Plugs PERIODIC MAINTENANCE
26
Figure 10-5 Remove Engine Oil Filter
10. Use a clean rag and wipe the oil filter mounting bracket surface clean where the oil filter gasket seats.
11. Coat new oil filter gasket with clean engine oil and install the oil filter onto the engine oil filter port (Figure 10-6).
NOTE: Use only Club Car oil filters (CC P/N 1016467) designed for this engine.
12. Hand tighten 2/3 to 3/4 turn after filter gasket contacts mounting surface.
13. Remove the dipstick and add engine oil into the dipstick port. Use a funnel or pour spout to direct the oil into the
dipstick port. With filter change, the engine requires 38 ounces (1.12 liters) of oil per change. Refer to oil viscosity
guidelines for selection of oil grade (Figure 10-7). Replace the dipstick.
SAE 40
SAE 30
SAE 10W-30/ SAE 10W-40
SAE 5 W-30
27 213
Figure 10-6 Coat Oil Filter Rubber Seal Figure 10-7 Oil Viscosity Chart
14. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles on page 1-3.
15. With the Forward/Reverse handle in the NEUTRAL position, run engine for 3 minutes and check for leaks.
Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks. If filter leaks, tighten
additional 1/4 turn and retest. If oil drain plug leaks, re-torque and retest.
16. Remove the dipstick and check the engine oil as a final step. Replace the dipstick.
SPARK PLUGS
See Spark Plug, Section 13, Page 13-1.

PERIODIC MAINTENANCE Gearcase Lubrication 10
GEARCASE LUBRICATION
NOTE: Dispose of used oil according to the environmental laws and regulations for your area.
See Unitized Transaxle Service on page 16-2 and Lubrication on page 16-3.
AIR FILTER REPLACEMENT
See Air Filter Replacement, Section 10, Page 10-11.
FUELING INSTRUCTIONS – GASOLINE VEHICLES
DANGER
• Turn the key switch to the OFF position before fueling.
• Do not pour fuel into the fuel tank when the engine is hot or while it is running.
• To avoid electric arc caused by static electricity, the fuel storage/pumping device must be grounded. If
the pump is not grounded, the vehicle must be grounded to the pump before and during the fueling
operation.
• If the vehicle has an all-weather enclosure installed, be sure the fuel tank is properly vented as
shown (Figure 10-8).
• To avoid the possibility of fire, clean up any spilled fuel before operating the vehicle.
CAUTION
• To allow for expansion, do not fill higher than 2.54 cm (one inch) from the top of the fuel tank. Avoid
spilling fuel.
NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles to be
stored for extended periods should be prepared for storage as instructed. See Preparing the Gasoline
Vehicle for Extended Storage on page 3-5.
1. Turn the key switch to the OFF position.

2. Lift and remove seat bottom.
3. The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with fresh unleaded
gasoline only. See preceding CAUTION.
4. Replace fuel cap on tank. Ensure cap is tightened securely.
5. Replace seat bottom.

10 Battery PERIODIC MAINTENANCE
1
2
24
Figure 10-8 Fuel Tank
BATTERY
Gasoline Vehicles: See Battery, Section 12, Page 12-33.
Electric Vehicles: See Batteries, Section 21, Page 21-1.

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM:
FE290 PEDAL-START GAS VEHICLE 11
DANGER
WARNING
GENERAL INFORMATION
This section contains the information required to correctly troubleshoot the vehicle. A troubleshooting guide is provided
for general troubleshooting.
In addition to troubleshooting, this section contains general information on the electrical system and the circuits
of the electrical system.
TROUBLESHOOTING GUIDE
The following troubleshooting guide will be helpful in identifying operating difficulties should they occur. The guide
includes the symptom, probable cause(s) and suggested checks. The procedures used in making these checks can be
found in the referenced sections of the maintenance and service manual.
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Spark plug is partially fouled or in poor
See Section 13 – Engine.
condition
Spark plug wire is damaged or loose See Section 13 – Engine.
Loose wire connection at ignition coil or RPM Test Procedures 13 – Ignition Spark, 14 – RPM
limiter Limiter, and 15 – Ignition Coil
Test Procedures 13 – Ignition Spark, 14 – RPM

Engine does not start easily. Intermittent ignition coil failure
Limiter, and 15 – Ignition Coil
Low cylinder compression See Section 13 – Engine.
Water or dirt in the fuel system and/or

See Section 14 – Fuel System.
carburetor; dirty or clogged fuel filter
Carburetor improperly adjusted See Section 14 – Fuel System.
Starter/generator belt is slipping Belt Tension Adjustment on page 12-12

TROUBLESHOOTING AND ELECTRICAL SYSTEM:
11 Troubleshooting Guide FE290 PEDAL-START GAS VEHICLE
Spark plug is fouled or in poor condition See Section 13 – Engine.
Spark plug wire is damaged or loose See Section 13 – Engine.

Intermittent ignition coil failure
Engine starts but does not run smoothly.
Water or dirt in the fuel system and/or
carburetor; dirty or clogged fuel filter
Fuel pump malfunction; fuel pressure to

carburetor too low
Fuel tank is empty See Section 14 – Fuel System.
Fuel line or filters clogged See Section 14 – Fuel System.
Fouled spark plug See Section 13 – Engine.
Spark plug wire damaged or loose See Section 13 – Engine.
Loose wire connection at ignition coil or RPM Test Procedures 13 – Ignition Spark, 14 – RPM
limiter Limiter, and 15 – Ignition Coil
Engine turns but fails to start. Test Procedures 13 – Ignition Spark, 14 – RPM
Ignition coil or RPM limiter failed
Engine flooded with fuel as result of excess See Owner’s Manual, Controls and Indicators.
choking See Choke.
Test Procedures 16 – Kill Limit Switch, 17

Kill circuit grounded – Key Switch (Engine Kill Circuit), and 18 –
Engine Kill Wire
Fuel pump malfunction or failure See Section 14 – Fuel System.
Fan screen is partially blocked or plugged See Section 13 – Engine.
Engine overheats. Governor is improperly adjusted See Section 14 – Fuel System.
Carburetor is too lean; check main jet size See Section 14 – Fuel System.
Excessive carbon deposits on piston head or

See Section 13 – Engine.
in combustion chamber
Engine pre-ignites.
Spark plug heat range is incorrect See Section 13 – Engine.
Unsuitable or contaminated fuel See Section 14 – Fuel System.
Exhaust valve is restricted with carbon deposit See Section 13 – Engine.
Muffler or exhaust pipe restricted with carbon See Section 15 – Exhaust System: Gasoline
or other substance Vehicles.

Ignition coil failed
Loss of engine power.
Air filter is dirty or clogged See Section 14 – Fuel System.
Governor is improperly adjusted See Section 14 – Fuel System.
Throttle linkage out of adjustment See Section 14 – Fuel System.
Low cylinder compression See Section 13 – Engine.

FE290 PEDAL-START GAS VEHICLE Troubleshooting Guide 11
Spark plug failed See Section 13 – Engine.
Restricted fuel flow See Section 14 – Fuel System.
See Section 17 – Torque Converter: Gasoline

Torque converter is not backshifting properly
Vehicle.
Incorrect plug See Section 13 – Engine.
Spark plug wire is damaged See Section 13 – Engine.
Unsuitable fuel, or incorrect (rich) fuel mixture See Section 14 – Fuel System.
Spark plug fouls repeatedly. Test Procedures 13 – Ignition Spark, 14 – RPM

Ignition coil failed
Check intake system for leaks.

Dirt entering combustion chamber
Rings are heavily worn, low cylinder pressure See Section 13 – Engine.
Inlet valve or seat is leaking, dirty, worn, or

damaged
Carburetor floods. Float is damaged and filled with fuel See Section 14 – Fuel System.
Float needle valve not functioning properly See Section 14 – Fuel System.
Carburetor vent is clogged See Section 14 – Fuel System.
Neutral lockout cam is in the wrong position Neutral Lockout Cam on page 12-20
Fuse is blown Test Procedure 2 – Fuse
Battery is dead Test Procedure 1 – Battery
Test Procedure 4 – Key Switch (Starter Circuit)

Starter control circuit is not operating
on page 11-13
Test Procedure 8 – Starter/Generator (Starter

Starter/generator failed
Function)
Starter solenoid failed Test Procedure 6 – Solenoid

Starter fails to operate.
Test Procedure 5 – Accelerator Pedal Limit
Accelerator pedal limit switch failed
Switch
Key switch failed Test Procedure 4 – Key Switch (Starter Circuit)
Test Procedure 7 – Neutral Lockout Limit

Neutral lockout limit switch failed
Switch

Loose or broken wire in starter/generator
Test Procedure8 – Starter/Generator (Starter
circuit
Function)
Cylinder and/or crankcase flooded with fuel See Section 14 – Fuel System.

11 Troubleshooting Guide FE290 PEDAL-START GAS VEHICLE
Loose or broken wire in the starter/ generator Test Procedure 10 – Starter/Generator
circuit (Generator Function)
Test Procedure 10 – Starter/Generator

Generator field coil is shorted
(Generator Function)
Starter/generator does not charge battery. Starter/Generator (Model 114–01–4005B) on

Brushes are worn or commutator is dirty
page 12-1
Starter/generator belt is loose or slipping Belt Tension Adjustment on page 12-12
Voltage regulator failed Test Procedure 11 – Voltage Regulator
Battery failed Test Procedure 1 – Battery
Transmission shifter linkage is binding or is

See Section 16 – Unitized Transaxle.
out of adjustment
Idle RPM setting is set too high See Section 14 – Fuel System.
Transmission does not engage or disengage Insufficient (low) level of lubricant or wrong
smoothly. type of lubricant in transmission
Internal gears are damaged or worn See Section 16 – Unitized Transaxle.
Synchronizer rings are worn, damaged or

jammed
Engine mounting nuts or bolts are loose See Section 13 – Engine.
Snubber on frame is worn or damaged See Section 13 – Engine.
See Section 15 – Exhaust System: Gasoline

Misaligned muffler mounting clamp
Vehicles.

Damaged drive belt or starter belt
Vehicle.
Excessive vehicle vibration. See Section 17 – Torque Converter: Gasoline
Damaged drive clutch
Vehicle.

Damaged driven clutch
Vehicle.
Starter/Generator (Model 114–01–4005B) on

Damaged starter/generator pulley
page 12-1
RPM setting is incorrect Engine RPM Adjustment on page 14-11

Drive belt is worn, cracked, glazed, or frayed
Vehicle.

Drive clutch malfunction
Torque converter does not shift smoothly. Vehicle.

Driven clutch malfunction
Vehicle.
Governor is sticking See Section 16 – Unitized Transaxle.

FE290 PEDAL-START GAS VEHICLE Troubleshooting Guide 11
Kill circuit wire is disconnected from the
Test Procedure 12 – Disconnected Kill Wire
ignition coil
Accelerator pedal linkage out of adjustment See Section 5 – Accelerator and Brake Pedal
causing engine kill limit switch not to activate Group.

Engine won’t stop running. Key switch failure Test Procedure 17 – Key Switch (Engine Kill
Circuit)
Carburetor is too lean; check main and pilot

jet sizes
Carburetor throttle stop screw out of

adjustment

11 Wiring Diagram – Gasoline Vehicle FE290 PEDAL-START GAS VEHICLE
WIRING DIAGRAM – GASOLINE VEHICLE
CENTER DASH
PANEL ASSEMBLY
OIL LIGHT OIL

18_YEL(W08) 18_YEL(W14)
SENDING
UNIT
COM
18_BLK(W10)
1
NO
NC
18_GRN(W11)
18_WHT(W03)
REVERSE FORWARD/REVERSE
BUZZER LIMIT SWITCHES
COM
2
POS (+)
NEG (-)
NO
18_RED/WHT(W05)
16_BLU(W09)
NO COM
NC 1
16_BLU(W09)
18_YEL(W01)
16_ORG(W24)
18_WHT/BLK(W06)
18_BLK(W21)
18_BLK(W22)
M+
COM
NO 2
KEY 1 2
SWITCH
TO ENGINE KILL HOOK UP
M- 16_BLK(W19)
18_WHT/BLK(W04)
FUSE BLOCK
10_RED(W23)
18_BLK(W20)
16_ORG(W02)
16_RED(W07)
WD1019173Y4-L
Figure 11-1 Wiring Diagram for Pedal-Start Gasoline Vehicle

FE290 PEDAL-START GAS VEHICLE Wiring Diagram – Gasoline Vehicle 11
6_BLK(W26)
10_NON INSUL(W16) BARE

ENGINE
BATTERY
6_RED(W25)
16_YEL(W13)
6_WHT(W12)
DF F2
6_GRN HIGH TEMP(W27)

16_BLU(W09)
A1 F1
A2
STARTER
18_RED(W17)
SOLENOID GENERATOR
16_ORG(W24)
VOLTAGE REGULATOR 5
6_BLK(W15)
18_YEL(W18)
4
16_BLK(W19)
10_RED(W23) 3
ELECTRICAL
COMPONENT BOX
WD1019173Y4-R
Figure 11-2 Wiring Diagram for Pedal-Start Gasoline Vehicle

11 Electrical System FE290 PEDAL-START GAS VEHICLE
ELECTRICAL SYSTEM
The electrical system on the gasoline vehicle is 12 volts DC with negative (–) ground to frame, and consists of the
following circuits that are easily identified:
• Starter Circuit
• Generator Circuit
• Engine Ignition Circuit
• Engine Kill Circuit
• Reverse Buzzer Circuit
• Low Oil Warning Light Circuit
• Neutral Lockout Circuit
• Fuel Gauge and Sending Unit Circuit
• Hour Meter Circuit
• Lighting Circuit
Recognizing and understanding the function of each of these circuits will help to quickly isolate the source of an
electrical problem. Use the appropriate test procedure to correct the electrical problem. See Test Procedures on
page 11-8.
For a complete wiring diagram, see page 11-6.
TEST PROCEDURES
Index of Test Procedures
1 – Battery
2 – Fuse
3 – Ground Cables
4 – Key Switch (Starter Circuit)
5 – Accelerator Pedal Limit Switch
6 – Solenoid
7 – Neutral Lockout Limit Switch
8 – Starter/Generator (Starter Function)
9 – Wire Continuity
10 – Starter/Generator (Generator Function)
11 – Voltage Regulator
12 – Disconnected Kill Wire
13 – Ignition Spark
14 – RPM Limiter
15 – Ignition Coil
16 – Kill Limit Switch
17 – Key Switch (Engine Kill Circuit)
18 – Engine Kill Wire
19 – Reverse Buzzer Limit Switch
20 – Reverse Buzzer

FE290 PEDAL-START GAS VEHICLE Test Procedures 11
21 – Low Oil Warning Light
22 – Oil Level Sensor
23 – Neutral Lockout Cam
24 – Battery Test (Under Load)
25 – Fuel Level Sending Unit
26 – Fuel Gauge
27 – Hour Meter
28 – Light Switch
29 – Voltage Limiter
30 – Voltage at Headlight Socket
TEST PROCEDURE 1 – Battery

DANGER
• Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near
a battery.
Antidotes:

NOTE: The battery must be properly maintained and fully charged in order to perform the following test procedures.
Battery maintenance procedures, including watering information and allowable mineral content, can be found
in section See Section 12 – Electrical Components: FE290 Pedal-Start Gas Vehicle. of this manual.
See Battery on page 12-33.
1. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE
position. Chock the wheels.
2. Check for loose or corroded battery terminal connections. Remove the negative (–) cable first and clean, tighten,
and replace connections as necessary.
Hydrometer Test
A hydrometer (CC P/N 1011478) measures the specific gravity. The greater the specific gravity, the greater the state of
charge of the battery. A fully charged battery should read between 1.250 and 1.280 at 80 °F (27 °C). Never add acid
to the battery to obtain a higher specific gravity (Figure 11-3, Page 11-10).

11 Test Procedures FE290 PEDAL-START GAS VEHICLE
CAUTION
• Do not allow battery acid from battery caps or hydrometer to drip onto the body. Battery acid will
cause permanent damage. Wash off immediately.
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 performing the
hydrometer test (Figure 11-4, Page 11-10).
2. Remove the vent cap.
3. Using a battery thermometer (CC P/N 1011767), record the electrolyte temperature of a center cell.
4. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing electrolyte
up into the glass tube of the hydrometer.
5. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not
strike the bottom of the rubber bulb. Remove the hydrometer from the cell and release the pressure from the bulb.
6. Hold the hydrometer vertically, ensuring that the float is not contacting the sides of the glass tube. Hold the
hydrometer at eye level and read the scale at the level of electrolyte (Figure 11-3, Page 11-10).
7. Record the reading.
8. Return the electrolyte to the cell from which it was taken. Replace vent cap.
9. Repeat steps 2 through 8 on all cells.
2
1
3
20
40
1.250
60
80
1.280
13 00
1. Level Indicator 2. Cap 3. Plates

Electrolyte level at least 1/2 inch (13 MM) above plates or to level
View at eye level. indicator.
717 22
Figure 11-3 Hydrometer Test Figure 11-4 Battery Electrolyte Level
Hydrometer Calibration
Most hydrometers are calibrated to read correctly at 80 °F (27 °C). The readings obtained as described above must be
corrected for temperature. For each 10 °F (5.6 °C) above 80 °F (27 °C), add 0.004 to the reading. For each 10 °F
(5.6 °C) below 80 °F (27 °C), subtract 0.004 from the reading.
Interpreting the Results of the Hydrometer Test
The approximate state of charge can be determined by referring to the following table:

SPECIFIC GRAVITY (TEMPERATURE CORRECTED) APPROXIMATE STATE OF CHARGE

1.250-1.280 100%
1.220-1.240 75%
1.190-1.210 50%
1.160-1.180 25%
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. When the variations between cells reach 0.050 or more, the battery should be replaced.
Voltage Test
1. Take a voltage reading with a multimeter set to 20 VDC by placing the red (+) probe on the positive (+) battery
post and the black (–) probe on the negative (–) battery post. If it shows less than 12.4 volts, or if the lowest
specific gravity reading from the Hydrometer Test is less than 1.225, recharge the battery. If battery voltage is
greater than 12.4 volts and specific gravity is greater than 1.225, the problem is not with the battery. If the battery
does not reach 12.4 volts, or if the specific gravity of a cell is still less than 1.225 after charging, replace the
battery. See following NOTE.
NOTE: A fully charged battery that is in good condition should have a specific gravity of at least 1.225 in all cells,
and the difference in the specific gravity of any two cells should be less than 50 points. Open circuit voltage
should be at least 12.4 volts.
Load Test
1. Connect a 160-ampere load tester to the battery posts.

2. Turn the switch on the load tester to the ON position.
3. Read the battery voltage after the load tester has been turned ON for 15 seconds. Compare the battery’s voltage
reading with the following table. Make sure you have the correct ambient temperature.
IF TEMPERATURE IS MINIMUM CRANKING VOLTAGE
70 °F (20 °C and above) 9.6 V
60 °F (16 °C) 9.5 V
50 °F (10 °C) 9.4 V
40 °F (4 °C) 9.3 V
30 °F (-1 °C) 9.1 V
20 °F (-7 °C) 8.9 V
10 °F (-12 °C) 8.7 V
0 °F (-18 °C) 8.5 V
4. If the battery is found to be good, or if the electrical problem continues after the battery has been replaced
with a good one, test the electrical circuits.
TEST PROCEDURE 2 – Fuse

The fuse (red 10-amp) is located in the electrical component box.
1. Disconnect battery. See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
2. Remove the cover from the electrical component box.
3. Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary.

4. Remove fuse to be tested from the fuse block. See Fuse Removal on page 12-16. The red 10-amp fuse
protects the solenoid for the starter (cranking) circuit. The 20-amp fuse at the yellow wire connection protects the
headlights and brake lights (if equipped). The fuse at the red/white wire connection protects the horn.
5. Connect the probes of a multimeter, set to 200 ohms, to the fuse terminals. The reading should be continuity. If
there is no continuity, determine and repair the cause of the fuse failure. Replace the fuse with a properly
rated new one.
6. Connect battery. See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
TEST PROCEDURE 3 – Ground Cables

1, Page 1-3.
2. Check the starter/generator ground cable.
2.1. Set the multimeter to 200 ohms. Place the red (+) probe on the (A2) terminal of the starter/generator and
place the black (–) probe on the vehicle frame (Figure 11-5, Page 11-12). The reading should be continuity.
If the reading is incorrect, clean and tighten cable connections. If the connections are good and the reading
is incorrect, repair or replace the cable.
3. Check the engine ground cable.
3.1. Place the red (+) probe of the multimeter on the ground cable terminal end located on the oil filler bracket
on the engine (Figure 11-6, Page 11-12). Place the black (–) probe on the vehicle frame. The reading
should be continuity. If the reading is incorrect, clean and tighten cable connections. If the connections are
good and the reading is incorrect, repair or replace the cable.
F2
00
1. Ground to Chassis 2. A2 Terminal 00
Place test probes at each end of ground cable.
Figure 11-5 Starter/Generator Ground Cable Test Figure 11-6 Engine Ground Cable Test
4. Check voltage regulator ground connection (at battery frame ground). Make sure it is clean and tight.
5. Check the battery ground cable.
5.1. A 6-gauge black cable connects the negative (–) battery post to the frame. The frame connection should
be clean and tight. Visual inspection of the connection on the frame is very difficult. The best check for
tightness is to pull on the black cable. If the cable moves at the connection end, disassemble the frame
connection and clean the bolt, ring terminal, and nut. Reinstall the frame connection.
5.2. Set the multimeter to 200 ohms. Place the red (+) probe on the unconnected end of the 6-gauge black
cable, and place the black (–) probe on the vehicle frame (Figure 11-7, Page 11-13). The reading should
be continuity. If the reading is incorrect, ensure that terminal connections are clean and tight. If the
connections are good and the reading is incorrect, repair or replace the cable.
6. Connect battery and spark plug wire(s). See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.

3
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1
2
1. 200 Ohm Setting

2. Disconnect the 6-gauge black wire from the battery. Place red
(+) probe on disconnected end of cable.
3. Place black (–) probe on frame.
Figure 11-7 Battery Ground Cable Test
TEST PROCEDURE 4 – Key Switch (Starter Circuit)

1, Page 1-3.
2. Remove the center dash assembly. See Key Switch Removal on page 12-13.
3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary.
4. Insert the key and turn the key to ON. Place the red (+) probe of the multimeter on the (2) terminal and the black
(–) probe on the (1) terminal of the key switch. The reading should be continuity. If the reading is incorrect,
replace the key switch (Figure 11-8, Page 11-13).
3
2
1
–M
WAVETEK
V OFF
5XL
V
4 2
+M
200
1000 500
200 7
20 200
2 2m
200 20
5
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
1
FUSED
750V
1. 200 Ohm Setting 2. Blue 3. Yellow 4. Black 5. Red 6. White

7. White/Black
1334
Figure 11-8 Key Switch Starter Circuit Test – For
Pedal-Start Vehicles

TEST PROCEDURE 5 – Accelerator Pedal Limit Switch

The accelerator pedal limit switch is the top switch located in the electrical component box. There is an 18-gauge
green wire and an 18-gauge orange wire connected to this limit switch.
1, Page 1-3.
2. Check for proper wiring and tight connections (Figure 11-1, Page 11-6).
3. Set the multimeter to 200 ohms. Place the red (+) probe on the common (COM) terminal (green wire) of the limit
switch and place the black (–) probe on the normally closed (NC) terminal (orange wire) of the limit switch.
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. If readings are incorrect, replace the switch.
TEST PROCEDURE 6 – Solenoid

1, Page 1-3.
2. Remove the electrical component box cover.
4. 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 to 16 ohms. If the reading is not within
limits, replace the solenoid.
5. Remove the 6-gauge white wire, the 18-gauge red wire, and 18-gauge white wire (if equipped) from the large
post of the solenoid. Do not allow the wires to touch the frame or other components of the vehicle (Figure
11-9, Page 11-14).
3 4
5
1. Cover 2. Electrical Component Box 3. 6 Ga. White Wire 4. 18

Ga. White Wire 5. 18 Ga. Red Wire 6. Solenoid
457
Figure 11-9 Solenoid Wire Removal
6. Set the multimeter to 200 ohms. Connect the red (+) probe to one of the large posts of the solenoid and connect
the black (–) probe to the other large post (Figure 11-10, Page 11-15).

8. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE
position. Turn the key switch to the ON position. With the accelerator in the UP position, the reading on the
multimeter should be no continuity. Press the accelerator pedal and listen for the solenoid click. There should be
continuity. If either reading is incorrect, replace the solenoid.
9. With the Forward/Reverse handle still in NEUTRAL and the neutral lockout switch in the MAINTENANCE
position, set the multimeter to 20 volts DC and place the red (+) probe on the large post that does not have wires
connected to it. Place the black (–) probe on the vehicle frame. Turn key switch to the ON position, press
accelerator pedal, and listen for solenoid click. The meter should read full battery voltage. If the reading is
incorrect, replace the solenoid (Figure 11-11, Page 11-15).
10. Disconnect the 6-gauge black wire from the negative (–) post of the battery before reconnecting the wires to
the solenoid.
WAVETEK 5XL
V V
WAVETEK 5XL
OFF
1000 500 V
V OFF
1000 500
200 200
200 200
20 200
20 200
2 2m
2 2m
200 20
m m 200 20
m m
200
2000
k m 200
2000
k m
200k
200 200k
20k
2k A
20k 200
2k A
V ! COM ! 200nA
V ! COM ! 200nA
MAX
1000 --- MAX
FUSED
750V 1000 ---
FUSED
750V
458 459
Figure 11-10 Solenoid Continuity Test Figure 11-11 Solenoid Ground Test
TEST PROCEDURE 7 – Neutral Lockout Limit Switch

This switch is located on the Forward/Reverse switch assembly. A black wire, a green wire, and a white wire
are connected to this limit switch.
1, Page 1-3.
2. Check for proper wiring and tight connections.
3. Set the multimeter to 200 ohms. Place the red (+) probe of the multimeter on the common (COM) terminal of
the limit switch. Place the black (–) probe on the normally open (NO) terminal of the switch. Without the lever
pressed, the reading should be no continuity. Press the lever, and the reading should be continuity. If either
reading is incorrect, replace the limit switch (Figure 11-12, Page 11-16).
4. Check to be sure the lobe on the cam is pressing the neutral lockout limit switch as the Forward/Reverse shifter is
being shifted. The limit switch should make an audible click as it is pressed. If it does not, check for wear on the
cam lobe and replace cam if necessary.

1 NC
NC
NO COM 2
NO COM
WAVETEK 5XL WAVETEK 5XL

V OFF V V OFF V
1000 500 1000 500
200 200 200 200
20 200 20 200
2 2m 2 2m
200 20 200 20
m m m m
200 200
2000 2000
m k m
k
200k 200k
20k 200 20k 200

2k A 2k A
V ! COM ! 200nA V ! COM ! 200nA
MAX MAX
1000 --- 1000 ---
FUSED FUSED
750V 750V
3 4
1. Lever Up 2. Lever Depressed 3. Tester light is OFF. Meter reads 1. 4. Tester light is ON. Meter reads approx. zero ohms.
460
Figure 11-12 Neutral Lockout Limit Switch Test
TEST PROCEDURE 8 – Starter/Generator (Starter Function)

1, Page 1-3.
2. Ensure that wires are connected correctly and are tight. If they are not, rewire or tighten as necessary.
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 finish to ensure a good
ground). While holding the black (–) probe against the housing, place the red (+) probe (one at a time) on the A1,
A2, F1, F2 and DF terminals respectively (Figure 11-13, Page 11-17). The readings should be no continuity. If
the readings are incorrect, the starter/generator will need to be removed from the vehicle and disassembled by a
qualified technician. See Starter/Generator Removal on page 12-1.
– An incorrect reading from the A1 or A2 terminal indicates three possible problems: 1) a grounded A1 or A2
terminal, 2) a grounded wire in the brush area, or 3) a grounded armature/commutator.
– If the F1 or F2 reading is incorrect, it indicates a possible grounded F1 or F2 terminal or a grounded field coil.
– If the DF reading is incorrect, it indicates a possible grounded DF terminal or a grounded field coil.
4. Disconnect the ground wire from the A2 terminal and the green wire from the A1 terminal on the starter/generator.
5. Using a multimeter set to 200 ohms, place the red (+) probe on the A1 terminal and the black (–) probe on the A2
terminal. The reading should be continuity. If the reading is incorrect, a possible open or poor contact in a brush
assembly and/or open armature windings may be the cause. The starter/generator will need to be removed from
the vehicle and disassembled by a qualified technician. See Starter/Generator Removal on page 12-1.
6. With the wires still disconnected, using a multimeter set on 200 ohms, place the red (+) probe on the F1 terminal
and the black (–) probe on the F2 terminal. The reading should be between approximately 0.1 and 0.3 ohms. If
the reading is incorrect, a possible open field coil or bad connections at terminals may be the cause. The
starter/generator will need to be removed from the vehicle and disassembled by a qualified technician. See
Starter/Generator Removal on page 12-1.
7. With the wires still disconnected, using a multimeter set to 200 ohms, place the red (+) probe on the DF terminal
and the black (–) probe on the F1 terminal. The reading should be between 4.5 and 5.5 ohms. If the reading is
incorrect, a possible grounded DF terminal and/or grounded field coil may be the cause. The starter/generator
will need to be removed from the vehicle and disassembled by a qualified technician. See Starter/Generator

F2 1
F2 DF
DF
A1
WAVETEK 5XL
A1
V OFF V
1000 500
20
200 200
200
F1 F1
2 2m
A2 A2
200 20
m m
200
2000
k m
200k
20k 200
A
2
2k
V ! COM ! 200nA
2
MAX
1000 ---
FUSED
750V
1. Yellow Wire 2. 200 Ohm Setting

1. Yellow Wire 2. Jumper Wire
461 462
Figure 11-13 Check Starter Terminal Continuity Figure 11-14 Jumper Wire Ground – DF to A2
TEST PROCEDURE 9 – Wire Continuity

1, Page 1-3.
2. To test a wire for continuity, disconnect either end from the electrical component it is attached to.
3. Set the multimeter to 200 ohms and place the red (+) probe on the terminal at one end of the wire. Place the
black (–) probe on the other terminal end of the wire. The reading should be continuity. If the reading is incorrect,
repair or replace the wire.
TEST PROCEDURE 10 – Starter/Generator (Generator Function)
NOTE: Keep the battery connected while performing this test procedure.
1. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch or cam in the
MAINTENANCE position. Chock the wheels.
3. Disconnect the yellow wire from the DF terminal on the starter/generator. Cover the connector on the yellow wire
to make sure the yellow wire will not short to ground. Then, using a jumper wire, ground the DF terminal to the
A2 terminal (Figure 11-14, Page 11-17).
4. Using a multimeter set to 20 volts DC, place the red (+) probe on the positive (+) post of the battery, and place the
black (–) probe on the negative (–) post. Start the engine and run it at full governed speed. The reading should
show the voltage rising on the meter. If the voltage rises above 15.3 volts DC, test the voltage regulator. See
Voltage Regulator on page 11-18. If the voltage does not rise, a tear-down inspection of the starter/generator
will be necessary. See Starter/Generator Removal on page 12-1.
5. Connect the yellow wire to the DF terminal on the starter/generator.

TEST PROCEDURE 11 – Voltage Regulator

3. Check the engine RPM setting to ensure that it is adjusted correctly. See Engine RPM Adjustment, Section
14, Page 14-11.
4. With the battery in good condition and fully charged, run the engine for several minutes to bring the voltage
regulator to operating temperature.
5. Turn the key switch to the OFF position, killing the engine. Using a multimeter set to 20 volts DC, place the red
(+) probe on the large post of the solenoid with the red wire from the voltage regulator attached. Place the black
(–) probe on the negative (–) battery post (Figure 11-15, Page 11-18). Turn the key switch to the ON position.
Press the accelerator to start the engine and run it at full governed speed. If the reading is between 14.7 and 15.3
volts, the regulator is good. If the reading is lower than 14.7 volts but rising steadily, check battery condition. If the
reading is lower than 14.7 volts and not rising, and the starter/generator is good; or if the reading is over 15.3
volts and continues to rise, replace voltage regulator. See Voltage Regulator Removal on page 12-12.
2
1
RED
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m
4
m
200
2000
k m
200k
20k 200
2k A
3
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. Voltage Regulator 2. Solenoid 3. Battery 4. 20 VDC Setting
463
Figure 11-15 Voltage Regulator Test

TEST PROCEDURE 12 – Disconnected Kill Wire
2. Disconnect the engine kill white/black wire at the bullet connector located next to the RPM limiter (Figure 11-17,
Page 11-19).
3. Start the engine in a well ventilated area.
– Turn the key switch to the ON position. Press the accelerator pedal to start the engine.
4. If the engine begins to run, test the engine kill circuit for a shorted wire or other failed components in the engine
kill circuit. See Key Switch (Engine Kill Circuit) on page 11-27. See following WARNING.
WARNING
• When the white/black engine kill wire is disconnected, the engine will not stop running after the
accelerator pedal is released. It will be necessary to pull and hold the choke handle until the engine
stops running.
5. If the engine does not run, proceed to Test Procedure 13 – Ignition Spark on page 11-19.
2 1
2
1. Ignition Gap Test Tool 2. Chassis

1. Disconnect White/Black Engine Kill Wire 2. RPM Limiter
464 465
Figure 11-16 Ignition Spark Test Figure 11-17 White/Black Engine Kill Wire
TEST PROCEDURE 13 – Ignition Spark


2. Remove the plug wire from the spark plug. Using an ignition spark gap test tool (Thexton 404® or equivalent),
check for correct spark (Figure 11-16, Page 11-19).
2.1. Adjust the tester probes to approximately 18,000 volts (18 Kv) setting (SE – Small Engine Setting on the
Thexton 404 tool). Connect the tester to the spark plug wire, and connect the alligator clip to a solid
engine ground.
2.2. Start the engine. There should be a strong blue spark between the probes of the spark gap tester. If
there is no spark, or if the spark is a faint yellow or red color, test components of the ignition circuit. See
Ignition Coil on page 11-21.
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. The gap should be set at 0.027 to 0.031 of an inch (0.69 to 0.79 mm). If the gap is correct,
replace the spark plug with a new part and test the engine for proper operation.
TEST PROCEDURE 14 – RPM Limiter

1, Page 1-3.
2. Disconnect both of the bullet terminals (Figure 11-18, Page 11-20).
3. Using a multimeter set to 200 ohms, place the red (+) probe on the brown ground wire and place the black (–)
probe on one of the black wire female bullet connectors. The reading should be no continuity. If the reading
is not correct, replace the RPM Limiter.
4. This test will find most bad RPM Limiters. Some of them may bench test okay but fail under a load due to heat
while operating. Another method of testing is to replace the RPM Limiter and then run the engine. If the engine
runs properly, keep the new RPM Limiter in the circuit.
00
00
3
00
4
1
2 3
1. Brown Wire 2. Black Wire 3. Female Bullet Terminal 4. White/Black Kill Circuit Wire 5. Ignition Coil Black Wire
466
Figure 11-18 RPM Limiter

TEST PROCEDURE 15 – Ignition Coil
The following test procedures will properly detect a coil that has failed in most cases; however, in rare cases, some
ignition coils can fail to operate at normal (warmer) operating temperatures. If the ignition coil has tested okay in
the vehicle and on the bench, but fails to operate reliably, replace the coil with a known good coil and operate the
engine for several minutes to ensure that the coil functions at normal operating temperature. If the new coil functions
properly, keep the new coil in the circuit.
Ignition Coil – In Vehicle Test
1, Page 1-3.
2. Using a multimeter set to 200 ohms, measure the primary coil resistance.
2.1. Disconnect both of the bullet terminals at the RPM limiter (Figure 11-18, Page 11-20). 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
11-19, Page 11-21).
2.2. If the resistance is not between 0.6 - 1.7 ohms, bench test the ignition coil.
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. 200 Ohm Setting
467
Figure 11-19 Primary Coil Resistance – In Vehicle Test

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. 20k Ohm Setting

468
Figure 11-20 Secondary Coil Test – In Vehicle Test
3. Using a multimeter set to 20k ohms, measure the resistance of the secondary coil and spark plug cap together.
3.1. Place the red (+) probe of the meter into the end of the spark plug cap that normally connects to the spark
plug and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-20,
Page 11-22).
3.2. If the resistance is between 12.0k - 14.0k ohms, the secondary coil and spark plug cap are within acceptable
limits; proceed to step 6 on page 12-25. If the resistance is not between 12.0k - 14.0k ohms, the spark plug
cap and secondary coil must be tested independently from each other.
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 11-21, Page 11-23).
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 11-22, Page 11-23).

2 1 3
CAP
469 470
Figure 11-21 Ignition Coil and Cap Figure 11-22 Spark Plug Cap Removal
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 11-23, Page 11-23). If the resistance is not between 4.5k - 6.0k ohms, the cap has
failed and must be replaced. Proceed to the next step with the spark plug cap still removed.
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
2
V ! COM ! 200nA
MAX
1000 ---
FUSED
1
750V
1. 20k Ohm Setting 2. Spark Plug Cap
471
Figure 11-23 Spark Plug Cap Test

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. 20k Ohm Setting

472
Figure 11-24 Secondary Coil Test Without Cap
5. Test the secondary coil separately from the spark plug cap.
5.1. Using a multimeter set to 20k ohms, place the red (+) probe of the meter into the end of the spark plug wire
and place the black (–) probe on a clean unpainted surface of the engine or frame (Figure 11-24, Page
11-24). If the resistance is between 6.0k - 11.0k ohms, the secondary coil is within acceptable limits. If the
resistance is not between 6.0k - 11.0k ohms, bench test the ignition coil.
6. If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges, but the coil
fails to function properly, proceed to the following bench test procedures.
Ignition Coil – Bench Test
1. Remove the coil from the engine. See Ignition Coil Removal on page 12-27.
2. Using a multimeter set to 200 ohms, measure the primary coil resistance.
2.1. Place the black (–) probe of the meter on the terminal on the ignition coil (1), and place the red (+) probe on
the core (2) (Figure 11-25, Page 11-25).

2 3
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
WAVETEK
V OFF
5XL
V
1 2
200
m
2m
20
m
1000 500 200

2000
k m
200 200
200k
20 200 20k 200
2k A
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
V ! COM ! 200nA
MAX
1000 ---
1
FUSED
750V
1. 20k Ohm Setting 2. Core 3. Spark Plug Cap

1. Ignition Coil Terminal 2. Core 3. 200 Ohm Setting
473 474
Figure 11-25 Primary Coil Resistance – Bench Test Figure 11-26 Secondary Coil and Cap Resistance – Bench
Test
2.2. If the resistance is not between 0.6 - 1.7 ohms, replace the ignition coil.
3. Using a multimeter set to 20k ohms, measure the resistance of the secondary coil and spark plug cap together.
3.1. Place the red (+) probe of the meter into the end of the spark plug cap (3) that normally connects to the
spark plug and place the black (–) probe on the core (2) (Figure 11-26, Page 11-25).

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. 20k Ohm Setting 2. Core 3. Spark Plug Wire
475
Figure 11-27 Secondary Coil Resistance – Bench Test
3.2. If the resistance is between 12.0k - 14.0k ohms, the secondary coil and spark plug cap are within acceptable
limits; proceed to step 6 on page 12-26. If the resistance is not between 12.0k - 14.0k ohms, the spark plug
cap and secondary coil must be tested independently from each other.
4. If not previously tested, 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 11-21, Page 11-23).
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 11-22, Page 11-23).
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 11-23, Page 11-23). If the resistance is not between 4.5k - 6.0k ohms, the cap has
failed and must be replaced. Proceed to the next step with the spark plug cap still removed.
5. Test the secondary coil separately from the spark plug cap.
5.1. Using a multimeter set to 20k ohms, place the red (+) probe of the meter into the end of the spark plug wire
(3) and place the black (–) probe on the core (2) (Figure 11-27, Page 11-26). If the resistance is between
6.0k - 11.0k ohms, the secondary coil is within acceptable limits. If the resistance is not between 6.0k -
11.0k ohms, the ignition coil has failed and must be replaced.
6. If the preceding tests indicate that the ignition coil resistance readings are within acceptable ranges, but the coil
fails to function properly, replace the ignition coil and cap.

TEST PROCEDURE 16 – Kill Limit Switch
The kill limit switch is located inside the electrical component box. The accelerator kill switch is the lower of the two
limit switches and has a white/black wire and black wire connected to it.
1, Page 1-3.
2. Check for proper wiring and tight connections.
3. Disconnect the wires from the limit switch and test the limit switch for continuity.
– Place the red (+) probe of the multimeter on the common (COM) terminal (white/black wire) of the limit switch.
Place the black (–) probe on the normally open (NO) terminal (black wire) of the limit switch. Without the lever
pressed, the reading should be no continuity. Press the lever, and the reading should be continuity. If either
reading is incorrect, replace the limit switch (Figure 11-28, Page 11-27).
4. Connect wires to limit switch and check for tight connections.
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200 NO
2 2m
200
m
20
m
200
COM
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. 200 Ohm Setting 2. Lever Up
476
Figure 11-28 Kill Limit Switch Test
TEST PROCEDURE 17 – Key Switch (Engine Kill Circuit)

1, Page 1-3.
3. Disconnect wires from the (+M) and (–M) terminals of the key switch.
4. Place the red (+) probe on the (+M) terminal and the black (–) probe on the (–M) terminal. With the key switch
OFF, the reading should be continuity. With the key switch ON, the reading should be no continuity. If either
reading is incorrect, replace the key switch (Figure 11-29, Page 11-28).
5. Connect wires to the key switch. Make sure wires are connected correctly and are tight. If they are not, rewire
or tighten as necessary.
6. Install dash panel in reverse order of removal.

1
WAVETEK 5XL –M
V
1000
OFF
500
V 2
200 200 +M
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1. 200 Ohm Setting
1337
Figure 11-29 Key Switch Test – Engine Kill Circuit
TEST PROCEDURE 18 – Engine Kill Wire

1, Page 1-3.
2. Disconnect white/black wire bullet connector located at the engine RPM limiter (Figure 11-17, Page 11-19).
3. Connect red (+) probe of multimeter to the male bullet terminal on the white/black wire and connect the black
(–) probe to the vehicle frame.
4. Turn the key switch ON, place the Forward/Reverse handle in FORWARD, and press the accelerator pedal.
There should be no continuity. If there is continuity, check for worn insulation on the white/black wire that may be
allowing the engine kill wire to ground to the frame.
TEST PROCEDURE 19 – Reverse Buzzer Limit Switch

The reverse buzzer limit switch is located on the Forward/Reverse shifter; red/white and orange wires are connected to
it.
2. Move the Forward/Reverse handle to REVERSE and listen for an audible click from the limit switch. If there is no
click, check the switch for proper alignment and switch arm movement.
3. If the switch is being activated but the buzzer does not function, place the red (+) probe of the multimeter on one
terminal and the black (–) probe on the other terminal of the limit switch. Without the lever pressed, the reading
should be no continuity. Press the lever and the reading should be continuity. If either reading is incorrect, replace
limit switch. See Reverse Buzzer Limit Switch Removal on page 12-22.

TEST PROCEDURE 20 – Reverse Buzzer
The reverse buzzer is mounted to the center dash assembly under the front body.
1, Page 1-3.
2. To test the front reverse buzzer, remove center dash panel. See Key Switch Removal on page 12-13.
3. Check for proper wiring and tight connections. Using a multimeter, individually check for continuity through each
wire that connects to the reverse buzzer. See Wiring Diagram – Gasoline Vehicle on page 11-6. If the buzzer
will not function when properly wired, replace the buzzer.
TEST PROCEDURE 21 – Low Oil Warning Light
1, Page 1-3.
3. Ensure that the wires are connected correctly and are tight. If they are not, rewire or tighten as necessary. See
Wiring Diagram – Gasoline Vehicle on page 11-6.
4. Disconnect the yellow wire (to the oil level sensor) from the terminal on the low oil warning light. Using an alligator
clip jumper wire, connect the low oil warning light terminal to the vehicle frame. Connect the red (+) battery cable
to the positive (+) battery post, then attach the black (–) cable to the negative (–) battery post.
5. Turn the key switch ON. The low oil warning light should illuminate. If it does not, check continuity of the yellow
wire that connects the key switch to the low oil warning light. If there is no continuity in the wire, replace the wire.
Then test the key switch. See Key Switch (Starter Circuit) on page 11-13. If the yellow wire and the key
switch test okay, then replace the low oil warning light.
TEST PROCEDURE 22 – Oil Level Sensor

1. Place the Forward/Reverse handle in the NEUTRAL position, the neutral lockout switch or cam in the
MAINTENANCE position, turn the key switch to the OFF position, disconnect the spark plug wire, and chock
the wheels.
2. Ensure that the low oil warning light and all connecting wires are functioning correctly. See Low Oil Warning
Light on page 11-29.
3. Drain the engine oil into an approved container and properly dispose of used oil.
4. Turn the key switch ON, closing the circuit. The low oil warning light should illuminate. If the low oil warning light
does not illuminate, the oil level sensor needs to be replaced. See Oil Level Sensor Removal on page 13-5.
5. Install a new oil filter and fill the engine with new oil before returning the vehicle to service. See Engine Oil –
Gasoline Vehicles on page 10-8.

TEST PROCEDURE 23 – Neutral Lockout Cam

Check to be sure the lobes on the cam are pressing the neutral lockout limit switch lever as the Forward/Reverse
handle is being shifted. The limit switch should make an audible click as it is pressed. If it does not, check for wear
on the cam lobes. Be sure the cam has snapped fully back into place. If the cam lobes still do not activate the limit
switch, replace the cam.
TEST PROCEDURE 24 – Battery Test (Under Load)

2. Set a multimeter to 20 volts DC and place the red (+) probe on the F2 (white wire) terminal on the starter/generator.
Place the black (–) probe on the negative (–) battery post.
3. Turn the key switch to the ON position, leave the Forward/Reverse shifter in the NEUTRAL position and press the
accelerator pedal (with the accelerator pedal pressed, the battery is under load).
3.1. If the voltage reading is over 9.6 volts, with an electrolyte temperature of 70 °F (21 °C), check the
starter/generator. See following NOTE.
NOTE: The voltage reading listed is for electrolyte at 70 °F (21 °C). At lower electrolyte temperatures the voltage
reading will be lower.
4. If the reading is below 9.6 volts, with an electrolyte temperature of 70 °F (21 °C), check the battery. See
Battery on page 11-9.
4.1. If the reading is zero, there may be no continuity across the large posts of the solenoid. See Solenoid
on page 11-14.
5. If all of the test results are good and the voltage reading is zero, there may be a broken or damaged 6-gauge
white wire from the solenoid to the starter/generator. See Starter/Generator (Starter Function) on page 11-16.
TEST PROCEDURE 25 – Fuel Level Sending Unit

WARNING
• To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place while
performing this test procedure.
2. Disconnect the orange wire from the center post of the fuel level sending unit.
3. With a multimeter set to 2k ohms, place the red (+) probe of the multimeter on the center post of the sending unit.
Place the black (–) probe on the ground connection of the sending unit (Figure 11-30, Page 11-31).
4. The following resistance readings (in ohms) should be obtained depending on the position of the float inside
the fuel tank. The resistance reading will vary according to the exact position of the float. The chart below may
be used as a guideline to determine if the fuel level sending unit is operating correctly. Make sure the float
is at the surface of the fuel in the tank.

FLOAT POSITION RESISTANCE READING FUEL GAUGE READINGS

Lower position (tank empty) 240 ± 20 ohms Empty
Center position (tank half full) 120 ± 20 ohms Half full
Upper position (tank full) 60 ± 20 ohms Full
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
! !
2
V COM 200nA
MAX
1000 ---
FUSED
750V
1
3
1. 2k Ohm Setting 2. Black Wire 3. Ground
479
Figure 11-30 Fuel Level Sending Unit Test
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 14-21.
6. If the readings are correct and the fuel gauge does not function correctly, check the continuity of the orange wire
from the fuel level sending unit to the fuel gauge/hour meter. Leave the battery disconnected while checking
continuity. Also check the continuity of the blue wire from the fuel gauge/hour meter to the key switch, and the
black ground wires at the fuel level sending unit and at the fuel gauge/hour meter. See Fuel Gauge/Hour
Meter Removal on page 12-24.
7. If the readings are correct according to the position of the float, but give an incorrect reading on the fuel
gauge/hour meter, test the fuel gauge/hour meter.

TEST PROCEDURE 26 – Fuel Gauge

1 2
6 7
1. Black(Jumper Wire From 6) 2. Blue 4. Orange 6. Black 7.

White
480
Figure 11-31 Fuel Gauge/Hour Meter
NOTE: Keep the battery connected during this test procedure.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL position.
Chock the wheels.
2. Remove the instrument panel to gain access to the back of the fuel gauge/hour meter. See Key Switch
3. Place a sheet of insulating material between the front frame and the electrical connections on the rear of the
instrument panel to prevent contact between the two.
4. Disconnect the orange wire from the fuel gauge/hour meter.
5. Set a multimeter to 20 volts DC and place the red (+) probe of the multimeter on the positive post of the battery.
Place the black (–) probe on the negative post of the battery. Record the voltage reading.
6. Set a multimeter to 20 volts DC and place the red (+) probe on the (2) terminal of the fuel gauge/hour meter with
the blue wire is connected. Place the black (–) probe on the (1) terminal of the fuel gauge/hour meter with the
black wire (Figure 11-32, Page 11-33).
8. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded earlier.
If not, check the continuity of the blue and black wires (Figure 11-32, Page 11-33).
9. The orange wire should remain disconnected for this step. Place the black probe of the multimeter on the (1)
terminal of the fuel gauge/hour meter and place the red (+) probe on the (4) terminal of the fuel gauge/hour
meter (Figure 11-33, Page 11-33). The voltage reading should be approximately 4.94 volts. If the reading is
incorrect, replace the fuel gauge/hour meter.

WAVETEK 5XL 1
V V
WAVETEK 5XL
OFF
1000 500
2 V
1000
OFF
500
V
200 200
200 200
1
20 200
2 2
20 200
2 2m
200 2 2m
m 20
m 200 20
m m
2000 200
k m 200
2000
m
200k 4 k
200k
2
20k 200
2k A 200
20k
2k A
6 4
7 6
7
V ! COM ! 200nA
V ! COM ! 200nA
MAX
5
1000 --- MAX
FUSED
750V 1000 ---
FUSED
750V
4
1 3 1
1. 20 VDC Setting 2. Orange 3. Black 4. White 5. Blue 1. 20 VDC Setting 2. Orange
481 482
Figure 11-32 Fuel Gauge Voltage Test - Terminal 2 Figure 11-33 Fuel Gauge Voltage Test - Terminal 4
TEST PROCEDURE 27 – Hour Meter

1. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.

2. With the key switch OFF, check the hour meter display. It is powered by an internal battery and should always be
on, even with the engine off and the key removed.
3. Start the engine and let it idle. See following DANGER.
DANGER
• Do not operate vehicle in an enclosed area without proper ventilation. The engine produces carbon
monoxide, which is an odorless, deadly poison.
4. With engine idling, the "hour glass" icon should flash. If not, check the low oil warning light and the oil pressure
switch. See following NOTE. See also Test Procedure 21 – Low Oil Warning Light on page 11-29.
NOTE: The hour meter is designed to record actual engine running time and will not start adding increments until the
engine is running and the oil pressure switch has opened.
5. If the hour meter still does not function after the low oil warning light, oil pressure switch, and all of the appropriate
wires have been checked for continuity, replace the fuel gauge/hour meter.
TEST PROCEDURE 28 – Light Switch

Chock the wheels.
1, Page 1-3.
3. Remove the instrument panel. See Key Switch Removal on page 12-13.
4. Using a multimeter set on 20 volts DC, place alligator clips on the multimeter probes. Connect the red (+) probe
to the light switch terminal with the blue wire connected to it (Figure 11-34, Page 11-34).


6. Connect the black (–) probe of the multimeter to the negative (–) post of the battery.
7. With the light switch in the OFF position, the reading should be zero volts. With the light in the ON position, the
reading should be between 11 and 12.5 volts. If the there is no voltage reading, check continuity of the 10-gauge
red wire from the fuse block to the solenoid. Check continuity of the 14-gauge yellow wire from the light switch
to the fuse block. Check the fuse. See Fuse on page 11-11. If the voltage limiter is functioning correctly, the
wires and fuse show continuity and the readings are still incorrect, replace the switch. See Headlight Switch
Removal, Section 12, Page 12-32.
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
483
Figure 11-34 Light Switch Test
TEST PROCEDURE 29 – Voltage Limiter

Chock the wheels.
1, Page 1-3.
3. Remove the instrument panel. See Key Switch Removal, Section 12, Page 12-13.
4. Using a multimeter set on 20 volts DC, connect the red (+) probe to the light switch terminal with the yellow
wire (Figure 11-35, Page 11-35).
5. Loosen the black wire connector (on the end of the long black wire) at the voltage limiter just enough to maintain
the connection and yet expose part of the metal terminal in the connector. Place black (–) probe on the connector
(Figure 11-35, Page 11-35).
6. Connect the battery cables temporarily, positive (+) cable first.
7. Pull the light switch to the ON position. The reading should be 11-12 volts. If the there is no voltage reading,
check continuity of the 16-gauge black wire from the headlight to the voltage limiter. Check continuity of the
16-gauge black wire from voltage limiter to the vehicle frame. If the wires show continuity and the readings are
still incorrect, replace the voltage limiter. See Voltage Limiter Removal, Section 12, Page 12-31.
8. With the Forward/Reverse handle in the NEUTRAL position and the wheels chocked, start the engine and
press the accelerator pedal to the floor.
9. Push the light switch to the OFF position. The reading should be 14.7-15.3 volts.
10. Pull the light switch to the ON position. The reading should be 11-13 volts. If the reading does not drop from
14.5-15.5 volts to 11-13 volts, replace the voltage limiter. See Voltage Limiter Removal, Section 12, Page 12-31.
11. Install the instrument panel. See Key Switch Installation, Section 12, Page 12-15.

TEST PROCEDURE 30 – Voltage at Headlight Socket
Chock the wheels.
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200
m
2000
20
m
200
m
4 6
k
200k
20k 200
2k A
V ! COM ! 200nA
3 7
MAX
1000 ---
FUSED
750V
1 2
1. 20 VDC Setting 2. Light Switch 3. Yellow Wire 4. Blue Wire 5. Voltage Limiter 6. Black Wires 7. Frame Ground
484
Figure 11-35 Voltage Limiter Circuit Test
2. Inspect wires at light bulb socket. Make sure wires are securely fastened to the contacts inside socket.
3. Remove the wire harness from the headlight (Figure 11-36, Page 11-36).
4. Using a multimeter set to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the
wire harness. Place the red (+) probe into the blue wire terminal.
5. Pull the light switch to the ON position. If the multimeter reads approximately 12 volts, replace the bulb.
6. If there is no voltage reading at the wire harness, check continuity of the 16-gauge blue wire from the headlight
to the light switch. Using a multimeter set to 20 volts DC, attach using an alligator clip, the black (–) probe of
multimeter onto the negative battery terminal and place the red (+) probe into the blue wire terminal of the wire
harness. If multimeter reading is approximately 12 volts, the blue wire has continuity.
7. Check continuity of the 16-gauge black wire from the headlight to the ground terminal. Using a multimeter set
to 20 volts DC, place the black (–) probe of multimeter into the black wire terminal of the wire harness and
attach using an alligator clip, the red (+) probe onto the positive battery terminal. If the multimeter reading is
approximately 12 volts, the black wire has continuity.

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
485
Figure 11-36 Check Voltage to Headlight Socket

SECTION 12 – ELECTRICAL COMPONENTS: FE290
PEDAL-START GAS VEHICLE 12
DANGER
WARNING
STARTER/GENERATOR (MODEL 114–01–4005B)
TESTING THE STARTER/GENERATOR

See Test Procedure 8 – Starter/Generator (Starter Function) on page 11-16.
See Test Procedure 10 – Starter/Generator (Generator Function) on page 11-17.
STARTER/GENERATOR REMOVAL
1, Page 1-3.
2. Place the neutral lockout switch or cam in the MAINTENANCE position. Remove the access panel on a DS
Golf Car or Villager 4 vehicle.
3. Mark and disconnect the wires from the starter/generator (1). Loosen the two pivot nuts (7) and bolts (5) (Figure
12-1, Page 12-2).
4. Remove the mounting/adjustment nut (12), washer (9) and bolt (11). Lower the starter/generator and remove
the belt (4) from the pulley (10).

ELECTRICAL COMPONENTS: FE290
12 Starter/Generator (Model 114–01–4005B) PEDAL-START GAS VEHICLE
1 5
2
7
17
DF
15
16
F2
14
A1
A2 F1
13
12 9 11 4
10
1338
Figure 12-1 Starter/Generator Removal
5. Support the starter/generator so that when the pivot bolts are removed the starter/generator will not fall to the
ground. Remove the two pivot nuts (7) and bolts (5) from the mounting bracket.
6. Remove the starter/generator.
DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE BRUSHES
1. Remove brush covers (29 and 30), screws (25) and lock washers (26), brush springs (28), and brushes (27)
(Figure 12-3, Page 12-3). Pull back each brush spring and pull the brushes back from the center of the
commutator end cover. The springs will rest on the sides of the brushes and help prevent them from sliding
towards the center of the cover (Figure 12-6, Page 12-4). See following NOTE.
NOTE: If the brushes are not removed, contact between the brushes and commutator as the commutator end cover is
being removed or installed could damage the brushes.
2. Remove the two bolts (20) and pull commutator end cover (23) free of starter/generator housing (24) (Figure
12-2, Page 12-3).
3. Remove terminal hardware (31), screws and lock washers (25), brush holder assembly (26), brush springs (28),
and brushes (27). Make note of the routing of the brushes and wires between the brush holder assembly and the
inside of the commutator end cover for later reassembly (Figure 12-3, Page 12-3). See following NOTE.
NOTE: Clean and inspect the armature/commutator and the bearings. See Disassembly of the Starter/Generator
to Service the Armature/Commutator on page 12-5.

PEDAL-START GAS VEHICLE Starter/Generator (Model 114–01–4005B) 12
23
23
29
26
25 31
20
30
24
27
28
487 1339
Figure 12-2 Commutator End Cover Figure 12-3 Brush Covers and Brushes
BRUSH INSPECTION AND REPLACEMENT
1. Visually inspect brushes. Replace brushes that are cracked or severely chipped.
2. Check the length of each brush. If the overall length of any brush is less than 0.79 inch (20 mm), replace all
four brushes (Figure 12-4, Page 12-3).
0
1/2
1/2
1340
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 12-3).
Insert the brush wiring terminal studs through the commutator end cover (23) and assemble using the terminal
hardware (31). Route the brush wiring between the brush holder assembly (26) and the inside of the commutator
end cover cover (23) and assemble using the screws and lock washers (25). Using a spring scale, test brush
spring tension. If any spring has a tension less than 14.8 ounces (4.1 N), replace all four springs (Figure 12-5,
Page 12-4). See following CAUTION.

CAUTION
• When checking brush spring tension, do not push springs beyond the point they would normally be if
there were new brushes installed. Exerting excessive force or pushing brush springs beyond their
normal maximum extension point will damage springs.
0
5
10
15
20
25
30
35
4
4 0
50 5
490
Figure 12-5 Brush Spring Tension Test
STARTER/GENERATOR ASSEMBLY
1. To prevent contact between the brushes and commutator as the commutator is installed, and possible damage
to the brushes, pull back each brush spring and pull the brushes back from the center of the commutator end
cover. The springs will rest on the sides of the brushes and help prevent them from sliding towards the center
of the cover (Figure 12-6, Page 12-4).
2. Install the commutator end cover (23) onto the armature shaft. Orient the commutator end cover with the field coil
housing as shown. Install two M5 x 20 mm bolts (20) and tighten to 60 in-lb (6.8 N·m) (Figure 12-2, Page 12-3).
3. Push the brushes down into the holders. Position springs so that brushes are being held against the commutator.
Install the brush cover (30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush
covers (29) in the openings in the commutator end cover (23) (Figure 12-3, Page 12-3).
1341
Figure 12-6 Pull Brushes Away From Center of the Commutator End Cover

DISASSEMBLY OF THE STARTER/GENERATOR TO SERVICE THE
ARMATURE/COMMUTATOR
1. Remove the commutator end cover to prevent damage to the brushes and armature. See Disassembly of the
Starter/Generator to Service the Brushes on page 12-2.
2. To separate armature and output end cover assembly from the field coil housing, first remove the two securing
bolts (43). Carefully remove armature and output end cover assembly from the field coil housing so components
are not damaged.
3. To separate armature (33) from output end cover (36), remove nut (41), lock washer (40), pulley (39). It may be
necessary to use the wedge attachment tool (CC P/N 1012812) to remove the pulley from the shaft.
4. Remove the internal retaining ring (32) to release the bearing (35) and armature (33) from the output end cover
(36) (Figure 12-7, Page 12-5).
33
32
35 33
36
43
39
40
41
1342
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 12-6).
2. Replace the bearing if it is noisy, does not spin smoothly, or has excessive play. Check the bearings and replace if
rusted, worn, cracked, or if there is an abnormal color change in the metal of the bearing. Bearings should be
replaced if there is extensive wear or pitting on the balls or on the rolling surfaces. Do not remove the bearings
unless they are to be replaced.

493
Figure 12-8 Bearing Play Inspection
BEARING REMOVAL
1. Place the wedge attachment tool (CC 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 (CC P/N 1012811) to the wedge attachment tool and pull the bearing off of the end of the armature shaft.
Support the armature so that it will not drop when the bearing is removed (Figure 12-9, Page 12-6).
2. Slide the bearing retainer ring (32) off of the output end of the shaft (Figure 12-7, Page 12-5).
2 7
1 5
4
6
1. Press Ram 2. Wedge Attachment Tool 3. Bearing sectioned for clarity 4. Support inner race of bearing 5. Use a 1/2 inch socket or pipe 6.
Press against armature shaft 7. Use bearing puller if a press is not available
494
Figure 12-9 Bearing Removal
FIELD COIL REMOVAL
Replace entire field coil housing assembly if coils, pole shoes or terminals are damaged (Figure 12-10, Page 12-7).

VISUAL INSPECTION OF ARMATURE
Obvious defects can be seen by examining the armature. If an armature has frayed or charred insulation, broken wires
or thrown solder, it is obvious without testing that it should be replaced. Faults seen during the visual inspection can aid
in diagnosing the original cause of the failure. Items to look for are listed below.
• Burned, charred, or cracked insulation
• Improperly cured varnish
• Thrown solder
• 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
2 2
1
3
6
5
7
7
1. Pole Set 2. Pole Piece Screw 3. Retaining Nut 4. Insulator 5. Field Coil Terminal 6. Housing 7. Field Coil
495
Figure 12-10 Field Coil Assembly
COMMUTATOR CLEANING AND INSPECTION
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. Slight roughness of the commutator can be polished
away with 400 grit (or finer) sandpaper. See following CAUTION.
CAUTION
• Do not use emery cloth on the commutator. Particles of emery are conductive and may short-circuit
the commutator bars. Do not use oil or lubricants on the commutator or brushes.

2. Using a micrometer, measure the outside diameter at two points along the commutator. If the commutator outside
diameter is less than 1.60 inches (40.6 mm), replace the armature and bearings (Figure 12-11, Page 12-8).
A1 A1
1
B1 B1
A1
A2
1. Measure each position in two places, 90 degrees apart
496
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.
1. Using a multimeter set on 200 (ohms), place the positive (+) probe on the commutator bars and the negative
(–) probe on the armature core. The reading should be no continuity. If the reading is incorrect, replace the
armature and the two bearings (Figure 12-12, Page 12-9).

- +
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
1 3
1. 200 Ohms Setting 2. Commutator 3. Armature Shaft
497
Figure 12-12 Armature Ground Test
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. Be sure the insulators are tight in the housing.
STARTER/GENERATOR REWORK
Any rework must be performed by a qualified technician. Starter/generator service specifications are listed in
the following table.
ITEM SERVICE LIMIT

Commutator diameter (minimum) 1.60 in. (41 mm)
Concentric with armature shaft within 0.002 in. (0.051 mm)
Minimum commutator diameter for reslotting 1.65 in. (42 mm)
Undercut (Commutator must have a minimum diameter of 1.65 in (42 mm) for
0.050 in. (1.3 mm)
reslotting):
Dielectric strength 500 VAC for one minute
Armature insulation resistance 0.2M (ohms) at 500 VDC
Starter field coil resistance 0.006-0.01 ohms
Generator field coil resistance 4.5-5.5 ohms
STARTER/GENERATOR ASSEMBLY
1. Slide the bearing retainer (32) onto the output end of the armature shaft (33) (Figure 12-7, Page 12-5).
2. Press a new ball bearing (35) onto the output end of the armature. Press a new ball bearing onto the commutator
end of the armature shaft. See following CAUTION.

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.
3. Install the drive end cover (36) onto the armature. Secure the bearing retainer ring (32).
4. Slide the housing with field coils over the armature. Use the tapped mounting holes to align housing to the cover,
rotate and orient as shown. See following NOTE.
NOTE: The terminal insulators should be on the commutator end of the housing.
5. 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. The springs will rest on the sides of the brushes and help prevent them
from sliding towards the center of the cover (Figure 12-6, Page 12-4).
6. Install the commutator end cover (23) onto the armature shaft. Use the tapped mounting holes to align housing to
the cover, rotate and orient as shown. Install the two M6 x 180 mm bolts (20), and tighten to 60 in-lb (6.8
7. Push the brushes down into the holders. Place springs into the notches in the brushes. Install the brush cover
(30) that has the drain hole in it next to the A2 terminal. Install the remaining three brush covers (29) in the
openings in the commutator end cover (23) (Figure 12-3, Page 12-3).
8. Install the belt pulley (39) onto the shaft, and install the lock washer (40) and M14 nut (41). Tighten the nut to 30
ft-lb (40.7 N·m) (Figure 12-7, Page 12-5).
STARTER/GENERATOR INSTALLATION
1. Install the green wire from the F1 terminal to the A1 terminal on the starter/generator (Figure 12-1, Page 12-2).
Install a flat washer, lock washer, and nut onto each terminal and tighten to 48 in-lb (5.4 N·m).
2. Install two 3/8-inch hex-head pivot bolts (5) into the mounting bracket with the heads of the bolts facing toward
the driver-side of the vehicle. Position the starter/generator in the mounting bracket so that the bolts will go
through the starter/generator before going through the bracket. Install a lock nut (7) onto each bolt. Tighten to
finger tight (Figure 12-13, Page 12-11).
3. Install the adjustment bolt (11) through the adjusting bracket (4) and then through the starter/generator. Install a
lock washer (9) and 5/16-inch nut (12) onto the end of the adjustment bolt (11). Tighten to finger tight (Figure
12-13, Page 12-11).
4. Install the belt (3), then tighten the mounting bolts. See Belt Tension Adjustment on page 12-12.
5. Connect the yellow wire from the voltage regulator to the DF terminal on the starter/generator. Install a flat
washer, lock washer, and nut onto the terminal. Tighten the nut to 18 in-lb (2.0 N·m).
6. Install the white wire from the solenoid to the F2 terminal on the starter/generator. Install the black wire from the
frame to the A2 terminal on the starter/generator. Install a flat washer, lock washer and nut onto each terminal,
and tighten the nut to 45 in-lb (5.1 N·m). Bundle and tie wrap excess wire.

2 5
13
7
10
12
9
4 11
498
Figure 12-13 Starter/Generator Installation
1. Belt Tension Gauge 2. End View
499
Figure 12-14 Belt Tension Gauge

12 Voltage Regulator PEDAL-START GAS VEHICLE
BELT TENSION ADJUSTMENT
Belt tension should be checked periodically. If the belt slips when starter/generator motor operates, adjust belt
to correct tension.
1, Page 1-3.
2. Remove the access panel on a DS Golf Car or Villager 4 vehicle.
3. Make sure the two pivot bolts (5) on the mounting bracket are finger tight. The carriage bolt (11) and hex nut (12)
are to be finger tight also (Figure 12-13, Page 12-11).
4. Push the starter/generator down so it is at the lowest point of its adjustment travel. With the starter/generator belt
in place around the drive clutch pulley, install the starter/generator belt (3) around the pulley (10) on the end
of the starter/generator.
5. 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.
6. While holding the pry bar, measure the belt tension using a Krikit® gauge (1) (available at NAPA® Auto Parts
stores), or equivalent. Proper tension for a new starter/generator belt should be 75 lb. (101.7 N) or 45 lb. (61
N) for an existing belt (Figure 12-14, Page 12-11).
7. While maintaining the tension, tighten the adjustment nut (12) to 144 in-lb (16.3 N·m). Tighten the two pivot bolts
(5) and hex nuts (7) to 23 ft-lb (31.2 N·m) (Figure 12-13, Page 12-11). See following CAUTION.
CAUTION
• Remove pry bar before starting engine.
VOLTAGE REGULATOR
TESTING THE VOLTAGE REGULATOR

See Test Procedure 11 – Voltage Regulator on page 11-18.
VOLTAGE REGULATOR REMOVAL
1, Page 1-3.
2. Remove the electrical component box cover.
3. Disconnect the voltage regulator red wire (1) at the large post on the solenoid, the yellow wire (4) at the bullet
connector, and the black wire (7) from the (NO) terminal of the kill limit switch and at the battery frame ground
(Figure 12-15, Page 12-13).
4. Remove the voltage regulator mounting screw (8) and remove the voltage regulator (9).

PEDAL-START GAS VEHICLE Key Switch 12
1
2
4
8
1. Red wire to solenoid. 2. To kill limit switch. 3. To frame

ground. 4. To bullet connector.
500
Figure 12-15 Voltage Regulator
VOLTAGE REGULATOR INSTALLATION
1. Position the voltage regulator (9) in the electrical component box and install the mounting screw (8) (Figure
12-15, Page 12-13). Tighten screw to 23 in-lb (2.6 N·m).
2. Connect the voltage regulator red wire (1) at the large post on the solenoid, the yellow wire (4) at the bullet
connector, and the black wire (7) at the battery frame ground (Figure 12-15, Page 12-13).
3. Install snap-on electrical component box cover. Be sure to firmly press down all corners. Install screw and
tighten to 18 in-lb (2 N·m).
5. Place Forward/Reverse handle in NEUTRAL and place the neutral lockout switch in the MAINTENANCE position.
Start the engine and check regulator for proper functioning as described in the voltage regulator test procedure.
See Voltage Regulator on page 11-18.
KEY SWITCH
TESTING THE KEY SWITCH

See Test Procedure 4 – Key Switch (Starter Circuit) on page 11-13.
See Test Procedure 17 – Key Switch (Engine Kill Circuit) on page 11-27.
KEY SWITCH REMOVAL
1, Page 1-3.

12 Key Switch PEDAL-START GAS VEHICLE
2. Remove the center dash panel.

2.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3)
(Figure 12-16, Page 12-14).
2.2. Loosen, but do not remove, the screw (2) on each side of the center dash panel (3).
2.3. Insert screwdriver at the top center of the dash between dash and cowl brace. Gently pry center dash out
slightly from under edge of cowl brace.
2.4. Pull center dash out from the frame and disconnect the wires from the electrical components mounted on
the dash panel. Do not allow wires to touch. See following NOTE.
NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash.
2
3
516
Figure 12-16 Center Dash Panel Removal
3. Slide center dash panel up steering column by snapping top out and then rotating the panel out and up.
4. Disconnect the wires from the key switch. Do not allow wires to touch.
5. From the back of the dash panel, push down on the retaining tabs surrounding the key switch (4) and remove
the key switch cap (8). Hold the key switch and remove the switch retaining nut (6) from the outside of the
dash panel (Figure 12-17, Page 12-15).

PEDAL-START GAS VEHICLE Solenoid 12
7 4
9
6
Figure 12-17 Key Switch
KEY SWITCH INSTALLATION
1. Position the key switch and flat washer (9) in the center dash, then install and tighten the switch retaining nut (6)
to 40 in-lb (4.5 N·m). Install key switch cap (8) in center dash. (Figure 12-17, Page 12-15)
2. Refer to the wiring diagram to connect the wires to the key switch terminals and tighten the terminal screws to 7
in-lb (0.8 N·m). See Wiring Diagram – Gasoline Vehicle, Section 11, Page 11-6. Coat the connectors with
Battery Terminal Protector Spray (CC P/N 1014305) to prevent corrosion.
3. Install center dash by reversing removal procedure. Make sure key switch terminals (7) do not touch frame and
that the center dash panel is properly seated and snapped into place (Figure 12-16, Page 12-14).
SOLENOID
TESTING THE SOLENOID

See Test Procedure 6 – Solenoid on page 11-14.
SOLENOID REMOVAL
1, Page 1-3.

12 Fuse PEDAL-START GAS VEHICLE
2. Remove electrical component box cover (Figure 12-18, Page 12-18).

3. Disconnect all the wires from the solenoid.
4. Remove the two screws securing the solenoid in place. Remove the solenoid.
SOLENOID INSTALLATION
1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box and
tighten to 14 in-lb (1.6 N·m).
2. Connect all wires as indicated. See Wiring Diagram – Gasoline Vehicle on page 11-6.
2.1. Connect the 6-gauge white wire from the starter/generator, the 18-gauge white wire from the fuel gauge/hour
meter (if equipped), and the 18-gauge red wire from the voltage regulator to the large post on the solenoid.
2.2. Connect the 6-gauge red wire from the battery terminal and the 10-gauge red wire from the fuse block to
the other large post on the solenoid.
2.3. Connect the 16-gauge orange wire from accelerator pedal limit switch to small post on the solenoid.
2.4. Connect the 16-gauge blue wire from the key switch to the other small post on the solenoid.
3. Tighten the hex nuts on the large solenoid posts to 55 in-lb (6.2 N·m). Tighten the nuts on the small solenoid
posts to 22 in-lb (2.5 N·m).
4. Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tightening to
18 in-lb (2 N·m).
FUSE
TESTING THE FUSE

See Test Procedure 2 – Fuse on page 11-11.
FUSE REMOVAL
2. Remove electrical component box cover.
3. Remove the fuse from the fuse block.
FUSE INSTALLATION
1. Install the fuse. See following WARNING.

PEDAL-START GAS VEHICLE Accelerator Pedal Limit Switch 12
WARNING
• If a fuse is blown, determine the cause of the failure and make necessary repairs before installing a
new fuse. Use the appropriately rated fuse; if a fuse with a higher amp rating is used, damage to the
vehicle electrical system may occur.
2. Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tightening to
18 in-lb (2 N·m).
ACCELERATOR PEDAL LIMIT SWITCH
TESTING THE ACCELERATOR PEDAL SWITCH
See Test Procedure 5 – Accelerator Pedal Limit Switch on page 11-14.
ACCELERATOR PEDAL LIMIT SWITCH REMOVAL
1, Page 1-3.
2. Remove electrical component box cover (1) (Figure 12-18, Page 12-18).
3. Disconnect the green wire and the orange wire from the accelerator pedal limit switch (11).
4. Remove the two nuts (9) and washers (10) that secure the accelerator limit switch in place.
5. Remove the accelerator pedal limit switch (11).
ACCELERATOR PEDAL LIMIT SWITCH INSTALLATION
1. Install the accelerator pedal limit switch (11) onto the two screws (16) and secure the switch using two washers
(10) and nuts (9). Torque to 5 in-lb (0.6 N·m) (Figure 12-18, Page 12-18). See following CAUTION.
CAUTION
• Do not overtighten the retaining nuts. If the nuts are overtightened, limit switches could be damaged.
2. Connect the green wire to common (COM) terminal and the orange wire to the normally closed (NC) terminal of
the accelerator pedal limit switch.
3. Press the accelerator pedal to make sure that the switch is being actuated when the pedal is released.
4. Install snap-on electrical component box cover (1). Be sure to press down firmly all corners. Install screw (20)
and tighten to 18 in-lb (2 N·m).

12 Kill Limit Switch PEDAL-START GAS VEHICLE
9
20
10
12
11
8
15 13
A
16
21
A. To Voltage Regulator
517
Figure 12-18 Accelerator Starter and Kill Limit Switches
KILL LIMIT SWITCH
TESTING THE KILL LIMIT SWITCH

See Test Procedure 16 – Kill Limit Switch on page 11-27.
KILL LIMIT SWITCH REMOVAL
1, Page 1-3.
2. Remove electrical component box cover (1) (Figure 12-18, Page 12-18).
3. Remove the two nuts (9) and washers (10) securing the accelerator pedal limit switch (11). Do not disconnect the
wires attached to switch (11) (Figure 12-18, Page 12-18).
4. Disconnect the two white/black wires and the black wire from the kill limit switch (12).
5. Remove the kill limit switch (12).
KILL LIMIT SWITCH INSTALLATION
1. Install the kill limit switch (12) onto the two screws (16) (Figure 12-18, Page 12-18).
2. Connect the two white/black wires to the common (COM) terminal and the black wire to the normally open (NO)
terminal of the kill limit switch (12) and place the switch on the mounting screws located in the electrical component
box. Place the accelerator limit switch (11) on the mounting screws located in the electrical component box.
3. Secure the switches using two washers (10) and two nuts (9). Tighten to 5 in-lb (0.6 N·m). See following
CAUTION.

PEDAL-START GAS VEHICLE Neutral Lockout Limit Switch 12
CAUTION
4. Press and release the accelerator pedal to make sure that both switches are being activated when the pedal
is released.
5. Install snap-on electrical component box cover (1). Be sure to press down firmly all corners. Install screw (20)
and tighten to 18 in-lb (2 N·m).
NEUTRAL LOCKOUT LIMIT SWITCH
TESTING THE NEUTRAL LOCKOUT LIMIT SWITCH
See Test Procedure 7 – Neutral Lockout Limit Switch on page 11-15.
NEUTRAL LOCKOUT LIMIT SWITCH REMOVAL
Chock the wheels.
1, Page 1-3.
3. Disconnect the wires from the lockout cam limit switch (1) located on the back of the Forward/Reverse shifter
assembly (2) (Figure 12-19, Page 12-20).
4. Remove two nuts (3) and washers (4) from the lockout cam limit switch (1) and slide the lockout cam limit
switch off of the screws.
NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION
1. Install the limit switch (1) with washers (4) and nuts (3) and tighten to 5 in-lb (0.6 N·m) (Figure 12-19, Page
12-20). Place the Forward/Reverse handle in REVERSE to make sure that both switches actuate. See following
CAUTION.
CAUTION
2. Connect the black wire to common (COM) terminal, the green wire to the normally open (NO) terminal and
the white wire to the normally closed (NC) terminal of the neutral lockout limit switch. See Wiring Diagram –
Gasoline Vehicle on page 11-6.
4. Place the Forward/Reverse handle in NEUTRAL and the neutral lockout cam in the OPERATE position.

12 Neutral Lockout Cam PEDAL-START GAS VEHICLE
5. Make sure everyone is clear of the vehicle. Turn the key switch ON. The engine should NOT crank when
pressing the accelerator. If the engine does crank, turn the key switch OFF and re-adjust the shift linkage. See
Forward/Reverse Shifter Cable Adjustment, Section 16, Page 16-21.
6. Test drive the vehicle in both forward and reverse for proper operation.
NEUTRAL LOCKOUT CAM
If the cam lobes have worn to the point where they will no longer actuate the lockout cam limit switch, the cam
must be replaced.
TESTING THE NEUTRAL LOCKOUT CAM
See Test Procedure 23 – Neutral Lockout Cam on page 11-30.
5
2
5
CO
M
NO
NC
CO
3
1
M
NO
NC
6 1 4 3
4 2
504 505
Figure 12-19 Neutral Lockout Cam and Reverse Buzzer Figure 12-20 Neutral Lockout Cam
Limit Switches
NEUTRAL LOCKOUT CAM REMOVAL
Chock the wheels.
1, Page 1-3.
3. Remove the external snap ring (1) (Figure 12-20, Page 12-20).
4. Remove the plastic washer (2) and the spring (3).
5. Remove the cam (4).

PEDAL-START GAS VEHICLE Reverse Warning Buzzer 12
NEUTRAL LOCKOUT CAM INSTALLATION
1. Install the cam (4) (Figure 12-20, Page 12-20).

2. Install the spring (3) and the plastic washer (2).
3. Install the external snap ring (1) into the groove on the shaft. The lockout limit switch (5) should be activated only
when the Forward/Reverse handle is in the NEUTRAL position.
REVERSE WARNING BUZZER
TESTING THE REVERSE WARNING BUZZER
See Test Procedure 20 – Reverse Buzzer on page 11-29.
REVERSE WARNING BUZZER REMOVAL
1, Page 1-3.
2. Remove the center dash panel. See Key Switch Removal on page 12-13.
3. Disconnect the wires from the reverse warning buzzer (2). Do not allow wires to touch (Figure 12-21, Page 12-22).
4. Remove the mounting screws (3) securing the buzzer to the center dash.
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 12-21, Page
12-22).
2. Connect the black wire from the key switch to the negative (–) terminal on the buzzer.
3. Connect the red/white wire from the wire harness to the positive (+) terminal on the buzzer.
4. Reverse removal procedures to install the center dash in the vehicle. Be sure that the key switch terminals cannot
touch the frame and that the panel is properly seated and snapped in place.

12 Reverse Buzzer Limit Switch PEDAL-START GAS VEHICLE
M- 1
2
M+
As seen from front driver side of vehicle with body removed.
520
Figure 12-21 Reverse Warning Buzzer
REVERSE BUZZER LIMIT SWITCH
TESTING THE REVERSE BUZZER LIMIT SWITCH

See Test Procedure 19 – Reverse Buzzer Limit Switch on page 11-28.
REVERSE BUZZER LIMIT SWITCH REMOVAL
1, Page 1-3.
2. Disconnect the wires from the reverse buzzer limit switch (4) located on the back of the Forward/Reverse
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. Do not disconnect the wires.
4. Remove the spacers (9) from the reverse buzzer limit switch (4) and slide the reverse buzzer limit switch off
the screws.
REVERSE BUZZER LIMIT SWITCH INSTALLATION
1. Install the reverse buzzer limit switch (4), and then install two spacers (9) against the limit switch (Figure 12-19,
Page 12-20).

PEDAL-START GAS VEHICLE Low Oil Warning Light 12
2. Install the neutral lockout limit switch (5) with two washers (6) and two nuts (2). Tighten to 5 in-lb (0.6 N·m).
CAUTION
• Do not overtighten the retaining nuts. If the nuts are over tightened, limit switches could be damaged.
3. Place the Forward/Reverse handle in REVERSE and make sure that both switches actuate.
4. Connect the orange wire to the common (COM) terminal and the red/white wire to the normally open (NO)
terminal of the reverse buzzer limit switch (4)
6. Turn the key switch to the ON position. Shift the Forward/Reverse handle to the REVERSE position. The
buzzer should sound.
LOW OIL WARNING LIGHT
TESTING THE LOW OIL WARNING LIGHT

See Test Procedure 21 – Low Oil Warning Light on page 11-29.
LOW OIL WARNING LIGHT REMOVAL
1, Page 1-3.
3. Disconnect the wires from the low oil warning light (11) (Figure 12-22, Page 12-24). Do not allow wires to touch.
4. Press the retaining tabs and remove the low oil warning light from the center dash.
LOW OIL WARNING LIGHT INSTALLATION
1. Push low oil warning light into hole in dash until plastic tabs engage dash (Figure 12-22, Page 12-24).
2. Connect yellow wire from the key switch and yellow wire from the oil level sensor to the low oil warning light.
3. Install the center dash in reverse order of removal. Be sure that key switch terminals cannot touch the frame and
that panel is properly seated and snapped in place.

12 Fuel Gauge/Hour Meter PEDAL-START GAS VEHICLE
11
521 522
Figure 12-22 Low Oil Warning Light Figure 12-23 Fuel Gauge/Hour Meter Installation
FUEL GAUGE/HOUR METER
TESTING THE FUEL GAUGE/HOUR METER

See Test Procedure 26 – Fuel Gauge on page 11-32. Also see Test Procedure 27 – Hour Meter on page 11-33.
GENERAL INFORMATION
With the key switch in the OFF position, the fuel gauge field is blank; however, the hour meter field is always ON.
When the key switch is turned to ON, the fuel gauge field activates. The fuel gauge initially registers full before
indicating the actual fuel level.
The hour meter displays the number of hours of use in increments of 0.1 (one tenth) hour, but does not record
additional time unless the key switch is in the ON position and the engine is on. When recording, the hourglass icon
on the left blinks.
FUEL GAUGE/HOUR METER REMOVAL
1, Page 1-3.
3. Disconnect the wires from the fuel gauge/hour meter (1). Do not allow wires to touch.
4. Remove the mounting clip (2) that secures the gauge/meter (Figure 12-23, Page 12-24). Alternate pulling the
lower and upper tabs away from the gauge housing to remove clip. Pull gauge/meter from the instrument panel.

PEDAL-START GAS VEHICLE Fuel Level Sending Unit 12
FUEL GAUGE/HOUR METER INSTALLATION
1. Install fuel gauge/hour meter (1) into the hole in the instrument panel until the flange seats against the dash.
2. Force the mounting clip (2) onto the back of the fuel gauge/hour meter until fully seated (Figure 12-23, Page
12-24).
3. Connect the wires to the fuel gauge/hour meter. See Wiring Diagram – Gasoline Vehicle on page 11-6.
4. Coat terminals with Battery Terminal Protector Spray (CC P/N 1014305).
FUEL LEVEL SENDING UNIT
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 – Fuel Level Sending Unit on page 11-30.
RPM LIMITER
TESTING THE RPM LIMITER

See Test Procedure 14 – RPM Limiter on page 11-20.
RPM LIMITER REMOVAL
Chock the wheels.
1, Page 1-3.
3. Disconnect the white/black wire (1) from the black wire (2) at the bullet connector (3) located near the RPM
limiter (4) (Figure 12-24, Page 12-26).
4. Disconnect the black wire (5) at the other bullet connector (6) near the RPM limiter.
5. Remove the flange head bolts (7) from the RPM limiter band (8) and remove the RPM limiter and damper
(9) (Figure 12-24, Page 12-26).

12 RPM Limiter PEDAL-START GAS VEHICLE
9
4
8
7
00
5
00
00
10 6
1
11
2 3
508
Figure 12-24 RPM Limiter Assembly
RPM LIMITER INSTALLATION
1. Place the RPM limiter (4) on the damper (9) squarely so that RPM limiter fits tightly against the damper (Figure
12-24, Page 12-26).
2. Place the RPM limiter with damper on the front of the RPM limiter mounting bracket (10).
3. Place the band (8) over the RPM limiter and align the holes. Place the brown wire ring connector (11) onto the
flange head bolt (7) and secure the left side of the band. Use another flange head bolt to secure the other side of
the band. Make sure the band holds the RPM limiter securely in place. Tighten fasteners to 7 ft-lb (9.5 N·m).
4. Connect the black wire (2) to the white/black kill circuit wire (1) at the female bullet connector (3).
5. Connect the black wire (2) to the black wire (5) at the female bullet connector (6).

PEDAL-START GAS VEHICLE Ignition Coil 12
IGNITION COIL
TESTING THE IGNITION COIL
See Test Procedure 13 – Ignition Spark on page 11-19 and Test Procedure 15 – Ignition Coil on page 11-21.
IGNITION COIL REMOVAL
1. Remove seat to access engine compartment.

1, Page 1-3.
3. Remove the governor guard (1) (Figure 12-25, Page 12-27).
4. Remove the muffler. See Muffler Removal on page 15-1.
5. Cut the wire tie holding the wire harness to the stiffener (1) and remove the bolts (2) and nuts (3) securing the
stiffener to the mounting plate (4) (Figure 12-26, Page 12-27).
6. Remove the pan-head bolts (5) securing the fan shroud (8) to the fan housing (9) (Figure 12-27, Page 12-28).
7. Loosen, but do not remove, the three bolts (6) attaching the fan housing as shown.
8. Remove the remaining four bolts (10) attaching the fan housing as shown (Figure 12-27, Page 12-28), then,
while opening the housing, detach the spark plug wire grommet (4) from the housing (Figure 12-29, Page 12-28).
9. 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 12-28).
2 3
4 3
Clu
bC
ar
2
4
Figure 12-25 Governor Guard Removal 523

Figure 12-26 Stiffener Removal

12 Ignition Coil PEDAL-START GAS VEHICLE
6
12
13
10
10
11
509 510
Figure 12-27 Fan Housing Removal Figure 12-28 Ignition Coil Removal
IGNITION COIL INSTALLATION

NOTE: If a new ignition coil is being installed, the spark plug cap, gasket, protector tube and grommet must be
removed from the old coil and installed on the new coil. See steps 1 through 8 for procedures to remove
and install these existing parts.
If the existing ignition coil will be remounted, proceed to step 9.
1. Remove the rubber gasket (1) on the plug cap (2) by rolling back the gasket onto the spark plug wire (Figure
12-29, Page 12-28).
2. Remove the cap (2) from the wire by turning the cap counterclockwise three or four revolutions while gently
pulling it off the wire.
2
CAP
1 3
6
4
7
6
0.012 Inch
(0.304 mm)
511 512
Figure 12-29 Clean Grommet Figure 12-30 Mount Ignition Coil Using Feeler Gauge

PEDAL-START GAS VEHICLE Ignition Coil 12
3. Remove the gasket (1) and protector tube (3) from the old coil. See following NOTE.
NOTE: Moisten the spark plug wire with water to make gasket removal and installation easier.
4. Remove the grommet (4) from the old spark plug wire. Clean the grommet and place it on the new spark plug
wire (5).
5. Install the protector tube onto the new wire.
6. Slide the gasket onto the end of the new spark plug wire.
7. Install the cap on the new coil spark plug wire by rotating it clockwise three or four revolutions while applying
light pressure on the cap.
8. Install the gasket (1) on the cap (2).
9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two mounting
bolts (6) to finger-tight at this time.
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 12-28).
11. Connect the 18-gauge black wire to the spade terminal on the coil.
12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch on the
housing.
13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder shroud.
The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in the housing
with the flanged bolts loosened earlier.
14. Install the four remaining flange bolts that secure the fan housing to the engine crankcase. Tighten all seven
mounting bolts to 90 in-lb (10.2 N·m) (Figure 12-27, Page 12-28).
15. Install the stiffener with four hex-head bolts and lock nuts. Tighten the hardware to 23 ft-lb (30.5 N·m).
16. Install the fan shroud with four pan-head bolts (5). Tighten to 50 in-lb (5.7 N·m) (Figure 12-27, Page 12-28).
17. Secure the wire harness to the stiffener with a wire tie. Place the wire tie through the lower hole at the back of
the stiffener (Figure 12-26, Page 12-27).
CAUTION
• Make sure wire harness is routed and secured away from the muffler.
18. Install the muffler. See Muffler Installation on page 15-1.

19. Place the governor guard (1) onto the throttle bracket and the 2-ended bolt. Install the two Torx screws (4) through
the governor guard into the throttle bracket and tighten to 15 in-lb (1.7 N·m). Place the 3/8 flat washer (3) onto the
2-ended bolt and secure with nylon lock nut (2). Tighten the nut to 50 in-lb (5.7 N·m) (Figure 12-25, Page 12-27).

12 Oil Level Sensor PEDAL-START GAS VEHICLE
OIL LEVEL SENSOR
TESTING THE OIL LEVEL SENSOR
See Test Procedure 22 – Oil Level Sensor on page 11-29.
OIL LEVEL SENSOR REMOVAL
See Oil Level Sensor Removal on page 13-5.
OIL LEVEL SENSOR INSTALLATION
See Oil Level Sensor Installation on page 13-5.
HEADLIGHTS
TESTING THE HEADLIGHT SOCKET

See Test Procedure 30 – Voltage at Headlight Socket on page 11-35.
HEADLIGHT BULB REMOVAL
2. From the front of vehicle, reach under cowl and turn the wire harness/halogen bulb assembly, (4 and 6), clockwise
one-quarter turn (Figure 12-31, Page 12-31).
3. Remove the wire harness/halogen bulb assembly (4 and 6) from the headlight lens (7).
4. Lift the retaining tabs on the connector (4) and remove halogen bulb assembly (6).

PEDAL-START GAS VEHICLE Voltage Limiter 12
6 4
513
Figure 12-31 Headlight Assembly
HEADLIGHT BULB INSTALLATION

NOTE: When handling halogen bulbs, do not touch glass portion of bulb. Oil from finger tips can cause premature
failure of bulb.
1. Connect wire harness (4) to the halogen bulb assembly (6). The retaining tab should lock onto the halogen bulb
2. From the front of vehicle, reach under cowl and insert wire harness/halogen bulb assembly (4 and 6), into the
headlight lens (7).
3. Turn the wire harness/halogen bulb assembly (4 and 6) counterclockwise one-quarter turn.
VOLTAGE LIMITER
TESTING THE VOLTAGE LIMITER

See Test Procedure 29 – Voltage Limiter on page 11-34.
VOLTAGE LIMITER REMOVAL
Chock the wheels.
1, Page 1-3.
3. Remove the instrument panel. See Key Switch Removal on page 12-13.

12 Headlight Switch PEDAL-START GAS VEHICLE
4. Disconnect wires from the voltage limiter (1). Do not allow wires to touch (Figure 12-32, Page 12-32).
NOTE: Identify terminal for solid black wire and terminal for black/white wire.
5. Remove the mounting hardware (2) from the voltage limiter and remove it from the vehicle.
VOLTAGE LIMITER INSTALLATION
1. Mount the voltage limiter to the frame using the mounting hardware and tighten to 25 in-lb (2.8 N·m) (Figure
12-32, Page 12-32).
2. Connect the black/white wire from harness to the negative (–) terminal on the limiter.
3. Connect the solid black wire from the ground terminal block to the positive (+) terminal on the limiter.
4. Install the dash panel in reverse order of removal. See Key Switch Removal on page 12-13.
5
4
1
2 1
2
3
514 515
Figure 12-32 Voltage Limiter Figure 12-33 Light Switch
HEADLIGHT SWITCH
TESTING THE LIGHT SWITCH

See Test Procedure 28 – Light Switch on page 11-33.
HEADLIGHT SWITCH REMOVAL
1, Page 1-3.
2. Loosen the set screw (5) locking the light switch knob (1) to the shaft (Figure 12-33, Page 12-32).
4. Disconnect the wires from the light switch.
5. Remove the outer nut (2) from the switch (Figure 12-33, Page 12-32).

PEDAL-START GAS VEHICLE Battery 12
6. Remove the light switch (3) from the center dash.
HEADLIGHT SWITCH INSTALLATION
1. Connect the wires to the light switch. See Wiring Diagram – Gasoline Vehicle on page 11-6.
2. Thread the check nut (4) onto the switch until an equal number of threads show on both sides. Insert the
switch through the center dash and install the nut on the outside of the dash. Tighten the nut to 14 in-lb (1.6
N·m) (Figure 12-33, Page 12-32).
3. Push the light switch shaft in. Screw the knob onto the end of the shaft until the knob touches the outer nut.
Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to the ground.
Tighten the set screw (5) to lock the knob to the shaft.
BATTERY
DANGER
• Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working
on or near batteries.
• Tools, wires, and metal objects can cause sparks when shorted across a battery.
• Follow all instructions carefully when working with batteries.
• Charge battery in a well-ventilated area only.
Antidotes:

– Internal: Drink large quantities of milk or water followed with milk of magnesia or vegetable
WARNING
• Do not jump start a dead battery using another battery and jumper cables.

12 Battery PEDAL-START GAS VEHICLE
GENERAL INFORMATION
See preceding DANGER and WARNING statements.

Gasoline vehicles are equipped with 12-volt, low-maintenance batteries that requires infrequent watering. When
changing a 12-volt battery in any gasoline-powered vehicle, the same size battery with adequate amperage ratings
should be used as a replacement.
A group 70, side-post battery (CC 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 is recommended. The group 70 classification 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 16.5 cm D x 18.4 cm H). It is important to
use the proper size to ensure that the battery clamp will fit correctly.
TESTING THE BATTERY
See Test Procedure 1 – Battery on page 11-9.

See Battery Test (Under Load) on page 11-30.
PREVENTIVE MAINTENANCE
1. To keep the battery in good operating condition, remove any corrosion immediately. Post connections should
be clean and tight. Any frayed or worn wires should be replaced. Properly connect and tighten cables.
See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-3. See preceding WARNINGS and
following CAUTION.
CAUTION
• If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do
so may cause them to overheat during operation and could result in a fire, property damage, or
personal injury.
2. The battery should be kept clean and dry to prevent self-discharge. Any dirt, grime or acid spillage should be
removed. Wash the battery with a bristle brush using water and bicarbonate of soda (1 cup (237 mL) baking
soda per 1 gallon (3.8 L) of water). Rinse with water. Do not allow solution to enter battery through the vent cap
holes. See Self-Discharge on page 12-34.
3. Maintain proper water level. See Water Level on page 12-35.
4. Check battery periodically to see that it is in a full state of charge. See Charging the Battery on page 12-36.
5. Keep battery hold-down clamp tight. See Vibration Damage on page 12-35.
SELF-DISCHARGE
Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery. To prevent
self-discharge, the battery should always be kept clean.
Hot weather also has an effect on a battery’s self-discharge rate. 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 on page 12-37.

PEDAL-START GAS VEHICLE Battery 12
WATER LEVEL
The water level should be checked semi-annually to be sure water is at its proper level (Figure 12-34, Page 12-35).
Never allow the water level to fall below the tops of the plates because this will cause the exposed part of the plate to
become permanently inactive. Check the water level more frequently in hot weather or when the battery becomes old.
2
1
3

Electrolyte level at least 1/2 inch (13 MM) above plates or to
level indicator.
22
Figure 12-34 Battery Electrolyte Level
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. The acid that is lost reduces the
capacity of the battery and cannot be replaced.
MINERAL CONTENT
For the longest battery life, distilled water should be used in the battery. However, if tap water is going to be used,
contact your local water department to be sure mineral contents are below the levels listed in the following table. See
following NOTE.
NOTE: Contact your local water department for mineral content analysis.
IMPURITY ALLOWABLE CONTENT (PARTS PER MILLION)
Suspended matter Trace
Total solids 100.0
Calcium and Magnesium Oxides 40.0
Iron 5.0
Ammonia 8.0
Organic matter 50.0
Nitrates 10.0
Nitrites 5.0
Chloride 5.0

12 Battery PEDAL-START GAS VEHICLE
BATTERY REMOVAL
See General Warnings on page 1-1. Also see DANGER at beginning of Battery topic.
Chock the wheels.
1, Page 1-3.
3. Remove the battery hold-down clamp from the battery.
4. Lift the battery from the vehicle. See following WARNING.
WARNING
• Keep the battery in an upright position to prevent electrolyte leakage. Tipping the battery beyond a
45° angle in any direction can allow a small amount of electrolyte to leak out of the vent hole. Do not
exceed this 45° angle when lifting, carrying or installing battery. The battery acid could cause severe
personal injury when accidentally coming in contact with the skin or eyes, and could damage clothing.
CHARGING THE BATTERY
1. Remove battery from vehicle. See Battery Removal on page 12-36.

2. Charge the battery using an automotive type 12-volt battery charger. Follow all warnings and procedures supplied
by the battery charger manufacturer.
3. Attach the positive (+) charger cable to the positive (+) battery post.
4. Attach the negative (–) charger cable to the negative (–) battery post.
5. 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. See following WARNING.
WARNING
• If the battery case feels hot (approximately 125 °F (52 °C) or more), emits gases, or fluid boils from
vents, stop charging immediately. Failure to stop charging battery when any of these conditions are
present could result in an explosion, personal injury and/or damage to the battery.
• Do not disconnect the charger DC leads from the battery when the charger is on. The resulting arcing
between the DC leads and battery post could cause an explosion.
• If the charger must be stopped, disconnect the AC supply cord from the wall outlet before
disconnecting the DC leads from the battery. Allow the battery to cool to room temperature and
resume charging battery at a lower amp rate.
BATTERY INSTALLATION
1. Place the battery into the vehicle with the battery posts facing the engine.
2. Secure the battery to the vehicle with the clamp and install bolt, washer and locknut and tighten to 144 in-lb (16.3
N·m). A loose battery clamp may allow the battery to become damaged from vibration or jarring.

PEDAL-START GAS VEHICLE Ground Cables 12
BATTERY STORAGE
1. Keep the battery clean and free of corrosion. See Preventive Maintenance on page 12-34.
2. The battery cables should be disconnected from the battery so the battery can be connected to the charger. The
battery can be left in the vehicle. Disconnect the negative (–) cable first.See Disconnecting the Battery –
3. Fully charge the battery prior to storage.
4. Store in a cool, dry area. The colder the area in which the battery is stored, the less the battery will self-discharge.
A battery stored at 0 °F (-17.8 °C) will discharge very little over a four-month period. A battery stored at 80 °F
(27 °C) will have to be recharged every few weeks.
5. Check the state of charge periodically. A battery that is discharged and left in a cold environment can freeze and
crack. If the specific gravity drops below 1.220, the battery should be recharged. See following WARNING.
WARNING
• If the battery is frozen or the container is bulged, discard battery. A frozen battery can explode.
6. The frequency of recharging required depends on the temperature of the storage area, but it is recommended
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. The battery will not charge effectively in cold temperatures for the same reasons that it does not
discharge as rapidly in cold temperatures.
CHARGING A DEAD BATTERY
The vehicle is equipped with a starter/generator. The generator is not designed to charge a dead battery. If the vehicle
battery has become discharged, it must be charged using a properly rated automotive type charger. See following
WARNING.
WARNING
• Do not jump-start a dead battery using another battery and jumper cables.
GROUND CABLES
TESTING THE GROUND CABLES

See Test Procedure 3 – Ground Cables on page 11-12.

SECTION 13 – ENGINE 13
DANGER
WARNING
GENERAL INFORMATION
This gasoline vehicle is powered by a 4-cycle, overhead valve, single cylinder, air-cooled engine. 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 component assemblies: the cylinder
assembly and the crankcase assembly. See following NOTE.
NOTE: Engine rotation is clockwise as viewed from the clutch side of the engine.
This section contains information for removing and replacing the engine. For complete instruction on engine
disassembly, repair, rebuilding, and reassembly, see the Engines and Drivetrain Components: Repair and Rebuild
manual, CC P/N 102396501.
BEFORE SERVICING
Carefully read the applicable information and instructions before beginning engine service. Diagrams, DANGER,
WARNING, CAUTION and NOTE statements and detailed descriptions have been included wherever necessary.
Anyone attempting engine service should have knowledge and experience in small engine service and repair.
ENGINE ROTATION
When turning the crankshaft by hand, always turn it clockwise as viewed from the clutch side of the engine. This
will ensure proper adjustments.
SPARK PLUG
Spark plugs are selected to suit specific engine design and vehicle operating conditions. The spark plug (CC P/N
AM10724) is designed to give maximum life and efficient combustion of fuel. The spark gap should be set to
0.027-0.031 inches (0.69-0.79 mm).

13 General Information ENGINE
Spark Plug Removal

CAUTION
• Before removal and disassembly, clean the engine.
Disconnect battery and spark plug wire(s). See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
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 mixture and
ignition system. If all of the above conditions are proper, the spark plug should be a light brown color. There should be
no bridging between the electrode and base. The electrode should not be eroded. Black color, excessive carbon,
and/or a wet plug indicates that the fuel is too rich. White, burned or melted electrodes indicate the fuel is too lean or
pre-igniting. Oily deposits on the plug electrode are an indication of worn rings, valve guides, cylinder wall, etc. Also
examine the spark plug wire. Remove rubber boot and inspect internal spring for damage. Inspect spark plug wire for
damage and be sure spring coil is securely attached to spark plug. See following WARNING.
WARNING
• Remove spark plug wire to avoid accidental start up of the engine when servicing vehicle. To avoid
ignition of fuel and serious personal injury or death, never try to start the engine with plug removed
from engine.
524
Figure 13-1 Spark Plug
Testing the Spark Plug
Check the sparking ability of a cleaned and properly gapped plug on a sparking comparator if possible. Spark should
be blue and strong and able to jump a 5/16-inch (8 mm) gap.
Setting the Spark Gap
1. Pass a contact point file between the electrodes to produce flat, parallel surfaces to facilitate accurate gauging.
2. Use a wire type gauge. Bend the outside or ground electrode so only a slight drag on the gauge is felt when
passing it between the electrode. Never make an adjustment by bending the center electrode. Set gap (A) to
0.027-0.031 inches (0.69-0.79 mm) (Figure 13-1, Page 13-2).

ENGINE Cylinder Head 13
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” and thread seizing for future replacements.
Install the spark plug by threading it in until finger tight, then tighten the spark plug to 20 ft-lb (27 N·m).
CYLINDER HEAD
GENERAL INFORMATION
Test cylinder compression using a standard compression tester. Low compression would normally indicate a problem
in the cylinder assembly such as defective rings, gaskets, etc. At a cranking speed of 550-600 RPM, the compression
should be 156-185 psi. See the Engines and Drivetrain Components: Repair and Rebuild manual, CC P/N
102396501, for inspection and repair.
BREATHER VALVE (REED VALVE)

General Information
The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the
engine through the piston rings, oil seals or gaskets. The breather has a reed valve which limits the direction of air flow
caused by the piston moving up and down. Air can flow out of the crankcase, but the one-way reed valve blocks return
flow and therefore maintains a vacuum in the crankcase.
Oil laden air in the crankcase passes through the reed valve and expands into the rocker chamber. In the rocker
chamber most oil separates from the air and drains back to the crankcase. The air passes through a tube and
vents to the intake manifold. See the Engines and Drivetrain Components: Repair and Rebuild manual, CC
P/N 102396501, for inspection and repair.
CRANKCASE
ENGINE REMOVAL
To perform repairs on crankcase components, remove engine from the vehicle. See following CAUTION.

13 Crankcase ENGINE
CAUTION
• Before removal and disassembly, clean the engine.
1. Remove the powertrain. See Unitized Transaxle Removal on page 16-7. See following NOTE.
NOTE: The crankshaft has left-hand threads at the clutch mounting hole.
2. Remove starter/generator. See Starter/Generator Removal, Section 12, Page 12-1.

3. Remove drive clutch. See Drive Clutch Removal on page 17-4 and following NOTE.
4. Remove muffler. See Muffler Removal on page 15-1.
5. Remove engine mounting hardware (items 1, 2, 5 and 6) (Figure 13-4, Page 13-5).
6. Lift engine from the mounting plate.
7. Remove crankcase oil drain plug and filler tube. Tip the engine slightly to allow all of the oil to drain from the
crankcase. Dispose of engine oil properly.
CRANKCASE COVER REMOVAL
1. Remove yellow jumper wire (11) from cord connector (12) (Figure 13-2, Page 13-4).
2. Remove nuts and clamps at two-ended bolts (1 and 2) (Figure 13-3, Page 13-4).
3. Remove eight bolts (3) and remove the crankcase cover (4). See following NOTE.
NOTE: If the crankcase cover sticks, tap lightly with a plastic mallet on alternate sides near the dowel pins (5) (Figure
13-3, Page 13-4).
4. Remove the crankcase cover gasket completely. It may stick to the flanged surface of the crankcase.
4
2
11
5 5
12
526 527
Figure 13-2 Oil Level Sensor Wire Figure 13-3 Crankcase Cover

ENGINE Crankcase 13
5 Clu
bC
ar
3
Clu
bC
ar
525
Figure 13-4 Engine Mounting Plate
OIL LEVEL SENSOR

Testing the Oil Level Sensor
See Test Procedure 22 – Oil Level Sensor on page 11-29.
Oil Level Sensor Removal
1. If not already removed, remove crankcase cover. See Crankcase Cover Removal on page 13-4.
2. Disconnect the oil level sensor wire (2) from the cord connection (1) (Figure 13-2, Page 13-4).
3. Remove the screw (3) from the wire clamp (4).
4. Remove the two mounting screws from the inside of the crankcase cover and remove the oil level sensor and
bracket.
5. If necessary, remove the three screws (7) that hold the sensor to the bracket (5).
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).

13 Crankcase ENGINE
2. Position the sensor and bracket on inside of crankcase and install two mounting screws.
3. Connect sensor wire (2) to cord connector (1) (Figure 13-5, Page 13-6).
4. Install screw (3) through wire clamp and into crankcase cover. Tighten to 30 in-lb (3.4 N·m).
2
3
1 7
4
6
8
9
528
Figure 13-5 Oil Level Sensor
CRANKCASE COVER INSTALLATION
CAUTION
• Before assembly, make sure parts are clean.
• Do not reuse the gasket. Install a new one.
• Install and tighten crankcase cover bolts as instructed. Failure to do so could cause the cover to
become warped.
1. Clean the gasket surfaces on the crankcase cover to fit a new gasket during installation and inspect the oil seal
for wear and damage.
2. Install crankcase cover. Using HANDS ONLY, seat cover completely against the crankcase. If the cover will not
seat, the camshaft is not installed correctly.
3. Install and finger tighten evenly the eight cover mounting bolts (Figure 13-6, Page 13-7).
4. Tighten the cover mounting bolts in two steps. First, in the sequence shown, tighten all eight bolts to approximately
130 in-lb (14 N·m). Then, repeating the sequence, tighten them to 250 in-lb (28.2 N·m) (Figure 13-6, Page 13-7).
5. Connect the yellow jumper wire (11) to the cord connector (12) (Figure 13-2, Page 13-4).

ENGINE Ignition Coil and Flywheel 13
1 7
6 4
530
Figure 13-6 Crankcase Cover Installation
IGNITION COIL AND FLYWHEEL
IGNITION COIL AND FLYWHEEL REMOVAL
1. Loosen three screws (2) and remove the remaining four screws (1) attaching the flywheel housing as shown,
then remove the housing (Figure 13-7, Page 13-7).
2. Disconnect the ignition coil (11) from its primary lead wire at the connector (12). Remove the two bolts (10) and
take out the ignition coil (Figure 13-8, Page 13-7).
12
2
13
10
1 11
1
531 510
Figure 13-7 Flywheel Housing Figure 13-8 Ignition Coil
3. Hold the flywheel (4), not the fan (7), with a strap wrench (5) and, using a 25 mm socket, remove the flywheel nut
(and flat washer) by turning it counterclockwise (Figure 13-9, Page 13-8). See following CAUTION.

13 Ignition Coil and Flywheel ENGINE
CAUTION
• The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen.
• Do not damage the fan blades with the strap wrench. Do not place screwdriver or pry bar in the
fan blades.
4. Remove the flywheel with a puller (CC P/N 1016627).

5. Remove the flywheel key from its groove.
48 1
5
MF 3
7 0.012 Inch
(0.304 mm)
532 512
Figure 13-9 Flywheel Nut Figure 13-10 Adjust Ignition Coil Air Gap
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.
2. Use a strap wrench (3) to keep the flywheel and fan assembly (1) from turning while tightening the flywheel nut to
63 ft-lb (85.4 N·m) (Figure 13-11, Page 13-9). See following CAUTION.
CAUTION
• The flywheel nut has right-hand threads. Turn it clockwise to tighten, or counterclockwise to loosen.
• Be careful not to damage the fan blades. Use a strap wrench to hold flywheel. Do not place screwdriver
or pry bar between fan blades.
3. Install the fan housing and tighten the screws to 90 in-lbs (10 N·m).

ENGINE Engine Installation 13
48 1
MF 3
533
Figure 13-11 Fan and Flywheel Installation
IGNITION COIL INSPECTION AND REPAIR
See Test Procedure 15 – Ignition Coil on page 11-21.
IGNITION COIL INSTALLATION
1. Installation is the reverse of removal.

2. While tightening the two bolts (6), use a bronze feeler gauge to adjust the ignition coil air gap to 0.012 inch
(0.304 mm) (Figure 13-10, Page 13-8).
3. Tighten the two ignition coil bolts to 30 in-lb (3.4 N·m).
CRANKCASE COVER INSTALLATION
See Crankcase Cover Installation on page 13-6.
ENGINE INSTALLATION
1. Place engine onto engine mounting plate and tighten the mounting hardware (1, 2 and 5) to 13 ft-lb (17.7 N·m).
Tighten nuts (6) to 17 ft-lb (23.1 N·m) (Figure 13-4, Page 13-5).
2. Install drive clutch. See Drive Clutch Installation on page 17-11.
3. Install drive belt. See Drive Belt Installation on page 17-3.
4. Install muffler. See Muffler Installation, Section 15, Page 15-1.
5. Install starter/generator and belt. See Belt Tension Adjustment on page 12-12.
6. Install the powertrain. See Unitized Transaxle Installation on page 16-15.
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 correct

13 Torque Specifications ENGINE
type of oil. This engine should be regarded as a new engine for next scheduled oil change. See Periodic
Maintenance, Section 10, Page 10-1.
8. Check all hardware for proper torque/tightness.
9. Check engine oil level (Figure 13-12, Page 13-10).
9.1. With vehicle on level surface, remove dip stick and clean with cloth (Figure 13-12, Page 13-10).
9.2. Reinsert dip stick until fully seated.
9.3. Oil must be in the SAFE LEVEL range.
CAUTION
• Do not overfill with oil.
1.Full level 2. Safe level 3. Low level.
23
Figure 13-12 Check Engine Oil Level
10. Install a new or cleaned spark plug gapped to 0.027-0.031 inch (0.69-0.79 mm).
12. Adjust the engine RPM setting. See Engine RPM Adjustment on page 14-11.
13. Test-drive vehicle to ensure all systems are functional and correctly adjusted.
TORQUE SPECIFICATIONS
ITEM SIZE LIMITS

Flywheel retaining nut M16 63 ft-lb (86 N·m)
Crankcase cover to block bolts M8 250 in-lb (28.3 N·m)
Starter/Generator bracket to block bolts M8 200 in-lb (23 N·m)
Oil drain plug M14 20 ft-lb (27.1 N·m)
Fan housing screws M6 90 in-lb (10 N·m)
Fan shroud screws M6 25 in-lb (2.8 N·m)
M8 130 in-lb (15 N·m)

Bolts marked with “4” (when used with nuts) M6 50 in-lb (5.9 N·m)
M5 30 in-lb (3.4 N·m)

ENGINE Adjustments and Settings 13
ADJUSTMENTS AND SETTINGS
ITEM LIMITS
Spark plug gap (standard) 0.027 to 0.031 in. (0.69 to 0.79 mm)
Ignition coil air gap (standard) 0.012 in. (0.304 mm)
Compression pressure (min.) 156 psi (1076 kPa)
Engine RPM 2700 (±30) RPM

SECTION 14 – FUEL SYSTEM 14
DANGER
WARNING
GENERAL INFORMATION
The engine is equipped with a float bowl type carburetor with fixed jets that require no adjustment. The carburetor
atomizes the fuel, mixes it with air, and feeds the combustible mixture into the cylinder.
CARBURETOR
Before suspecting the carburetor as the cause of poor engine performance, make sure the fuel and ignition systems
are in proper operating condition. Check the following items:
• Spark plug and gap condition. See Spark Plug on page 13-1.
• Air filter element. See Air Filter on page 14-15.
• Fuel filters. See Fuel Filters on page 14-16.
• Choke and air intake system (for restriction of air flow). See Choke and Air Intake System on page 14-12.
• Fuel pump.
• Fuel lines. See Fuel Lines on page 14-24.
• Exhaust system (for restrictions). See Exhaust System: Gasoline Vehicles, Section 15, Page 15-1.
If the carburetor floods or leaks fuel at the float bowl gasket or carburetor vent tube, the fuel inlet valve could be worn
or dirty. Another cause of this condition may be a damaged float that has filled with fuel and sinks.
For elevations above 3000 feet, main jets other than standard operate more effectively. The following chart lists the
elevation ratings for various jet sizes. No adjustment is required for the pilot jet. If the vehicle idles roughly, turn
the pilot air screw out until the vehicle idles smoothly.

14 Carburetor FUEL SYSTEM
1
2
3
000
000 000
10
000
11
21 000
30
15
21
000
12
13
14
26
000
000
16
17
18
19 22
23
534
Figure 14-1 Carburetor Mounting

FUEL SYSTEM Carburetor 14
MAIN JET ELEVATION/SIZE CHART
ALTITUDE FE290D-FS17 ENGINE MAIN JET SIZE

0-3000 ft. (0-914.4 m) 82
3000-5000 ft. (914.4-1524 m) 80
5000-8000 ft. (1524-2438.4 m) 78
8000-10,000 ft. (2438.4-3048 m) 75
10,000 ft. and over (3048 m and over) 72
ALTITUDE FE290D-GS17 ENGINE MAIN JET SIZE

0-3000 ft. (0-1000 m) 85
3000-10,000 ft. (1000-3000 m) 82
10,000 ft. and over (3000 m and over) 80
CHANGING THE MAIN JET
1, Page 1-3.
2. Remove the carburetor.
2.1. Turn fuel shut-off valve on fuel tank to the closed (OFF) position (Figure 14-18, Page 14-25).
2.2. Loosen the intake air hose clamp (22) and disconnect the intake air hose (23) at the carburetor end only
2.3. Remove the governor guard (5).
2.4. Disconnect the governor cable (30) from the carburetor.
2.5. Disconnect the carburetor vent line (14).
2.6. Disconnect the fuel supply line (26) at the carburetor end only. Temporarily plug the end of the fuel line to
prevent fuel leakage.
2.7. Remove the carburetor retaining nuts (19), intake pipe (17), and carburetor (12). See following NOTE.
NOTE: Note the orientation of the gasket (16), between the carburetor intake pipe (17) and the carburetor body (12)
so that it can be replaced in the same orientation (Figure 14-1, Page 14-2).
When removing the carburetor body, the throttle return spring (11) must be disconnected. Note its proper
orientation so that it can be replaced in the same orientation.
The carburetor must be kept upright during removal.
3. Position the carburetor with the drain screw (11) over a catch basin (Figure 14-4, Page 14-4).
4. Turn the carburetor bowl drain screw counterclockwise two or three turns and drain all the fuel from the bowl
into the catch basin (Figure 14-2, Page 14-4). Tighten the drain screw to 10 in-lb (1.1 N·m). Return fuel to the
fuel tank or dispose of properly.
5. Mark the body of the carburetor and the carburetor fuel bowl with an indelible ink marker so that, after removal,
the bowl can be installed again in the same position (Figure 14-3, Page 14-4).

14 Carburetor FUEL SYSTEM
535 536
Figure 14-2 Drain Bowl Figure 14-3 Mark Carburetor and Bowl for Alignment
6. Remove the carburetor fuel bowl retaining screw and washer (12), then remove the fuel bowl (10) and clean it
with a nonflammable solvent (Figure 14-4, Page 14-4). See following NOTE.
NOTE: Make sure the fuel bowl gasket (9) remains properly seated in the carburetor body when the fuel bowl
is removed (Figure 14-4, 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.
7. Remove the main jet (8) from the carburetor body and discard it (Figure 14-4, Page 14-4). See following NOTE.
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 14-4, Page 14-4).
3 2
1
4
9
7
8 11
10 12
537
Figure 14-4 Carburetor Components

FUEL SYSTEM Carburetor 14
8. Select the proper size main jet. See Main Jet Elevation/Size Chart on page 14-3. Check the size designation
on the jet to make sure it is the correct part.
9. Install the new main jet and tighten it to 12 in-lb (1.4 N·m). See following CAUTION and NOTE.
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 (Figure 14-4,
Page 14-4). Replace any part that is clogged with contamination. Replace the float if it is damaged, or
if the float valve is damaged or worn. Examine the float valve/spring assembly to make sure the spring is
installed correctly (Figure 14-5, Page 14-5).
10. Install the fuel bowl. Make sure that it is positioned properly by aligning the marks applied in step 4. See
following CAUTION.
CAUTION
• Make sure the fuel bowl is properly seated against the carburetor fuel bowl gasket, and the gasket
is not pinched.
5
2
1. If spring looks like this... 2. then adjust spring to look like this by... 3. holding float firmly and rotating valve counterclockwise to seat
spring in seat of float bowl 4. Check for coil located in groove above both ears. 5. Check for spring seated in recess of float.
538
Figure 14-5 Inspect Float Valve/Spring Assembly – Adjust If Required
11. Install the fuel bowl retaining screw and tighten it to 61 in-lb (6.9 N·m).
12. Write the size of the main jet on the fuel bowl with an indelible ink marker. This should be written in a location that
will be visible when the carburetor is installed on the engine.
13. Install the carburetor on the engine (Figure 14-1, Page 14-2).
13.1.Attach the throttle return spring (11) to the carburetor and then to the throttle bracket (4) just before
positioning the carburetor and securing it to the engine (Figure 14-1, Page 14-2).
13.2.Install the intake pipe gasket (16) (check for proper orientation) and intake pipe (17).
13.3.Install the carburetor retaining nuts (19) and tighten them to 50 in-lb (5.7 N·m).
14. Connect fuel supply line (26) and tighten screw clamp to 9 in-lb (1.0 N·m) (Figure 14-1, Page 14-2).

14 Engine Control Linkage FUEL SYSTEM
15. Install carburetor vent line (14) and clamp (13).

16. Install the governor cable (30).
17. Install the governor guard (5), flat washer and nylon lock nut. Tighten to 30 in-lb (3.4 N·m).
18. Install the intake hose (23) and secure with hose clamp.
NOTE: Make sure the intake hose is not twisted during installation.
19. Turn fuel shut-off valve on top of fuel tank to the ON position (Figure 14-18, Page 14-25).
21. Test drive the vehicle.
ENGINE CONTROL LINKAGE
DANGER
• To ensure the vehicle does not run over you while you disconnect or adjust the accelerator push
rod, do the following:
– Turn key switch OFF and remove key, place Forward/Reverse handle in the NEUTRAL position,
and chock the wheels prior to servicing the vehicle.
– Disconnect battery cables, negative (–) cable first.
– Disconnect the spark plug wire from the spark plug.
– See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-3.
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
• Improper adjustment can result in poor vehicle performance and/or damage to the engine components.
ACCELERATOR ROD
Accelerator Rod Removal
1. Raise the front of the vehicle. Place chocks at the rear wheels and lift the front of the vehicle with a chain hoist or
floor jack. Place jack stands under the round frame cross tube to support the vehicle. See preceding DANGER.
See also WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-1.
2. Remove the accelerator rod by disconnecting the ball joint (1) from the ball stud (2) on the accelerator pedal
(Figure 14-6, Page 14-7) and from the bell crank at the electrical box (Figure 14-8, Page 14-8).

FUEL SYSTEM Engine Control Linkage 14
3
1
539
Figure 14-6 Accelerator Rod
Accelerator Rod Installation and Adjustment
1. Before installing the accelerator rod, adjust accelerator pedal position. See Pedal Group Adjustment –
Gasoline Vehicles on page 5-10.
2. Install the ball joint on the ball stud at the accelerator pedal (Figure 14-6, Page 14-7).
4. Remove the electrical box screw and cover (Figure 14-7, Page 14-8).
5. Adjust length of accelerator rod. With the ball joint jam nuts (3) loose (Figure 14-6, Page 14-7), adjust the
length of the rod to obtain an accelerator cable cam position of 14° as shown (Figure 14-7, Page 14-8). See
following CAUTION.
CAUTION
• Be sure that approximately an equal number of threads are exposed at each end of the accelerator rod.
6. Install the accelerator rod on the bell crank ball joint on the electrical component box (Figure 14-8, Page 14-8).
CAUTION
• Inspect the limit switch inside the electrical box. If the limit switch lever is bent, replace the switch.

14°
1344 1345
Figure 14-7 Accelerator Cable Cam Position – 14° (Top Figure 14-8 Accelerator Rod – Pull Spring Release to
View) Attach (Bottom View)
7. Before tightening the jam nuts, set the park brake to the first latch and pawl position and check for proper
activation of switches.
8. While pressing the accelerator pedal, the following events should occur in exactly the order shown:
EVENT APPROXIMATE PEDAL TRAVEL
Park brake release 0°-4°
Solenoid activation 4°-8°
Carburetor throttle actuation 8°-12°
9. While holding the accelerator ball joint with pliers, tighten the jam nuts against the ball joints, accelerator ball joint
first, at each end of the accelerator rod.
10. Check rod adjustment for proper switch activation.
11. After the pedal group and accelerator rod are properly adjusted, adjust the engine RPM setting. See Engine
RPM Adjustment, Section 14, Page 14-11.
12. Install the electrical box cover and tighten retaining screw to 18 in-lb (2.0 N·m).
GOVERNOR CABLE
Governor Cable Removal
1. Turn the key switch to the OFF position and remove the key, place the Forward/Reverse handle in the NEUTRAL
position, and chock the wheels.
1, Page 1-3.
4. Remove the governor guard (if equipped).
5. Disconnect the governor cable (2) at the carburetor throttle.
6. Disconnect the governor cable (2) from the governor lever arm (15) (Figure 14-9, Page 14-9).
7. Remove the governor cable (2) from the governor cable engine bracket (11), and governor cable support bracket
(10) (Figure 14-9, Page 14-9). Remove the cable (2) from the vehicle.

Governor Cable Installation and Adjustment
1. Install the cable onto the governor cable support bracket (10) and the engine bracket (11) (Figure 14-9, Page
14-9).
2. Push the cable dust shields onto the ends of the cable conduit.
3. Connect the governor cable to the carburetor throttle at the carburetor.
4. Connect the governor cable to the governor lever arm (15) (Figure 14-9, Page 14-9).
5. With the governor lever arm loose on the governor shaft, use a 1/8-inch punch or scratch awl to turn the governor
arm shaft counterclockwise until it stops. Then pull the governor lever arm rearward until the carburetor throttle is
in the “wide open throttle” (WOT) position.
6. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to
36 in-lb (4.0 N·m).
7. Check engine RPM adjustment. See Engine RPM Adjustment, Section 14, Page 14-11.
16
4 3
6
2
1
2 15
10
17
6
12
13
11
14
542
Figure 14-9 Governor and Accelerator Cables

ACCELERATOR CABLE
Accelerator Cable Removal
1, Page 1-3.
3. Remove the electrical box screw and cover and loosen the cable housing retaining nuts (Figure 14-7, Page 14-8).
4. Disconnect cable (1) from cam (17) in the electrical box (Figure 14-9, Page 14-9).
5. Disconnect the spring (16) from the engine governor arm.
6. Remove the accelerator cable from the accelerator cable bracket (5). Remove the cable assembly from the
vehicle.
Accelerator Cable Installation
1. Connect the cable to the cam (17) in the electrical box (Figure 14-9, Page 14-9).
2. Insert the cable housing into the mounting slot in the wall of the electrical box, with approximately the same
number of threads visible between the jam nuts as are visible from the nut inside the box to the end of the cable
housing (Figure 14-7, Page 14-8). Tighten the nuts finger-tight.
3. Connect the spring (16) to the engine governor arm (Figure 14-9, Page 14-9).
4. Install cable in accelerator cable bracket (5) (Figure 14-9, Page 14-9).
5. Push the cable dust shield onto the spring end of the cable conduit.
6. Before tightening the cable housing retaining nuts, make sure the engine RPM adjustment is correct. See
Engine RPM Adjustment, Section 14, Page 14-11.
7. Install the electrical box cover, and tighten the retaining screw to 18 in-lb (2.0 N·m).
CLOSED THROTTLE OR IDLE ADJUSTMENT
When the accelerator pedal is released, the engine will stop. Therefore, it is not possible to measure or set idling
speed under normal vehicle operating conditions. Set throttle valve as follows:
1. Loosen the carburetor idle screw so that it is not touching the throttle lever (Figure 14-10, Page 14-11).
2. Slowly tighten the idle screw until it lightly touches the throttle lever, then tighten it an additional 3/4 turn.

543
Figure 14-10 Idle Screw
ENGINE RPM ADJUSTMENT
DANGER
1. If the governor is adjusted, proceed to step 2; otherwise, adjust the governor. See Governor Cable Installation
and Adjustment on page 14-9.
3. Place the Forward/Reverse handle in the NEUTRAL position, chock the wheels, and the neutral lockout cam in
the MAINTENANCE position.
4. Connect a tachometer (CC P/N 1016112) to the spark plug lead.
5. With the tachometer connected, and the engine at normal operating temperature, check high speed RPM. With
the accelerator pedal pressed to the floor, the tachometer should read 2700 ±30 RPM.
6. To reduce RPM, loosen the accelerator cable retaining nut on the outside of the electrical box wall and tighten
the retaining nut on the inside of the wall until the specified RPM is reached (Figure 14-7, Page 14-8). To
increase RPM, loosen the cable retaining nut inside the electrical box and tighten the nut outside the box until
the specified RPM is reached.
7. Be sure both retaining nuts are locked against the electrical box and then check the RPM again. If the RPM
needs to be adjusted, repeat step 6.
8. If more adjustment is required than the cable housing will allow, make sure the spring on the other end of the
accelerator cable is properly positioned. Excessive belt and torque converter wear can also prevent proper RPM
adjustment. Check them for excessive wear. See Section 17 – Torque Converter: Gasoline Vehicle.

14 Choke and Air Intake System FUEL SYSTEM
CHOKE AND AIR INTAKE SYSTEM
CHOKE BUTTON REMOVAL
1. Remove the mounting screws (22) from the back side of the choke. Remove the choke assembly from the
vehicle body (Figure 14-12, Page 14-14).
CHOKE BUTTON INSTALLATION
1. Position the choke assembly (2) on the vehicle body. Install the mounting screws (22) from inside the vehicle
body and tighten to 18 in-lb (2.0 N·m) (Figure 14-12, Page 14-14).
2. Check for proper operation. If the choke button does not adequately engage the choke lever (20), loosen the
screw (30) and adjust the choke bracket (23) on the choke lever (20). Move the bracket toward the choke button
to increase choke engagement and away from the choke button to reduce choke engagement.
AIR BOX REMOVAL
1, Page 1-3.
3. Remove the air intake box from the vehicle by removing intake hose (21) and three screws (1) and washers (29)
that mount the intake box to the vehicle (Figure 14-12, Page 14-14).
AIR BOX INSTALLATION

NOTE: The intake duct must be in place before the air box can be installed.
1. Check to be sure the intake seal (11) is seated correctly (Figure 14-12, Page 14-14). The seal fits tightly onto the
bottom side of the air box. If seal is not in place, moisture will enter the air intake system.
2. Place the air box assembly into vehicle and install three flat washers (29) and screws (1) from underside of air
box mounting plate into air box (Figure 14-12, Page 14-14). Tighten to 33 in-lb (3.7 N·m).
3. Place hose onto air box and secure with wire clamp. If equipped with screw clamp, tighten to 17 in-lb (1.9 N·m).
4. Test choke for proper operation.
INTAKE DUCT REMOVAL
2. Remove the front left wheel. See Wheel Removal, Section 8, Page 8-1.
3. Remove the steering joint assembly (Figure 14-11, Page 14-13).

FUEL SYSTEM Choke and Air Intake System 14
2
TYPICAL 3
3 PLACES
1
544
Figure 14-11 Compound Steering Joint
4. Drill out the two pop rivets (27) securing the intake duct to the floorboard (Figure 14-12, Page 14-14).
5. Remove three screws (1) and flat washers (29) from the bottom of the air box assembly.
6. Lift air box assembly off the intake duct. Be careful that the intake seal on the bottom of the air box assembly is
not dislodged in the process.
7. Pull the intake duct forward and out of the vehicle.
INTAKE DUCT INSTALLATION
The intake duct assembly is installed from the front of the vehicle.
1. Slide the intake duct between the round crossmember and the floorboard, moving it to the rear along the underside
of the floorboard. Insert the end of the intake duct through the slot in the front of the air box mounting plate.
2. Secure the front of the duct to the underside of the floorboard with two pop rivets (27) and flat washers (28)
(Figure 14-12, Page 14-14).
3. Install air box. See Air Box Installation on page 14-12.
4. Install steering joint assembly (1) (Figure 14-11, Page 14-13). Tighten bolts (2) to 15 ft-lb (20.3 N·m). See
following NOTE.
NOTE: Make sure steering wheel and front wheels are properly aligned before installing steering joint.
5. Install front left wheel. See Wheel Installation, Section 8, Page 8-1.
6. Install front body. See Front Body Installation, Section 4, Page 4-6.

14 Choke and Air Intake System FUEL SYSTEM
22
23
8 26 19
21 20
10
12
26
15
22
2 18
4 16
5
3 17
14
00
0
00
11
24 27
28
27
28
28
29
28
1346
Figure 14-12 Air Intake and Choke Assemblies

FUEL SYSTEM Choke and Air Intake System 14
AIR FILTER
General Information
The air filter should be checked every year or 100 hours. More frequent service may be required in extremely dirty
operating environments. Need for immediate servicing will be indicated by a loss of power, sluggish acceleration, or an
engine which runs roughly with excessive black exhaust smoke.
Air Filter Replacement
1. Lift two latches (12) on the side of the air box (Figure 14-12, Page 14-14).
2. Remove the hose clamp (26) from the air hose (21) and remove hose from the air box assembly.
3. Standing on driver side of vehicle, grasp air hose mounting inlet and open box fully. Remove filter element (7).
4. Using a clean cloth, wipe away any dust or dirt from inside the air box. Remove all dirt build-up around the
inside lip of the box or the box will not seal properly.
5. Install new air filter by inserting back edge first, and pushing down using the palm of your hand to seat filter
evenly onto inside lip of air box. Ensure filter fits correctly and that the wire latches are not caught between
lid and air box. Close the lid.
6. Fasten wire latches (12). Make sure latches securely engage the bottom half of the box. See following
CAUTION.
CAUTION
• Engine damage will occur if the air box cover is not properly secured.
• If air box is extremely dirty, remove air box from vehicle and clean thoroughly.
• Use only Club Car replacement air filters (CC P/N 1015426). The use of other air filters could result
in engine damage. If the air filter is too thin, the cover will seat before the filter can seal, leaving
space for dirt to pass into the engine on all sides of the element. This will damage the engine and
void the warranty.
7. Install hose (21) and hose clamp (26) (Figure 14-12, Page 14-14). If equipped with screw clamp, tighten to 17
in-lb (1.9 N·m). Make sure clamp ends are located in the 12:00 o’clock position.

14 Fuel Filters FUEL SYSTEM
FUEL FILTERS
FUEL FILTER REMOVAL
3. To prevent fuel drainage, turn the fuel shut-off valve (15) (Figure 14-13, Page 14-17) on the fuel tank to the
closed (OFF) position (Figure 14-18, Page 14-25).
4. Remove the clamps (16) and fuel lines (1 and 2) from the filter and plug the fuel lines.
FUEL FILTER INSTALLATION
CAUTION
• Fuel filters are marked with flow direction arrows. Make sure that filters are installed with arrows
pointing in the direction of fuel flow from tank to carburetor.
NOTE: This gasoline vehicle complies with the California Air Resources Board (CARB) evaporative emissions
regulations when equipped with MARK 4 DAYPERM C-U-06-030 or AVON GREENBAR G-05-018 fuel
hose (CC P/N 102865101). To remain in compliance with California regulations, replace any fuel hose on
this vehicle with Club Car P/N 102865101 having ‘DAYPERM C-U-06-030’ or ‘AVON GREENBAR G-05-018’
printed on the hose, or equivalent.
1. Install the fuel filter (17) in the fuel line. Use new clamps (16) (Figure 14-13, Page 14-17).
2. Turn the fuel shut-off valve to the ON position (Figure 14-18, Page 14-25).
the MAINTENANCE position. See following DANGER.
DANGER
• Repair all fuel leaks before operating the vehicle.
5. Start the engine and check for fuel leaks.

6. Place the neutral lockout cam in the OPERATE position.

FUEL SYSTEM Fuel Filters 14
5 14
15
18
14 10
2 16 17
19
16
1
16
16 11
16 24
3 16 12
23 4 14
16
26 25 6
FUEL LINE NO. ROUTING
1 Fuel tank to fuel filter
2 Fuel filter to fuel pump
3 Fuel pump to carburetor
4 Vent tube (Carburetor)
5 Vent tube (Fuel Tank)
6 Impulse line
1347
Figure 14-13 Fuel and Vent Lines

14 Fuel Pump FUEL SYSTEM
FUEL PUMP
NOTE: A plastic fuel pump replaced the metal fuel pump during the 2010 model year. This plastic pump cannot
be disassembled and must be replaced.
GENERAL INFORMATION
The gasoline vehicle is equipped with an impulse fuel pump. If the fuel pump is not operating properly, perform
the following tests:
• Make sure all hose clamps are tight.
• Inspect the impulse line and fuel lines for damage or clogging.
• Make sure the air vent on the fuel pump is not clogged with dirt.
• Make sure the fuel filters are not clogged.
NOTE: To clean the air vent, the fuel pump must be disassembled (metal pump) or replaced (plastic pump).
FUEL PUMP REMOVAL
3. Turn fuel shut-off valve on top of the fuel tank to the closed (OFF) position (Figure 14-18, Page 14-25).
4. Remove hardware attaching the fuel pump (24) and lift the fuel pump out of the engine compartment (Figure
14-13, Page 14-17).
5. Remove the clamp and impulse line (7) from fuel pump.
6. Disconnect the fuel lines (2 and 3) from the pump and plug them to prevent fuel leakage. See following
WARNING.
WARNING
• Carefully drain any fuel remaining in the pump into an approved container. Add drained fuel back
into fuel tank or dispose of properly.
FUEL PUMP DISASSEMBLY (METAL PUMP ONLY)
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. If leaking occurs, all new gaskets and
diaphragms must be installed.
NOTE: A fuel pump rebuild kit is available from your distributor/dealer (CC P/N 1014524). This kit includes all
gaskets, diaphragms, and valves.
1. Match mark the fuel pump and cover before disassembly.

FUEL SYSTEM Fuel Pump 14
2. Remove four screws (24) and lock washers (25) from front of the fuel pump (Figure 14-14, Page 14-19).
3. Remove the front cover (37) of the fuel pump while holding the rest of the pump intact.
4. Note the orientations of the impulse gasket (27), the diaphragm (28), and the gasket (29), then remove them
from the pump.
5. If the impulse gasket (27) and the diaphragm (28) come off with the front cover, note their orientations and
remove them (Figure 14-14, Page 14-19).
6. Remove the pumping chamber (30).
7. Remove the back cover (36), the fuel diaphragm (34), and gasket (35) (Figure 14-14, Page 14-19).
FUEL PUMP CLEANING AND INSPECTION (METAL PUMP ONLY)
1. Using a nonflammable solvent, clean the front cover, pumping chamber, and back cover. Be sure the vent
(40) on the front cover is clean both inside and out.
2. Inspect the valve assemblies (31, 32, and 33) and all gaskets and diaphragms for damage (Figure 14-14,
Page 14-19).
3. If a valve assembly is damaged, the rubber retaining plug (33) and valve assembly must be replaced.
33 32
2
24 31 1
40 39 30
25
37
38 3
27
5
34
4
28
35
29
36
1. Fuel Outlet 2. Vent 3. Fuel Inlet 4. Impulse Line 5. Direction of
Fuel Flow
547 548
Figure 14-14 Fuel Pump Figure 14-15 Fuel Pump Orientation
FUEL PUMP ASSEMBLY (METAL PUMP ONLY)
1. Install the fuel gasket (35) and diaphragm (34) on the back cover (36) (Figure 14-14, Page 14-19).
2. Install the valve assembly in the pumping chamber (30). See following CAUTION.

14 Fuel Pump FUEL SYSTEM
CAUTION
• If the valve assembly is not installed exactly as shown (Figure 14-14, Page 14-19), the impulse fuel
pump will not operate properly.
3. Install the pumping chamber (30) on top of the fuel diaphragm (34). Be sure the fuel inlet (38) and the fuel outlet
(39) align with the arrows on the front of the front cover (Figure 14-14, Page 14-19).
4. Install the gasket (29), clear impulse diaphragm (28), and the paper impulse gasket (27) to the pumping chamber
(30).
5. Install the front cover (37) and then the lock washers (25) and four screws (24) on the assembly (Figure 14-14,
Page 14-19). Be sure the arrows on the front cover point from the fuel inlet to the fuel outlet (Figure 14-15,
Page 14-19). Tighten the screws to 26 in-lb (3.0 N·m).
FUEL PUMP INSTALLATION

1. Connect to the fuel pump the fuel line (2) that comes from the fuel filter (17). Install a new clamp (16). Route
the fuel lines as shown (Figure 14-13, Page 14-17).
NOTE: Be sure to connect the fuel line (2), that comes from the fuel filter (17), to the inlet nipple on the pump.
Direction of fuel flow is indicated by the arrows on the fuel pump (Figure 14-13, Page 14-17). See also
Figure 14-15, Page 14-19.
2. Connect to the output side of the fuel pump, the fuel line (3) that goes to the carburetor.
3. Connect the impulse line (7) to the bottom nipple on the fuel pump. Use a new clamp (16).
4. Install the fuel pump. Tighten hardware to 40 in-lb (4.5 N·m) (Figure 14-13, Page 14-17).
6. Turn the fuel shut-off valve on top of the fuel tank to the open position (Figure 14-18, Page 14-25).
DANGER
8. Start the engine and check for fuel leaks. If the fuel pump leaks, a rebuild kit must be installed to replace all
gaskets and diaphragms.

FUEL SYSTEM Fuel Tank 14
FUEL TANK
GENERAL INFORMATION
The vehicle is equipped with a high impact plastic, seven gallon (26.5 liter) fuel tank.
WARNING
• If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank removal
and disposal procedure.
CAUTION
• Add only unleaded fuel to the tank. Do not put oil in the fuel tank.
FUEL TANK REMOVAL
the MAINTENANCE position.
2. Remove the rear body.
3. Turn fuel shut-off valve to the closed (OFF) position and run the engine until fuel remaining in the carburetor, fuel
pump, and fuel lines is used up and the engine stalls (Figure 14-18, Page 14-25).
4. Turn the key switch to the OFF positon, and remove the key.
6. Return the neutral lockout cam to the OPERATE position.
7. Loosen, but do not remove, the carburetor drain screw (11) and drain fuel remaining in the carburetor bowl into an
approved container (Figure 14-4, Page 14-4). Retighten carburetor drain screw.
8. Using a siphon with a suction device, siphon all fuel out of the tank and into an approved container. See
following DANGER and WARNING.
DANGER
• Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Service only in a well-ventilated area.

14 Fuel Tank FUEL SYSTEM
WARNING
• Do not attempt to siphon fuel using a hose that does not have a built-in suction device.
• Do not attempt to siphon fuel using your mouth.
9. If vehicle is equipped with a fuel gauge, disconnect the black wire and orange wire from the fuel level sending
unit on the tank (Figure 14-16, Page 14-22). Do not remove the lower nut on the center stud of the sending
unit. See following WARNING.
WARNING
• Make sure the key switch is off before disconnecting wiring.
10. Remove the vent tube (6) and fuel line (1) from the fuel tank (Figure 14-13, Page 14-17).
11. Loosen the strap (18) by removing the screw (12) from the speed nut (11).
12. Lift the fuel tank out of the vehicle.
549
Figure 14-16 Fuel Level Sending Unit
FUEL TANK DISPOSAL
1. Remove the cap from the tank and thoroughly rinse it with water. The cap may be discarded or kept as a spare.
2. In a well-ventilated area, flush the fuel tank with water to remove any remaining fuel.
3. In a well-ventilated area, set the tank upside down so that the water can drain out of it. To make sure that the tank
dries completely, allow the tank to sit for 24 hours. See following CAUTION.
CAUTION
• Dispose of wastewater and fuel tank in accordance with local, state, and federal laws and ordinances.
FUEL TANK STORAGE
1. Remove the cap from the tank and thoroughly rinse it with water.
2. In a well-ventilated area, flush the fuel tank with water to remove any remaining fuel.

FUEL SYSTEM Fuel Tank 14
3. In a well-ventilated area, set the tank upside down so that the water can drain out of it. To make sure that the tank
dries completely, allow the tank to sit for 24 hours.
4. Store the tank upside down, with the cap installed, in a well-ventilated area.
FUEL TANK INSTALLATION

1. With the retaining strap correctly positioned, install the fuel tank in the vehicle.
2. Secure the tank with the retaining strap (18) (Figure 14-13, Page 14-17).
2.1. Position the strap in the indention on the tank.
2.2. Install the screw (12) into the speed nut (11). Tighten screws and nuts to 25 in-lb (2.8 N·m).
3. Install the rear body on the vehicle if removed.
4. Install seat back support if removed.
5. Connect the vent tube (6) to the fuel tank vent (Figure 14-13, Page 14-17).
6. Connect the fuel line (1) to the fuel tank shut-off valve (15). Use a new clamp (Figure 14-13, Page 14-17).
7. If the vehicle has a fuel gauge, connect the black wire from the fuel gauge to one of the fuel level sending unit
screws. Connect the orange wire to the center stud and install the flat washer, lock washer, and nut. Tighten to
18 in-lb (2.0 N·m).
8. Slide the rubber boot over the stud (Figure 14-16, Page 14-22).
9. Add fuel to the tank.
11. Check to be sure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 14-18,
Page 14-25).
13. Turn the key switch to the ON position and press the accelerator to start the engine. See following DANGER.
DANGER
• After installing the fuel tank and adding fuel, carefully check all fuel lines and connections for leaks.
Repair any fuel leaks before operating the vehicle.
14. Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel.
15. Inspect each fuel line for leaks.
15.1.Check all of the fuel line clamps at the carburetor, fuel filter, fuel pump, and fuel tank for leaks.
15.2.Inspect each fuel line to ensure that the lines are not cracked, cut, or worn.

14 Fuel Lines FUEL SYSTEM
1
2
24
Figure 14-17 Fuel Tank
FUEL LINES
The fuel lines must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean.
See following WARNING.
WARNING
• Make sure fuel lines are the right length and are properly routed. Failure to heed this warning could
result in damage to fuel lines and fire.
Fuel line no. 1 runs directly from the fuel tank to the fuel filter (17). The fuel filter (17) has an arrow indicating fuel
flow direction (Figure 14-13, Page 14-17).
Fuel line no. 2 runs directly from the fuel filter to the fuel inlet of the fuel pump.
Fuel line no. 3 runs directly from the fuel outlet of the fuel pump to the carburetor.
Small spring steel band clamps are used on all hose connections except at the carburetor. A screw band clamp (16)
should be used at the carburetor.

FUEL SYSTEM Fuel Shut-Off Valve 14
FUEL SHUT-OFF VALVE
The fuel shut-off valve is located on top of the fuel tank (Figure 14-18, Page 14-25). The fuel shut-off valve should
always be turned to the closed (OFF) position during vehicle storage, towing or trailering. Unless the engine will be
run as part of a procedure, the fuel shut-off valve should also be closed (OFF) before performing maintenance or
service procedures.
1. Fuel Shut-off Valve 2. Closed (OFF) 3. Open (ON) NOTE:

When selecting valve position, ensure that it is fully opened or
fully closed.
449
Figure 14-18 Fuel Shut-off Valve – 49-State Fuel Tank
FUELING INSTRUCTIONS
DANGER
• Turn the key switch to the OFF position before fueling.
• Do not pour fuel into the fuel tank when the engine is hot or while it is running.
• To avoid electric arc caused by static electricity, the fuel storage/pumping device must be grounded. If
the pump is not grounded, the vehicle must be grounded to the pump before and during the fueling
operation.
• If the vehicle has an all-weather enclosure installed, be sure the fuel tank is properly vented as shown
(Figure 14-17, Page 14-24).
• To avoid the possibility of fire, clean up any spilled fuel before operating the vehicle.

14 Fueling Instructions FUEL SYSTEM
CAUTION
• To allow for expansion, do not fill higher than 2.54 cm (one inch) from the top of the fuel tank. Avoid
spilling fuel.
NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles to be
stored for extended periods should be prepared for storage as instructed. See Preparing the Gasoline
Vehicle for Extended Storage, Section 3, Page 3-5.
1. Turn the key switch to the OFF position.

2. The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with fresh unleaded
gasoline only. See preceding CAUTION.
3. Replace fuel cap on tank. Ensure cap is tightened securely.

SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES 15
DANGER
WARNING
MUFFLER
MUFFLER REMOVAL
WARNING
• Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning could
result in severe burns.
1, Page 1-3.
Remove the muffler clamp (6) from the muffler (1) and clamp bracket (2) (Figure 15-1, Page 15-2).
2. Remove the hex-head cap screw (7), lock washer (8), and flat washer (9) from mounting bracket. Retain the
governor cable bracket (13).
3. Remove the hex nuts (10) and lock washers (11) from the manifold.
4. Remove the muffler (1) from the vehicle.
MUFFLER INSTALLATION
NOTE: Any time the muffler is removed from the vehicle, install a new muffler clamp (6) (CC P/N 1017689) and muffler
gasket (12) (CC P/N 1015330) (Figure 15-1, Page 15-2).
1. Loosely secure muffler (1) to muffler bracket (2) with clamp (6).
2. Place a new gasket (12) on the cylinder block exhaust stud bolts.
3. Attach muffler manifold with lock washers (11) and hex nuts (10) and finger tighten.
4. Loosely secure muffler (1), mounting bracket, and governor cable bracket (13) using hex-head cap screw (7), lock
washer (8), and flat washer (9).
5. Tighten manifold hex nuts (10) to 11 ft-lb (14.9 N·m).
6. Tighten the hex cap screw (7) to 14 ft-lb (18.9 N·m).
7. Tighten the muffler clamp (6) to 40 in-lb (4.5 N·m).
NOTE: Removing and installing the governor cable bracket may change the RPM setting. See Engine RPM
Adjustment, Section 14, Page 14-11.

15 Muffler EXHAUST SYSTEM: GASOLINE VEHICLES
9. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout cam in the MAINTENANCE
position (Figure 16-1, Page 16-2). Start the engine and check for exhaust leaks and proper engine operation.
See following DANGER.
DANGER
10. Return the neutral lockout cam to the OPERATE position (Figure 16-2, Page 16-2).
7 6
12
000
10
11 000
1
2
5
4
3
13
835
Figure 15-1 Exhaust System

SECTION 16 – UNITIZED TRANSAXLE 16
DANGER
WARNING
GENERAL INFORMATION
The vehicles addressed in this manual are equipped with heavy-duty, fully-synchronized Unitized Transaxles. The
unitized transaxle utilizes fully-synchronized internal gearing to change vehicle direction. Because the unitized
transaxle is used to reverse vehicle direction, the engine, drive clutch, belt, and driven clutch rotate in the same
direction; therefore, the engine and clutches are not subjected to reversing loads. This reduces maintenance
requirements on the engine and clutches. With the unitized transaxle, power is transferred from the engine through the
drive clutch, the drive belt, the driven clutch, and then through the unitized transaxle to the wheels.
SHIFTER LEVER
A shifter lever, connected to a shifter arm, is used to change the gears to one of three shift positions: FORWARD (F),
NEUTRAL (N), or REVERSE (R) (Figure 16-3, Page 16-2). Bring the vehicle to a complete stop before changing
FORWARD or REVERSE direction.
NEUTRAL LOCKOUT
During normal vehicle operation, the neutral lockout feature prevents the engine from running when the
Forward/Reverse handle is in the NEUTRAL position. If a vehicle is started in FORWARD or REVERSE and then
shifted to NEUTRAL, the engine will stop running.
For the convenience of the trained technician, there is a neutral lockout cam (yellow knob) located on the back of the
Forward/Reverse shifter, inside the engine compartment. If the neutral lockout cam is pulled out approximately 3/8
inch (10 mm) and then rotated one-half turn until it snaps into place, the cam will be in the MAINTENANCE position
(Figure 16-1, Page 16-2). When the switch is in the MAINTENANCE position, it will allow the technician to run
the engine in the NEUTRAL position to perform certain maintenance and/or repair functions. With the cam in this
position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE
position. See following WARNING and NOTE.
WARNING
• With the cam in the MAINTENANCE position and the engine running, the vehicle may move suddenly if
the Forward/Reverse handle is shifted or accidentally bumped. To prevent this, chock the front and
rear wheels and firmly set the park brake before servicing or leaving the vehicle.
NOTE: Be sure to return the cam to the OPERATE position (Figure 16-2) after servicing the vehicle, or it will not run
with the Forward/Reverse handle in either the FORWARD or REVERSE position.

16 General Information UNITIZED TRANSAXLE
8 9
Figure 16-1 Neutral Lockout – Maintenance Figure 16-2 Neutral Lockout – Operate
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, readjustment of the
governor linkage is required. See Governor Cable Installation and Adjustment on page 14-9.
UNITIZED TRANSAXLE SERVICE
The unitized transaxle is extremely durable and should require very little service under normal operating conditions.
The only service required is to maintain proper lubricant level. See Periodic Lubrication Schedules, Section 10,
Page 10-6. Under normal operating conditions, adjustment to the system should not be required.
C l u bC a r
F N R
1348 553
Figure 16-3 Shifter Positions (Top View) Figure 16-4 Lubricant Level (should be level with bottom
of hole) and Drain Plug

UNITIZED TRANSAXLE Axle Shaft 16
TOOLS REQUIRED FOR THIS SECTION
Hydraulic floor jack (or chain hoist) Torque wrench, 3/8-in. drive 1/2-in. combination wrench
Jack stands (2) (one ton capacity) 3/8-in. socket, 3/8-in. drive 9/16-in. combination wrench
Standard slip joint pliers 7/16-in. socket, 3/8-in. drive Small flat blade screwdriver
External snap ring pliers (.047-in. tip) 1/2-in. socket, 3/8-in. drive Medium flat blade screwdrivers (2)
90° Internal snap ring pliers (.090-in. tip) 9/16-in. socket, 3/8-in. drive No. 2 phillips-head screwdriver
16-in. rolling head prybar 5/8-in. socket, 3/8- in. drive 1/4-in. nut driver
Plastic or rubber mallet Axle seal tool (CC P/N 1014162) 5/16-in. nut driver
Ratchet wrench, 3/8-in. drive 7/16-in. combination wrench
LUBRICATION
There are two oil port plugs located on the right (driven clutch) side of the unitized transaxle (Figure 16-4, 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. Use the lower plug for draining. When draining lubricant, remove both plugs to
allow the lubricant to drain faster. Clean and reinstall the drain plug and gasket before filling the transaxle with new
lubricant. Tighten drain plug to 20 ft-lb (27.1 N·m). Use a funnel when filling the transaxle through the lubricant level
indicator hole. Fill with 27 oz. (0.8 liter) 80-90 WT. API class GL or 80-90 WT. AGMA class 5 EP gear lubricant (or until
lubricant begins to run out of the level indicator hole). Install upper plug and gasket and tighten to 20 ft-lb (27.1 N·m).
AXLE SHAFT
Removal of the unitized transaxle is not required for servicing or replacing axle shafts, axle bearings, or axle shaft oil
seals. If the unitized transaxle is to be removed from the vehicle, do not remove the wheels, axle shafts, or axle tubes
first. Instructions for removing the unitized transaxle from the vehicle begin on page 16-7.
AXLE SHAFT AND OIL SEAL REMOVAL
1, Page 1-3.
3. Loosen the lug nuts on the wheel to be removed.
4. Place chocks at the front wheels and lift the rear of the vehicle with a floor jack. Then place jack stands
under the axle tubes to support the vehicle. See WARNING “Lift only one end of the vehicle...” in General
Warnings on page 1-1.
5. Remove the rear wheel and brake drum.
6. Use 90° internal snap ring pliers (0.090-in. tip) to remove internal retaining ring (1) from axle tube (Figure
16-5, Page 16-4).
7. Carefully pull the axle shaft (2) straight out of the axle tube (Figure 16-5, Page 16-4).

16 Axle Shaft UNITIZED TRANSAXLE
1
0
554
Figure 16-5 Retaining Ring
8. Position a 16-inch (40 cm) rolling head prybar (Figure 16-6, Page 16-4) under the inside lip of the seal and pull
the oil seal out (Figure 16-7, Page 16-4). See following CAUTION.
CAUTION
• Do not scar or damage the inside surfaces of the tube when removing the oil seal. A damaged tube
might have to be replaced.
555 556
Figure 16-6 Rolling Head Prybar Figure 16-7 Seal Lip
9. Inspect the axle shaft assembly to be sure the bearing (71) and collar (73) have not slipped and are still seated
against the shoulder on the axle shaft (Figure 16-8, Page 16-5).
10. Inspect the bearing. If the bearing is damaged or worn, replace it.
AXLE BEARING
Axle Bearing Removal
1. Use external retaining ring pliers (0.047-inch tip) to remove the retaining ring (74). Place a bearing puller wedge
attachment (CC P/N 1012812) on the axle shaft between the wheel mounting flange and the bearing (Figure
16-8, Page 16-5). See also Figure 16-9, Page 16-7.See following CAUTION.

UNITIZED TRANSAXLE Axle Shaft 16
CAUTION
• Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage the axle
shaft when pressing the bearing and collar off.
2. Press the bearing (71) and collar (73) off together (Figure 16-8, Page 16-5). See also Figure 16-9, Page 16-7.
See following NOTE.
NOTE: It may be necessary to heat the collar to remove it.
Do not remove the large axle retaining ring (70) from the axle (Figure 16-8, Page 16-5). Since the inner
diameter of the retaining ring (70) is smaller than the outer diameter of the bearing (71), the ring must be
in place on the axle before a new bearing and collar are pressed on.
75
74
71
72
72
73
70
67
76 68
74 70
71
73 73
74
71
70
557
Figure 16-8 Differential Gear Case and Axle Tubes
Axle Bearing Installation
1. Ensure that the retaining ring (70) is loosely placed on the axle shaft. See preceding NOTE.

16 Axle Shaft UNITIZED TRANSAXLE
2. Install a new axle bearing (71) on axle (67 or 68). Push bearing onto axle until bearing is flush against axle
shoulder (Figure 16-8, Page 16-5).
3. Apply two drops of Loctite 271® to inside of the collar. See following CAUTION.
CAUTION
• Apply Loctite 271 to the inside of the collar only, not to the shaft, so that the Loctite will be pushed
away from the bearing as the collar and bearing are pressed on. If Loctite gets on or in the bearing,
the bearing must be replaced.
• The collar should be removed no more than two times. If a collar is removed a third time, the shaft
and collar will not fit properly.
4. Place a new sealed bearing (71) on shaft (67 or 68) (Figure 16-8, Page 16-5).
5. Install collar (73) onto axle shaft. Place axle assembly on bearing puller wedge attachment and press collar
onto axle.
6. Place the bearing puller wedge attachment against collar and press both bearing and collar onto shaft. See
following CAUTION.
CAUTION
• If the bearing was removed from the shaft, replace it with a new one.
• Do not tighten the bearing puller wedge attachment against the axle shaft. This could damage the axle
shaft when the bearing and collar are pressed on.
7. Use external snap ring pliers (0.047-in. tip) to install collar retaining ring (74) (Figure 16-8, Page 16-5).
AXLE SHAFT INSTALLATION
1. Clean bearing and seal seats in axle tube (75 or 76) (Figure 16-8, Page 16-5).
2. Place a new oil seal (72) in axle tube with seal lip facing inside of the axle tube (Figure 16-8, Page 16-5). Use
an axle seal tool (CC P/N 1014162) to press it in until it seats firmly in position (Figure 16-10, Page 16-7).
See following NOTE.
NOTE: The new seal can be installed by tapping the axle seal tool with a mallet.
CAUTION
• Clean any residual oil from the exposed end of the axle shaft and from the oil seal area prior to
installing the axle shaft.
3. Clean the axle shaft and splines and then insert the shaft, splined end first, through the seal and into the axle
tube. Be careful not to damage the seal. Then advance the shaft through the inner bearing and rotate it to
align the shaft splines with the splined bore of the differential side gear. Continue advancing the shaft until the
bearing seats against the axle tube shoulder.
4. Install the bearing retaining ring (70) in the axle tube (Figure 16-8, Page 16-5). See also Figure 16-5, Page 16-4.
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.

UNITIZED TRANSAXLE Unitized Transaxle Removal 16
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. Loss
of vehicle control could result in severe personal injury or death.
558 559
Figure 16-9 Press Bearing and Collar From Shaft Using Figure 16-10 Axle Seal and Seal Tool
Bearing Puller Wedge Attachment
UNITIZED TRANSAXLE REMOVAL
1. Turn the key switch to the OFF position and remove the key, and place the Forward/Reverse handle in the
NEUTRAL position.
1, Page 1-3.
3. Close the fuel shut-off valve on fuel tank (Figure 14-18, Page 14-25).
4. Detach all wires, hoses, etc. connecting the powertrain to the vehicle.
4.1. Disconnect the carburetor vent tube from the carburetor (Figure 16-11, Page 16-8).
4.2. Disconnect the air intake hose from the carburetor (Figure 16-12, Page 16-8).

16 Unitized Transaxle Removal UNITIZED TRANSAXLE
847 561
Figure 16-11 Carburetor Vent Tube Figure 16-12 Air Intake Hose
4.3. Disconnect impulse line from fuel pump (Figure 16-13, 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 16-14, Page 16-8).
562 846
Figure 16-13 Impulse Line Figure 16-14 Fuel Line
4.5. Remove the cover from the electrical component box. Then loosen the hardware securing the accelerator
cable to the box. Disconnect the cable from the actuator cam and remove it from the box (Figure 16-15,
Page 16-9).
4.6. Remove retaining nut and disconnect the engine ground wire from the oil filler tube mounting bracket
(Figure 16-16, Page 16-9).

564 565
Figure 16-15 Throttle Cable and Retaining Nuts (Top View) Figure 16-16 Engine Ground Wire and Retaining Nut
4.7. Loosen nuts securing shifter cable to shifter cable mounting bracket. Then disconnect the shifter cable rod
end from the shifter arm on the unitized transaxle and remove the cable from the cable mounting bracket
(Figure 16-17, Page 16-9).
4.8. Mark for identification and then disconnect the 6-gauge white wire (F2 post), 6-gauge black ground wire (A2
post), and 16-gauge yellow wire (DF post) from starter/generator (Figure 16-18, Page 16-9).
1 DF
2
DF
F2 3
1 2
1. Loosen nuts. 2. Pull spring release back to remove shifter cable

from lever. 1. Yellow Wire 2. White Wire 3. Ground Wire at A2 Terminal
1349 1350
Figure 16-17 Shifter Cable (Top View) Figure 16-18 Generator Wires
4.9. Disconnect the engine oil level sensor wire (18-gauge yellow) at the connector just to the rear of the
starter/generator) (Figure 16-19, Page 16-10).
4.10.Disconnect the engine kill switch wire (18-gauge white/black) from the bullet connector at the lower right
front of the engine (Figure 16-20, Page 16-10).
4.11. Cut away the wire ties securing the engine kill wire at the lower right front of the engine (below the exhaust
header), the wire harness at the governor cable bracket, and the wire harness to the plate beneath the
muffler.

568 569
Figure 16-19 Oil Level Sensor Jumper Wire Figure 16-20 Ignition Kill Wire
5. Disconnect the brake cables.
5.1. Remove bow tie pins (1), brake cable clevis pins (2), and E-clips (3) (Figure 16-21, Page 16-10).
5.2. Remove the cable from the cable support bracket (Figure 16-21, Page 16-10).
3 1
570
Figure 16-21 Brake Cable (Rear View)
6. Remove the lower shock mounting hardware from both rear shocks (Figure 16-22, Page 16-11).
7. Position a floor jack under the vehicle frame crossmember or trailer hitch mount (Figure 16-23, Page 16-11).

Position floor jack under hitch bracket or frame.
1351 1352
Figure 16-22 Shock Absorbers Figure 16-23 Floor Jack Positioned Under Vehicle
8. Raise vehicle just enough to relieve tension from leaf springs, then remove the bolts securing the leaf springs to
the shackles (Figure 16-24, Page 16-11).
9. Remove the bolts securing the leaf springs to their front mounts (Figure 16-25, Page 16-11).
838 574
Figure 16-24 Rear Shackles Figure 16-25 Spring Retainer Bolts
10. Continue raising vehicle until frame or trailer hitch is higher than the top of the unitized transmission (enough to
allow transaxle and engine to be rolled under and out of vehicle) (Figure 16-26, Page 16-12).
11. Position jack stands, adjusted to support the vehicle at this height, under the frame crossmember between the
leaf spring mounts and side stringers, just forward of each rear wheel. Lower the floor jack to allow the jack
stands to support the vehicle (Figure 16-27, Page 16-12).

Clu
bC
ar
Club
Ca
r
Clu
bC
ar
Club
Ca
r
1353 1354
Figure 16-26 Raise Vehicle Figure 16-27 Position Jack Stands On Both Sides of
Frame
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 16-28,
Page 16-12). The powertrain should be completely disconnected from the vehicle and resting on the floor.
14. Grasp the ends of the leaf springs at the rear of the vehicle and roll the powertrain out from under the vehicle
(Figure 16-29, Page 16-12).
r
Ca
Club
1355 1356
Figure 16-28 Snubber and Bracket Figure 16-29 Remove Powertrain
15. Place blocks under the engine pan so they will completely support the engine and keep it level to the floor
NOTE: Place the blocks so they will support the engine when the transaxle is detached and moved away from
the engine.
16. Remove the drive belt.

16.1.Grasp belt midway between drive and driven clutch and pull up on belt to force the driven clutch sheaves
apart. Roll the belt counterclockwise while pulling it off driven clutch (Figure 16-31, Page 16-13).
6 in. (15.24 cm)
579 580
Figure 16-30 Position Powertrain on Wood Blocks Figure 16-31 Remove Drive Belt
17. Remove the driven clutch retaining bolt and remove the driven clutch from the unitized transaxle (Figure 16-32,
Page 16-13).
18. Loosen, but do not remove, the governor arm retaining bolt (1) (Figure 16-33, Page 16-13). Remove the
governor arm from the shaft. Do not disconnect cables.
581 582
Figure 16-32 Driven Clutch Figure 16-33 Governor Arm
19. Remove screws (1) securing the governor cable bracket to transaxle (Figure 16-34, Page 16-14).
20. Remove screws (1) securing the accelerator cable bracket to transaxle (Figure 16-35, Page 16-14).

583 584
Figure 16-34 Governor Cable Bracket Figure 16-35 Accelerator Cable Bracket
21. Remove screws (2) securing the transmission shift cable bracket (1) to transaxle (Figure 16-37, Page 16-14).
See following NOTE.
NOTE: The governor cable and the accelerator cable should remain attached to the governor arm.
22. Remove the six bolts mounting the unitized transaxle to the engine.
22.1.Remove four transaxle mounting bolts (one at each corner of the transaxle mounting plate) (Figure 16-36,
Page 16-14).
22.2.Remove two middle transaxle mounting nuts from the engine block studs.
23. Remove leaf springs, wheels and brake assemblies from the transaxle.
585 Figure 16-37 Gear Case and Cable Bracket

Figure 16-36 Transaxle Mounting

UNITIZED TRANSAXLE Unitized Transaxle Installation 16
UNITIZED TRANSAXLE INSTALLATION
1. Install the wheels. See Wheel Installation, Section 8, Page 8-1.

2. Install the leaf springs. See Leaf Spring Installation, Section 9, Page 9-4.
3. Position the transaxle mounting plate on the two mounting studs at the rear of the engine, and then install the two
mounting nuts finger tight (Figure 16-38, Page 16-15).
4. Install the remaining four mounting bolts and four nuts (one bolt and nut at each corner of the mounting plate)
finger tight.
5. Tighten the four corner nuts (with bolts) to 30 ft-lb (40.7 N·m). Tighten the two center nuts (on the engine block
studs) to 17 ft-lb (23.1 N·m) (Figure 16-38, Page 16-15).
6. Install the accelerator cable bracket on transaxle case. Tighten the mounting screws to 134 in-lb (15.1 N·m)
(Figure 16-35, Page 16-14).
585 586
Figure 16-38 Transaxle Mounting Figure 16-39 Governor Arm
7. Install the governor cable bracket on transaxle case. Tighten the mounting screws to 134 in-lb (15.1 N·m)
(Figure 16-34, Page 16-14).
8. Install governor lever arm on governor shaft (Figure 16-39, Page 16-15).
8.1. With the governor lever arm loose on the governor shaft, turn the governor arm shaft counterclockwise
until it stops. Then pull the governor lever arm rearward until the carburetor throttle is in the “wide open
throttle” (WOT) position (Figure 16-39, Page 16-15).
8.2. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to
35 in-lb (4.0 N·m) (Figure 16-39, Page 16-15).
9. Install the key onto the input shaft (Figure 16-40, Page 16-16).
10. Position the driven clutch on the transaxle input shaft and install the washer (yellow side facing out) and mounting
bolt. Tighten the mounting bolt to 14 ft-lb (19.0 N·m) (Figure 16-40, Page 16-16).
11. Install the drive belt. See Drive Belt Installation, Section 17, Page 17-3.
12. Remove the blocks from under the engine and roll the powertrain into position under the vehicle. Then lift the front
of the powertrain and place the snubber into the snubber bracket in the vehicle frame (Figure 16-41, Page 16-16).

16 Unitized Transaxle Installation UNITIZED TRANSAXLE
ar
bC
Clu
587 588
Figure 16-40 Driven Clutch and Key Figure 16-41 Snubber and Bracket
13. Position the floor jack under the rear frame crossmember and raise the jack high enough to support the vehicle
(Figure 16-42, Page 16-16). Make sure the vehicle is stable on the jack, then remove the jack stands.
14. After the jack stands are removed, lower the vehicle to approximately its normal height. Position the leaf springs
in the front spring mounts and install the bolts and lock nuts. Tighten to 15 ft-lb (20.3 N·m).
15. Adjust the vehicle height with the floor jack to position the leaf springs for mounting in the shackles. Install the
mounting bolts and lock nuts (Figure 16-43, Page 16-16). Tighten lock nuts to 27 ft-lb (36.6 N·m).
1358 1359
Figure 16-42 Leaf Springs Figure 16-43 Leaf Springs and Shackles
16. Position shocks in the shock mounts and install cushions, mounting washers and nuts (Figure 16-44, Page
16-17). Tighten nuts until cushions expand to be the same diameter as the mounting washers.
17. Connect brake cables.
18. Connect the engine kill switch wire (18-gauge white/black) to the bullet connector at the lower right front of
the engine (Figure 16-45, Page 16-17).
19. Install three wire ties to secure the engine kill wire to the accelerator cable where they both route together on the
passenger side of the engine.

1351 569
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 16-17).
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). Connect the 16-gauge yellow wire to the DF post on the starter/generator and tighten
to 30 in-lb (3.4 N·m) (Figure 16-47, Page 16-17).
1 DF
2
DF
F2 3
1. Yellow Wire 2. White Wire 3. Ground Wire at A2 Terminal
568 1350
Figure 16-46 Oil Level Sensor Jumper wire Figure 16-47 Starter/Generator
22. Connect the Forward/Reverse shifter and bracket to the transaxle.
22.1.Install the three screws (2) securing the Forward/Reverse shifter cable bracket (1) to the transaxle and
tighten them to 135 in-lb (15.3 N·m) (Figure 16-37, Page 16-14).
22.2.Place the woodruff key (10) on the shifter shaft (9).
22.3.Place the shifter lever (6) (aligned with the woodruff key) onto the Forward/Reverse shaft (9).
22.4.Install the nut (3), washer (4), and bolt (7) on the Forward/Reverse shifter lever and tighten to 23 in lb
(4.1 N·m).
23. Position the shifter cable in the shifter cable mounting bracket on the transaxle and tighten the mounting nuts to
22 ft-lb (29.8 N·m). Connect shifter cable rod end to the shifter arm (Figure 16-48, Page 16-18).
24. Attach the ground wire to the mounting screw on the oil filler tube mounting bracket and tighten to 50 in-lb
(5.7 N·m) (Figure 16-49, Page 16-18).

16 Unitized Transaxle Installation UNITIZED TRANSAXLE
1 2
1. Nuts. 2. Pull spring release back to connect shifter cable to lever.
1349 565
Figure 16-48 Shifter Cable (Top View) Figure 16-49 Engine Ground and Retaining Nut
25. Connect accelerator cable to actuator cam in the electrical box. Position the accelerator cable in the mounting
slot in the wall of the electrical box and tighten mounting nuts to 18 in-lb (2.0 N·m) (Figure 16-50, Page 16-18).
Install electrical box cover and tighten mounting screw.
26. Remove the 1/4-inch bolt from the fuel line and connect the fuel line to the carburetor and secure with a hose
clamp (Figure 16-51, Page 16-18).
564 846
Figure 16-50 Connect Cable to Cam and Secure with Figure 16-51 Connect Fuel Line
Retaining Nuts
27. Connect the impulse line to the fuel pump and secure it with the hose clamp (Figure 16-52, Page 16-19).
28. Connect air intake hose to carburetor and secure hose clamp (Figure 16-53, Page 16-19).

562 561
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 16-19).
847
Figure 16-54 Carburetor Vent Tube
30. Install transaxle drain plug and tighten to 21 ft-lb (28.5 N·m).
31. Fill transaxle with 27 oz. (0.8 liter) 80-90 Wt. API class GL-3 or 80-90 WT. AGMA class EP gear lube. Install and
tighten the level indicator hole plug to 21 ft-lb (28.5 N·m).
32. Ensure that all wiring is secured properly. See following WARNING.
WARNING
• If wires are removed or replaced make sure wiring and wiring harness is properly routed and secured
to vehicle frame. Failure to properly route and secure wiring could result in vehicle malfunction,
property damage or personal injury.
34. Turn the fuel shut-off valve on top of the fuel tank to the open position (Figure 14-18, Page 14-25).

16 Forward/Reverse Shifter Cable UNITIZED TRANSAXLE
DANGER
36. Start the engine and check for fuel leaks. If the fuel pump leaks, a rebuild kit must be installed to replace all
gaskets and diaphragms.
38. Adjust the engine RPM setting. See Engine RPM Adjustment on page 14-11.
FORWARD/REVERSE SHIFTER CABLE
If the Forward/Reverse shifter cable is damaged in any way, it must be replaced.
FORWARD/REVERSE SHIFTER CABLE REMOVAL

NOTE: Before removing cable, note cable routing and positions of wire ties or other devices securing the cable to the
vehicle. When installed, cable must be routed and secured as it was originally.
1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL
position and chock the wheels.
1, Page 1-3.
3. Remove the ball joint socket (2) from the Forward/Reverse shifter assembly ball stud (3) (Figure 16-56, Page
16-22).
4. Remove the ball joint socket (10) from the shifter arm ball stud (11) on the transaxle.
5. Loosen the retaining nuts (5) on both ends of the cable and remove the wire tie.
6. Remove cable from the vehicle.
FORWARD/REVERSE SHIFTER CABLE INSTALLATION
1. From the Forward/Reverse shifter, route the cable toward the driver side of the vehicle so it lies against the side
of the front body, turns 90° and passes to the driver side of air intake box, over the battery, beside the fender
and then turns again to connect with the shifter arm on the transaxle (Figure 16-55, Page 16-21). Make sure
cable does not touch muffler.
2. Secure the cable with a retaining nut (5) on each side of the shifter cable support bracket at the transaxle (Figure
16-56, Page 16-22). Tighten nuts to 22 ft-lb (29.8 N·m).
3. Secure the cable with a retaining nut (5) on each side of the shifter cable support bracket at the Forward/Reverse
assembly. Tighten nuts to 43 in-lb (4.9 N·m).
4. Install the ball joint socket (10) on the shifter lever ball stud (11) on the transaxle.
5. Install the ball joint socket (2) on the Forward/Reverse shifter assembly ball stud (3).
6. Attach Forward/Reverse cable at cable retainer (7).
7. Install wire tie (8) to secure wire harness to cable at the support bracket near the Forward/Reverse shifter
assembly. See following WARNING.

UNITIZED TRANSAXLE Forward/Reverse Shifter Cable 16
WARNING
• If wires are removed or replaced, make sure wiring and wiring harness is properly routed and secured.
1361
Figure 16-55 Forward/Reverse Shifter Cable Routing
FORWARD/REVERSE SHIFTER CABLE ADJUSTMENT
With the shifter lever of the unitized transaxle in the NEUTRAL position, the Forward/Reverse handle (9) should be
straight up (Figure 16-56, Page 16-22). For minor adjustments, the nut (1) may be loosened and the ball joint socket
(2) rotated to get the proper adjustment. See following CAUTION.
CAUTION
• Be sure threads of cable are engaged in ball joint socket at least 1/4 inch (6.35 mm). If ball joint socket
comes loose from the cable, the Forward/Reverse shifter will not operate properly.

16 Forward/Reverse Shifter Cable UNITIZED TRANSAXLE
CO
M
NO
NC
3
8 2 10
1
11
4
5
7
5
1360
Figure 16-56 Forward/Reverse Shifter Cable
For major adjustments, the cable jacket retaining nuts (6) must be loosened and adjusted. When the cable is properly
adjusted, with the Forward/Reverse handle (9) (Figure 16-56, Page 16-22) in the NEUTRAL position, the shifter arm of
the transaxle will also be in the NEUTRAL position (Figure 16-57, Page 16-22). Retighten nuts at the transaxle to 22
ft-lb (29.8 N·m); retighten nuts at the Forward/Reverse assembly to 43 in-lb (4.9 N·m).
F N R
1348
Figure 16-57 Forward/Reverse Shifter Positions

SECTION 17 – TORQUE CONVERTER: GASOLINE VEHICLE 17
DANGER
WARNING
GENERAL INFORMATION
The torque converter consists of a drive clutch, a driven clutch, and a drive belt. The drive clutch, which is mounted to
the engine, is in the open position when the engine is at idle. At this point, the belt is riding at a low position (smaller
diameter) on the drive clutch. The driven clutch is mounted on the transaxle. It is in the closed position, and the drive
belt is riding at a high position (large diameter) on it when the engine is at idle.
At the point of clutch engagement, the speed ratio of the drive clutch to the driven clutch is 3.5 to 1. This ratio provides
excellent starting and low-speed torque.
As engine speed increases, centrifugal force on internal weights close the drive clutch, pushing the belt up to a higher
position on the clutch (increasing the diameter of the belt loop). As the diameter of the belt loop increases at the drive
clutch, the driven clutch is forced open as the diameter of its belt loop decreases. At governed top speed, the ratio
of drive clutch to driven clutch is 0.92 to 1.
On steep grades, or when the vehicle is heavily loaded, higher torques are achieved through the use of a
torque-sensing ramp device on the driven clutch. This device overcomes the force of the centrifugal weights to close
the driven clutch and open the drive clutch, thus increasing axle torque with little or no change in engine RPM.
The engine and torque converter rotate clockwise as viewed from the clutch side of the engine.
To provide optimum performance for the OHV engine and powertrain, the vehicle uses a pair of tuned clutches.
To properly assemble and disassemble the torque converter, the following tools should be used:
• Torque Converter Tool Kit (CC P/N 1014510) (Figure 17-1, Page 17-2).
• Scribe or small pick (not included in torque converter tool kit).
TROUBLESHOOTING
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 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.
If the torque converter is not operating properly, perform the following steps:

17 Drive Belt TORQUE CONVERTER: GASOLINE VEHICLE
1. Check the governor and throttle settings. See Governor Cable on page 14-8.
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. If cleaning the driven clutch does not solve the problem, disassemble and thoroughly clean all parts of the drive
clutch. Be sure to clean the plastic drive buttons (10) (Figure 17-5, Page 17-6).
3
(CC P/N 101809101)
1
2
(CC P/N 1014497)
(CC P/N 1014508)
5
WARNI
NG
(CC P/N 1014507)
4 (CC P/N 1015524)
6 (CC P/N 1014496)
(CC P/N 101808401)

1. Drive Clutch Hub Puller 2. Driven Clutch Cam Puller 3. Driven Clutch Cam Press Tool 4. Drive Clutch Holder Tool 5. Driven Clutch Puller
Plug 6. Cam Installation Tool 7. Drive Clutch Puller
593
Figure 17-1 Torque Converter Tool Kit
DRIVE BELT
The drive belt should be inspected semiannually for wear and (or) glazing. If it is excessively worn, frayed, or
glazed, replace the belt.
As the drive belt wears, the engine RPM will increase to compensate for the change in torque converter ratio. This will
keep the vehicle’s maximum ground speed correct. See Section 2 – Vehicle Specifications.

TORQUE CONVERTER: GASOLINE VEHICLE Drive Belt 17
DRIVE BELT REMOVAL
1, Page 1-3.
2. Grasp the belt midway between the drive (2) and driven (1) 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 counterclockwise
(Figure 17-2, Page 17-3). See following CAUTION.
CAUTION
• Make sure fingers are not underneath the belt when rolling the belt off the driven clutch.
3. Remove the belt from the drive clutch.
594
Figure 17-2 Drive Belt Removal
DRIVE BELT INSTALLATION
1. Position the new belt on the drive clutch, then start the belt over the top of the driven clutch.
2. With the belt started onto the driven clutch, rotate the driven clutch counterclockwise and roll the belt over the
driven clutch sheaves and onto the clutch.

17 Drive Clutch TORQUE CONVERTER: GASOLINE VEHICLE
DRIVE CLUTCH
CAUTION
• Be very careful when handling the clutches. A clutch that has been dropped will not be properly
balanced. If either clutch is dropped, assume that it is damaged and replace it.
DRIVE CLUTCH REMOVAL
1. Remove the drive belt as instructed. See Drive Belt Removal on page 17-3.
2. Loosen the starter/generator mounting and adjusting hardware and then remove the starter belt. See WARNING
“Moving parts! Do not...” in General Warnings on page 1-1.
1
WARNING
2 2
1
(CCI P/N 1014496)
595 596
Figure 17-3 Loosen Retaining Bolt Figure 17-4 Drive Clutch Removal
3. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Place jack stands
under the axle tubes to support the vehicle. This will allow the weight of the centerline of the drive clutch to drop
below the frame I-beam for access to the bolt securing the drive clutch. See following WARNING.

TORQUE CONVERTER: GASOLINE VEHICLE Drive Clutch 17
WARNING
4. Remove the drive clutch retaining bolt (17) and mounting washer (19) (Figure 17-5, Page 17-6). See also Figure
17-3, Page 17-4. See following NOTE.
NOTE: The drive clutch mounting bolt has left-hand threads.
The crankshaft has left-hand threads at the clutch mounting hole.
4.1. Use the drive clutch holder tool (1) while tightening or loosening the drive clutch retaining bolt (2) (Figure
17-3, Page 17-4).
4.2. Hook clutch holder on boss (3) of pulley located behind drive clutch and push against the adjacent boss
with holder.
5. Lubricate the threaded portion of the clutch puller tool (1) with a light oil and thread the clutch puller tool into the
clutch retaining bolt hole (Figure 17-4, Page 17-4).
6. Use a 1/2-inch drive air wrench to tighten the clutch puller tool. The drive clutch (2) will pull free of the crankshaft.
7. Support the drive clutch assembly in your hand and back the clutch puller tool out of the crankshaft.
CAUTION
• Do not hit or tap the clutch with a hammer. Do not pry the clutch. These actions will damage the 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 17-5, Page 17-6). Do
not use a brush or steel wool. These will damage the surface of the shaft.
• Do not use solvents. Solvents will damage the lubricating characteristics of the bushings.
2. Inspect the belt contact surfaces of the clutch sheaves for wear. If any area of a sheave contact surface has
wear of 0.060 inch (1.52 mm) or more, the clutch should be replaced.

2
7
6
10
5
4
1
13
12
3 12
11
15
22 16 14
21
20
19
17
597
Figure 17-5 Drive Clutch Assembly

DRIVE CLUTCH DISASSEMBLY
CAUTION
• The drive clutch is balanced as an assembly. Before disassembly, make match marks on the drive
clutch hub and on the moveable face assembly so they can be reassembled in the same positions
1. Make match marks on the drive clutch hub and on the moveable face casting (Figure 17-6, Page 17-7).
2. Remove the drive clutch hub (1) (Figure 17-5, Page 17-6):
2.1. Remove the three plugs (22) from the clutch puller attachment holes (Figure 17-5, Page 17-6).
2.2. Thread the center bolt of the Drive Clutch Hub Puller (1) (CC P/N 1014497) into clutch until the stop nut
touches the clutch, then back the bolt out one-half turn (Figure 17-7, Page 17-7).
2.3. Thread the three small bolts of the puller (1) into corresponding holes in the clutch. Tighten bolts evenly,
making sure the face of the puller plate is parallel to the face of the clutch (Figure 17-7, Page 17-7).
2.4. Unscrew the puller center bolt out of the clutch to pull drive clutch hub off.
1
(CCI P/N 1014497)
598 599
Figure 17-6 Mark Drive Clutch Hub Figure 17-7 Remove Drive Clutch Hub
3. Remove the thrust washer (11) from the moveable face (14) (Figure 17-5, Page 17-6).
4. Remove the drive buttons (3) by removing the screws (1), flat washers (2), and drive button take-up springs
(4) as shown (Figure 17-8, Page 17-8).

1 2
2
3
600 601
Figure 17-8 Drive Button Mounting Figure 17-9 Weight Position
5. Remove the clutch weights:
5.1. Remove the screws (1) and flat washers (2) attaching the weights (3) as shown (Figure 17-9, Page 17-8).
5.2. Pull the weight assemblies (3), with pins, from slots (4) in the clutch. See following NOTE.
NOTE: Before removing, note the orientation of the wave washer (1) and secondary weight (2) on the primary
weight (3) (Figure 17-10, Page 17-8).
5.3. Remove the plastic washers, weights (2 and 3) and wave washer (1) from the pin (4). Retain all parts.
4 2
602
Figure 17-10 Primary and Secondary Weights, Wave
Washer and Pin

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 17-5, Page 17-6). See following NOTE.
NOTE: If the moveable face is removed from the hub of the fixed face, the spiral back-up rings (12) must be replaced
with new ones (Figure 17-5, Page 17-6).
7. Remove the spacer (16), and spring (4) and retainer (5). The spring retainer can be removed from the spring
if necessary (Figure 17-5, Page 17-6).
8. If necessary, remove idler bearing (2). Use a press (1) and bearing puller (3) to remove the bearing from the
fixed face assembly (4) (Figure 17-11, Page 17-9). See following NOTE.
NOTE: Do not remove the idler bearing unless it needs to be replaced. If idler bearing is removed, replace it with a
new bearing.
9. Use a scribe or small pick to remove the spiral backup rings (12) from each end of the bore in the fixed face
assembly (Figure 17-5, Page 17-6). See also Figure 17-12, Page 17-9. Discard the rings.
2
3
604 605
Figure 17-11 Remove Idler Bearing Figure 17-12 Spiral Back-up Rings
INSPECTION OF DRIVE CLUTCH PARTS
1. Inspect the idler bearing (6) for smooth rotation or seal damage (Figure 17-5, Page 17-6). See following NOTE.
NOTE: It is normal for a small amount of grease to be present at the edge of seal.
2. Inspect the bore of the moveable face assembly (14) for scarring or wear. The moveable face assembly must be
replaced if the bore is worn to a diameter of 0.883 inch (22.4 mm) or larger (Figure 17-5, Page 17-6).
3. Inspect the steel shaft (7) on the fixed face assembly. There should be no measurable wear anywhere on the
shaft. Replace the shaft if it is worn, scratched, or damaged.
4. Inspect the thrust washer (11) for wear. If it is worn more than 0.030 inch (0.76 mm), turn it over or replace
it with a new one.
5. Inspect the primary weights (2) and the hub casting for wear. If the primary weights show signs they are touching
the casting, the tips of the weights have worn beyond specification and they must be replaced.
6. Inspect the pins on the primary weights (2). There should be no measurable wear. Replace them if they are
worn, scratched, or damaged.
7. Inspect the drive belt pulley sheaves for excessive wear or damage. If the sheaves are excessively worn or
damaged, replace the entire fixed face drive assembly.

DRIVE CLUTCH ASSEMBLY
1. Press idler bearing (6) onto the shaft of the fixed face assembly (7). Press on the inner race of the bearing only.
Make sure that the cup side of bearing is facing away from the fixed face (Figure 17-5, Page 17-6).
2. Using needle nose pliers, install the spring retainer (5) onto the spring (4).
3. Install the spring (4) and retainer (5) into the cup of the idler bearing (6).
4. Install the spacer (13) onto the shaft of the fixed face.
5. Install a new spiral backup ring (12) in each end of the bore of the moveable face assembly (14).
6. Install the moveable face assembly (14) onto the shaft of the fixed face assembly (7).
CAUTION
• To avoid damaging the spiral back-up rings, be very careful when installing the moveable face.
6.1. Rotate the moveable face assembly clockwise while installing it onto the shaft.
6.2. Install the retaining ring (3) (Figure 17-5, Page 17-6).
7. Install the primary weights (3) on the mounting pins (4) (Figure 17-10, Page 17-8).
8. Install a wave washer (1) on each mounting pin (4). Make sure that the concave side of the washer faces the side
of the primary weight (3) with the small guide pin protruding from it (Figure 17-10, Page 17-8).
9. Install the secondary weights (2) onto the mounting pins (4) with the weight pins on the secondary weights
pointing away from the primary weights (3). The wave washers should be between the primary and secondary
weights (Figure 17-10, Page 17-8).
10. Install white plastic flat washers on each end of the mounting pin and push them against the outside surfaces of
the weights. Center the weights and washers on the mounting pin (Figure 17-13, Page 17-10).
11. Install the weight assemblies into the slots (4) in the hub casting (Figure 17-9, Page 17-8). Make sure the
mounting pin protrudes an equal amount on each side of the weights when the assemblies are in position
(Figure 17-13, Page 17-10).
606
Figure 17-13 Install White Washers
12. Install the 1/4-20 bolts and washers (2) and tighten them to 10 ft-lb (13 N·m) (Figure 17-5, Page 17-6). See
following NOTE.
NOTE: Make sure there is at least a (minimum) gap of 0.020 inch (0.51 mm) between each end of the mounting pin
and the mounting bolt.
13. Install three drive button take-up springs.

13.1. Install each spring on right-hand side of the three button mounting posts (when looking into the interior of
the clutch drive hub, and with the rib at a twelve o’clock position) as shown (Figure 17-14, Page 17-11).

14. Compress each take-up spring and install the drive button over the rib and take-up spring (Figure 17-8, Page
17-8).
15. Install a no. 10-24 button retaining screw with flat washer through each button and into the rib. Tighten the
screws to 34 in-lb (3.8 N·m) (Figure 17-9, Page 17-8).
16. Install the thrust washer (11) onto the moveable face assembly (Figure 17-5, Page 17-6).
17. Install the hub assembly (8) on the moveable face assembly and align the match marks made before
disassembling the clutch. Press the hub assembly on by hand.
18. Replace the three plastic plugs (22) into the hole protectors (Figure 17-5, Page 17-6).
607
Figure 17-14 Correct Orientation of Drive Button Take-up Springs
DRIVE CLUTCH INSTALLATION
1. Place the drive clutch assembly on the crankshaft taper. Position the mounting washer (19) on the bolt (17) and
start the bolt into the crankshaft (Figure 17-5, Page 17-6). See following NOTE.
NOTE: The drive clutch retaining bolt has left-hand threads. The manufacturer recommends replacing the drive clutch
retaining bolt (CC PN 103345701) when installing the drive clutch. If a new bolt is not available, clean the
threads of the original bolt and apply Loctite® 242 to the threaded end prior to installation.
2. Tighten the drive clutch retaining bolt (17) to 25 ft-lb (33.9 N·m) (Figure 17-5, Page 17-6).
3. Install the starter/generator belt and adjust belt tension as instructed. See Belt Tension Adjustment on page
12-12. Tighten the starter/generator mounting hardware to 23 ft-lb (31.2 N·m) and the adjusting hardware to
13 ft-lb (17.6 N·m).
4. Install the drive belt as instructed. See Drive Belt Installation on page 17-3.
6. Drive the vehicle and check for proper operation.

17 Driven Clutch TORQUE CONVERTER: GASOLINE VEHICLE
DRIVEN CLUTCH
DRIVEN CLUTCH REMOVAL
1. Remove the drive belt as instructed. See Drive Belt Removal on page 17-3.
2. Remove the bolt (11) and mounting washer (12) from the clutch shaft (Figure 17-17, Page 17-14).
3. Grasp the driven clutch assembly and slide it off the shaft.
4. Leave the key (9) in the keyway.
DRIVEN CLUTCH DISASSEMBLY
1. Using external snap ring pliers, remove the retaining ring (4) (Figure 17-15, Page 17-13). See following
WARNING.
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.
2. Insert a puller plug (2) (CC P/N 1014507) (Figure 17-16, Page 17-13) into the shaft bore and use a driven clutch
cam puller (1) (CC P/N 1014508) to remove the cam (3) from the fixed face shaft (Figure 17-17, Page 17-14).
3. Remove the spring (5) (Figure 17-17, Page 17-14).
4. Retain the key (3).
5. Slide the moveable face (7) off the fixed face shaft (8).

TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch 17
4
1
2 3
608 609
Figure 17-15 Remove Retaining Ring Figure 17-16 Driven Clutch Disassembly
DRIVEN CLUTCH INSPECTION
1. Inspect the cam (4) for excessive wear. Replace it if necessary (Figure 17-17, Page 17-14).
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.
3. Inspect the smooth surface on the fixed and moveable face assemblies. Assemblies must be replaced if surfaces
are worn more than 0.060 inch (1.5 mm).
4. Inspect the bronze bearing in the moveable face. If the bearing bore diameter is more than 1.384 inch (35.15
mm), the entire moveable face assembly must be replaced.
5. Inspect the shaft of the fixed face assembly. There should be no noticeable wear. Replace the shaft if it is
worn, scratched or damaged.
DRIVEN CLUTCH ASSEMBLY
1. Place the three drive buttons (6) in position. Apply one drop of Loctite® 222 to each of the socket-head cap
screws and then install and tighten them to 8 in-lb (0.9 N·m) (Figure 17-17, Page 17-14).
2. Slide the moveable face assembly (7) onto the fixed face shaft (8).
3. Place the end of the spring (5) into the hole in the moveable face assembly.
4. Install the key (3) into the keyway of the fixed face assembly (8) shaft.

5
4 8
12
11
1
10
610
Figure 17-17 Driven Clutch Assembly
5. Holding the cam (4) in position for assembly on the shaft, install the other end of the spring (5) into the center
spring hole of the cam. Rotate the cam until the keyway is aligned with the key (3) on the fixed face assembly,
and then start the cam onto the shaft approximately 1/4 to 3/8 inch (6.3 to 9.5 mm).
5.1. Press Assembly Process:

TORQUE CONVERTER: GASOLINE VEHICLE Driven Clutch 17
5.1.1. Place the clutch assembly in a press and position the cam press tool (CC P/N 101809101) on the
cam as shown (Figure 17-18, Page 17-15).
5.1.2. Hold the fixed face assembly (3) and rotate the moveable face assembly (1) one-third turn
clockwise, then press the cam (2) onto the fixed face assembly (Figure 17-18, Page 17-15).
5.1.3. Install the retaining ring (2) (Figure 17-17, Page 17-14). See following NOTE.
NOTE: The retaining ring can be reused if the O.D. does not exceed 1.607 inches (40.82 mm); otherwise, it must be
replaced with a new ring (CC P/N 1014080).
5.1.4. While holding onto the cam, tap the end of the fixed face shaft lightly with a plastic mallet until the
cam seats against the retaining ring. See following CAUTION.
CAUTION
• Do not use a metal hammer to tap the fixed face hub. A metal hammer will damage the shaft.
1
5
3
4
6
2
1
2 2
3
611 612
Figure 17-18 Cam Press Tool Figure 17-19 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. Use the cam installation tool (CC P/N 101808401) for this process.
5.2.1. With the clutch loosely assembled, set the edge of the clutch body (5) on a clean, flat surface
(Figure 17-19, Page 17-15).
5.2.2. Assemble the threaded bolt (1) through the washer (2), the thrust bearing assembly (3), the second
washer (2), and the hub guide (4).
NOTE: It is very important that the bolt, washers, and thrust bearing assembly be assembled in the order described
and shown.
5.2.3. Slide the bolt (1) through the clutch body (5) until the threaded bolt, washers, bearing, and hub
guide are against the fixed face hub (Figure 17-19, Page 17-15).
5.2.4. Hold the clutch assembly and cam installation tool together and place the fixed face down on
spaced blocks (Figure 17-18, Page 17-15).
5.2.5. Place the cam press hub (6) onto the cam installation bolt and thread it down onto the cam hub,
centering the press hub onto the cam hub.

5.2.6. Hold the fixed face assembly of the clutch (5) and rotate the moveable face of the clutch one-third
turn clockwise.
5.2.7. Use two wrenches, and hold the bolt head while tightening the cam press hub (6) pressing the cam
onto the keyed shaft. Advance the press hub until it is firm against the shaft end.
5.2.8. Remove the cam press hub (6) and installation tool, and install the retaining ring.
NOTE: The retaining ring can be reused if the O.D. does not exceed 1.607 inches (40.82 mm); otherwise, it must be
replaced with a new ring (CC P/N 1014080).
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 17-17, Page 17-14). Secure with a new bolt (11).
See following NOTE.
NOTE: The bolt (11) must be replaced with a new bolt (CC P/N 102242101) containing a locking patch that will
prevent the bolt from loosening.
2. Tighten the bolt (11) to 18 ft-lb (24.4 N·m).


SECTION 18 – IQ SYSTEM TROUBLESHOOTING 18
DANGER
WARNING
• Shorting of battery terminals can cause personal injury or death.
– Do not place component mounting plate directly on top of batteries when removing or installing
plate.
• Remove plate from vehicle completely.
GENERAL INFORMATION
The IQ System vehicle uses a 48-volt electrical system that is powered by four 12-volt lead-acid batteries and
includes an onboard computer. The IQ System vehicle uses a shunt-wound 3.2 hp motor and includes several
additional features.
• Shunt-Wound Motor: The shunt-wound motor, unlike a series motor, is designed so that the speed controller is
able to vary the amount of current passing through the field coils independently from the current passing through
the armature.
• Motor Braking: Under certain conditions a shunt-wound motor also has the ability to act as an electrical brake to
slow the vehicle. There are three features of the IQ electrical system which will activate the motor braking function:
Walk Away Braking, Pedal Down Motor Braking, and Pedal Up Motor Braking (adjustable with the IQDM-P handset).
• Walk Away Braking: This prevents the vehicle from rolling away uncontrolled should the driver park on a slope and
leave the vehicle without locking the park brake. The vehicle will roll at about 1 mph (1.6 km/h). If the walk away
braking function remains engaged for two seconds or more, a warning buzzer will sound to alert the driver that
motor braking has been activated.
WARNING
• Walk Away Braking will not limit vehicle speed to 1 mph (1.6 km/h) on very steep grades. Do not
operate vehicle on slopes exceeding 20% grades.
• Pedal Down Motor Braking: This feature helps to control vehicle downhill speed. Motor braking is activated when
the vehicle reaches the programmed top speed and holds the vehicle at that speed. Motor braking is automatically
disengaged when vehicle speed slows below the programmed top speed.

18 Wiring Diagram – Electric Vehicle IQ SYSTEM TROUBLESHOOTING
WIRING DIAGRAM – ELECTRIC VEHICLE
SONIC WELD
18_LT_GRE EN(W23)
18_RED(W06 )
6_RED(W57)
18_P INK(W21)
18_GRN(W25)
18_LT_BLU(W11)
18_GRA Y(W31)
REVERSE
BUZZER
FRONT
18_ORG(W24)
10_B LK(W58)
WARNING LIGHT SOLEN OID

10_B LK(W60)
18_WHT(W22)
POS (+)
RESIST OR
NEG (-)
18_B RN_WHT(W08)
16_B LK_WHT(W42)
REVE RS E
6_YEL(W59)
KEY
2 1
SW ITCH
6_BLK(W55 )
10_BL K(W49)
FOR WARD 3 PIN PROGRAMMER
18_BLU(W0 3)
10_ORG(W61 ) PLUG
CONNECT OR
#18 BLU/YEL
#18 BLK/YEL
#18 GRN/YEL
#18 RED/YEL
10_BL U(W63 ) 18_B RN(W16)
18_GRA Y(W01)
6_WHT(W62) 18_B LU(W17)

4 PIN
18_B LU_WHT_STP (W20 ) CONNECT OR
SONIC WELD
18_RE D_YEL(W29)
6_YEL(W59 ) 18_B LU_YEL(W33)
18_GRN_ YEL(W15)
6_GRN(W64) 10_ORG(W61 )
18_Y EL(W13)
18_B LK_YEL(W14)
6_WHT(W62)
18_TAN(W12)
18_ORG_WHT(W05)
SONIC
18_BLU(W07)
WELD
18_L HT_BLU(W10)
18_GRN(W28)
DETAIL B CONTROLLE R
(CONTROLLER)
18_GRN(W32)
18_PUR_WHT(W34)
MCOR S P EED SW ITCH AS M
(THROTTLE DEVICE)
2 P IN
CONNECT OR
10_B LU(W63)
18_YEL(W18)
6_GRN(W64)
18_WHT(W04)
18_B LK_WHT(W09)
18_LT_G REEN(W02)
18_RE D(W19)
18_GRN_ WHT(W30)
3 PIN 10_B LK(W49)

CONNECT OR
6_BLK(W55)
(PIN 13) BL K/WHT : TO LOW SIDE OF MOT OR S PEE D SENSOR
(PIN 14) LT GRE EN: TO MOTOR SPEED SE NSOR O UTPUT (PIN 12) BL U/WHT : TO LOW SIDE OF S OLENOID COI L
(PIN 15) RED : TO HIGH SPEED OF MOT OR SPEED S ENSOR (PIN 11) : OPEN
(PIN 16) BL UE : TO FNR SWIT CH "RE V" (PIN 10) T AN : TO KEY SWITCH SONIC WELD
(PIN 9) GRA Y : AUX
16 9
8 1
(PIN 8) BROWN : T O FNR SWITCH " FOR" (PIN 1) WHITE : T O HIGH SIDE OF POTE NTIOMETER
(PIN 7) ORG/WHT : TO LOW SIDE OF REV ERSE BUZZER (PIN 2) YELLOW : TO SLIDER OF POT ENTIOMETER
(PIN 6) GREEN : TO ACCELERA TOR LIMIT SWITCH (PIN 3) PUR/WHT : TO LOW SIDE OF P OTENTIOMETER
(PIN 4) GRN/WHT : TO S. O. C
(PIN 5) LT BLUE : T O OBC " CONTROL LER LOCKOUT"
WD1029133B5-L
Figure 18-1 Wiring Diagram – IQ System

IQ SYSTEM TROUBLESHOOTING Wiring Diagram – Electric Vehicle 18
18_LT_G REEN(W23)
6_RED(W57) 6_RED(W57)
18_PINK (W21 )
TOW S WITCH
18_PIN K(W27)
FUSE & RECEP TACLE
SONI C WELD BRACKET ASM
18_GRA Y(W65)
18_WHT(W22)
18_BRN_ WHT(W08)
6_BLK
18_BRN_WHT(W08)
10_BLK(W51 )
6_BLK
18_RED(W26)
FUSE(101 8949 01)
(INCLUDED WITH FUSE
10_BLK(W54) & RECEPT ACLE ASM)
8 VOLT 6_BLK
BATTERIES
6_BLK
18_GRA Y(W52)
10_ORG(W61 ) 6_BLK
18_YEL (W13 )
ON-BOARD
6_WHT(W62) COMP UTER
18_LHT_ BLU(W10)
6_BLK
A2
MOTOR
F1
F2
A1
10_BLK(W50)
10_B LU(W63)
RE
K
3 PIN
BL
D
GRN
6_GRN(W64)
CONNECT OR
18_BL K_WHT(W09)
18_LT_GRE EN(W02)
18_RED(W19 )
18_GRN_WHT(W30 )
10_BL K(W49)
6_BLK(W55 )
12 VOLT
BATTERIES
6_RED(W57)
6_BLK(W55 ) TO ONBOARD COMPUT ER
6_BLK(W68 )
6_BLK(W66)
6_BLK(W69)
WD1029133B5-R
Figure 18-2 Wiring Diagram – IQ System (Continued)

18 Wiring Diagram – Electric Vehicle IQ SYSTEM TROUBLESHOOTING
DC-DC DRIVER-SIDE DRIVER-SIDE PASS-SIDE PASS-SIDE

CONVERTER TURN SIGNAL HEADLIGHT HEADLIGHT TURN SIGNAL
48V 13V OUTPUT

20 AMP
INPUT (to accessories)
FUSE
WHITE/BLACK
BLACK/WHITE
BLACK/WHITE
RED
GREEN
BLUE
WHITE/BLACK
YELLOW
BLACK
RED
BLUE
BLUE
WHITE
SONIC
WELD
BLACK/WHITE
BLACK/WHITE
WHITE/BLACK
SONIC
WELD
SOLENOID BLUE
BROWN
BLUE
RED
KEY
LIGHT
RED
SWITCH
RED
SWITCH
BROWN
48V HORN
YELLOW
RED
RED
YELLOW
BLACK
WHITE/BLACK
WHITE/BLACK
BLACK/WHITE
RELAY
SEE NOTE** COIL
BLACK
**
VOLTAGE
BLACK/WHITE
B– ACCESSORY
BLACK/WHITE
SUPPRESSOR
ORANGE
MOUNTING
TERMINAL
YELLOW/BLACK
SONIC
WELD
TURN SIGNAL SWITCH
RED
SONIC
ON DELUXE LIGHT KIT
WELD
YELLOW/BLACK
OR
HORN SWITCH ON
WHITE/BLACK
STANDARD LIGHT KIT

BLACK/ORANGE
GREEN
TAN
SONIC
WELD
BLACK
BLACK/WHITE
ORANGE
RED
GREEN
TAN
WHITE
BRAKE
SWITCH
YELLOW
LT BLUE GREEN ORANGE

WHITE/BLACK
RELAY PARK BRAKE

BROWN
BLACK/WHITE
SWITCH
BROWN
ORANGE
BLACK
BLACK
WHITE
NOTE**
BLACK WIRE FROM LIGHT
HARNESS MUST BE TERMINAL
DISCONNECTED FROM B– STRIP
ACCESSORY MOUNTING
TERMINAL AND PROTECTED
WITH TAPE WHEN DC/DC
CONVERTER IS INSTALLED. DRIVER-SIDE DRIVER-SIDE PASS-SIDE PASS-SIDE
TURN SIGNAL TAILLIGHT TAILLIGHT TURN SIGNAL
WD1029147
Figure 18-3 Wiring Diagram – DC/DC Converter

IQ SYSTEM TROUBLESHOOTING Troubleshooting 18
• Pedal Up Motor Braking: When vehicle speed is above 11 mph (17.7 km/h), releasing the accelerator pedal will
activate motor braking, which slows the vehicle speed. Once vehicle speed slows to below approximately 11 mph
(17.7 km/h), with the accelerator pedal still released, motor braking will be deactivated and the vehicle will coast
freely. This feature is selectable. Contact your Club Car dealer/distributor to inquire about this selectable feature.
• Regenerative Braking: When motor braking is activated, the vehicle motor acts as a generator, slowing the vehicle
as it creates energy that is used to charge the batteries.
• Tow/Run Switch: When the Tow/Run switch is in the RUN position, the vehicle will function normally. When the
switch is in the TOW position, power to the OBC and controller is shut off, disabling the vehicle operating circuit and
walk away braking, allowing the vehicle to be towed.
• Motor Protection Circuit: The operator should never attempt to hold the vehicle on an incline by pressing the
accelerator pedal instead of the brake pedal, as motor overheating could result. By reducing the current to the
motor during such an occurrence, the motor protection circuit reduces the possibility of motor damage. When this
situation arises, a motor stall fault is recorded by the speed controller and will be displayed on an IQDM handset in
the Diagnostic History menu. See Motor Stall on page 19-11.
• High Pedal Detect: This function prevents unexpected vehicle movement if the key switch is turned ON after the
accelerator is pressed, or the accelerator pedal is pressed when Forward/Reverse switch is used to change the
direction of travel. The vehicle will not move until the accelerator is released and pressed again. When this
situation arises, a HPD fault is recorded by the speed controller and will be displayed on an IQDM handset in the
Diagnostic History menu. See HPD on page 19-11.
• Onboard Computer (OBC): The OBC, 1) monitors battery condition, 2) monitors the number of energy units used
by the vehicle, 3) determines the number of energy units required to recharge the batteries and shuts the charger
off when this number is reached, 4) determines when to activate regenerative motor braking, 5) locks out vehicle
movement while the charger is plugged into the vehicle charger receptacle, 6) stores operating data, which can be
read by the Communication Display Module (CDM). See Communication Display Module (CDM) on page 18-35.
TROUBLESHOOTING
The following troubleshooting guides will be helpful in identifying operating difficulties should they occur. The guides
include the symptom, probable cause(s) and suggested checks. The procedures used in making these checks can be
found in the referenced sections of this maintenance and service manual.
TROUBLESHOOTING THE VEHICLE WITH THE IQDM
Club Car recommends the use of the IQDM handset for troubleshooting vehicles equipped with the IQ electrical
system. Troubleshooting Guide 1 is to be used in conjunction with the IQDM handset. See IQ Display Module (IQDM)
and IQDM-P Diagnostics: IQ System on page 19-1 for operating instructions. See following WARNING.
WARNING
• The vehicle operator should not monitor the IQDM while the vehicle is in motion. A technician can
monitor the IQDM while traveling as a passenger in the vehicle. Failure to heed this warning could
result in severe personal injury or death.
In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1, the technician
should proceed to Troubleshooting Guide 2.
If an IQDM handset is unavailable, the technician should proceed to Troubleshooting Guide 2.

18 Troubleshooting IQ SYSTEM TROUBLESHOOTING
TROUBLESHOOTING GUIDE 1
The following troubleshooting guide is intended for use with an IQDM handset. See following NOTE.
NOTE: Before troubleshooting the vehicle, check the diagnostic history from the Special Diagnostics Menu. Note
any fault codes.
Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector
the MCOR or broken wire to the MCOR
Test Menu – THROTTLE % value does not
increase as the accelerator pedal is pressed Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
or Diagnostic Menu – THROTTLE FAULT 1 speed controller or broken wire to the speed controller
fault code
Test Procedure 4 – MCOR Voltage on page
Failed MCOR
18-14
Test Menu – HEATSINK °C indicates that Over-adjusted brakes Section 6 – Wheel Brake Assemblies
temperature is above 85 °C (145 °F) or
Diagnostic Menu – THERMAL CUTBACK fault Ensure that vehicle is not over-loaded before
Vehicle is over-loaded
code returning to operation
Test Menu – ARM PWM value does not reach Test Procedure 4 – MCOR Voltage on page
Failed MCOR
100% when vehicle is at full speed 18-14
See Pedal Group Adjustment – Electric

Improper pedal group adjustment
Vehicles, Section 5, Page 5-15.
Loose or disconnected motor speed sensor Repair and/or connect the three-pin connector
or broken wire to the motor speed sensor
Test Menu – SPEED PULSES menu item
indicates that speed pulses are OFF when Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
the vehicle is in motion or Diagnostic Menu – speed controller or broken wire to the speed controller
SPEED SENSOR fault code
Test Procedure 21 – Motor Speed Sensor on
Failed motor speed sensor
page 18-31
Loose or disconnected two-pin connector at Repair and/or connect the two-pin connector
Test Menu – FOOT INPUT menu item indicates
Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
that the MCOR internal limit switch is always
speed controller or broken wire to the speed controller
ON or always OFF.
Test Procedure 8 – Key Switch and MCOR
Failed MCOR
Limit Switch Circuit on page 18-18
Loose or disconnected Forward/Reverse

Repair and/or connect the quick disconnect
rocker switch (quick disconnect terminals) or
terminals to the Forward/Reverse switch
broken wire
Test Menu – FORWARD INPUT and/or Loose or disconnected Forward/Reverse Repair and/or connect the three-pin connector
REVERSE INPUT does not indicate the rocker switch (three-pin connector) or broken from the Forward/Reverse switch to the wire
correct reading or Diagnostic Menu – wire harness
PROC/WIRING fault code Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
Test Procedure 23 – Forward/Reverse Rocker

Failed Forward/Reverse rocker switch
Switch on page 18-32

Disconnect the batteries and allow the speed
controller capacitors to discharge. See
Speed controller logic malfunction Disconnecting the Batteries – Electric
Vehicles, Section 1, Page 1-5. Reconnect
Test Menu – MAIN CONT (solenoid) does
the batteries and see if the symptom returns.
not indicate ON when the solenoid should be
activated. or Diagnostic Menu – MAIN CONT Loose, broken, or disconnected wire(s) at Repair and/or connect the loose or
DNC (main contactor (solenoid) did not close) solenoid or B+ speed controller terminal disconnected wire(s)
fault code Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
Replace solenoid. See Solenoid Removal on

Failed solenoid
page 20-7.
Loose or disconnected wires at key switch Repair and/or connect the quick disconnect
terminals or broken wire terminals to the Forward/Reverse switch
Test Menu – KEY INPUT does not indicate ON Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
when key switch is in the ON position speed controller or broken wire to the speed controller

Failed key switch
Loose or disconnected three-pin connector at Repair and/or connect the three-pin connector
Diagnostic Menu – THROTTLE FAULT 1 fault Loose or disconnected 16-pin connector at Repair and/or connect the 16-pin connector
code speed controller or broken wire to the speed controller

Failed MCOR
18-14
Armature drive FET’s (field-effect transistors) Replace the speed controller. See Speed
inside speed controller have failed Controller Removal on page 20-10.
Diagnostic Menu – HW FAILSAFE (Hardware Disconnect the batteries and allow the speed
Failsafe) fault code controller capacitors to discharge. See
Vehicles, Section 1, Page 1-5. Reconnect
the batteries and see if the symptom returns.
Diagnostic Menu – MAIN WELDED (main Replace solenoid. See Solenoid Removal on
Solenoid contacts have failed closed
solenoid contacts welded) fault code page 20-7.
Disconnect the batteries and allow the speed

controller capacitors to discharge. See
Diagnostic Menu – MAIN DRIVER ON or MAIN Vehicles, Section 1, Page 1-5. Reconnect
DRIVER OFF fault code the batteries and see if the symptom returns.
Failure of the FET that controls the solenoid Replace the speed controller. See Speed
coil Controller Removal on page 20-10.
Diagnostic Menu – MAIN COIL FAULT fault

Replace solenoid. See Solenoid Removal on
code or Diagnostic Menu – MAIN DROPOUT Solenoid coil has failed in an open condition
page 20-7.
fault code

Loose or disconnected motor field coil wires at
Repair and/or connect the field coil wires
motor or speed controller or broken wire
See Section 23 – Motor (Models EJ4-4001

Diagnostic Menu – FIELD MISSING fault code Failure of the motor field windings
and EJ8-4001A).
Replace the speed controller. See Speed

Failure of the FET’s that control field current
Controller Removal on page 20-10.
Train operators to fully remove foot from

Diagnostic Menu – HPD (high pedal detect) accelerator pedal before turning key switch
Operator error
fault code to the ON position or changing the selected
direction with the Forward/Reverse switch
Place batteries on battery charger and allow

Batteries require charging
Diagnostic Menu – LOW BATTERY fault code them to fully charge
Improperly maintained or failed batteries See Section 21 – Batteries.
Train operators to use the brake to hold the

Diagnostic Menu – MOTOR STALL fault code Operator error vehicle on a hill, rather than holding the vehicle
on a hill using the accelerator pedal
Loose or disconnected motor armature wires Repair and/or connect the motor armature
at motor or speed controller or broken wire wires
Diagnostic Menu – OPEN ARMATURE fault See Section 23 – Motor (Models EJ4-4001
Failure of the motor armature or brushes
code and EJ8-4001A).
Failure of the FET’s that control armature Replace the speed controller. See Speed
current Controller Removal on page 20-10.

Batteries – Batteries discharged Charge batteries
Check vehicle wiring. See Wiring Diagram –

Batteries – Battery connections
Electric Vehicle on page 18-2.
Battery charger is connected to the vehicle

Disconnect the battery charger from the
– Solenoid lockout feature has disabled the
vehicle.
vehicle
Test Procedure 2 – Onboard Computer

Onboard computer failure
Solenoid Lockout Circuit on page 18-12
Check for loose or disconnected wires at key

Key switch and MCOR limit switch circuit
switch and MCOR

Failed key switch

Limit Switch Circuit on page 18-18 See also
Failed MCOR
18-14.
Vehicle does not operate Test Procedure 23 – Forward/Reverse Rocker

Forward/Reverse rocker switch
Switch on page 18-32
Test Procedure 3 – Solenoid Activating Coil

Solenoid – loose wires
on page 18-13
Test Procedure 3 – Solenoid Activating Coil

Solenoid – failed coil
on page 18-13
Allow controller to cool and ensure that vehicle

Speed controller thermal cutback
is not over-loaded before returning to operation
Check for loose or disconnected wires at the

16-pin connector at speed controller 16-pin connector. See also Test Procedure 9
– 16-Pin Connector on page 18-19.
High pedal detect Cycle accelerator pedal
Motor stall Cycle accelerator pedal
See Section 23 – Motor (Models EJ4-4001

Motor Failure
and EJ8-4001A).
Replace speed controller. See Speed

Speed controller failure

Test Procedure 21 – Motor Speed Sensor on
Speed sensor disconnected or failed
page 18-31
To change the programmed top speed of the

Incorrect speed setting
vehicle, an IQDM-P handset must be used

Wiring – improperly wired
Electric Vehicle on page 18-2.
Batteries – Batteries discharged Charge batteries

MCOR malfunction
18-14
Vehicle runs slowly Inspect and tighten all wire connections at the
Motor – loose wires
motor.
Replace motor. See Motor Removal on page

Failed motor
23-4.
Ensure that vehicle is not over-loaded before

Vehicle is over-loaded
returning to operation.
Replace speed controller. See Speed

Speed controller failure
Brakes – improperly adjusted See Section 6 – Wheel Brake Assemblies.
Tires – under-inflated or flat tires See Section 8 – Wheels and Tires.

Wiring – improperly wired
Vehicle operates, but motor braking function Electric Vehicle on page 18-2.
does not Test Procedure 21 – Motor Speed Sensor on
Speed sensor disconnected or failed
page 18-31
Forward/Reverse rocker switch – improperly Test Procedure 23 – Forward/Reverse Rocker

wired Switch on page 18-32
Vehicle will run in forward, but not in reverse or Check motor wiring. See Wiring Diagram –
Motor – improperly wired
will run in reverse but not forward Electric Vehicle on page 18-2.
Speed controller – improperly wired or failed Check vehicle wiring. See Wiring Diagram –
speed controller FET Electric Vehicle on page 18-2.
Test Procedure 19 – Onboard Computer Gray

Onboard computer – gray wire
Wire on page 18-30
Vehicle operates, but battery charger does not Battery charger connections – loose wires at Check wire connections and tighten if
charge batteries receptacle or batteries necessary.
Refer to the appropriate battery charger

Battery charger
maintenance and service manual.

IQ SYSTEM TROUBLESHOOTING Test Procedures 18
TEST PROCEDURES
Using the following procedures, the entire IQ electrical system can be tested without major disassembly of the vehicle.
WARNING
• If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.
1 – Batteries / Voltage Check

2 – Onboard Computer Solenoid Lockout Circuit
3 – Solenoid Activating Coil
4 – MCOR Voltage
5 – A1 and A2 Motor Voltage
6 – Tow/Run Switch
7 – Battery Pack Voltage (Under Load)
8 – Key Switch and MCOR Limit Switch Circuit
9 – 16-Pin Connector
10 – Pins 1, 2, and 3
11 – Pin 5
12 – Pin 6
13 – Pin 7
14 – Pins 8 and 16
15 – Pin 9
16 – Pin 10
17 – Pin 12
18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit
19 – Onboard Computer Gray Wire
20 – Voltage at Charger Receptacle Red Wire Socket
21 – Motor Speed Sensor
22 – Solenoid Continuity
23 – Forward/Reverse Rocker Switch
24 – Reverse Buzzer
25 – Rebooting the Onboard Computer
26 – Battery Warning Light
TEST PROCEDURE 1 – Batteries / Voltage Check

NOTE: The batteries must be properly maintained and fully charged in order to perform the following test procedures.
Battery maintenance procedures, including watering information and allowable mineral content, can be found
in the Battery section of this manual. See Battery Care, Section 21, Page 21-13.
The battery voltage can be displayed with the IQDM handset. If an IQDM handset is not available, proceed to
Batteries / Voltage Check without the IQDM Handset.
Batteries / Voltage Check with the IQDM Handset
1. Connect the IQDM to the vehicle. See Plugging the Handset into the Vehicle, Section 19, Page 19-1.

18 Test Procedures IQ SYSTEM TROUBLESHOOTING
2. Access the Test menu and select BATT VOLTAGE by using the SCROLL DISPLAY buttons. The IQDM should
indicate at least 48 volts with the batteries fully charged. If not, check for loose battery connections or a battery
installed in reverse polarity. Refer to See Section 21 – Batteries. for further details on battery testing.
Batteries / Voltage Check without the IQDM Handset
1. With batteries connected and using a multimeter set to 200 volts DC, place red (+) probe on the positive (+) post
of battery no. 1 and the black (–) probe on the negative (–) post of battery no. 4 (Figure 18-5, Page 18-12) or
battery no. 6 (Figure 18-4, Page 18-12). The multimeter should indicate at least 48 volts with the batteries fully
charged. If not, check for loose battery connections or a battery installed in reverse polarity. Refer to Batteries
on page 21-1 for further details on battery testing.
WAVETEK 5XL WAVETEK 5XL

V OFF V V OFF V
1000 500 1000 500
200 200 200 200
20 200 20 200
2 2m 2 2m
200 20 200 20
m m m m
200 200
2000 2000
k m m
k
200k 200k
20k 200 20k 200
2k A 2k A
S
O
P
(+)
G
E
N
V ! COM ! 200nA V ! COM ! 200nA
MAX MAX
1000 --- 1000 ---
FUSED FUSED
750V 750V
3
1
4
N
E
G
P
(–)
O
S
N
E
S
G
O
P
1
O
2
G
S
E
N
3
2
4
5
6
RED probe to battery no. 1 (+).
RED probe to battery no. 1 (+).
BLACK probe to battery no. 4 (-).
BLACK probe to battery no. 6 (-).
1842 1316
Figure 18-4 Battery Voltage Test – 6x8-Volt Battery Figure 18-5 Battery Voltage Test – 4x12-Volt Battery
Configuration Configuration
TEST PROCEDURE 2 – Onboard Computer Solenoid Lockout Circuit

The solenoid lockout circuit disables the vehicle when the battery charger is plugged into the vehicle. Use the following
procedure to test the solenoid lockout circuit:
1. With batteries connected, place the Tow/Run switch in the RUN position.
2. Using a multimeter set to 200 volts DC, place black (–) probe on battery no. 4 (4 x 12-Volt battery set) or battery
no. 6 (6 x 8-Volt battery set) negative post and red (+) probe (with insulation-piercing probe) on the light
blue onboard computer wire (at a point between the OBC and the six-pin connector). The reading should be
approximately 48-50 volts (full battery voltage). If the reading is not 48-50 volts, proceed to step 3. If the reading
is 48-50 volts, proceed to Test Procedure 3 – Solenoid Activating Coil on page 18-13.
3. Place insulation-piercing probe on the light blue 18-gauge wire at a point between OBC six-pin connector and
main wire harness. If reading is 48-50 volts, check the wire terminal connectors inside six-pin connector at
OBC six-pin connector. Make sure pins are properly aligned inside housing. Make sure wire colors match and
are connected to the correct terminals.
4. If reading is zero volts, plug the charger DC cord into the vehicle charger receptacle. If the dash light illuminates
for 10 seconds, the OBC is now powered-up. Unplug the DC cord; the reading at the OBC light blue wire should
be approximately 48-50 volts. If the vehicle now operates normally, the DC cord has powered up the electrical

system. The electrical system should also power-up when the accelerator pedal is pressed. To check the
accelerator pedal function, see Test Procedure 4 – MCOR Voltage on page 18-14.
5. If the dash light illuminates for 10 seconds and the vehicle does not operate:
5.1. Using a multimeter set to 200 volts DC, place black (–) probe on battery number 4 and place red (+) probe
(with insulation-piercing probe) on light blue 18-gauge wire at OBC six-pin connector.
5.2. With Tow/Run switch in the RUN position, the voltage reading should be approximately 48 volts.
6. If the dash light does not illuminate and the vehicle does not operate, check the OBC activation circuit.
6.1. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt
battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe (with
insulation-piercing probe) on the red 18-gauge wire located on the OBC side of the six-pin connector.
The reading should be approximately 48 volts. If the reading is incorrect, test the Tow/Run switch and
connecting wires. See Test Procedure 6 – Tow/Run Switch on page 18-16.
6.2. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt
insulation-piercing probe) on the red 18-gauge wire (harness side of six-pin connector). Multimeter should
indicate 48 volts. If voltage is correct, check connections in the six-pin connector. If connections are correct,
OBC activation circuit has failed. Replace OBC.
TEST PROCEDURE 3 – Solenoid Activating Coil

NOTE: Be aware that one of two different solenoids may be found on the vehicle. Visually, the production solenoid is
smaller than the service replacement. On the labels, the larger service replacement solenoid has SOL0605
and the smaller production solenoid has SOL5006. Internally, specifications and test results differ between
the two.
1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles
on page 1-5.
2. Remove the two small wire terminals from the solenoid.
3. Place red (+) probe of the multimeter on the positive (+) solenoid terminal. Place the black (–) probe on the
other small solenoid terminal.
– A reading of 200 to 250 ohms should be obtained for factory-installed solenoids (Figure 18-6, Page 18-13). If
not, replace the solenoid.
– A reading of 180 to 190 ohms should be obtained for service replacement solenoids (Figure 18-7, Page
18-13). If not, replace the solenoid.
WAVETEK 5XL
V OFF V
1000 500
200 200
WAVETEK 5XL 20 200

V OFF V
1000 500
2 2m
20
200 200
200
200
m
2000
k
20
m
200
m
+
2 2m
200k
200 20
m m 20k 200
2k A
200
2000
k m
200k
20k
2k
200
A
+
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
V ! COM ! 200nA
MAX
1000 ---
750V
FUSED 1
1. 2k Ohm Setting
2377 2500-20000-10283
Figure 18-6 Activating Coil Test – Factory-installed Figure 18-7 Activating Coil Test – Service Replacement
Solenoid Solenoid

TEST PROCEDURE 4 – MCOR Voltage

The accelerator position, which is proportional to the MCOR voltage, can be displayed with the IQDM handset. If an
IQDM handset is not available, proceed to MCOR Voltage Test without the IQDM Handset.
MCOR Voltage Test with the IQDM Handset
1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack stands
under the frame rails just forward of each spring mount. See WARNING “Lift only one end...” in General
Warnings on page 1-1. See also following WARNING.
WARNING
• The key switch should be placed in the OFF position and left in the OFF position for the duration
of this test.
2. Connect the IQDM to the vehicle.

3. Access the Test menu and select THROTTLE % by using the SCROLL DISPLAY buttons.
4. The IQDM should indicate 0 % with the pedal not pressed. While monitoring the IQDM display screen, slowly
press the accelerator pedal. As the pedal is pressed, the IQDM should indicate a rise from 0 % (pedal not
pressed) to 100 % (pedal fully pressed).
5. If the MCOR does not operate as described in previous step, proceed to MCOR Voltage Test without the
IQDM Handset.
MCOR Voltage Test without the IQDM Handset
WARNING
of this test.
2. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place
red (+) probe on battery no. 1 positive post and place black (–) probe (with insulation-piercing probe) on the
purple/white wire at a point close to the three-pin connector at the MCOR. The reading should be approximately
48-50 volts (full battery voltage).
3. If reading is zero volts, check the purple/white wire continuity from the three-pin connector at the MCOR to the
16-pin connector at the speed controller. Check terminal positions in three-pin connector at the MCOR and the
16-pin connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the
speed controller.
4. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 4 (4 x 12-Volt battery set) or battery
no. 6 (6 x 8-Volt battery set) negative post and the red (+) probe (with insulation-piercing probe) on the white wire
at a point close to the three-pin connector at the MCOR. The reading should be approximately 4.65 volts.
5. If reading is zero volts, check the white wire continuity from the three-pin connector at the MCOR to the 16-pin
connector at the speed controller. Check terminal positions in three-pin connector at the MCOR and the 16-pin
connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the
speed controller.
6. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 4 (4 x 12-Volt battery set) or battery
no. 6 (6 x 8-Volt battery set) negative post and the red (+) probe (with insulation-piercing probe) on the yellow

wire at a point close to three-pin connector at the MCOR. The reading should be approximately 0.32 volts with the
pedal up. Slowly press the accelerator pedal and note the readings on the multimeter. As the pedal is pressed,
the reading should increase until it reaches approximately 4.65 volts when the pedal is fully pressed.
7. If reading does not increase as the pedal is pressed, replace the MCOR.
8. If the reading is not approximately 4.65 volts with the pedal fully pressed, the vehicle will not operate at rated
top speed. Check the MCOR resistance.
8.1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric
8.2. Disconnect the 16-pin connector at the speed controller.
8.3. Using a multimeter set for 20k ohms, connect the red (+) probe of the multimeter to the yellow wire at the
MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the purple/white
wire with an insulation-piercing probe.
8.4. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k ohms.
8.5. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should rise as the
pedal is pressed. When the pedal is all the way to the floor, the multimeter should indicate between
5.67k ohms and 7.43k ohms.
8.6. Using a multimeter set for 20k ohms, connect the red (+) probe of the multimeter to the yellow wire at the
MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the white wire with
an insulation-piercing probe.
8.7. With the accelerator pedal fully up (not pressed), the multimeter should indicate between 5.67k ohms
and 7.43k ohms.
8.8. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should drop as the pedal
is pressed. When the pedal is all the way to the floor, the multimeter should indicate approximately 1k ohms.
8.9. If the MCOR does not operate as described, replace the MCOR.
TEST PROCEDURE 5 – A1 and A2 Motor Voltage

WARNING
• Keep people and equipment clear from rotating rear wheels. Do not allow persons under the car.
Contact with rotating rear wheels could result in serious personal injury.
2. With the batteries connected and using a multimeter set to 200 volts DC, place the black (–) probe on the A2
motor terminal (white wire) and connect the red (+) probe to the A1 (green wire) motor terminal.
3. With Tow/Run switch in the RUN position, place the Forward/Reverse switch in the FORWARD position, turn key
switch to the ON position and slowly press accelerator pedal.
4. As the accelerator pedal is pressed, the voltage reading should increase from approximately 5 volts RMS when
the MCOR limit switch closes, to approximately 48 volts RMS with the accelerator pedal fully pressed.
NOTE: Voltage can vary depending on controller speed setting.
Example: Speed setting 1 may only read 30 volts.
4.1. If there is no voltage reading, check the MCOR. See Test Procedure 4 – MCOR Voltage on page
18-14. Also check the continuity of the large posts of the solenoid. See Test Procedure 22 – Solenoid
Continuity on page 18-32.

4.2. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric
4.3. Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts.
Also, check continuity of all motor wires. See Section 23 – Motor (Models EJ4-4001 and EJ8-4001A).
TEST PROCEDURE 6 – Tow/Run Switch
Tow/Run Switch Test with the IQDM Handset
1. With the Tow/Run switch in the RUN position, connect the IQDM to the vehicle.
2. Immediately after the IQDM is connected to the vehicle, the screen should display a copyright notice and the
IQDM model number.
3. If the IQDM display screen is blank, drive the vehicle a short distance to activate the onboard computer.
4. If the IQDM display screen begins to work after the vehicle has been driven, turn the key switch to the OFF
position and proceed to step 5; otherwise, perform the following procedure, Tow/Run Switch Test without
the IQDM Handset.
5. With the IQDM still connected to the vehicle, place the Tow/Run Switch in the TOW position and wait 90 seconds.
6. If the IQDM display screen goes blank after 90 seconds, the Tow/Run switch and connecting wires are operating
correctly.
7. If the IQDM display screen is still active after 90 seconds, the switch has failed closed. Replace the Tow/Run
switch. See Tow/Run Switch Removal on page 20-4.
Tow/Run Switch Test without the IQDM Handset
1. With the batteries connected and using a multimeter set on 200 volts DC, connect the black (–) probe to the
negative post of battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) and connect red (+)
probe (with insulation-piercing probe) on the light green wire close to the connector on the Tow/Run switch.
WARNING
of this test.
2. With the Tow/Run switch in the RUN position, the reading should be approximately 48-50 volts. With the switch in
the TOW position, the reading should be below approximately 5 volts.
3. If the reading is above 5 volts with the switch in the TOW position, replace the switch.
4. If the reading is below 5 volts with switch in the RUN position, check continuity of the pink 18-gauge wire from
the large post of the solenoid to the connector at the Tow/Run switch.
5. If the continuity readings are correct, replace the Tow/Run switch.

TEST PROCEDURE 7 – Battery Pack Voltage (Under Load)
1. Be sure the batteries are fully charged and that the electrolyte level is correct in all cells.
2. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (4 x 12-Volt
battery set) (Figure 21-3, Page 21-5) or battery no. 6 (6 x 8-Volt battery set) (Figure 21-5, Page 21-10).
3. Turn the discharge machine on and record the voltage reading of battery pack while under load.
4. A fully charged set of batteries in good condition should read between 46-49 volts while under load.
5. A reading of 32-46 volts indicates discharged or failed batteries. Each battery should be checked with a
multimeter while under load.
6. A reading of 32 volts or less will not activate discharge machine. If the voltage of the batteries is below 32 volts,
the batteries are deeply discharged or have failed.
7. Recording the battery pack voltage reading while under load provides a more accurate diagnosis of the condition
of the batteries. When the discharge machine is ON, it places the battery pack under load and many times
can help determine if one or more batteries in the set have failed. Testing battery voltage while the batteries
are not under load will not always indicate the true condition of the batteries. For more information about the
batteries, refer to See Section 21 – Batteries. .

TEST PROCEDURE 8 – Key Switch and MCOR Limit Switch Circuit

Key Switch and MCOR Limit Switch Circuit Test with the IQDM Handset
1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position jack
stands under the frame rails just forward of each spring mount. See WARNING “Lift only one end...” in
General Warnings on page 1-1.
2. Turn the key switch to the OFF position and place the Forward/Reverse switch in the NEUTRAL position.
4. Test the key switch.
4.1. Access the Test menu and select KEY INPUT by using the SCROLL DISPLAY buttons. The IQDM should
indicate OFF when the key switch is in the OFF position.
4.2. While monitoring the IQDM display screen, turn the key switch to the ON position. The IQDM should
indicate ON.
4.3. If the IQDM does not indicate that KEY INPUT is ON when the key switch is in the ON position, proceed to
the following procedure, Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset. If
the key switch functions as described, proceed to the following step. See following NOTE.
NOTE: The key switch MUST function properly in order to test the MCOR limit switch with the IQDM handset.
5. Test the MCOR limit switch.

5.1. Select FOOT INPUT on the Test menu by using the SCROLL DISPLAY buttons on the IQDM.
5.2. The IQDM should indicate that FOOT INPUT is OFF when the accelerator pedal is not pressed, regardless
of the key switch position.
5.3. With the key switch in the ON position, press the accelerator pedal. The IQDM should indicate that FOOT
INPUT is ON when the accelerator pedal is pressed.
6. If any reading is obtained that is not described in steps 4 and 5, perform the following steps:
6.1. Check the wiring of the key switch and MCOR. See Wiring Diagram – Electric Vehicle, Section 18,
Page 18-2.
6.2. Check the continuity of the key switch wires and the MCOR limit switch wires.
7. If the problem was not found, proceed to the following procedure, Key Switch and MCOR Limit Switch Circuit
Test without the IQDM Handset.
Key Switch and MCOR Limit Switch Circuit Test without the IQDM Handset
4. Test the key switch.
4.1. Remove the instrument panel. See Key Switch Removal, Section 20, Page 20-1.
4.2. Using a multimeter set to 200 ohms, place the red (+) probe on the key switch terminal with the blue wire.
Place the black (–) probe on the other key switch terminal.
4.3. With the key switch in the OFF position, the multimeter should indicate that continuity is not present.
4.4. With the key switch in the ON position, the multimeter should indicate that continuity is present.
4.5. If any other reading is obtained, replace the key switch. See Key Switch Removal, Section 20, Page 20-1.

4.6. If the key switch operates as described in the previous steps, install the instrument panel in the reverse
order of removal and proceed to the following step.
5. Test the MCOR limit switch. See following NOTE.
NOTE: Make sure that the key switch is operating correctly and that the key switch and instrument panel are properly
installed before proceeding.
5.1. With batteries connected and using a multimeter set to 200 volts DC, place the black (–) probe on the
battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post and place
the red (+) probe (with insulation-piercing probe) on the green wire close to the two-pin connector on
the MCOR. See following WARNING.
WARNING
• The Forward/Reverse switch must be in the neutral position to avoid personal injury due to contact
with rotating wheels.
5.2. With Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse rocker switch
in the NEUTRAL position, the voltage reading should be zero volts. When the accelerator pedal is pressed,
the voltage reading should be approximately 48 volts (full battery voltage).
5.3. If the voltage reading is 48 volts when the accelerator pedal is not pressed, check pedal group for proper
adjustment. See Pedal Group Adjustment – Electric Vehicles on page 5-15.
5.4. If the voltage reading is zero volts when the accelerator pedal is pressed, check the limit switch circuit using
the following test procedures.
5.4.1. Using a multimeter set to 200 volts DC, place black (–) probe on battery no. 4 (4 x 12-Volt battery
set) or battery no. 6 (6 x 8-Volt battery set) negative post and the place red (+) probe (with
insulation-piercing probe) on the blue wire where it connects to the MCOR. With the key switch ON,
the reading should be approximately 48 volts (full battery voltage).
5.4.2. If the reading is zero volts, check the continuity of the blue wire that goes from the key switch to
the MCOR.
5.4.3. If the reading is approximately 48 volts, proceed to the following step.
5.4.4. Using a multimeter set to 200 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt
insulation-piercing probe) on the green wire where it connects to the MCOR. With the Tow/Run
switch in the RUN position, the key switch ON, the Forward/Reverse rocker switch in NEUTRAL and
the accelerator pedal pressed, the reading should be approximately 48 volts (full battery voltage).
5.4.5. If the reading is zero volts, test the continuity of the MCOR limit switch and the green wire. If the
limit switch does not pass the continuity test, replace the MCOR. See MCOR Removal, Section
20, Page 20-5.
TEST PROCEDURE 9 – 16-Pin Connector

2. Disconnect the 16-pin connector from the speed controller. Inspect terminal ends inside plug to ensure they are in
position and seated in plug housing. If any terminals look like they are not pushed all the way into the connector,
gently push the terminals until they are firmly seated in the 16-pin connector. After each terminal has been
pushed into the housing, gently pull on the wire to ensure it is locked into place.
3. Check wires in the plug to make sure none are broken at the terminal pin crimp. Repair or replace as required.

4. Check the wire colors of each wire and make sure that the colors for each pin position match the wire colors in the
wiring diagram. See Wiring Diagram – Electric Vehicle on page 18-2.
5. When connecting the 16-pin connector to the controller, push plug into controller receptacle with enough force to
lock plug into place. An audible click will be heard when plug is properly seated to the controller.
A procedure is provided for testing each of the wires in the 16-pin connector. Refer to the following chart for the
appropriate procedure for each pin in the 16-pin connector.
If the results of any of the referenced procedures are different from those described in the procedure, check the
continuity of the wires in the wire harness and test the connected components with the appropriate test procedures.
See Index of Test Procedures.
SPEED CONTROLLER 16-PIN CONNECTOR WIRE TEST PROCEDURE

Pin 1 – White (18-gauge)
Pin 2 – Yellow (18-gauge) Test Procedure 10 – Pins 1, 2, and 3 on page 18-20
Pin 3 – Purple/White (18-gauge)
Pin 4 – Green/White (18-gauge) To State of Charge meter
Pin 5 – Light Blue (18-gauge) Test Procedure 11 – Pin 5 on page 18-21
Pin 6 – Green (18-gauge) Test Procedure 12 – Pin 6 on page 18-22
Pin 7 – Orange/White (18-gauge) Test Procedure 13 – Pin 7 on page 18-24
Pin 8 – Brown (18-gauge) Test Procedure 14 – Pins 8 and 16 on page 18-25
Pin 9 – Gray (18-gauge) Test Procedure 15 – Pin 9 on page 18-26
Pin 10 – Tan (18-gauge) Test Procedure 16 – Pin 10 on page 18-27
Pin 11 – Open (no wire)
Pin 12 – Blue/White (18-gauge) Test Procedure 17 – Pin 12 on page 18-28
Pin 13 – Black/White (18-gauge)

Test continuity of each wire and perform Test Procedure 21 – Motor
Pin 14 – Light Green (18-gauge)
Speed Sensor on page 18-31
Pin 15 – Red (18-gauge)
Pin 16 – Blue (18-gauge) Test Procedure 14 – Pins 8 and 16 on page 18-25
TEST PROCEDURE 10 – Pins 1, 2, and 3

Pins 1, 2, and 3 in the 16-pin connector provide a connection point from the MCOR potentiometer to the speed
controller.
3. Disconnect the 16-pin connector at the speed controller.
4. Using a multimeter set for 20k ohms, insert the red (+) probe of the multimeter into pin 2 (yellow wire) of the
16-pin connector. See following CAUTION. Insert the black (–) probe into pin 3 (purple/white wire) of the
16-pin connector (Figure 18-8, Page 18-21).

CAUTION
• Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection.
5. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k ohms.
6. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should rise as the pedal is
pressed. When the pedal is all the way to the floor, the multimeter should indicate between 5.67k ohms and
7.43k ohms.
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
20k Ohm Setting (reading with pedal not pressed)
685
Figure 18-8 Pins 1, 2, and 3 Test
7. Using a multimeter set for 20k ohms, insert the red (+) probe of the multimeter into pin 2 (yellow wire) at the
16-pin connector. Connect the black (–) probe into pin 1 (white wire). See previous CAUTION.
8. With the accelerator pedal fully up (not pressed), the multimeter should indicate between 5.67k ohms and
7.43k ohms.
9. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should drop as the pedal is
pressed. When the pedal is all the way to the floor, the multimeter should indicate approximately 1k ohms.
10. If any other reading is observed, check the continuity of the wires in the wire harness.
TEST PROCEDURE 11 – Pin 5

Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard computer to
the speed controller.
4. Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 5 (light blue wire) of the
16-pin connector. See following CAUTION. Using an alligator clip, connect the black (–) probe to the B– terminal
of the speed controller (Figure 18-9, Page 18-22).

CAUTION
WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
200 DCV Setting (reading with OBC powered-up and battery charger disconnected)
686
Figure 18-9 Pin 5 Test
5. Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-5.
6. Place the Tow/Run switch in the RUN position.
7. The multimeter should indicate zero volts DC at this time.
8. While monitoring the multimeter, plug the battery charger into the vehicle charger receptacle.
9. After a short delay, the onboard computer should power-up (come out of sleep mode), charger relay should click,
and the ammeter on the charger should indicate that the vehicle batteries are being charged.
10. The multimeter should indicate zero volts DC while the charger is connected to the vehicle.
11. While observing the multimeter, disconnect the DC plug from the vehicle charger receptacle.
12. The multimeter should indicate full battery voltage when the charger is not connected to the vehicle.
13. If any other reading is obtained, check the following items:
– Continuity of the wires in the wire harness
– Onboard computer for proper operation. See Test Procedure 19 – Onboard Computer Gray Wire on
page 18-30.
– Tow/Run switch for proper operation. See Test Procedure 6 – Tow/Run Switch on page 18-16.

Pin 6 in the 16-pin connector provides a connection point for the MCOR limit switch to the speed controller.

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
200 DCV Setting (reading with OBC powered-up and accelerator pedal pressed)
687
4. Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 6 (green wire) of the
CAUTION
6. Place the Tow/Run switch in the RUN position, key switch in the ON position, and Forward/Reverse switch in
the FORWARD position.
7. The multimeter should indicate zero volts DC at this time.
8. While monitoring the multimeter, slowly press the accelerator pedal and hold the pedal at approximately 20%
of full travel.
9. After a short delay, the onboard computer should power-up (come out of sleep mode).
10. The multimeter should indicate full battery voltage (approximately 48 volts) when the accelerator pedal is pressed.
11. While observing the multimeter, release the accelerator pedal.
12. The multimeter should indicate zero volts when the accelerator pedal is not pressed.
– Onboard computer for proper operation. See Test Procedure 19 – Onboard Computer Gray Wire on
page 18-30.
– Key switch and MCOR limit switch for proper operation. See Test Procedure 8 – Key Switch and MCOR
Limit Switch Circuit on page 18-18.
– Ensure the pedal group is adjusted correctly. See Pedal Group Adjustment – Electric Vehicles on page 5-15.


Pin 7 in the 16-pin connector provides a connection point for the reverse buzzer to the speed controller.
4. Place a jumper wire with an alligator clip between the B– terminal of the speed controller (use alligator clip for this
connection) and pin 7 (orange/white wire) of the 16-pin connector (Figure 18-11, Page 18-24). See following
CAUTION.
CAUTION
7. The reverse buzzer should sound when the Tow/Run switch is in the RUN position.
8. If any other activity is observed, check the following items:
– Reverse buzzer for proper operation. See Test Procedure 24 – Reverse Buzzer on page 18-33.
688

TEST PROCEDURE 14 – Pins 8 and 16
Pins 8 and 16 in the 16-pin connector provide a connection point for the Forward/Reverse rocker switch to the speed
controller. The switch provides a +48 volt signal to the speed controller through pin 8 when the Forward/Reverse
switch is in the FORWARD position and provides a +48 volt signal on pin 16 when the Forward/Reverse switch is in
the REVERSE position.
under the frame crossmember between the spring mount and side stringer, just forward of each rear wheel. See
WARNING “Lift only one end...” in General Warnings on page 1-1.
4. Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 8 (brown wire) of the
CAUTION
6. Place the Tow/Run switch in the RUN position and the Forward/Reverse switch in the NEUTRAL position. The
multimeter should indicate zero volts DC at this time.
7. While monitoring the multimeter, place the Forward/Reverse switch in the REVERSE position. The multimeter
should still indicate zero volts.
8. Place the Forward/Reverse switch in the FORWARD position. The multimeter should indicate full battery voltage
(approximately 48 volts).
9. Insert the red (+) probe of the multimeter into pin 16 (blue wire) of the 16-pin connector. Leave the black (–) probe
(alligator clip) connected to the B– terminal of the speed controller. See previous CAUTION.
10. Place the Forward/Reverse switch in the NEUTRAL position. The multimeter should indicate zero volts DC
at this time.
11. While monitoring the multimeter, place the Forward/Reverse switch in the FORWARD position. The multimeter
should still indicate zero volts.
12. Place the Forward/Reverse switch in the REVERSE position. The multimeter should indicate full battery voltage
(approximately 48 volts).
– Forward/Reverse switch for proper operation. See Test Procedure 23 – Forward/Reverse Rocker Switch
on page 18-32.

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
200 DCV Setting (reading with Tow/Run switch in RUN and Forward/Reverse switch in FORWARD)
689
Figure 18-12 Pins 8 and 16 Test
Pin 9 in the 16-pin connector provides a connection point for the Tow/Run switch to the speed controller. The switch
provides a +48 volt signal to the speed controller through pin 9 when the Tow/Run switch is in the RUN position.
NOTE: There is a diode in the wire connected at Pin 9.
4. With the multimeter set to the diode test function (ç), connect the black (–) probe of the multimeter to the light
green wire terminal of the two-pin connector at the Tow/Run switch and the red (+) probe of the multimeter to the
pin 9 terminal (Figure 18-13, Page 18-27). See following CAUTION. The reading should indicate an overload
(no continuity). A diode is designed to conduct current in one direction only. If a diode conducts current (shows
continuity) with the meter probes as described, the diode has failed and must be removed from the wire harness.
See Pin 9 Diode Removal, Section 20, Page 20-14.
CAUTION
5. Reverse the multimeter probes and note the reading (Figure 18-14, Page 18-27). With the black (–) probe of
the multimeter on the pin 9 terminal of the multi-pin connector and the red (+) probe of the multimeter on the
light green wire at the Tow/Run switch, the meter should read approximately 500 mV, however, a range of
400-600 mV is acceptable.

7. If items in step 6 test out okay, the diode has failed open and should be removed from the harness. See Pin 9
Diode Removal, Section 20, Page 20-14.
WAVETEK 5XL
V OFF V
1000 500
200 200
WAVETEK 5XL 20 200

V OFF V
1000 500
2 2m
200 200 200 20
m m
20 200
200
2000
k m
2 2m
200 200k
20
m m 20k 200
2k A
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
Red probe to light green wire terminal of Tow/Run switch Black probe to light green wire terminal of Tow/Run switch
Black probe to pin 9 terminal of 16-pin connector Red probe to pin 9 terminal of 16-pin connector
1317 1318
Figure 18-13 Diode Test Figure 18-14 Diode Test – Probes Reversed

Pin 10 in the 16-pin connector provides a connection point for the key switch to the speed controller. The key switch
provides a +48 volt signal to the speed controller through pin 10 when the key switch is in the ON position.
4. Using a multimeter set for 200 volts DC, insert the red (+) probe of the multimeter into pin 10 (tan wire) of the
CAUTION
6. With the Tow/Run switch in the TOW position, the multimeter should indicate zero volts.
7. Place the Tow/Run switch in the RUN position and the key switch in the ON position.

WAVETEK 5XL
V OFF V
1000 500
200 200
20 200
2 2m
200 20
m m
200
2000
k m
200k
20k 200
2k A
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
200 DCV Setting (reading with Tow/Run switch in RUN and key switch in the ON position)
691
8. With the key switch in the ON position, the multimeter should indicate full battery voltage (approximately 48 volts).
With the key switch in the OFF position, the reading should be zero volts.
– Key switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit
on page 18-18.

Pin 12 in the 16-pin connector provides a connection point for the solenoid coil to the speed controller. The speed
controller activates the solenoid coil by providing a ground to the solenoid coil at the appropriate time.
4. Place a jumper wire with an alligator clip between the B– terminal of the speed controller (use alligator clip for this
connection) and pin 12 (blue/white wire) of the 16-pin connector (Figure 18-16, Page 18-29). See following
CAUTION.
CAUTION
6. Place the Tow/Run switch in the RUN position and the key switch in the ON position.

692
7. The solenoid should click when the key switch is placed in the ON position.
8. If any other activity is observed, check the following items:
– Reverse buzzer for proper operation. See Test Procedure 24 – Reverse Buzzer on page 18-33.
– Key switch for proper operation. See Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit
on page 18-18.
– Solenoid for proper operation. See Test Procedure 22 – Solenoid Continuity on page 18-32.
TEST PROCEDURE 18 – Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit
The silicon controlled rectifier (SCR), located inside the onboard computer, acts as a switch on the negative side
of the circuit.
This allows the onboard computer (OBC) to control the battery charging current.
Use the following procedure to test the SCR:
1. With batteries connected and using a multimeter set to 200 volts DC, place the red (+) probe on the positive post
of battery no. 1 and place the black (–) probe on the charger receptacle socket that has the black 10-gauge wire
attached to it. The reading should be approximately 36-42 volts.
2. If the reading is zero volts, check the black 10-gauge wire connection to the OBC connector. Check the continuity
of the black 10-gauge wires. If the wires and connections are okay, the SCR has failed. Replace the OBC. If
the reading is correct, proceed to the following step.
3. Plug in AC and DC cords. When the battery charger relay clicks on, reading should be approximately 48 volts
(full battery voltage). If the reading does not rise from approximately 40 volts to full battery voltage when the
DC cord is plugged in and the relay clicks on, check the following items:
– Black wire terminal socket in the charger receptacle.
– Onboard computer gray wire. See Test Procedure 19 – Onboard Computer Gray Wire on page 18-30.
– Red wire at the charger receptacle. See Test Procedure 20 – Voltage at Charger Receptacle Red Wire
Socket on page 18-30.

TEST PROCEDURE 19 – Onboard Computer Gray Wire

1. With batteries connected and the DC cord disconnected, pull back on the boot (1) on the gray wire (2) connection
at the OBC (3) (Figure 18-17, Page 18-30). Using a multimeter set to 200 volts DC, connect the red (+) probe to
the positive post of battery no. 1 and black (–) probe to gray 16-gauge wire at the OBC connection (4). Reading
should be approximately 48 volts. If reading is zero volts, replace the OBC.
4 1
693
Figure 18-17 OBC Connections
2. If the reading in step 1 is 48 volts, plug the DC cord into the vehicle’s charger receptacle. The voltage reading
should drop to approximately 4.0 volts before the charger relay clicks on.
3. When the charger relay is activated, the reading should rise to approximately 48 volts.
4. If voltage does not drop to approximately 4.0 volts when the DC cord is plugged in and then rise to approximately
48 volts when the charger relay clicks on, the gray wire circuit in the OBC has failed. Replace the OBC.
TEST PROCEDURE 20 – Voltage at Charger Receptacle Red Wire Socket

1. With batteries connected, DC cord disconnected, and using a multimeter set to 200 volts DC, place the black
(–) probe on the negative post of battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set)
and place the red (+) probe on the charger receptacle socket connected to the red 10-gauge wire. The reading
should be 48-50 volts (full battery voltage).
2. If the reading is zero volts, check the continuity of the 10-gauge red wire from the positive post of battery no. 1
to the receptacle socket.

TEST PROCEDURE 21 – Motor Speed Sensor
Motor Speed Sensor Test with the IQDM Handset
CAUTION
• Perform the following procedure only on a level surface. To avoid injury or property damage, ensure
that the path of the vehicle is clear before pushing vehicle.
3. Access the Test menu and select SPEED PULSES by using the SCROLL DISPLAY buttons. The IQDM should
indicate OFF when the vehicle is at rest.
4. While monitoring the IQDM display screen, slowly push the vehicle a short distance (about 3 feet (1 meter)). The
IQDM should indicate ON for speed sensor pulses while the wheels are in motion.
5. If the IQDM does not indicate ON while the wheels are in motion, proceed to the following procedure, Motor
Speed Sensor Test without the IQDM Handset.
Motor Speed Sensor Test without the IQDM Handset
2. With batteries connected, disconnect the three-pin connector at the motor speed sensor.
3. Check voltage at black/white wire:
3.1. Using a multimeter set to 200 volts DC, place the red (+) probe on the battery no. 1 positive post and
place the black (–) probe on the black/white wire terminal socket in the three-pin connector. The voltage
reading should be 48 to 50 volts (full battery voltage).
3.2. If the reading is zero volts, check the continuity of the black/white wire from the 16-pin connector at the
speed controller to the three-pin connector at the motor speed sensor. If the continuity is correct, replace
4. Check voltage at the red motor speed sensor wire:
4.1. With Tow/Run switch in the RUN position and using a multimeter set to 20 volts DC, place the black (–)
probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative post
and place red (+) probe on red wire terminal socket in three-pin connector. The voltage reading should
be approximately 15-16 volts.
4.2. If the voltage reading is zero volts, check the continuity of the red wire from the 16-pin connector at the
speed controller to the three-pin connector at the motor speed sensor. If the wire continuity is correct,
replace the speed controller.
4.3. If the reading is below 14 volts, replace the speed controller.
4.4. If the voltage reading is correct, proceed to the following step.
5. Check voltage at the light green wire:
5.1. Using a multimeter set to 20 volts DC, place the black (–) probe on the battery no. 4 (4 x 12-Volt battery
set) or battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe on the light green
wire female terminal in the three-pin connector at the motor speed sensor. The voltage reading should be
from 4.60 to 4.90 volts.
5.2. If the voltage is zero volts, check the continuity of the light green wire from the 16-pin connector at
the speed controller to the three-pin connector at the motor speed sensor. If the continuity is correct,
replace the speed controller.
5.3. If reading is below 3.50 volts, check the continuity of the wires and plug and replace the speed controller if
necessary.

6. Reconnect the three-pin connector at the motor speed sensor. Using a multimeter set to 20 volts DC, place the
black (–) probe on the battery no. 4 (4 x 12-Volt battery set) or battery no. 6 (6 x 8-Volt battery set) negative
post and place the red (+) probe (with insulation-piercing probe) on the green wire between the three-pin
connector and the motor speed sensor.
6.1. Raise one rear wheel off ground. Slowly turn the rear wheel to rotate the motor armature. As the armature
rotates, the voltage reading should alternate from zero to approximately 4.85 volts. The voltage reading will
fluctuate from zero to 4.85 volts and back to zero four times for each revolution of the motor armature.
NOTE: The voltage reading of 4.85 is an approximate reading. The actual reading may vary from 4.50 to 5.00 volts.
6.2. Replace the speed sensor if:

– There is no voltage reading.
– The voltage reading is not above 3.50.
– The voltage reading does not fluctuate as the motor is turned.
TEST PROCEDURE 22 – Solenoid Continuity

3. Disconnect the three wires that are crimped together from the forward large post of the solenoid.
4. Using a multimeter set to 200k ohms, place the black (–) probe on one solenoid large post and place the red
(+) probe on the other large post. The reading should be no continuity.
5. Connect the three wires crimped together to the forward large solenoid post. Install washer and nut on large
solenoid post and tighten to 77 in-lb (8.7 N·m).
WARNING
• Keep people and equipment clear from rotating rear wheels. Do not allow persons under the car.
Contact with rotating rear wheels could result in serious personal injury.
7. Place the Tow/Run switch in the RUN position, turn the key switch to the ON position, place the Forward/Reverse
rocker switch in the FORWARD position, and press the accelerator pedal. The solenoid should click and the
multimeter should indicate continuity. If the reading is no continuity, replace the solenoid.
TEST PROCEDURE 23 – Forward/Reverse Rocker Switch
Forward/Reverse Rocker Switch Test with the IQDM Handset
3. Test FORWARD INPUT.
3.1. Access the Test menu and select FORWARD INPUT by using the SCROLL DISPLAY buttons. The IQDM
should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or REVERSE position.

3.2. Place the Forward/Reverse switch in the FORWARD position. The IQDM should indicate that FORWARD
INPUT is ON. If the IQDM indicates any other reading, check vehicle wiring. See Wiring Diagram –
Electric Vehicle, Section 18, Page 18-2. Also check the 16-pin connector at the speed controller. See
Test Procedure 9 – 16-Pin Connector on page 18-19.
4. Test REVERSE INPUT.
4.1. Access the Test menu and select REVERSE INPUT by using the SCROLL DISPLAY buttons. The IQDM
should indicate OFF when the Forward/Reverse switch is in the NEUTRAL or FORWARD position.
4.2. Place the Forward/Reverse switch in the REVERSE position. The IQDM should indicate that REVERSE
INPUT is ON. If the IQDM indicates any other reading, check vehicle wiring. See Wiring Diagram –
Electric Vehicle, Section 18, Page 18-2. Also check the 16-pin connector at the speed controller. See
Test Procedure 9 – 16-Pin Connector on page 18-19.
5. If the IQDM displays readings other than those described above and the wiring is found to be correct, proceed to
the following procedure, Forward/Reverse Rocker Switch Test without the IQDM Handset.
Forward/Reverse Rocker Switch Test without the IQDM Handset
2. Remove the three screws securing the rocker switch case to the vehicle body.
3. Disconnect the three wires from the rocker switch. Using a multimeter set to 200 ohms, place the black (–)
probe on the blue wire terminal 3 position on the rocker switch, and place the red (+) probe on the red wire
terminal 2 position. With the switch in NEUTRAL or REVERSE, there should be no continuity. With the switch in
FORWARD, there should be continuity. If the readings are incorrect, replace the switch.
4. Place the black (–) probe on the brown wire terminal 1 position on the rocker switch and place the red (+)
probe on the orange wire terminal. With the switch in REVERSE, there should be continuity. If the readings
are incorrect, replace the switch.
TEST PROCEDURE 24 – Reverse Buzzer

2. Remove the instrument panel. See Key Switch Removal, Section 20, Page 20-1.
3. Disconnect the orange/white and pink wires from the reverse buzzer.
5. Place the key switch in the OFF position and the Tow/Run switch in the RUN position.
6. Using a multimeter set to 200 volts DC, place the black (–) probe on battery no. 4 (4 x 12-Volt battery set) or
battery no. 6 (6 x 8-Volt battery set) negative post and place the red (+) probe on the pink wire terminal end that
was disconnected from the reverse buzzer. The reading should be approximately 48 volts (full battery voltage).
6.1. If the voltage reading is correct, proceed to step 7.
6.2. If reading is zero volts, check pink wire continuity and Tow/Run switch. See Test Procedure 2 – Onboard
Computer Solenoid Lockout Circuit on page 18-12. See also Test Procedure 6 – Tow/Run Switch
on page 18-16.
6.3. If the continuity readings are not correct, repair or replace the pink wire.
6.4. If the continuity readings are correct, proceed to step 7.
7. Place the Forward/Reverse switch in REVERSE. Using a multimeter set to 200 volts DC, place the black (–)
probe on the orange/white wire terminal end (that was disconnected from the reverse buzzer) and place the red
(+) probe on battery no. 1 positive post. The reading should be approximately 48 volts (full battery voltage).
7.1. If the voltage reading is correct, replace the reverse buzzer.
7.2. If reading is zero volts, check orange/white wire continuity and connection at Pin 7 in 16-Pin connector.

18 Battery Warning Light IQ SYSTEM TROUBLESHOOTING
7.3. If there is no continuity in the orange/white wire, or the Pin 7 terminal in the 16-Pin connector is not properly
seated, repair or replace as required.
7.4. If the orange/white wire continuity and 16-Pin connector are correct and there is no voltage at the orange
wire, replace the controller.
TEST PROCEDURE 25 – Rebooting the Onboard Computer
It is possible the onboard computer (OBC) can become “locked up”, causing the OBC solenoid lockout circuit to
malfunction. If this condition is suspected, restart the computer as follows:
Section 1, Page 1-5. See following NOTE.
NOTE: Wait at least 90 seconds for the capacitors in the speed controller to discharge. The capacitors in the speed
controller must be fully discharged in order to reboot the OBC.
3. Place Tow/Run switch in the RUN position.
4. Test drive the vehicle. If the vehicle functions normally the problem is corrected. If the problem still exists, refer
to Wiring Diagram – Electric Vehicle on page 18-2.
TEST PROCEDURE 26 – Battery Warning Light

1. Reboot the OBC and drive the vehicle a short distance. When vehicle is first driven, the battery warning light
should illuminate for 10 seconds. See Test Procedure 25 – Rebooting the Onboard Computer on page 18-34.
If the battery warning light does not illuminate when rebooting the OBC, proceed to step 2.
2. Turn key switch OFF, place Tow/Run switch in TOW and place Forward/Reverse rocker switch in NEUTRAL.
3. Disconnect the six-pin connector at the OBC.
4. Remove the wedge lock from the six-pin connector housing that is connected to the vehicle wire harness.
Remove the brown/white wire from the connector plug.
5. Using a jumper wire with an alligator clip at each end, connect one alligator clip to the negative post of battery
no. 1 and the other alligator clip to the brown/white wire terminal socket that was removed from the six-pin
connector plug.
6. Install the wedgelock in the six-pin connector housing and reconnect the six-pin connector plug. Place the
Tow/Run switch in the RUN position and the battery light should illuminate. If the light does not illuminate,
replace the battery warning light assembly.
BATTERY WARNING LIGHT
IQ System vehicles feature a dash mounted battery warning light (above the steering column) that, when the vehicle is
in operation, indicates low battery voltage or, when the vehicle is being charged, indicates a charging problem. The
battery warning light is controlled by the onboard computer.
When the batteries receive an incomplete charge because 1) the DC power cord is disconnected, 2) AC power to
charger is interrupted, 3) automatic charger shut-off occurs after 16 hours of operation, or 4) charger malfunctions, the
warning light will indicate as follows:

IQ SYSTEM TROUBLESHOOTING Communication Display Module (CDM) 18
• The battery warning light will not illuminate if the charge is 90% or more complete. The onboard computer will
retain in memory the amount of charge needed to replenish the batteries and will complete the charge during the
next charge cycle.
• When the charger DC cord is unplugged during a charge cycle, the battery warning light will illuminate and remain
illuminated for 10 seconds if the charge is less than 90% complete but the vehicle has enough power for 60
minutes of operation. This will alert the fleet operator that the vehicle may be used, but that it must be charged to
completion as soon as possible.
• The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, if the charger times out at
16 hours and the batteries are not sufficiently charged. This indicates an abnormal charge cycle. The charger and
batteries should be checked by your Club Car distributor/dealer.
• The battery warning light will repeatedly illuminate for 10 seconds, at 4 second intervals, during a charge cycle (with
the DC plug still connected) if AC power to the charger is interrupted. The light will go out when AC power is restored.
• The battery warning light will flash quickly, after inserting the DC plug, indicating the charger’s voltage suppressor
has failed closed.
COMMUNICATION DISPLAY MODULE (CDM)
COMMUNICATION LOW
DISPLAY MODULE BATTERY
DISPLAY FUNCTIONS:
PRESS AND HOLD
BUTTON TO SHOW
FUNCTION NUMBER.
RELEASE BUTTON TO
SHOW FUNCTION VALUE.
Func1 - Battery voltage.
Func2 - Energy units removed since last charge cycle.
Func3 - Total accumulated energy units removed.
3
Func4 - Last charge termination type (1 = Incomplete,
2 = DVDT, 4 = Normal, 8 = Max. timer).
R
POWER
ON
OFF
Club Car
PART #17075
1. Low Battery 2. Display Window 3. Function Button
2500-19200-10300
Figure 18-18 CDM
The CDM can be used to retrieve from the onboard computer four important items of information that can be useful in
troubleshooting the IQ System vehicle. To access one of these items, the item’s corresponding Function Code must be
selected on the CDM. This is done by pressing the Function Button until the desired function code is displayed in the
window. See Figure 18-18, Page 18-35 for CDM features. Releasing the button when the desired code is displayed
will display the data. Function codes and corresponding data are as follows:
• F1 – Battery voltage:

18 Communication Display Module (CDM) IQ SYSTEM TROUBLESHOOTING
• This displays the battery pack’s current state of charge. A reading of less than 48 volts indicates that the batteries
need to be charged. If a reading of less than 48 volts is obtained immediately after a charge cycle, there may be
a problem in the charge circuit.
• F2 – Energy units removed since last charge cycle:
• If the display reads over 75 (the vehicle battery warning light should be illuminated), the vehicle batteries need
to be recharged before being used again. This data can be used to make sure all vehicles in a fleet receive
equal usage on a short-term basis.
• F3 – Total accumulated energy units removed since initial vehicle start-up:
• This information is most useful in making sure that all vehicles in a fleet receive equal usage over long periods
of time.
• F4 – Last charge termination type (1 = incomplete, 2 = DVDT, 4 = normal, 8 = max. timer):
• A 1, 2, 4, or 8 will be displayed.
• 1 – Indicates the last charge cycle was incomplete and the batteries were not fully charged. Batteries should be
charged again at the earliest opportunity.
• 2 – Indicates a back-up charge program was employed by the OBC to complete the charge cycle if a normal charge
(4) is not possible. DVDT refers to an increase in voltage within a time period. The OBC monitors battery voltage
during charging and will terminate the charge when the voltage does not increase within the time period. A DVDT
charge may be displayed the first few times a new set of batteries is charged, and the first time a set of batteries is
charged after the batteries have been disconnected and reconnected. A problem may exist if persistent DVDT
readings are obtained.
• 4 – Indicates the last charge cycle was normal.
• 8 – Indicates the charger ran for sixteen hours and shut itself off without completing the charge cycle. This means
there may be a problem in the charge circuit.
The CDM also has a low battery indicator, which illuminates when CDM batteries are weak and need to be replaced.
Weak batteries in the CDM may cause the CDM to register inaccurate information or no information.
USING THE CDM TO RETRIEVE DATA FROM THE ONBOARD COMPUTER
1. Turn the CDM ON.

2. Position CDM on seat bottom so it is aligned directly with the battery warning light. Ensure CDM infrared LED
receiver is pointed at battery warning light and there is a clear path between them. See following NOTE.
NOTE: If, by positioning CDM on seat bottom, the CDM is unable to collect the data stream from the onboard
computer, hold CDM approximately 6 inches (15.2 cm) from battery warning light.
3. Wait approximately 30 seconds for a value to appear in the display window.

4. If a value does not appear in the display window after 30 seconds, try adjusting the aim of the CDM and repeating
step 3 until a value appears. If there is still no reading, check for weak batteries in the CDM.
4.1. Adjust aim of CDM.
4.2. Drive vehicle a short distance to ensure OBC is not in powerdown mode.
4.3. Check for weak batteries in CDM.
4.4. If reading is still not obtained, go to the CDM Troubleshooting Guide on page 18-37.
Once a value has been obtained in the display window, the CDM may be removed from its receiving position and
the data reviewed. The CDM will hold the values for F1, F2, F3, and F4 until the CDM is turned OFF or it receives
another line of data from the same or another onboard computer. Use the following procedure to review the data
stored in the CDM:

IQ SYSTEM TROUBLESHOOTING CDM Troubleshooting Guide 18
• The value currently displayed will be F1 (battery voltage).
• To view F2, press and hold the button on the CDM. When “Func 2” appears in the display window, release the
button. The value for F2 will then be displayed.
• To view F3, press and hold the button on the CDM until “Func 3” appears in the display window. Release the
button. The value for F3 will be displayed.
• To view F4, press and hold the button on the CDM until “Func 4” appears in the display window. Release the
button. The value for F4 will be displayed.
NOTE: The values of all four functions can be recalled by pressing and releasing the CDM button.
CDM TROUBLESHOOTING GUIDE
Use the following chart as a starting point for troubleshooting problems with communication between the CDM and
onboard computer. Contact your Club Car representative for more comprehensive information.
OBC Will Not Communicate

With The CDM
CDM battery
is discharged Failed CDM unit Failed OBC
Replace CDM battery Replace CDM Replace OBC
Failed Dash Light
Replace Dash Light

OBC program is
"locked-up"
OBC is in a Batteries discharged
powerdown mode
Remove "+" battery
lead and discharge Failed Wiring
Restart OBC by
See the instructions in
driving vehicle or by Recharge Batteries
the WARNING on
connecting charger Check wires and connections
page 11-1.
DC plug
After a short time,
replace the lead and
restart the OBC.
2500-19200-10301
Figure 18-19 Flow Chart – CDM Troubleshooting Guide

SECTION 19 – IQ DISPLAY MODULE (IQDM) AND IQDM-P
DIAGNOSTICS: IQ SYSTEM 19
DANGER
WARNING
NOTE: For information specific to the IQDM-P handset programming features, see IQ Display Module Programmer
(IQDM-P): IQ System on page 25-1.
The information presented in this section addresses the Series 2 versions of the IQDM-P and IQDM handsets.
PLUGGING THE HANDSET INTO THE VEHICLE
1. Connect one end of the cable to the port located on the bottom of the handset.
2. Connect the cable adaptor to the IQDM cable.
3. Find the IQDM port on the vehicle (Figure 19-1, Page 19-1).
4. Remove the dust cap from the IQDM port.
5. Align the keyed portion of the plug with the IQDM port and connect the plug to the port.
Seat shown may not match all models.
1319
Figure 19-1 IQDM Port

IQ DISPLAY MODULE (IQDM) AND IQDM-P
19 Introductory Display DIAGNOSTICS: IQ SYSTEM
INTRODUCTORY DISPLAY
Immediately after the handset is connected to the vehicle, it begins loading the vehicle speed controller information.
After a few seconds, the screen displays the following menu items:
• Program (IQDM-P only)
• Monitor
• Faults
• Functions
• Information
• Programmer Setup
In the event that the handset does not display any information, or the screen is difficult to read, refer to the
IQDM troubleshooting procedures. See IQDM and IQDM-P Handset Troubleshooting on page 19-18.
MENU NAVIGATION
The NAVIGATION BUTTON (1) is the four-arrow button located on the left side of the handset (Figure 19-2, Page
19-3). This button is used to navigate through and select menus. Pressing the up or down arrows allows the user to
scroll through the menu items. When the box beside the desired menu is blinking, pressing the right arrow selects that
menu item. Pressing the left arrow allows the user to go back one screen (2).
The CHANGE VALUE BUTTON (3) is the button located on the right side of the handset (Figure 19-2, Page 19-3).
This button allows the user to change values by pressing + or –.
The three yellow buttons labeled 1, 2 and 3 are BOOKMARK BUTTONS (4) (Figure 19-2, Page 19-3). These buttons
allow the user to bookmark up to three specific screens for rapid return to those screens. To bookmark a specific
display screen, have the desired screen displayed and simply press and hold a bookmark button until the statement
“bookmark set” is displayed. When it is necessary to go back to the bookmarked screen, rapidly press and release the
appropriate bookmark button. See following NOTE.
NOTE: When going to a bookmarked display screen, be sure to rapidly press and release the button. If the button is
pressed and held for too long, the bookmark will be overridden with the current screen.
The three yellow buttons also allow for quicker input of serial number and car decal number. Press and hold “+” or “-”
while holding buttons 1, 2 or 3 to accelerate a number search.

DIAGNOSTICS: IQ SYSTEM Menu Navigation 19
2
1
1 3
2
695
Figure 19-2 Handset Controls
The following menus are accessible on the IQDM handset:
PROGRAM (IQDM-P ONLY)
The program menu allows the user to view and change custom speed controller settings. See Program Menu on
page 25-2.
MONITOR
The monitor menu displays values for certain parameters to facilitate speed controller troubleshooting. See Monitor
Menu on page 19-4.

19 Monitor Menu DIAGNOSTICS: IQ SYSTEM
FAULTS
The faults menu displays all faults recorded by the speed controller since the history was last cleared. Each fault is
listed only once, even if the fault has occurred multiple times. See Faults Menu on page 19-7.
FUNCTIONS
The functions menu allows the user to transfer all current settings from the speed controller to the handset and from
the handset to the speed controller. See Functions Menu on page 19-13.
INFORMATION
The information menu displays the model number, serial number, manufacturer date and software version of the speed
controller. See Information on page 19-16.
PROGRAMMER SETUP
The programmer setup menu allows the user to set the LCD contrast, display the fault history of the programmer as
well as various other information pertaining to the handset such as model number, serial number, OEM information,
etc. See Programmer Setup on page 19-17.
MONITOR MENU
The monitor menu is accessed by using the up or down arrow to scroll to monitor and pressing the right arrow key
to activate the menu. All information in the monitor menu is updated in real time, allowing the trained technician to
troubleshoot the vehicle by monitoring the handset as the key switch is cycled, Forward/Reverse switch is activated, etc.
Since the monitor menu is updated while the vehicle is in operation, the trained technician has the ability to monitor
the status of several components in conditions or locations where a problem with vehicle performance has been
reported. See following WARNING.
WARNING
• The vehicle operator should not monitor the handset while the vehicle is in motion. A technician
can monitor the handset while traveling as a passenger in the vehicle. Failure to heed this warning
could result in severe personal injury or death.
The following parameters can be monitored in real time with the handset from the monitor menu:
THROTTLE
Indicates the position of the accelerator pedal from 0% (pedal not pressed) to 95 - 100% (pedal fully pressed). This
item can be monitored when the key switch is in the ON or OFF position.

DIAGNOSTICS: IQ SYSTEM Monitor Menu 19
BATT VOLTAGE
Displays the current battery voltage at the speed controller.
HEATSINK
Displays the temperature (in degrees Celsius) of the speed controller heatsink. During normal operating conditions, the
heatsink temperature should be below 85 °C ±5 °C (185 °F ±9 °F). See following NOTE.
NOTE: Improper brake adjustment can sometimes cause the operating current to be higher than normal. This higher
current increases the temperature of the speed controller heatsink.
ARM CURRENT
Displays the motor armature current (in amperes).
FIELD CURRENT
Displays the motor field current (in amperes).
ARM PWM
Displays motor armature PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When
the vehicle is operating at full speed, the pulse width modulation should be at 100%.
FIELD PWM
Displays motor field PWM (pulse width modulation). The range of pulse width modulation is 0% to 100%. When the
vehicle is in operation, the pulse width modulation will fluctuate in response to the terrain and throttle input.
SPEED PULSES
The speed pulses menu item displays the activity of the motor speed sensor. With the key switch in the OFF
position, the Forward/Reverse switch in the NEUTRAL position, and the vehicle at rest, the handset should should
indicate that speed pulses are off. When the vehicle is gently pushed a short distance, the handset should indicate
that speed pulses are on.
FOOT INPUT
Indicates the status of the MCOR (motor controller output regulator) internal limit switch: on or off. When the
accelerator pedal is unpressed, the handset should indicate that the limit switch is off. When the accelerator pedal is
pressed and the key switch is in the ON position, the display should indicate that the limit switch is on.

19 Monitor Menu DIAGNOSTICS: IQ SYSTEM
FORWARD INPUT
With the Forward/Reverse switch in the NEUTRAL or REVERSE position, the handset should indicate that the
forward input is off. When the Forward/Reverse switch is placed in the FORWARD position, the handset should
indicate that the forward input is on.
REVERSE INPUT
With the Forward/Reverse switch in the NEUTRAL or FORWARD position, the handset should indicate that the
reverse input is off. When the Forward/Reverse switch is placed in the REVERSE position, the handset should
indicate that the reverse input is on.
MAIN CONT
Displays the current solenoid (main contactor) state. When the contactor is activated, the handset indicates that the
solenoid is on. When the contactor is not activated, the handset indicates that the solenoid is off.
KEY INPUT
Displays the position of the key switch: OFF or ON.
PASSWORD TRIES (IQDM-P ONLY)
A password is required to place the vehicle in “private speed mode” (speed setting 4). The speed controller will log
unsuccessful and unauthorized attempts to place the speed controller in “private speed mode”. If repeated attempts
are unsuccessful, the speed controller will permanently lock out access to “private speed mode”. In the event that
“private speed mode” is locked out, the controller must be removed and shipped to Club Car before it can ever be
placed in “private speed mode”. See Code A, Code B, and Code C on page 25-3.
10.3 TRANSAXLE
This menu is reserved for possible future use and has no application at this time.
20+ SPEED
This menu is reserved for possible future use and has no application at this time.
The remaining items that display under the Monitor menu are fault condition occurrences. The display indicates the
fault name and the number of fault occurrences. See following Faults Menu section.

DIAGNOSTICS: IQ SYSTEM Faults Menu 19
FAULTS MENU
The faults menu is accessed by using the up or down arrow to scroll to faults and pressing the right arrow key to
activate the menu.
Faults displayed in the faults menu will aid the trained technician in troubleshooting the vehicle. Faults displayed often
indicate which components in the electrical system need to be tested.
Since the faults menu is updated while the vehicle is in operation, the trained technician has the ability to monitor
the occurrence of faults in conditions or locations where a problem with vehicle performance has been reported.
WARNING
• The vehicle operator should not monitor the handset while the vehicle is in motion. A technician
can monitor the handset while traveling as a passenger in the vehicle. Failure to heed this warning
could result in severe personal injury or death.
SYSTEM FAULTS
The system faults menu displays all of the faults detected by the speed controller since the last time the fault history
has been cleared. The faults displayed in this menu may or may not be currently active. Once a fault has been
detected, it is stored in the memory of the speed controller for display on the fault history menu. Each detected fault is
listed only once, even if the fault has occurred multiple times.
Causes of Faults
Some common causes of faults are:
• Loose, broken, or disconnected wires or connectors
• Failed components
• Improper adjustment or installation of electrical or mechanical components (examples: brake adjustment, improper
MCOR installation)
• Improper wiring of electrical components
As shown above, there are many possible causes for faults to occur, and the speed controller has a programmed
reaction to each fault that is based on the fault currently detected. The technician should be familiar with the detected
faults and the controller’s reactions to faults to ensure a proper diagnosis.
An example of a possible mis-diagnosis of a vehicle due to a fault: If the three-pin speed sensor wire has been
disconnected, the speed controller will detect a speed sensor fault. When a speed sensor fault is detected, the
controller responds to the fault by limiting the vehicle speed to 1/2 of its normal top speed. If the technician reaches
the conclusion that the vehicle is running slowly because batteries are heavily discharged, he has made an improper
diagnosis of the problem.
The vehicle speed controller should be checked for fault codes before any service is performed.

19 Faults Menu DIAGNOSTICS: IQ SYSTEM
The speed controller, after detecting a fault, will respond in one or more of the following ways:
• A. Reduce vehicle speed to zero by reducing armature current
• B. Reduce vehicle speed to zero by reducing field current to zero
• C. Turn off the solenoid
• D. Cause the vehicle to run at half speed
• E. Gradually reduce the armature current limit
• F. Quickly reduce the armature current until speed sensor pulses occur
• G. Reduce field current and beep reverse buzzer at a fast rate
CONTROLLER FAULT CONTROLLER RESPONSE

HW FAILSAFE A, B, C
KEY SWITCH SRO C
THROTTLE FAULT 1 A
SPEED SENSOR D
MAIN WELDED D
MAIN DRIVER ON D
MAIN DRIVER OFF A, C
HIGH SPEED WALKAWAY D
MAIN COIL FAULT A
FIELD MISSING A, B, C
HPD A
PROC/WIRING A
OVERVOLTAGE A, B, G
LOW BATTERY E
THERMAL CUTBACK E
MOTOR STALL F
MAIN DROPOUT A, C
OPEN ARMATURE A
MAX PASSWORD TRIES (no action taken)
INCORRECT PASSWORD (no action taken)

Fault Recovery
When a fault is detected by the speed controller, the speed controller will attempt to recover from the fault and resume
normal operation. In the case of an intermittent problem such as a loose wiring connection, the controller may be able
to recover and operate normally for a while, but the problem should be repaired before placing the vehicle in service.
Depending on the type of fault, the controller will attempt to recover immediately after the condition clears or after the
accelerator pedal has been cycled (released and pressed again).
CONTROLLER FAULT CONTROLLER FAULT CODE CONTROLLER ATTEMPTS TO RECOVER

HW FAILSAFE 24 When key switch is cycled
KEY SWITCH SRO 3 When key switch is cycled
THROTTLE FAULT 1 28 When condition clears
SPEED SENSOR 18 When condition clears
MAIN WELDED 8 When condition clears
MAIN DRIVER ON 15 When condition clears
MAIN DRIVER OFF 14 When accel. pedal is cycled
When Tow/Run switch is cycled or a charge

HIGH SPEED WALKAWAY 5
cycle is completed
MAIN COIL FAULT 13 When accel. pedal is cycled
FIELD MISSING 26 When accel. pedal is cycled
HPD 4 When accel. pedal is cycled
PROC/WIRING 30 When condition clears
OVERVOLTAGE 9 When condition clears
LOW BATTERY VOLTAGE 25 When condition clears
THERMAL CUTBACK 2 When condition clears
MOTOR STALL 20 When condition clears
MAIN DROPOUT 11 When accel. pedal is cycled
OPEN ARMATURE 23 When condition clears and accel. pedal is cycled
MAX PASSWORD TRIES 7 When Tow/Run switch is cycled
INCORRECT PASSWORD 6 When Tow/Run switch is cycled
The following faults can be detected by the IQ System controller:
HW FAILSAFE
The armature drive FET’s (field effect transistors) regulate the armature current. If the speed controller detects a failure
of the armature drive FET’s or circuitry, a hardware failsafe fault is detected.
KEY SWITCH SRO (STATIC RETURN TO OFF)
The controller detects a key switch sro fault and the vehicle will be disabled when the controller is powered up with the
key switch on and after any of the following events have occured: 1. the run/tow switch had been placed in the tow
position, 2. the DC plug of the charger had been plugged into the vehicle, 3. the battery set had been disconnected or 4.

if the vehicle had gone into sleep mode and the accelerator was pressed while the key switch was switched on. The key
switch sro fault detect is by default disabled but can be enabled via the program menu KSI SRO ENABLE parameter.
THROTTLE FAULT 1
If the MCOR (Motor Controller Output Regulator) voltage is less than 0.20 volts or greater than 4.80 volts, the controller
detects a throttle fault 1 fault.
SPEED SENSOR
If the speed controller does not detect pulses from the speed sensor while the controller outputs power (greater than
75% armature PWM) to the motor, a speed sensor fault is detected.
MAIN WELDED
If the speed controller detects that the solenoid contacts are welded closed, a main welded fault is detected.
MAIN DRIVER ON
If the FET that controls the closing of the solenoid contacts is found to be energized when it should not be, a main
driver on fault is detected by the speed controller.
MAIN DRIVER OFF
If the FET that controls the closing of the solenoid is not energized when it should be, a main driver off fault is
detected by the speed controller.
HIGH SPEED WALKAWAY
If the key switch is turned off or the Forward/Reverse (F&R) switch is placed in neutral while the vehicle is being driven
downhill at full speed for more than 8 seconds, the controller detects a high speed walkaway fault.
MAIN COIL FAULT
If the speed controller determines that the solenoid is not closing as a result of a solenoid coil failure, a main coil fault
is detected.

FIELD MISSING
If the speed controller is operating at a duty cycle of greater than 90% (almost full speed) and the field current is less
than 3 amps, a field missing fault is detected by the speed controller.
HPD
The HPD (High Pedal Detect) fault is detected if the accelerator pedal is already depressed when the key switch is
turned to the ON position. This fault is also detected if the accelerator pedal is pressed when the selected direction
is changed by pressing the Forward/Reverse switch. This fault, when not caused by the operator, can indicate
that the pedal limit switch has failed closed.
PROC/WIRING
This fault is detected if the Forward/Reverse switch is giving a signal to place the controller in forward and reverse at
the same time. This rare fault can be caused by a failed Forward/Reverse switch or improper vehicle wiring.
OVERVOLTAGE
If the speed controller detects that the battery voltage is too high (68.4 to 75.6 volts DC), the overvoltage fault
is detected.
LOW BATTERY VOLTAGE
If the battery voltage falls below 34 volts ±5%, the low battery voltage fault is detected by the speed controller.
THERMAL CUTBACK
If the controller heatsink temperature is found to be in excess of 85 °C ±5 °C (185 °F ±9 °F) or below –25 °C ±5 °C
(–13 °F ±9 °F), the thermal cutback fault is detected.
MOTOR STALL
If the motor current is high and there is no movement of the vehicle wheels for a short period of time, a motor stall is
detected by the speed controller. This fault can be caused by an operator holding the vehicle on a hill by depressing
the accelerator pedal instead of the brake pedal.
MAIN DROPOUT
If the controller detects that the solenoid contacts have opened while the vehicle is in operation, a main dropout fault
is detected.

OPEN ARMATURE
If the accelerator pedal is pressed 2/3 to the floor, the armature current is less than 20 amps, and there are no
speed sensor pulses, an open armature fault is detected.
INCORRECT PASSWORD (IQDM-P ONLY)
Each vehicle has a password in the form of a unique set of codes used to place the vehicle in “private speed mode”.
If a set of codes has been entered incorrectly, the incorrect password fault is declared. For additional information
on codes, refer to Code A, Code B, and Code C. See Code A, Code B, and Code C on page 25-3. See also
Password Tries (IQDM-P only) on page 19-6.
MAX PASSWORD TRIES (IQDM-P ONLY)
The max password tries fault is declared when the incorrect password fault has been declared several times. In the
event that the max password tries fault is indicated, the speed controller must be removed and shipped to Club Car
before it can ever be placed in “private speed mode”. See Code A, Code B, and Code C on page 25-3. See
also Password Tries (IQDM-P only) on page 19-6.
FAULT HISTORY
The fault history menu can be useful in determining the cause of a vehicle problem; however, the fault history alone
should not be the factor that determines when a component is replaced. Some faults detected by the speed controller
are not the result of a failed component, and are instead the result of vehicle operator error. If a fault appears in the
fault history menu, the trained technician should attempt to determine when and where the fault has occurred. For
example, if the motor stall fault is present in the fault history, the trained technician may be able to determine the
location on the course where an operator has held the vehicle on a hill by using the accelerator pedal.
CLEARING FAULT HISTORY
After a repair has been made, the fault history should be cleared. This will enable the trained technician to properly
troubleshoot the vehicle in the future, in the event that another problem occurs. It is recommended that the fault history
be cleared in order to avoid the replacement of a component that caused a fault in the past, but has been replaced and
is now functioning correctly. For example, if the MCOR device was disconnected and the speed controller detected a
fault code associated with the throttle, the fault history should be cleared so that any future problem is not diagnosed
incorrectly as a throttle problem. See Clear Fault History on page 19-17.

DIAGNOSTICS: IQ SYSTEM Functions Menu 19
FUNCTIONS MENU
The functions menu is accessed by using the up or down arrow to scroll to functions and pressing the right arrow
key to activate the menu.
GET SETTINGS FROM CONTROLLER
This function transfers all of the speed controller settings (except for “private speed mode”) from the vehicle speed
controller to the handset. This enables the trained technician to “clone” a speed controller. Once the speed controller
settings have been transferred to the handset, the technician can then connect the handset to another vehicle and
transfer the stored settings into the speed controller.
Speed Controller Cloning – Transferring Settings from the Vehicle to the Handset
1. Locate a vehicle that has the desired speed controller settings.
2. Turn the key switch to the OFF position, place the Forward/Reverse handle in the NEUTRAL position, and
lock the park brake.
3. Plug the handset into the vehicle.
3.1. Connect one end of the cable to the port located on the bottom of the handset.
3.2. Connect the cable adaptor to the IQDM cable.
3.3. Remove the dust cap from the IQDM port.
3.4. Align the keyed portion of the plug with the IQDM port and connect the plug to the port (Figure 19-1,
Page 19-1).
4. Scroll to the functions menu and select.
5. Select settings.
6. Select get settings from controller.
7. Press + on the change value button to confirm the operation.
8. The handset will display an “executing...” message for the next few seconds while the controller settings are being
stored in the handset’s memory (Figure 19-3, Page 19-14).
9. When the handset is finished recording the speed controller settings, a confirmation message is displayed
(Figure 19-4, Page 19-14).
10. With the controller settings stored in the memory of the handset, the handset can be used to transfer all of
the desired speed controller settings to any IQ System vehicle or group of IQ System vehicles. See Speed
Controller Cloning – Transferring Settings from the Handset to the Vehicle on page 19-14.

19 Functions Menu DIAGNOSTICS: IQ SYSTEM
1 3 1 3
2 2
696 697
Figure 19-3 Handset Executing Figure 19-4 Confirmation Message
WRITE SETTINGS TO CONTROLLER
This function transfers all of the speed controller settings (except for “private speed mode”) from the handset to the
vehicle speed controller. This enables the trained technician to “clone” a speed controller. Once the speed controller
settings have been transferred to the handset, the technician can then connect the handset to another vehicle and
transfer the stored settings into the speed controller.
Speed Controller Cloning – Transferring Settings from the Handset to the Vehicle
1. Perform this procedure with a handset that has the desired speed controller settings. See Speed Controller
Cloning – Transferring Settings from the Vehicle to the Handset on page 19-13.
2. Locate a vehicle that does not have the desired speed controller settings.
4. Plug the handset into the vehicle.
4.1. Connect one end of the cable to the port located on the bottom of the handset.
4.2. Connect the cable adaptor to the IQDM cable.
4.3. Remove the dust cap from the IQDM port.
4.4. Align the keyed portion of the plug with the IQDM port and connect the plug to the port (Figure 19-1,
Page 19-1).
5. Scroll to the functions menu and select.
6. Select settings.

DIAGNOSTICS: IQ SYSTEM Functions Menu 19
7. Select write settings to controller.
10. When the handset is finished transferring the speed controller settings, a confirmation message is displayed
(Figure 19-5, Page 19-15).
11. Repeat this procedure for additional vehicles that need to be programmed with the same handset settings.
1 3 1 3
2 2
698 699
Figure 19-5 Confirmation Message Figure 19-6 Confirmation Message
RESET ALL SETTINGS
In the event that a mistake was made and one or more changes should not have been made with the handset, the
speed controller settings can be reverted to the original settings from the beginning of the session (when the handset
was plugged into the vehicle). This function is similar to the “undo” command on a PC and will work correctly only
when the handset has not been unplugged and power to the speed controller has not been interrupted.
Resetting All Settings
1. During an active session when the settings need to be returned to the original values (the values that were active
at the beginning of the session), scroll to the functions menu and select.
2. Select settings.
3. Select reset all settings.

19 Information DIAGNOSTICS: IQ SYSTEM
6. When the handset is finished resetting the speed controller settings, a confirmation message is displayed (Figure
19-6, Page 19-15).
INFORMATION
The information menu is accessed by using the up or down arrow to scroll to information and pressing the right
arrow key to activate the menu.
This menu selection displays information pertaining to the speed controller. The information provided from this
menu selection includes:
MODEL NUMBER
Displays the model number of the speed controller.
SERIAL NUMBER
Displays the serial number of the speed controller.
MFG DATE
Displays the date the speed controller was manufactured.
SOFTWARE VERSION
Displays the speed controller software version.

DIAGNOSTICS: IQ SYSTEM Programmer Setup 19
PROGRAMMER SETUP
The programmer setup menu selection allows the user to set the LCD display contrast, records the fault history of the
handset, and displays information pertaining to the handset.
PROGRAM
This menu allows the user to adjust the contrast on the display screen. After selecting the LCD–Contrast menu, use
the change value buttons to adjust the contrast for the best readability.
FAULTS
This menu selection displays faults that have been detected within the handset. This faults menu does not pertain to
any faults detected in the speed controller.
The following faults can be detected within the handset:
CODE NUMBER TEXT DISPLAYED

14 Communication error with controller
15 Error in handset
16 Handset does not support this function
17 Serial port overrun error
18 Security lockout on program menu
Fault History
This menu displays any faults that have been detected within the handset itself.
Clear Fault History
The clear fault history function will erase the history of faults that are stored in the handset.
INFORMATION
This menu selection displays information pertaining to the handset. The information provided in this menu selection
includes model number, serial number, the date the handset was manufactured, the handset software version, etc.

19 IQDM and IQDM-P Handset Troubleshooting DIAGNOSTICS: IQ SYSTEM
IQDM AND IQDM-P HANDSET TROUBLESHOOTING
In the event that the handset does not function as described in this manual, the following troubleshooting guide should
be studied and the referenced test procedures should be performed to troubleshoot the handset.
See Plugging the Handset into the Vehicle
Handset cord and/or adaptor is disconnected
on page 19-1.
Vehicle batteries – loose terminals or corrosion See Section 21 – Batteries. .
Vehicle batteries – improperly wired See Section 21 – Batteries. .
Vehicle batteries – batteries failed See Section 21 – Batteries. .
Vehicle batteries – batteries not fully charged See Section 21 – Batteries. .
Test Procedure 1 – Handset Cord on page

Handset cord has failed
19-19
Test Procedure 2 – Handset Cord Adaptor on

Handset cord adaptor has failed
page 19-19
Handset display screen is blank
Test Procedure 3 – IQDM Jack Located On
IQDM port has failed
Speed Controller on page 19-20
Contrast Setting is too light See Program on page 19-17..
Drive the vehicle for a short distance and

Onboard computer is in power-down mode
reconnect the handset to the vehicle.
Onboard computer malfunction See Section 18 – IQ System Troubleshooting.

Loose vehicle wire harness connections
Speed controller malfunction See Section 18 – IQ System Troubleshooting.
Handset has failed Replace handset
Disconnect the IQDM cord from the vehicle.

Handset malfunction Wait a few seconds and reconnect the handset
to the vehicle

Loose connection at IQDM port
Display screen shows jumbled or Speed Controller on page 19-20
undecipherable characters Test Procedure 1 – Handset Cord on page
Intermittent handset cord failure
19-19
Test Procedure 2 – Handset Cord Adaptor on

Intermittent handset cord adaptor failure
page 19-19

Loose vehicle wire harness connections

DIAGNOSTICS: IQ SYSTEM Test Procedures 19
Disconnect the IQDM cord from the vehicle.
Handset malfunction Wait a few seconds and reconnect the handset
to the vehicle
Vehicle batteries – loose terminals or corrosion See Section 21 – Batteries. .

Handset is “locked-up” – buttons do not
respond Vehicle batteries – improperly wired See Section 21 – Batteries. .
Vehicle batteries – batteries failed See Section 21 – Batteries. .
Vehicle batteries – batteries not fully charged See Section 21 – Batteries. .
TEST PROCEDURES
The following test procedures enable the technician to test the IQDM and IQDM-P handsets and the components of the
IQ System vehicle that are related to the proper operation of the handset.
WARNING
• If wires are removed or replaced, make sure wiring and wire harness is properly routed and secured.
1 – Handset Cord
2 – Handset Cord Adaptor
3 – IQDM Jack Located On Speed Controller
TEST PROCEDURE 1 – Handset Cord

1. Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the cord with
the square plug.
2. Place the black (–) probe on each of the pins, one at a time, on the plug on the other end of the cord.
3. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the cord must be
replaced.
4. Repeat the procedure three more times, each time with the red (+) probe inserted into a different terminal on
the end of the cord with the square plug.
TEST PROCEDURE 2 – Handset Cord Adaptor

The procedure for testing the handset cord adaptor is similar to the cord test.
1. Using a multimeter set for 200 ohms, place the red (+) probe into one of the terminals on the end of the adapter
with the square plug.
2. Place the black (–) probe on each of the pins, one at a time, on the other plug of the adaptor.

19 Test Procedures DIAGNOSTICS: IQ SYSTEM
3. The multimeter should indicate continuity on only one pin. If any other reading is obtained, the adaptor must
be replaced.
4. Repeat the procedure three more times, each time with the red (+) probe inserted into a different terminal on the
end of the adaptor with the square plug.
TEST PROCEDURE 3 – IQDM Jack Located On Speed Controller
Inspect the IQDM ports for damage or corrosion.
2. Place the Tow/Run switch in the TOW position, disconnect the batteries, negative (–) cable first, and wait 90
seconds for the speed controller capacitors to discharge. See General Warnings on page 1-1.
3. Check the IQDM jack on the speed controller.
3.1. Remove the two screws securing the rear body access panel and remove the access panel.
3.2. Remove the two screws (5) securing the controller cover (1) to the component mounting plate (Figure
19-7, Page 19-20).
3.3. Disconnect the square four-pin connector (3) from the speed controller.
3.4. Connect the handset cord to the handset.
3.5. Connect the other end of the handset cord (without the adapter) (4) to the four-pin connector of the speed
controller (2).
3.6. Connect the vehicle batteries, positive (+) cable first.
3.7. If the handset functions when connected directly to the speed controller, the adapter plug or vehicle wire
harness should be thoroughly tested. See Test Procedure 2 – Handset Cord Adaptor on page 19-19
and See IQ System Troubleshooting, Section 18, Page 18-1..
2 5
4
1
1320
Figure 19-7 IQDM Connector On Speed Controller

SECTION 20 – ELECTRICAL COMPONENTS 20
DANGER
WARNING
KEY SWITCH
TESTING THE KEY SWITCH
See Test Procedure 8 – Key Switch and MCOR Limit Switch Circuit on page 18-18.
KEY SWITCH REMOVAL
2. Remove the center dash panel (Figure 20-1, Page 20-2).
2.1. Remove the plastic cap (1) covering the mounting screw (2) on each side of the center dash panel (3).
2.2. Loosen, but do not remove, the screw (2) on each side of the center dash panel (3).
2.3. Insert screwdriver at the top center of the dash between dash and cowl brace. Gently pry center dash out
slightly from under edge of cowl brace.
2.4. Pull center dash out from the frame and disconnect the wires from the electrical components mounted on
the dash panel. Do not allow wires to touch. See following NOTE.
NOTE: Take care to prevent key switch terminals and wires from touching the metal frame around the dash.

20 Key Switch ELECTRICAL COMPONENTS
Figure 20-1 Dash Removal

3. Slide center dash panel up steering column by snapping top out and then rotating the panel out and up.
4. Disconnect the wires from the key switch. Do not allow wires to touch.
5. From the back of the dash panel, push down on the retaining tabs surrounding the key switch (4) and remove the
key switch cap (8). Hold the key switch and remove the switch retaining nut (6) from the outside of the dash
panel (Figure 20-2, Page 20-2).
7 4
9
6
Figure 20-2 Key Switch
KEY SWITCH INSTALLATION
1. Position the key switch and flat washer (9) in the center dash, then install and tighten the switch retaining nut (6)
to 40 in-lb (4.5 N·m). Install key switch cap (8) in center dash (Figure 20-2, Page 20-2).

ELECTRICAL COMPONENTS Forward/Reverse Rocker Switch 20
2. Refer to the wiring diagram to connect the wires to the key switch terminals and tighten the terminal screws to
7 in-lb (0.8 N·m). See Wiring Diagram – Electric Vehicle, Section 18, Page 18-2. Coat the connectors with
Battery Terminal Protector Spray (CC P/N 1014305) to prevent corrosion.
3. Install center dash by reversing removal procedure. Make sure key switch terminals (7) do not touch frame and
that the center dash panel is properly seated and snapped into place (Figure 20-1, Page 20-2).
FORWARD/REVERSE ROCKER SWITCH
TESTING THE FORWARD/REVERSE ROCKER SWITCH
See Test Procedure 23 – Forward/Reverse Rocker Switch on page 18-32.
FORWARD/REVERSE ROCKER SWITCH REMOVAL
2. Remove two screws (3) that hold Forward/Reverse rocker switch housing (2) to the vehicle (Figure 20-3, Page
20-3).
3. Remove the three wires from the rocker switch.
4. Press in on the locking tabs on each side of switch (11) and push switch out of housing.
11
2
RUN
TOW 7
9
10
3
1321
Figure 20-3 Tow/Run Switch and Forward/Reverse Rocker Switch
FORWARD/REVERSE ROCKER SWITCH INSTALLATION
1. Press the locking tabs (11) on each end of the rocker switch and push switch into case (Figure 20-3, Page 20-3).

20 Tow/Run Switch ELECTRICAL COMPONENTS
2. Connect the 18-gauge brown, orange, and blue wires to the rocker switch exactly as shown in the wiring diagram.
See Wiring Diagram – Electric Vehicle, Section 18, Page 18-2.
3. Place the switch case (2) in position on the body and install the two screws (3). Tighten to 20 in-lb (2.3 N·m).
6. Inspect the vehicle for proper operation. See following WARNINGS.
WARNING
• Make sure that the vehicle operates in the forward direction when the Forward/Reverse switch is
in the FORWARD position.
• 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.
TOW/RUN SWITCH
TESTING THE TOW/RUN SWITCH
See Test Procedure 6 – Tow/Run Switch on page 18-16.
TOW/RUN SWITCH REMOVAL
2. Remove Tow/Run switch boot/hex nut (6) (Figure 20-3, Page 20-3).
3. Remove Tow/Run switch (10) and nut (9) from bracket (5).
4. Disconnect the two-pin connector (7) and remove switch.
TOW/RUN SWITCH INSTALLATION
1. Installation is reverse of removal. Make sure groove on switch is aligned with tang on bracket. Tighten Tow/Run
switch boot/hex nut (6) to 16 in-lb (1.8 N·m) (Figure 20-3, Page 20-3). Tighten Tow/Run switch boot/hex nut
(1) to 16 in-lb (1.8 N·m).

ELECTRICAL COMPONENTS Motor Controller Output Regulator (MCOR) 20
MOTOR CONTROLLER OUTPUT REGULATOR (MCOR)
TESTING THE MCOR
See Test Procedure 4 – MCOR Voltage on page 18-14 and Test Procedure 8 – Key Switch and MCOR Limit
Switch Circuit on page 18-18.
MCOR REMOVAL
2. Place chocks at rear wheels and lift the front of the vehicle with a chain hoist or floor jack. Place jack stands
under the round tube crossmember of the frame to support vehicle.
3. Disconnect the two-pin and three-pin connectors (1) from the MCOR (2) (Figure 20-4, Page 20-6).
4. Remove the hex-head screws (3) connecting the MCOR to the frame I-beam.
5. Remove the MCOR from vehicle.
6. Push the drive bar (4) into the hole in the I-beam to disengage it from the accelerator pivot rod (5).

20 Motor Controller Output Regulator (MCOR) ELECTRICAL COMPONENTS
GO
4 3
1322
Figure 20-4 Motor Controller Output Regulator (MCOR) Mounting
MCOR INSTALLATION
1. Insert the splined end of the drive bar (4) through the hole in the passenger-side frame I-beam as shown (Figure
20-4, Page 20-6).
2. Position the opposite end of the drive bar so that the accelerator pedal sits between the two pins.
3. Place the MCOR (2) onto the splined end of the drive bar. See following NOTE.
NOTE: The MCOR is keyed to ensure correct positioning on the drive bar.
4. Insert the alignment pins on the MCOR into the holes in the I-beam as shown.
5. Secure the MCOR to the frame I-beam with two hex-head screws (3). Tighten screws to 23 in-lb (2.6 N·m).
6. Connect the two-pin and three-pin connectors (1) from the wire harness to the MCOR.

ELECTRICAL COMPONENTS Reverse Buzzer 20
REVERSE BUZZER
TESTING THE REVERSE BUZZER
See Test Procedure 24 – Reverse Buzzer on page 18-33.
REVERSE BUZZER REMOVAL
2. Remove center dash. See Key Switch Removal on page 20-1.
3. Disconnect the 18-gauge red and orange/white wires from reverse buzzer.
4. Remove the two screws from the reverse buzzer. Remove the reverse buzzer from the center dash panel.
REVERSE BUZZER INSTALLATION
1. Install the reverse buzzer in the reverse order of removal. Tighten screws to 4 in-lb (0.45 N·m).
SOLENOID
The solenoid is located on the driver side of the electrical component mounting plate.
TESTING THE SOLENOID
See Test Procedure 3 – Solenoid Activating Coil on page 18-13 and Test Procedure 22 – Solenoid Continuity on
page 18-32.
SOLENOID REMOVAL
2. Remove the rear body access panel.
3. Disconnect all wires from the solenoid (3) (Figure 20-5, Page 20-8).
4. Slide solenoid (3) up to disengage the mounting tabs and remove from component mounting plate.

20 Onboard Computer (OBC) ELECTRICAL COMPONENTS
7
9
8
1323
Figure 20-5 Solenoid
SOLENOID INSTALLATION
1. Mount solenoid (3) onto component mounting plate by engaging slot (Figure 20-5, Page 20-8).
2. Using the wiring diagram, install the wires, resistor (9), washers (8), and nuts (7) onto the large mounting posts.
Tighten nuts to 77 in-lb (8.7 N·m). See Wiring Diagram – Electric Vehicle on page 18-2.
3. Install the blue/white and light blue wires onto the small terminals of the solenoid.
4. Install rear body access panel.
ONBOARD COMPUTER (OBC)
TESTING THE ONBOARD COMPUTER
See Test Procedure 2 – Onboard Computer Solenoid Lockout Circuit on page 18-12, Test Procedure 18 –
Onboard Computer Silicon-Controlled Rectifier (SCR) Circuit on page 18-29, and Test Procedure 19 – Onboard
Computer Gray Wire on page 18-30.
ONBOARD COMPUTER REMOVAL
2. Remove rear body access panel and unplug the six-pin connector (16) at the OBC (Figure 20-6, Page 20-9).
3. Remove the two screws (5) from the speed controller cover (1) and remove the cover (Figure 20-7, Page 20-10).
4. Remove the wire tie (3) securing the speed controller wires to the mounting plate.

ELECTRICAL COMPONENTS Onboard Computer (OBC) 20
5. Remove black wire assembly (14) from the speed controller B– terminal (Figure 20-6, Page 20-9).
6. Disconnect the gray wire fuse holder at the charger receptacle.
7. Disconnect the black 10-gauge wire (8) at the charger receptacle.
8. Cut the wire tie that secures the OBC wire harness to the I-beam.
9. Loosen, but do not remove, the two self-tapping screws (17) holding OBC to component mounting plate.
10. Slide OBC towards outside of vehicle and align heads of self-tapping screws (17) with the two holes in the OBC
face plate. Pull OBC towards rear of vehicle and remove from component mounting plate.
13
1
14
14 2
17
16
1324
Figure 20-6 Onboard Computer
ONBOARD COMPUTER INSTALLATION
1. Install the OBC onto the component mounting plate by aligning the two holes on the OBC face plate with two
holes on component mounting plate. Slide OBC towards inside of vehicle and align heads of self-tapping screws
(17) with smaller part of two holes in OBC face plate (Figure 20-6, Page 20-9). Tighten screws to 60 in-lb
(6.7 N·m). See following NOTE.
NOTE: The aluminum plate on the OBC should face toward the rear of the vehicle. The white potting material side of
the OBC should face toward the front of the vehicle.
2. Attach wire tie so the OBC wire harness is secured to the I-beam.
3. Connect the black 10-gauge wire (8) to the charger receptacle. Tighten nut to 23 in-lb (2.6 N·m).
4. Connect the gray wire fuse holder to the charger receptacle.
5. Connect the black wire assembly (14) to the speed controller B– terminal with the washer (2) and bolt (1) and
tighten to 108 int-lb (12.2 N·m).
6. Plug the six-pin connector (16) from the OBC into the vehicle wire harness
7. Install a wire tie (3) to tightly secure the speed controller wires to the component mounting plate (Figure 20-7,
Page 20-10).
8. Place the edge of the speed controller cover (1) into the slot (2). Press the controller cover onto the component
mounting plate over the speed controller and install the two screws (5). Tighten screws (5) to 60 in-lb (6.8 N·m).
See following NOTE.
NOTE: Make sure that the speed controller cover gasket forms a tight seal between the cover and the component
mounting plate.

20 Speed Controller ELECTRICAL COMPONENTS
1325
Figure 20-7 Speed Controller Cover
SPEED CONTROLLER
TESTING THE SPEED CONTROLLER
See Test Procedure 5 – A1 and A2 Motor Voltage on page 18-15.
SPEED CONTROLLER REMOVAL
2. Remove the rear body access panel.
3. Remove the two screws (5) from the speed controller cover (1) and remove the cover (Figure 20-7, Page 20-10).
4. Disconnect all wires and multi-pin connectors from the speed controller (Figure 20-8, Page 20-11).
5. Remove the three self-tapping screws (17) that hold the controller (6) to the component mounting plate and
remove the controller from the vehicle.

ELECTRICAL COMPONENTS Speed Controller 20
S1 S2
2
1
B–
S1 S2
M–
B+
17
2
1
1326
Figure 20-8 Speed Controller
SPEED CONTROLLER INSTALLATION
1. Install the three self-tapping screws (17) that hold the controller (6) to the component mounting plate and tighten
to 60 in-lb (6.8 N·m) (Figure 20-8, Page 20-11).
2. Using the wiring diagram, install the multi-pin connectors and all wires as illustrated. See Wiring Diagram –
Electric Vehicle on page 18-2. Tighten bolts (1) to 9 ft-lb (12.2 N·m).
3. Place the edge of the speed controller cover (1) into the slot (2). Press the controller cover onto the component
mounting plate over the speed controller and install the two screws (5) (Figure 20-7, Page 20-10). Tighten the
screws (5) to 60 in-lb (6.8 N·m). See following NOTE.
NOTE: Make sure that the speed controller cover gasket forms a tight seal between the cover and the component
mounting plate.

7. Inspect the vehicle for proper operation. See following WARNINGS.
WARNING
is in REVERSE.
WARNING CONTINUED ON NEXT PAGE

20 Charger Receptacle ELECTRICAL COMPONENTS
WARNING
position.
CHARGER RECEPTACLE
The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them for cracks,
loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger plug or receptacle
show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts and plug terminals should be
cleaned with a good electrical contact cleaner or lightly sprayed with WD-40® brand spray lubricant. The plug should
then be inserted and removed several times to ensure ease of insertion, ease of removal, and good electrical contact.
Testing the Charger Receptacle

See Test Procedure 20 – Voltage at Charger Receptacle Red Wire Socket on page 18-30.
See also the appropriate battery charger maintenance and service manual.
CHARGER RECEPTACLE INSPECTION
Inspect the receptacle for cracks, loose connections and frayed wiring. See following NOTE.
NOTE: Disassembly of the charger receptacle, for the purpose of removal or installation, is not recommended.
CHARGER RECEPTACLE REMOVAL
2. Remove the 10-gauge red wire (4) from the positive post of battery no. 1 (Figure 20-9, Page 20-13).
3. Remove black 10-gauge OBC wire (5) from the receptacle fuse link (6).
4. Disconnect the gray wire (9) from the receptacle at the yellow fuse holder.
5. Remove the four screws (1) that secure the charger receptacle bezel (7) to the receptacle backing plate (8)
and to the vehicle body.
6. Move the receptacle assembly toward the front of the vehicle and tilt receptacle upwards in order for the
receptacle to pass through the hole in the vehicle body.
CHARGER RECEPTACLE INSTALLATION
1. Insert the 10-gauge red wire (4) and the 18-gauge gray wire (3) through the hole in the vehicle body and the
receptacle backing plate (8) (Figure 20-9, Page 20-13).
2. Insert receptacle into vehicle body.

ELECTRICAL COMPONENTS Charger Receptacle 20
3. Install the four screws (1) that secure the receptacle to the vehicle body and receptacle backing plate (8).
Tighten screws to 16 in-lb (1.8 N·m).
4. Connect 18-gauge gray wire (9) to yellow fuse holder. Make sure fuse (11) is installed in fuse holder.
5. Connect the 10-gauge black wire (5) to the receptacle fuse link (6) on the charger receptacle. Tighten to
23 in-lb (2.6 N·m).
6. Connect the 10-gauge red wire (4) to the positive post of battery no. 1.
1 2
8 11
9
7
1333
Figure 20-9 Charger Receptacle
RECEPTACLE FUSE LINK
The fuse link on the 48-volt electric vehicle should not blow under normal operating conditions; however, if the fuse
link has blown, the vehicle will not charge and the fuse must be replaced. The fuse link (6) is mounted on top of the
charger receptacle in the battery compartment (Figure 20-9, Page 20-13).
Receptacle Fuse Link Removal
1. Remove the fuse link (6) from the charger receptacle (7) by removing the two nuts (2) and washers used to
secure the 10-gauge black wire (5) from the computer and the 10-gauge black wire from the receptacle (Figure
20-9, Page 20-13).
2. Remove the fuse link (6) from the charger receptacle.
Receptacle Fuse Link Installation
1. Insert the two fuse link mounting posts into the mounting holes in the charger receptacle.
2. Place the two 10-gauge black wires in their original positions on the fuse link mounting posts.
3. Install nuts (2) on fuse link mounting posts and tighten to 23 in-lb (2.6 N·m).

20 Battery Warning Light ELECTRICAL COMPONENTS
BATTERY WARNING LIGHT
TESTING THE BATTERY WARNING LIGHT
See Test Procedure 26 – Battery Warning Light on page 18-34.
BATTERY WARNING LIGHT REMOVAL
2. Remove instrument panel. See Key Switch Removal on page 20-1.
3. Disconnect the wires at the warning light.
4. Press the two retaining tabs (11) and remove the light from the center dash.
BATTERY WARNING LIGHT INSTALLATION
1. Install in reverse order of removal.

PIN 9 DIODE
NOTE: For 2011 model year, a change inside the controller allowed this diode to be removed from the wire harness.
TESTING THE PIN 9 DIODE
See Test Procedure 15 – Pin 9 on page 18-26.

If the pin 9 diode has failed open, it should be removed from the harness. Instead of replacing the diode with a new
one, we recommend installing an IQ Main Dropout Harness (CC P/N 102355201) between the Tow/Run switch and
the wire harness.
PIN 9 DIODE REMOVAL
2. Locate diode in flex loom near 16-pin connector and cut diode from gray/white and gray wires (Figure 20-10,
Page 20-15).
3. Splice the ends of the two wires together and seal with electrical tape or shrink wrap.

ELECTRICAL COMPONENTS Pin 9 Diode 20
4. Install a Main Dropout Harness. See IQ Main Dropout Harness Installation on page 20-15.
1327
Figure 20-10 Pin 9 Diode
IQ MAIN DROPOUT HARNESS INSTALLATION
1. Disconnect the two-pin connector (1) at the Tow/Run switch (Figure 20-11, Page 20-15).
2. Connect the main dropout harness (2) between each end of the two-pin connector.
1
RUN
TOW
1328
Figure 20-11 Install Main Dropout Harness

20 Ferrite Beads – CE Mark Vehicles ELECTRICAL COMPONENTS
FERRITE BEADS – CE MARK VEHICLES
These beads make the vehicle comply with EMC requirements for use in the European Union.
1. Black Ferrite Bead Around White, Green, Orange, and Blue Wires Close To Motor
2. Grey Ferrite Bead In Looped Orange and Blue Wires Near Black Ferrite Bead (1)
3. Black Ferrite Bead Around White, Green, Orange, and Blue Wires Just Past Looped Orange and Blue Wires
4. Black Ferrite Bead Around Main Wire Harness Near Contoller
5. Black Ferrite Bead Around Yellow and Black Wires Near B- Accessory Terminal Block
6. Make sure both field wires (blue and orange) and both armature wires (green and white) are tie wrapped to the frame away from the
motor housing.
1370
Figure 20-12 Ferrite Bead Placement For DS IQ System
DC/DC CONVERTER
DC/DC CONVERTER REMOVAL
1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric Vehicles
on page 1-5.
2. Disconnect the DC/DC converter three pin (3) and two pin (4) plugs from the wire harness (5).
3. Remove the two locknuts (2) securing the DC/DC converter (1) to the frame and remove converter.

ELECTRICAL COMPONENTS DC/DC Converter 20
DC/DC CONVERTER INSTALLATION
1.
2. Connect the batteries. See Connecting the Batteries – Electric Vehicles on page 1-5.
3. Install the DC/DC converter (1) to the frame and secure with locknuts (2). Tighten locknuts (2) to 65 in-lb (7.3 N·m).
4. Connect the three pin (3) and the two pin plugs (4) of the wire harness (5) to the DC/DC converter (1) leads.

SECTION 21 – BATTERIES 21
DANGER
WARNING
DANGER
• Charge batteries in a well-ventilated area only. Batteries emit hydrogen while being charged. Hydrogen
is an explosive gas and must never exceed a level of 2% of the air.
Antidotes:

WARNING
• Wear safety glasses or approved eye protection when servicing the vehicle or battery charger. Wear a
full face shield and rubber gloves when working on or near batteries.
• Ensure battery connections are clean and properly tightened. See Battery Care on page 21-13.
CAUTION
• On all electric vehicles, turn off all accessories before charging batteries.
NOTE: Recycle or dispose of discarded batteries in accordance with local, state, and federal regulations.
GENERAL INFORMATION
The batteries supplied with an electric vehicle are different from those supplied with an automobile. The outward
appearance of these two batteries is similar, but the operating characteristics are very different. The electric vehicle
battery is a deep-cycle battery, and the automotive battery is a “starting, lighting and ignition” (SLI) battery. They
should never be substituted for one another.

21 Battery Troubleshooting Chart BATTERIES
BATTERY TROUBLESHOOTING CHART
Vehicle not operating to expectation.
Fully Charge Batteries.
Battery Charger T est
Reading of 6 amps or more.

Reading below 6 amps and on-charge
voltage above 56 volts.
Check electrical system and charger

for problems.
SeeTroubleshooting Guide
On-Charge V oltage T est
If problem is not found, go to
on-charge voltage test.
Any reading below 9.3 volts and not All readings above 9.3V and
within 0.7V
.
All readings below 9.3V but within 0.7V
within 0.7 volts of those batteries
above 9.3 volts, replace battery
.
Possible old batteries. Hydrometer T est

Go to hydrometer testing.
No apparent problems.
Replace any battery with a variation Entire battery set with specific gravity
of more than 50 points of specific gravity readings below 1.250 is being
between cells or has a cell with no consistently undercharged.
reading at all. Evaluate charging practices. Discharge T est
If discharge time is less than 60 minutes, If discharge time is 60 minutes or

replace all batteries below 6.7 volts. more, problem is not with the batteries.
716
Figure 21-1 Battery Troubleshooting Chart

BATTERIES Battery Testing – 12 Volt 21
BATTERY TESTING – 12 VOLT
Four tests have been developed to help diagnose problems with batteries that have not performed as expected.
Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow
through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart
BATTERY CHARGER TEST
The easiest way to monitor the condition of a vehicle’s batteries is simply to observe the reading on the battery charger
ammeter at the end of the charge cycle. After a full charge, disconnect the charger DC plug, wait 20 to 30 seconds and
reconnect the charger DC plug. The ammeter needle will jump to 15 amps or more and then taper to below 6 amps
within 10 to 20 minutes, indicating sound, fully charged batteries.
Continued poor performance may indicate a problem in the vehicle electrical system, brakes or battery charger. If the
problem is not found in the vehicle or charging system, proceed to the on-charge voltage test. Batteries that remain at
8 amps or higher should be tested further using the on-charge voltage test.
ON-CHARGE VOLTAGE TEST
When the batteries are fully charged, disconnect the charger DC plug. Wait 20 to 30 seconds and reconnect the DC
plug to restart the charger. After 5 minutes, use a multimeter to check and record the voltage of the battery set as
well as the individual batteries. Set the multimeter to 200 volts DC. Place the red (+) probe on the positive (+) post of
battery no. 1 and the black (–) probe on the negative (–) post of battery no. 4 (Figure 1-1, Page 1-4). Record reading.
Then set multimeter to 20 volts DC and place the red (+) probe on the positive (+) post and the black (–) probe at the
negative (–) post of each battery. Record the readings.
The on-charge voltage for the set should be between 56.0 volts and 63.0 volts depending on the age and state of
charge of the batteries being tested. If individual batteries read above 14.0 volts and are within 1.0 volts of each other,
go to the hydrometer test. If any battery reads below 14.0 volts and not within 1.0 volts of those batteries above
14.0 volts, replace battery. If readings are below 14.0 volts but within 1.0 volts of each other, the batteries are old.
Old batteries may have enough capacity left to last several more months. Go to hydrometer test. See Battery
Troubleshooting Chart on page 21-2 and the examples on the following pages.
HYDROMETER TEST
A hydrometer measures the specific gravity of the battery’s electrolyte. The higher the specific gravity, the higher the
state of charge of the batteries. A fully charged battery should read between 1.250 and 1.280 at 80 °F (26.7 °C). Never
add acid to batteries to obtain a higher specific gravity.
1. Be sure batteries have sufficient electrolyte to cover plates by approximately 1/2 inch (13 mm) and are fully
charged prior to beginning test. If water must be added, recharge the batteries before performing the hydrometer
test. See following CAUTION.

21 Battery Testing – 12 Volt BATTERIES
CAUTION
• Do not allow battery acid from battery caps or hydrometer to drip onto the front or rear body of the
vehicle. Battery acid will cause permanent damage. Wash immediately.
2. Remove the vent cap. Using a battery thermometer (CC P/N 1011767), record electrolyte temperature of the
no. 2 cell.
4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does
not strike the top of the glass tube. Remove the hydrometer from the cell and release the pressure from the bulb.
5. Hold the hydrometer vertically, ensuring that the float is not touching the sides of the barrel. Hold the hydrometer
at eye level and read the scale at the level of electrolyte (Figure 21-2, Page 21-4).
6. Record the reading and return the electrolyte to the cell from which it was taken. Replace vent cap.
Most hydrometers are calibrated to read correctly at 80 °F (26.7 °C). The readings obtained as described above must
be corrected for temperature. For each 10 °F (5.6 °C) above 80 °F (26.7 °C), add 0.004 to the reading. For each 10 °F
(5.6 °C) below 80 °F (26.7 °C), subtract 0.004 from the reading.
20
40
1.250
60
80
1.280
13 00
View at eye level.
717
Figure 21-2 Hydrometer Test

The approximate state of charge can be determined from the following table:
APPROXIMATE
SPECIFIC GRAVITY (TEMPERATURE CORRECTED)
STATE OF CHARGE
1.250-1.280 100%
1.220-1.240 75%
1.190-1.210 50%
1.160-1.180 25%

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. When the variations between cells reach 0.050 or more, the battery with the low
cell should be replaced.
ELEC- CORRECTED SPECIFIC GRAVITY

VEHI- BAT- CORREC-
TROLYTE REQUIRED
CLE TERY TION CELL CELL CELL CELL CELL CELL
TEMPER- ACTION
NO. NO. FACTOR 1 2 3 4 5 6
ATURE
1.275 1.280 1.280 1.275 1.280 1.280
20 °F Sound Battery – Fully
12 1 –0.024 –0.024 –0.024 –0.024 –0.024 –0.024 –0.024
(–6.6 °C) Charged
= 1.251 = 1.256 = 1.256 = 1.251 = 1.256 = 1.256
1.260 1.200 1.270 1.265 1.270 1.260

50 °F
54 3 –0.012 –0.012 –0.012 –0.012 –0.012 –0.012 –0.012 Bad no. 2 Cell
(10 °C)
= 1.248 = 1.188 = 1.258 = 1.253 = 1.258 = 1.248
1.200 + 1.180 + 1.170 + 1.200 + 1.180 + 1.198 + Discharged Battery

100 °F
38 2 +.008 0.008 = 0.008 = 0.008 = 0.008 = 0.008 = 0.008 = – Recharge and
(37.8 °C)
1.208 1.188 1.178 1.208 1.188 1.198 Recheck
1.240 1.245 Float 1.235 1.250 1.240

80 °F no.3 Cell Dead –
22 4 .000 – 0 = – 0 does – 0 = – 0 = – 0 =
(26.7 °C) Replace Battery
1.240 = 1.245 not rise 1.235 1.250 1.240
DISCHARGE TEST
If the previous tests have failed to identify the problem, conduct a discharge test. The discharge test comes closest
to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage
drops to 42.0 volts.
The discharge test is the hardest test on the batteries and the most time-consuming to perform. Use the battery
discharge tester (CC P/N 101831901).
Performing the Discharge Test
2. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 4 (Figure
21-3, Page 21-5).
1 (+)
TER
TES
S
O
P
G
E
N
1
N
E
G
P
O
S
2
N
E
S
G
O
P
P
O
2
G
S
E
N
(–) 3
4
1. RED probe to battery no. 1 (+).

2. BLACK probe to battery no. 4 (-).
1329
Figure 21-3 Battery Discharge Test
3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive
post) in each battery.
4. Reset discharge machine and turn the tester ON.

5. When the batteries have been discharging for approximately 60 minutes, set the discharge machine to function 3
and check battery set voltage. Check voltage every 10 minutes throughout the rest of the test. As soon as the
battery set voltage reaches 0.5 volts above the shut-off point (42.0 volts), use a multimeter to measure individual
battery voltages. Measure and record the voltage of each battery to the nearest 0.01 volt. See following NOTE.
NOTE: The tester will shut off automatically when shut-off voltage is reached.
Interpreting Discharge Test Results

1. If discharge time is 60 minutes or higher, the problem is not with the batteries.
2. If discharge times are low (less than 60 minutes), replace batteries below 10.05 volts.
BATTERY VOLTAGES
BATTERY CONDITION
1 2 3 4
10.50 V 10.50 V 10.50 V 10.50 V Excellent
10.60 V 10.60 V 10.83 V 9.75 V Battery no. 4 is near end of useful life
10.8 V 10.8 V 10.01 V 9.41 V Battery nos. 3 and 4 are near end of useful life
3. In general, battery sets that discharge in less than 60 minutes at 78 °F (25.6 °C) on the discharge test will
typically not hold a charge for an entire work shift. However, discharge time is dependent on the electrolyte
temperature. The table shown gives the discharge times, at various temperatures, of a set of batteries that
delivers 62 minutes at 80 °F (26.7 °C).
ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO
TEMPERATURE SHUT-OFF POINT TEMPERATURE SHUT-OFF POINT
40-49 °F 85-89 °F
40 Minutes 64 Minutes
(4-9 °C) (29-32 °C)
50-59 °F 89-99 °F
(10-15 °C) (32-37 °C)
60-64 °F 100-109 °F
(16-18 °C) (38-43 °C)
65-69 °F 110-119 °F
(18-21 °C) (43-48 °C)
70-74 °F 120-129 °F
(21-23 °C) (49-54 °C)
75-79 °F 130-150 °F
(24-26 °C) (54-66 °C)
80-84 °F
62 Minutes ***** *****
(27-29 °C)
BATTERY TROUBLESHOOTING EXAMPLES
The following information represents a few examples of troubleshooting battery problems.
Example 1
Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test
was performed. After a full charge, the battery charger ammeter read 8.0 amps. Next, the on-charge voltage test
was performed and the following results were recorded:
BATTERY NO. 1 2 3 4
On-Charge Voltage 15.22 V 15.90 V 14.70* V 15.24 V
*Battery no. 3 appears suspect. Battery nos. 1 and 4 are also suspect. Next, a hydrometer test should be conducted
on all batteries.

Hydrometer test results:
BATTERY NUMBER
CELL NUMBER
1 2 3 4
Cell 1 (Positive Post) 1.200* 1.265 1.300 1.250
Cell 2 1.285 1.275 1.290 1.270
Cell 3 1.265 1.270 1.275 1.265
Cell 4 (Negative Post) 1.275 1.270 1.285 1.265
Cell 5 1.270 1.265 1.280 1.270
Cell6 1.275 1.280 1.280 1.260
*After the hydrometer test, it appears that battery no. 1 is the problem. Next, the discharge test was performed.
Discharge test results:

BATTERY NO. 1 2 3 4
Discharge Voltage 8.16* V 10.99 V 11.60 V 10.72 V
*After a discharge test which lasted 45 minutes, battery no. 1 is clearly shown to be the problem. Battery no. 4 should
be watched a little more closely but appears to be okay. Battery no. 1 should be replaced with a battery that has about
the same age and usage as the other batteries in the set.
Example 2
Vehicle no. 70 was also suspected of having a bad battery due to its performance. The battery charger test showed
7.0 amps after a full charge. After confirming there were no problems with the electrical system, charger or brakes, the
on-charge voltage was recorded as follows:
BATTERY NO. 1 2 3 4
On-Charge Voltage 15.72 V 14.66* V 15.80 V 15.85 V
*Battery no. 2 was immediately suspected as the problem. After checking battery no. 2 with a hydrometer, it was
discovered that the negative post cell was completely dead. Battery no. 2 should be replaced with a battery that has
BATTERY TESTING – 8 VOLT
Four tests have been developed to help diagnose problems with batteries that have not performed as expected.
Because each test becomes progressively more detailed and time-consuming, begin with the first test and follow
through with the other tests until the problem has been identified as outlined in the Battery Troubleshooting Chart
BATTERY CHARGER TEST
The easiest way to monitor the condition of a vehicle’s batteries is simply to observe the reading on the battery charger
ammeter at the end of the charge cycle. After a full charge, disconnect the charger DC plug, wait 20 to 30 seconds and
reconnect the charger DC plug. The ammeter needle will jump to 15 amps or more and then taper to below 6 amps
within 10 to 20 minutes, indicating sound, fully charged batteries.
Continued poor performance may indicate a problem in the vehicle electrical system, brakes or battery charger. If the
problem is not found in the vehicle or charging system, proceed to the on-charge voltage test. Batteries that remain at
8 amps or higher should be tested further using the on-charge voltage test.

ON-CHARGE VOLTAGE TEST
When the batteries are fully charged, disconnect the charger DC plug. Wait 20 to 30 seconds and reconnect the DC
plug to restart the charger. After 5 minutes, use a multimeter to check and record the voltage of the battery set as
well as the individual batteries. Set the multimeter to 200 volts DC. Place the red (+) probe on the positive (+) post of
battery no. 1 and the black (–) probe on the negative (–) post of battery no. 6. Record reading. Then set multimeter to
20 volts DC and place the red (+) probe on the positive (+) post and the black (–) probe at the negative (–) post of
each battery. Record the readings.
The on-charge voltage for the set should be between 56.0 volts and 63.0 volts depending on the age and state of
charge of the batteries being tested. If individual batteries read above 7.0 volts and are within 0.5 volts of each
other, go to the hydrometer test. If any battery reads below 7.0 volts and not within 0.5 volts of those batteries
above 7.0 volts, replace battery. If readings are below 7.0 volts but within 0.5 volts of each other, the batteries are
old. Old batteries may have enough capacity left to last several more months. Go to hydrometer test. See Battery
Troubleshooting Chart on page 21-2 and the examples on the following pages.
HYDROMETER TEST
A hydrometer measures the specific gravity of the battery’s electrolyte. The higher the specific gravity, the higher the
state of charge of the batteries. A fully charged battery should read between 1.250 and 1.280 at 80 °F (26.7 °C). Never
add acid to batteries to obtain a higher specific gravity.
1. Be sure batteries have sufficient electrolyte to cover plates by approximately 1/2 inch (13 mm) and are fully
charged prior to beginning test. If water must be added, recharge the batteries before performing the hydrometer
test. See following CAUTION.
CAUTION
2. Remove the vent cap. Using a battery thermometer (CC P/N 1011767), record electrolyte temperature of the
no. 2 cell.
4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does
not strike the top of the glass tube. Remove the hydrometer from the cell and release the pressure from the bulb.
5. Hold the hydrometer vertically, ensuring that the float is not touching the sides of the barrel. Hold the hydrometer
at eye level and read the scale at the level of electrolyte (Figure 21-4, Page 21-9).
6. Record the reading and return the electrolyte to the cell from which it was taken. Replace vent cap.
Most hydrometers are calibrated to read correctly at 80 °F (26.7 °C). The readings obtained as described above must
be corrected for temperature. For each 10 °F (5.6 °C) above 80 °F (26.7 °C), add 0.004 to the reading. For each 10 °F
(5.6 °C) below 80 °F (26.7 °C), subtract 0.004 from the reading.

20
40
1.250
60
80
1.280
13 00
View at eye level.
717
Figure 21-4 Hydrometer Test
The approximate state of charge can be determined from the following table:
APPROXIMATE
SPECIFIC GRAVITY (TEMPERATURE CORRECTED)
STATE OF CHARGE
1.250-1.280 100%
1.220-1.240 75%
1.190-1.210 50%
1.160-1.180 25%
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. When the variations between cells reach 0.050 or more, the battery with the low
cell should be replaced.
VEHICLE BATTERY ELECTROLYTE CORRECTION CORRECTED SPECIFIC GRAVITY REQUIRED
NO. NO. TEMPERATURE FACTOR CELL 1 CELL 2 CELL 3 ACTION
1.275 –0.024 1.280 – 0.024 1.280 – 0.024 Sound Battery –

12 1 20 °F (-6.6 °C) – 0.024
= 1.251 = 1.256 = 1.256 Fully Charged
Discharged
1.155 + 0.004 1.165 + 0.004 1.160 + 0.004
35 6 90 °F (32.2 °C) + 0.004 Battery –
= 1.159 = 1.169 = 1.164
Recharge
1.260 –0.012 1.200 – 0.012 1.270 – 0.012

54 3 50 °F (10 °C) – 0.012 Bad no. 2 Cell
= 1.248 = 1.188 = 1.258
1.250 – 0 = 1.255 – 0 = 1.230 – 0 = Weak no. 3 Cell –

69 5 80 °F (26.7 °C) 0.000
1.250 1.255 1.230 Catch-up Charge
Discharged
1.200 + 0.008 1.180 + 0.008 1.170 + 0.008 Battery –
38 2 100 °F (37.8 °C) + 0.008
= 1.208 = 1.188 = 1.178 Recharge and
Recheck
1.240 – 0 = 1.245 – 0 Float does no.3 Cell Dead –

22 4 80 °F (26.7 °C) 0.000
1.240 = 1.245 not rise Replace Battery

DISCHARGE TEST
If the previous tests have failed to identify the problem, conduct a discharge test. The discharge test comes closest
to simulating actual vehicle operating conditions by continuously drawing current from the batteries until voltage
drops to 42.0 volts.
The discharge test is the hardest test on the batteries and the most time-consuming to perform. Use the battery
discharge tester (CC P/N 101831901).
Performing the Discharge Test
2. Connect the tester leads to the positive (+) post of battery no.1 and negative (–) post of battery no. 6 (Figure
21-5, Page 21-10).
3. Check and record the electrolyte temperature of the battery packs. Check cell no. 2 (second cell from positive
post) in each battery.
4. Reset discharge machine and turn the tester ON.
5. When the batteries have been discharging for approximately 60 minutes, set the discharge machine to function 3
and check battery set voltage. Check voltage every 10 minutes throughout the rest of the test. As soon as the
battery set voltage reaches 0.5 volts above the shut-off point (42.0 volts), use a multimeter to measure individual
battery voltages. Measure and record the voltage of each battery to the nearest 0.01 volt. See following NOTE.
NOTE: The tester will shut off automatically when shut-off voltage is reached.
1
TER
TES
(+)
3
4
2 (–)
2
5
6

1. RED probe to battery no. 1 (+).
2. BLACK probe to battery no. 6 (-).
1843
Figure 21-5 Battery Discharge Test – 6 x 8 Volt Battery
Configuration

Interpreting Discharge Test Results
1. If discharge time is 60 minutes or higher, the problem is not with the batteries.
2. If discharge times are low (less than 60 minutes), replace batteries below 6.7 volts.
BATTERY VOLTAGES
BATTERY CONDITION
1 2 3 4 5 6
7.00 7.00 7.00 7.00 7.00 7.00
Excellent
V V V V V V
7.07 7.07 7.22 6.50 7.07 7.07

Battery no. 4 is near end of useful life.
V V V V V V
7.20 7.20 6.67 7.33 6.27 7.33

Battery nos. 3 and 5 are near end of useful life.
V V V V V V
3. In general, battery sets that discharge in less than 60 minutes at 78 °F (25.6 °C) on the discharge test will
typically not hold a charge for an entire work shift. However, discharge time is dependent on the electrolyte
temperature. The table shown gives the discharge times, at various temperatures, of a set of batteries that
delivers 62 minutes at 80 °F (26.7 °C).
ELECTROLYTE DISCHARGE TIME TO ELECTROLYTE DISCHARGE TIME TO

TEMPERATURE SHUT-OFF POINT TEMPERATURE SHUT-OFF POINT
40-49 °F 85-89 °F
(4-9 °C) (29-32 °C)
50-59 °F 89-99 °F
(10-15 °C) (32-37 °C)
60-64 °F 100-109 °F
(16-18 °C) (38-43 °C)
65-69 °F 110-119 °F
(18-21 °C) (43-48 °C)
70-74 °F 120-129 °F
(21-23 °C) (49-54 °C)
75-79 °F 130-150 °F
(24-26 °C) (54-66 °C)
80-84 °F
62 Minutes ***** *****
(27-29 °C)
BATTERY TROUBLESHOOTING EXAMPLES
The following information represents a few examples of troubleshooting battery problems.

Example 1
Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger test
was performed. After a full charge, the battery charger ammeter read 8.0 amps. Next, the on-charge voltage test
was performed and the following results were recorded:
BATTERY NO. 1 2 3 4 5 6
On-Charge Voltage 10.15 V 10.60 V 9.80* V 10.16 V 10.56 V 10.61 V
*Battery no. 3 appears suspect. Batteries no. 1 and 4 are also suspect. Next, a hydrometer test should be conducted
on all batteries.

21 Battery Replacement BATTERIES
Hydrometer test results:
BATTERY NUMBER
CELL NUMBER
1 2 3 4 5 6
Cell 1 (Positive Post) 1.200* 1.265 1.300 1.250 1.280 1.260
Cell 2 1.285 1.275 1.290 1.270 1.295 1.265
Cell 3 1.265 1.270 1.275 1.265 1.280 1.275
Cell 4 (Negative Post) 1.275 1.270 1.285 1.265 1.275 1.275
*After the hydrometer test, it appears that battery no. 1 is the problem. Next, the discharge test was performed.
Discharge test results:
BATTERY NO. 1 2 3 4 5 6
Discharge Voltage 5.44* V 7.33 V 7.73 V 7.15 V 7.43 V 7.41 V
*After a discharge test which lasted 45 minutes, battery no. 1 is clearly shown to be the problem. Battery no. 4 should
be watched a little more closely but appears to be okay. Battery no. 1 should be replaced with a battery that has about
Example 2
Vehicle no. 70 was also suspected of having a bad battery due to its performance. The battery charger test showed
7.0 amps after a full charge. After confirming there were no problems with the electrical system, charger or brakes, the
on-charge voltage was recorded as follows:
BATTERY NO. 1 2 3 4 5 6
On-Charge Voltage 10.48 V 9.77* V 10.53 V 10.57 V 10.55 V 10.33 V
*Battery no. 2 was immediately suspected as the problem. After checking battery no. 2 with a hydrometer, it was
discovered that the negative post cell was completely dead. Battery no. 2 should be replaced with a battery that has
BATTERY REPLACEMENT
WARNING
• To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position.
Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak
out the vent hole. Do not exceed this 45° angle when lifting, carrying, or installing batteries. Battery
acid can cause severe personal injury to skin or eyes, and can damage clothing.
• When replacing batteries in the Single Point Watering System, place the battery cap from the new
replacement battery onto the used battery being removed from the car. Important safety warnings on
the battery cap must remain with the battery after it has been removed from the car.
1. Before removing batteries, note the orientation of the batteries and the connecting wires. Disconnect the batteries
and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-5.
Remove remaining wires and batteries.
2. Visually inspect the new batteries for any damage that may have occurred in transit. New batteries will not deliver
their full capabilities until they have been discharged and recharged 20 to 50 times. To obtain the maximum
service life from new batteries, restrict vehicles with new batteries to one hour of operation between charges for

BATTERIES Battery Care 21
the first two months vehicle is in service. Batteries should be fully charged before first use of new vehicle, before
first use of a vehicle after storage, and before use each day.
3. If the battery cables are to be reused, inspect them for broken or frayed wires, damaged terminals, or worn
insulation. Remove any corrosion on the connectors. A solution of baking soda and water (1 cup (237 mL) baking
soda per 1 gallon (3.8 L) of water) does an excellent job of neutralizing and removing the corrosion. Be careful
not to allow the baking soda solution to enter the battery.
4. Check and clean the battery rack and hold-downs. The nuts and bolts on the hold-downs may corrode. It is
therefore advised they be cleaned periodically and replaced as necessary.
5. Install batteries in the proper orientation (Figure 1-1, Page 1-4). Install battery hold-downs. The hold-downs
should be tight enough so batteries do not move while vehicle is in motion, but not so tight as to crack or buckle
battery case. For 12 volt batteries: tighten hold-down retaining nuts to 72 in-lb (8.1 N·m), alternating between
hold-down bolts. For 8 volt batteries: tighten outboard hold-down retaining nuts to 55 in-lb (6.2 N·m) and inboard
hold-down retaining nuts to 115 in-lb (13 N·m), alternating between hold-down bolts.
6. Install wires in proper sequence. Install black wire to negative post of battery no. 4 (4 x 12-Volt battery set)
or battery no. 6 (6 x 8-Volt battery set) last. See Connecting the Batteries – Electric Vehicles, Section
1, Page 1-5.
7. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the cells are
equalized prior to use.
BATTERY CARE
WATER QUALITY
To keep batteries in good working condition, the purity of water used is very important. Distilled water is quite pure
and is the most common type of water used in batteries. Other acceptable types are deionized water and water from
reverse osmosis. Ordinary tap water should not be used because it contains an excessive amount of impurities that
will degrade battery performance.
Distilled water is produced by distillation, a process in which water is boiled, the steam is collected and then condensed
back into water. This process creates a finished product free of minerals, having left all the impurities in the original
water sample. Club Car, along with our battery manufacturers, highly recommends that distilled water be used in
electric vehicle batteries.
Deionized water is the purest form of water, but it is also the most expensive. Deionization removes all ionizable
particles (organic and inorganic) from water through ion exchange. Positively and negatively charged ions are removed
from the water and replaced with H+ and OH- ions. When these two ions are combined, they form H2O, or purified
water.
Reverse osmosis is a method of removing solids from water by forcing it through a membrane. The membrane
rejects all solids while allowing purified water to pass through. The choice of membrane determines the amount
of impurities that the water may contain.
Water from municipal supplies, ponds and wells usually contain detrimental levels of dissolved minerals and chemicals.
If using tap water, it is important to use an in-line deionizer to remove impurities that can damage batteries and
significantly reduce battery life. If tap water is used without a deionizer, regular water analyses must be conducted to
check for impurities because water companies commonly revise their additives on a periodic basis. The following
chart lists the maximum allowable minerals, solids, and contaminates in parts per million and their impact on battery
performance. Your local water company should be able to perform testing and compare their results to the chart.
If using tap water, Club Car’s Service Parts Department offers two different deionizer systems: one for vehicles
equipped with the Single Point Water System (SPWS) P/N AM1240701 and the other for vehicles without SPWS,
P/N AM10974.

21 Battery Care BATTERIES
Mineral Content
ALLOWABLE CONTENT (PARTS

IMPURITY EFFECTS OF IMPURITY
PER MILLION)
Suspended matter Trace -
Total solids 100.0 -
Organic and volatile matter 50.0 Corrosion of positive plates
Ammonia 8.0 Slight self-discharge of both plates
Self-discharge, reduces life, lower

Antimony 5.0
on-charge voltage
Arsenic 0.5 Self-discharge, can form poisonous gas
Calcium 40.0 Increase of positive plate shedding
Loss of capacity in plates, greater loss

Chloride 5.0
in positive plates
Increased self-discharge, lower

Copper 5.0
on-charge voltage
Increased self-discharge, lower

Iron 3.0
on-charge voltage
Magnesium 40.0 Reduced life
Nickel None allowed Intense lowering of on-charge voltage
Nitrates 10.0 Increased sulfation of negative plate
Nitrates 5.0 Plate corrosion, loss of capacity, reduced life
Platinum None allowed Violent self-discharge, lower on-charge voltage
Selenium 2.0 Positive plate shedding
Zinc 4.0 Slight self-discharge of negative plates
BATTERY CARE – VEHICLES EQUIPPED WITH THE SINGLE-POINT WATERING SYSTEM
To keep batteries in good working condition, follow this maintenance program on a regular basis:
1. Keep the batteries clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking
soda and water (1 cup (237 mL) baking soda per gallon (3.8 L) of water). Rinse solution off of the batteries. Do
not allow this solution to enter the battery. Be sure terminals are tight. Let the terminals dry and then coat with
Battery Terminal Protector Spray (CC P/N 1014305). See following NOTE.
2. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion,
but not so tight as to crack or buckle the battery case. Tighten hold-down retaining nuts to the proper torque.
See step 5 of Battery Replacement on page 21-12. The terminal connections should be clean and tight,
and any worn insulation or frayed wires should be replaced. Tighten battery terminals to 110 in-lb (12.4 N·m).

BATTERIES Battery Care 21
WARNING
• If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to
do so may cause them to overheat during operation and could result in fire, property damage, or
personal injury.
3. After use, charge the batteries. The batteries should never be left discharged any longer than absolutely
necessary (do not leave discharged overnight).
4. Water the batteries monthly or according to the watering interval. See Establishing the Watering Interval for
New Vehicles on page 21-15. See Watering Batteries with the SPWS on page 21-18.
CAUTION
• The watering interval must adequately maintain the electrolyte level above the top of the plates.
See Figure 21-6, Page 21-17.
• Water the batteries only AFTER charging.

Establishing the Watering Interval for New Vehicles
If you do not already have a battery watering interval for your vehicles, manually check the battery water level weekly
to establish the correct watering interval. Thereafter, water batteries according to the established interval. During
periods of heavy use, add additional watering as required.
Single-Point Watering System Maintenance
1. For vehicles newly equipped with the Single-Point Watering System, the initial electrolyte level check on all
battery cells verifies that all the valves in the SPWS are functioning correctly. See Periodic Service Schedules
on page 10-3. If a valve is fails to open, the cell will eventually dry out. The initial one-time inspection of all cells
will identify any occurrence of a valve that fails to open. If a valve fails to close, it will become evident due to
the cell overflowing during routine watering. Either failure scenario is rare, but should be monitored in the initial
inspection and during routine watering sessions. Replace malfunctioning valves to ensure maximum battery
life. See following CAUTION.
CAUTION
• After checking the electrolyte, fully tighten the battery caps to prevent electrolyte leakage.
2. After the initial six-week inspection, manually check the electrolyte level at least once per year, particularly after
long-term storage or any other period of vehicle inactivity. See preceding CAUTION.
BATTERY CARE – VEHICLES WITHOUT THE SINGLE-POINT WATERING SYSTEM
To keep batteries in good working condition, follow this maintenance program on a regular basis:
1. Keep the batteries clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking
soda and water (1 cup (237 mL) baking soda per gallon (3.8 L) of water). Rinse solution off of the batteries. Do
not allow this solution to enter the battery. Be sure terminals are tight. Let the terminals dry and then coat with
Battery Terminal Protector Spray (CC P/N 1014305). See following NOTE.
2. Check the electrolyte level weekly (Figure 21-6, Page 21-17). Add water only after charging unless the
electrolyte level is below the top of the plates. In this case, add just enough water to cover the plates, charge,
and then check the level again. Never charge batteries if plates are exposed above electrolyte level. For best
battery life, add only distilled water. See following CAUTION and NOTE.

21 Battery Care BATTERIES
CAUTION
• Do not overfill the batteries.
NOTE: A battery watering gun or bottle is available at many auto parts dealers.
3. The battery hold-downs should be tight enough so that the batteries do not move while the vehicle is in motion,
but not so tight as to crack or buckle the battery case. Tighten hold-down retaining nuts to the proper torque.
See step 8 of Battery Replacement on page 21-12. The terminal connections should be clean and tight,
and any worn insulation or frayed wires should be replaced. Tighten battery terminals to 110 in-lb (12.4 N·m).
WARNING
• If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to
do so may cause them to overheat during operation and could result in fire, property damage, or
personal injury.
4. After use, charge the batteries. The batteries should never be left discharged any longer than absolutely
necessary (do not leave discharged overnight).
SELF-DISCHARGE
Contaminants on dirty batteries can provide a path for a small current draw that can slowly discharge batteries, thus
wasting valuable energy. To prevent self-discharge, batteries should always be kept clean.
Hot weather also has an effect on a battery’s self-discharge rate. The higher the temperature, the quicker a set of
batteries will discharge. In hotter climates, batteries should be checked more often. When storing batteries, keep in
a cool place. See Battery Storage on page 21-22.
ELECTROLYTE LEVEL
CAUTION
Add water only after charging unless the electrolyte is below the level of the plates. If the electrolyte level is below the
level of the plates, add just enough water to cover the plates and then charge the batteries. After charging, fill with
water to the level indicator. Filling a battery to the level indicator before charging will result in overfilling because the
electrolyte level will rise during charging and some of the electrolyte may bubble out of the cap. This reduces the
battery’s capacity and corrodes the metal parts around it.
The electrolyte level should be checked weekly to be sure electrolyte is at its proper level (Figure 21-6, Page 21-17).
Never allow the electrolyte level to fall below the tops of the plates because this will cause the exposed part of the plate
to become permanently inactive. For best results, use a battery watering gun to add water to batteries. Check the
electrolyte level more frequently in hot weather or when batteries are old.

BATTERIES Single Point Watering System (SPWS) 21
2
1
3

Electrolyte level at least 1/2 inch (13 MM) above plates or to level indicator.
17
Figure 21-6 Battery Electrolyte Level
VIBRATION DAMAGE
The battery hold-downs should always be tight enough to keep the battery from bouncing. Battery life may be severely
shortened if the battery hold-downs are too loose. See step 8 of Battery Replacement on page 21-12. Excessive
vibration causes the plates to shed prematurely and 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. The acid which is lost reduces the capacity of the
battery and cannot be replaced. Battery hold-downs should NOT be so tight as to crack or buckle the battery case. This
may cause leaks which would dry out a cell or cause internal short circuits. See Battery Replacement on page 21-12.
SINGLE POINT WATERING SYSTEM (SPWS)
WARNING
• When replacing batteries in the Single Point Watering System, place the battery cap from the new
replacement battery onto the used battery being removed from the car. Important safety warnings on
the battery cap must remain with the battery after it has been removed from the car
CAUTION
• Water the batteries only AFTER charging.
• Use only the water deionizer equipment (P/N AM1240701) to water batteries with the SPWS.
INITIAL MAINTENANCE OF THE SPWS
After six-weeks of operation, remove the valves from the batteries and manually check the battery water level to ensure
that the SPWS is not leaving any cells dry. This initial electrolyte level check on all the battery cells verifies that all the
valves in the SPWS are functioning correctly. If a valve fails to open, the cell will eventually dry out. The initial one-time

21 Single Point Watering System (SPWS) BATTERIES
inspection of all cells will identify any occurrence of a valve that fails to open. If a valve fails to close, it will become
evident due to the cell overflowing during routine watering. Either failure scenario is rare, but should be monitored in the
initial inspection and during routine watering sessions. Replace malfunctioning valves to ensure maximum battery life.
After the initial six-week inspection, manually check the battery water levels at least once per year, particularly after
winter storage or any other period of vehicle inactivity. See following NOTE.
NOTE: For the longest battery life, be sure the mineral contents of the water meet the minimum requirements as
stated in the vehicle’s appropriate maintenance and service manual. See Mineral Content on page 21-14.
WATERING BATTERIES WITH THE SPWS

Checking the Water Flow Rate
1. Connect the water hose with the built-in screen filter (2) to the water faucet (1) (Figure 21-7, Page 21-18).
CAUTION
• Make sure the screen filter is clean.
• Do not use a longer garden hose than provided with the System (20 feet), as a decrease in water
pressure could overfill the batteries and damage the refill system.
2. Before screwing the hose-end assembly (3) onto the opposite end of the water hose, check the screen filter (4)
inside the end of the assembly to make sure it is clean (Figure 21-7, Page 21-18).
3. Connect the purger (5) to the female coupler (8) on the hose-end assembly (Figure 21-8, Page 21-18).
8
7
3
1 5
3 6
4
2
68 725
Figure 21-7 Connecting Hose with Filter to Water Source Figure 21-8 Checking the Water Flow Rate
4. Completely open the water faucet until the water flows out of the hose-end assembly (3), and note the movement
of the red flow indicator balls (6). See following NOTE.
NOTE: The water flow rate must be at least two gallons-per-minute for the SPWS to function properly.
This step also eliminates any trapped air from the water hose.
5. After ensuring adequate water flow rate, press the grey button (7) on the end of the female coupler (8) to
disconnect the purger from the pressure regulator.

BATTERIES Battery Charger 21
Refilling the Batteries
1. Locate the battery fill coupling (9) on the driver side of the battery compartment, remove the dust cover (10)
from the male connector (Figure 21-9, Page 21-19), and connect the hose-end assembly (3) (Figure 21-10,
Page 21-19). The water flow will begin immediately.
9 10
8
9
726 727
Figure 21-9 Dust Cap Figure 21-10 Connecting Hose-end Assembly to Battery
Fill Connector
2. The red flow indicator balls should swirl, indicating that the batteries are being filled. See following CAUTION.
CAUTION
• If at any time water overflows from the batteries, immediately stop the refill process, disconnect the
pressure regulator from the battery fill coupling, and call for service.
3. When the red flow indicator balls stop moving, immediately press the grey button to disconnect the hose-end
assembly from the battery fill coupling (9), and squeeze the dust cover (10) to lightly secure it to the male
connector of the battery fill coupling (Figure 21-9, Page 21-19).
4. Place the battery fill coupling into the space between the battery bucket and the car body. Leaving the fill coupling
on top of the battery bank or tucked between the batteries and the battery bucket can result in coupling damage.
Turn the water faucet off when finished filling the vehicle(s).
BATTERY CHARGER
The charger supplied with the electric vehicle resolves the most common problems associated with battery charging.
Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself. Also, all cells are
automatically given an equalization charge at low current, which prolongs battery life. Batteries should never be left in a
discharged state, as this too affects the internal components and can reduce the capacity of the battery. The batteries
should be charged every day they are used. However, the batteries should not be charged if they have not been used.

21 Battery Charger BATTERIES
CHARGING BATTERIES
WARNING
• Be sure all wire connections at the receptacle and the fuse link are clean and tight.
• Do not rock or bend the plug. To connect the charger plug to the vehicle receptacle, grasp the plug
handle and push the plug straight into the receptacle (Figure 21-11, Page 21-21).
• Do not pull on the DC cord (Figure 21-12, Page 21-21). Do not twist, rock or bend the plug. To
disconnect the charger plug from the vehicle receptacle, grasp the plug by the handle and pull the
plug straight out of the receptacle.
• Do not connect a charger to the receptacle if the charger cord, plug, or the vehicle receptacle is
broken, damaged in any manner, or does not make a good electrical connection. Fire or personal
injury can result. Have it replaced by a qualified service person immediately.
• Failure to follow these instructions could result in damage to the charger cord, the plug, and (or)
the vehicle receptacle.
• Do not use a charger if:
– The plug is too loose or does not make a good connection.
– The plug and receptacle feel hotter than normal during charge.
– The plug pins or receptacle contacts are bent or corroded.
– The plug, receptacle, or cords are cut, worn, have any exposed wires or are damaged in any way.
• Using the charger with any of the above symptoms could result in a fire, property damage, personal
injury, or death.
NOTE: When temperatures fall below 65 °F (18.3 °C), batteries charged in unheated areas should be placed on
charge as soon as possible after use. Batteries are warmest immediately after use, and cold batteries
require more time to fully charge.
Insert the charger DC plug into the vehicle receptacle. The charger will turn on two to ten seconds later (Figure 21-11).
When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push
straight in slowly.
Club Car battery chargers interact with the vehicle onboard computer. The computer records the amount of energy
consumed during vehicle use. While the charger is plugged in, the vehicle’s control circuit is locked out, preventing
operation of the vehicle as well as the possibility of consequent damage to the charger and the vehicle.
Once the lockout is actuated, the charger turns on. The onboard computer then records the amount of energy being
returned to the batteries. When the optimum amount of energy needed to replenish the batteries is returned, the
charger will shut off. The control circuit lockout remains activated until the charger plug is disconnected from the vehicle.

BATTERIES Battery Charger 21
18A 43
Figure 21-11 Correct Insertion of Charger DC Plug Figure 21-12 Incorrect Insertion of Charger DC Plug
Only PowerDrive System 48 and IQ System vehicles are compatible with PowerDrive chargers. Other Club Car models
or vehicles made by other manufacturers are not compatible.
As long as the charger is allowed to shut off by itself, the batteries will be fully charged. Overcharging and
undercharging will normally be prevented.
Batteries should be put on charge even if they have been used for only a short period (9 holes of golf or 10 minutes).
The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating
properly, or if the batteries seem weak, contact your local Club Car distributor/dealer.
PLUG AND RECEPTACLE
The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them for cracks,
loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger plug or receptacle
show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts and plug terminals should
be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40® brand spray lubricant. The plug
should then be inserted and removed several times to ensure ease of insertion, ease of removal, and good electrical
contact. See following NOTE.
NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately.
CHARGER SHUTS OFF AFTER 16 HOURS
This may be due to 1) new batteries, 2) hard use, or 3) cold temperatures. A catch-up charge may be necessary when
these conditions are present. On those days when all or some of the vehicles do not get used, check the batteries
for state of charge. Any battery with a specific gravity lower than 1.250 will need a catch-up charge. If the problem
continues after a catch-up charge has been performed, check the battery charger. Refer to the appropriate battery
charger maintenance and service manual. See Section 22 – Battery Charger. .
DEEP-DISCHARGE
Never discharge batteries to the point the vehicle will no longer operate. This will considerably shorten the cycle life of
the batteries, and may permanently damage the batteries. It is possible the batteries will not accept a charge if they are
completely discharged. The deeper the discharge, the harder it is on the batteries. For this reason, it is recommended
that electric vehicle batteries be charged after each use (provided the charge cycle will not be interrupted and the

21 Battery Storage BATTERIES
charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of
discharge and prolongs battery life.
EARLY EXCESSIVE DISCHARGING
When vehicle batteries are new, they do not reach their full capacity until they have been used and recharged 20 to 50
times. If they are excessively discharged early in their life, their effective service life will be shortened. It is advisable to
limit the use of any vehicle with new batteries for at least the first four weeks and then gradually increase their range.
INCOMING AC SERVICE
Make sure the incoming AC line service is sufficient. If circuit breakers are tripping, fuses blow during the night or the
charger does not give the required starting rate when sound batteries are put on charge, an AC line problem exists.
The electrical service to the vehicle storage facility should be sufficient to deliver adequate voltage and current to each
charger with all the chargers turned on. If not, consult your local power company or electrical contractor. Refer to the
appropriate battery charger maintenance and service manual. See Section 22 – Battery Charger.
FLEET ROTATION
Rotate vehicle usage. It is very hard on batteries if the last vehicles in at night are the first ones out in the morning.
Spread the workload evenly, giving all vehicles the same amount of use. This will keep your fleet in balance and will
not overwork certain sets of batteries. See following NOTE.
NOTE: When vehicles are being rotated, the CDM (Communication Display Module) can be a very helpful service tool.
Monitoring the value of function 3 with the CDM simplifies vehicle usage scheduling. See Communication
Display Module (CDM) on page 18-35.
NUMBERING VEHICLES AND CHARGERS
Return the vehicles to the same charger each night if possible. If the vehicles are put in a storage facility at random
and a vehicle dies while in use and testing shows the batteries are sound, then the problem is most likely with the
charger. However, finding the problem charger may prove to be quite time consuming. Numbering the vehicles and
the chargers and returning each vehicle to its designated charger each night can significantly reduce the amount
of time spent troubleshooting a problem.
BATTERY STORAGE
When storing batteries during the off-season or when maintaining a replacement stock, follow these guidelines:
1. Keep the batteries clean and free of corrosion. See Battery Care on page 21-13.
2. Batteries that are in vehicles for winter storage should be left disconnected in the vehicles if the batteries are
not going to be connected to a charger.
3. Fully charge the batteries prior to storage.

BATTERIES Charging a Battery Pack that has Low Voltage 21
4. Store in a cool area. The colder the area in which the batteries are stored, the less the batteries will self-discharge.
Batteries stored at 0 °F (–17.8 °C) will discharge very little over a four-month period. Batteries stored at 80 °F
(26.7 °C) will have to be recharged every few weeks.
5. 48-volt electric vehicles and compatible battery chargers are designed to be left connected, with AC power to the
charger ON, during off-season storage. The storage charge feature will automatically charge the batteries as
needed throughout the storage period.
CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE
See the appropriate battery charger maintenance and service manual.

SECTION 22 – BATTERY CHARGER 22
Refer to the appropriate battery charger maintenance and service manual.

SECTION 23 – MOTOR (MODELS EJ4-4001 AND EJ8-4001A) 23
DANGER
WARNING
GENERAL INFORMATION
The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed
for use in IQ and Excel System vehicles only. Club Car recommends that motors requiring major repair be sent to a
qualified motor repair shop; however, there are many relatively simple tasks that can be performed by a technician with
general knowledge and experience in electric motor repair.
MOTOR IDENTIFICATION
There are two types of motors used in these electric vehicles: Model EJ4-4001 and EJ8-4001A. Both have a black
housing. The EJ4-4001 and EJ8-4001A motors are from the same manufacturer and share some internal components
but differ in the following aspects:
MOTOR TERMINAL STUDS INTERNAL PARTS MOUNTING BOLTS USED

EJ4-4001 All four studs are 5/16" (8mm) Brush plate assembly, stoning 4
diameter hole cover, frame & field assembly
EJ8-4001A A1 and A2 studs stay Brush plate assembly, stoning 3

5/16" (8mm) diameter hole cover, frame & field assembly
F1 and F2 studs are 1/4"
(6.35mm) diameter
Do not attempt to service a motor that has not been properly identified. If the motor cannot be properly identified,
contact your local Club Car dealer or distributor.

23 External Motor Testing MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
EXTERNAL MOTOR TESTING
The following tests can be performed without disassembling the motor using a multimeter or continuity tester.
NOTE: Tag the motor wires for identification before disconnecting.
Scrape a small amount of paint from motor housing (ground) and use this location when testing motor
terminals to electrical ground.
1 – Internal Short Circuits

2 – Armature Circuit Open
3 – Field Circuit Open
MOTOR TERMINALS CONTINUITY TEST

RESULT
A1 to A2
Continuity
F1 to F2
A1 to F1
No Continuity
A1 to F2
A2 to F1
No Continuity
A2 to F2
A1 to Ground
No Continuity
A2 to Ground
F1 to Ground
No Continuity
F2 to Ground
TEST PROCEDURE 1 – Internal Short Circuits

2. Disconnect wires from terminals on motor using two wrenches to prevent posts from turning.
3. With a multimeter set to 200 ohms, place black (–) probe on motor housing. Scratch through paint to ensure a
good connection. Place red (+) probe on A1, A2, S1, and S2 terminals respectively. Multimeter should indicate no
continuity between the motor housing and all individual terminals. If readings are incorrect, motor will need to be
removed from the vehicle and repaired by a qualified technician. See Motor Removal on page 23-4.
3.1. An incorrect reading from the A1 or A2 terminal indicates three possible problems: a grounded A1 or A2
terminal, a grounded wire in the brush area, or a grounded armature/commutator. An incorrect reading for
the S1 or S2 terminal indicates a possible grounded S1 or S2 terminal or field coil.
4. If readings are correct, reconnect the motor wires. See Motor Installation on page 23-15.
TEST PROCEDURE 2 – Armature Circuit Open


MOTOR (MODELS EJ4-4001 AND EJ8-4001A) External Motor Testing 23
2. Disconnect wires from the A1 and A2 terminals on the motor using two wrenches to prevent posts from turning.
Set a multimeter to 200 ohms and place the red (+) probe on the A1 terminal and black (–) probe on the A2
terminal. The multimeter should indicate continuity. If the reading is incorrect, a possible open or poor contact in a
brush assembly and/or open armature windings may be the cause. The motor will need to be removed from the
vehicle and repaired by a qualified technician. See Motor Removal on page 23-4.
3. If reading is correct, reconnect the motor wires. See Motor Installation on page 23-15.
TEST PROCEDURE 3 – Field Circuit Open

2. Disconnect wires from the S1 and S2 terminals on the motor using two wrenches to prevent posts from turning.
Set a multimeter to 200 ohms and place the red (+) probe on the S1 terminal and the black (–) probe on the
S2 terminal. The multimeter should indicate continuity. If the reading is incorrect, a possible open field coil or
bad connections at the terminals may be the cause. The motor will need to be removed from the vehicle and
repaired by a qualified technician. See Motor Removal on page 23-4.
3. If reading is correct, reconnect the motor wires. See Motor Installation on page 23-15.

23 Motor MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
MOTOR
MOTOR REMOVAL
2. Disconnect wires from the terminals on the motor using two wrenches to prevent posts from turning. Label
the wires to ensure proper reconnection.
3. Slightly loosen all the lug nuts on both rear wheels.
4. Place floor jack under transaxle and raise rear of vehicle (Figure 23-1, Page 23-4) then place jack stands under
frame crossmember between the spring mount and the side stringer, just forward of each rear wheel. Lower the
vehicle to let the jack stands support the vehicle (Figure 23-2, Page 23-4). See following WARNING.
WARNING
729 682
Figure 23-1 Lift Vehicle with Floor Jack Figure 23-2 Vehicle Supported on Jack Stands
5. Remove both rear wheels.
6. Remove the nut, cup washer, and bushing from the bottom side of the shock absorber. Compress the shock
absorber (pushing upwards) to move it out of the way (Figure 23-3, Page 23-5).
7. Remove the nuts and bolts mounting the rear leaf springs to the shackles.
8. To gain easier access to the motor, lower the transaxle as low as it will go. If more room is needed, remove the
jack from beneath the transaxle and allow the springs to rest on the floor (Figure 23-3, Page 23-5).

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor 23
731
Figure 23-3 Lower Axle
9. Remove the bolts and lock washers that secure the motor to the transaxle (Figure 23-24, Page 23-17). See
following CAUTION.
CAUTION
• Do not position fingers under motor when sliding motor off of the input shaft in step 9. Fingers may
get pinched when motor disengages.
10. Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove
the motor from the vehicle.
748 749
Figure 23-4 Speed Sensor Magnet Figure 23-5 End Cap
MOTOR DISASSEMBLY
1. Before beginning disassembly, place match marks on the motor end cap and motor frame.
2. Remove speed sensor and magnet.
2.1. Remove the two screws (25) that secure the speed sensor (10) to the end cap (11) (Figure 23-15, Page
23-12).

23 Motor MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
2.2. Remove the screw securing the magnet to the armature shaft (Figure 23-4, Page 23-5).
2.3. Inspect the speed sensor magnet. See Speed Sensor Magnet Inspection on page 23-11.
3. Loosen, but do not remove, the two screws securing the end cap to the motor frame (Figure 23-5, Page 23-5).
750 751
Figure 23-6 End Cap Disengagement Figure 23-7 End Cap Removal
4. Orient the motor so that the splined end of the armature is facing down.
5. Inspect the area where the end cap mates with the motor frame. If the end cap appears to be loose where it
connects to the motor frame, proceed to step 6; otherwise, disengage the end cap from the motor frame using
the following procedure:
5.1. With the end cap bolts loose (about 1/4 inch between the end cap and the head of the bolt), place a socket
on the head of the bolt. See following CAUTION.
CAUTION
• Ensure that there is sufficient thread engagement of the end cap bolts before proceeding. Performing
the procedure without having adequate thread engagement could damage the motor frame, end
cap, or end cap bolts.
5.2. Gently tap each bolt, alternating between blows, until the end cap and motor frame become disengaged
6. Remove the two end cap bolts.
7. Remove the end cap and armature from the motor frame (Figure 23-7, Page 23-6).
8. Inspect the brush springs for proper tension. See Motor Brush, Spring, and Terminal Insulator Inspection on
page 23-10.
9. Remove the armature from the end cap bearing. See following CAUTION and NOTE.
CAUTION
• Removing the armature from the end cap requires two people: one to operate the press, and another
to hold the armature. Failure to heed this CAUTION could result in personal injury and/or damage
to the armature resulting from an unsupported armature falling after it becomes disengaged from
the end cap bearing.
NOTE: Replacement of the end cap bearing is recommended if the armature is removed.

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor 23
9.1. Place the end cap in a press with the armature facing down.
9.2. Place a bearing press tool with an outer diameter smaller than that of the armature shaft between the press
ram and the armature shaft (Figure 23-8, Page 23-7).
9.3. Have an assistant support the armature while the press is activated.
10. Inspect the armature for wear and damage. See Armature Inspection and Testing on page 23-8.
11. Inspect the motor frame and field windings. See Motor Frame and Field Windings Inspection on page 23-10.
12. Remove the brush rigging.
12.1.Mark the brush terminal posts (A1 and A2).
12.2.Remove the two nuts securing the brush terminals (A1 and A2) to the end cap (Figure 23-9, Page 23-7).
12.3.Remove the two screws and the brush rigging to the end cap (Figure 23-10, Page 23-8).
13. Inspect the terminal insulators. See Terminal Insulator Inspection on page 23-10.
14. Remove the bearing from the end cap.
14.1.Remove the retaining ring that secures the bearing in the end cap (Figure 23-11, Page 23-8).
14.2.Use an arbor press to remove the bearing from the end cap.
15. Inspect the bearing for wear and damage. See Bearing Inspection on page 23-11.
752 753
Figure 23-8 Armature Removal Figure 23-9 A1 and A2 Terminals

23 Motor Component Testing and Inspection MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
754 755
Figure 23-10 Brush Rigging Figure 23-11 Bearing Retaining Ring
MOTOR COMPONENT TESTING AND INSPECTION
ARMATURE INSPECTION AND TESTING
1. Remove the motor from the vehicle. See Motor Removal on page 23-4.
2. Remove the end cap and armature by performing steps 1 through 7 of Motor Disassembly on page 23-5.
Visual Inspection
• Burned, charred or cracked insulation
• Improperly cured varnish
• Thrown solder
• Flared armature windings
• Damaged armature core laminations
• Worn, burned or glazed commutators
• Dirty or oily commutators
• Raised commutator bars
• Worn armature bearing or shaft
A dirty or oily commutator should be cleaned and wiped dry. Abnormalities identified during the inspection can help
determine original cause of failure. Slight roughness of the commutator can be polished smooth with 400 grit or
finer sandpaper. See following CAUTION and NOTE.

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection 23
CAUTION
• Do not use emery cloth to polish the commutator. Particles of emery are conductive and may
short-circuit the commutator bars. Do not use oil or lubricants on the commutator or brushes.
NOTE: Oil on the commutator may indicate a faulty transaxle input shaft oil seal.
Armature Ground Test

CAUTION
• Do not submerge the armature in solvent.
NOTE: Before testing the armature, wipe it clean with a clean cloth. Remove any carbon dust and metal particles from
between the commutator bars.
1. With a multimeter set to 200 ohms, place one probe on the commutator (1) and the other on the armature
core (2). The multimeter should indicate no continuity (Figure 23-12, Page 23-9). If the reading is incorrect,
replace the armature.
1 2
734
Figure 23-12 Armature Test

MOTOR FRAME AND FIELD WINDINGS INSPECTION
2. Remove the and cap and armature by performing steps 1 through 7 of Motor Disassembly on page 23-5.
3. Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or
grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or
the stator shell assembly.
MOTOR BRUSH, SPRING, AND TERMINAL INSULATOR INSPECTION

Brush Spring Tension Test
3. Inspect the brush springs (14) (Figure 23-15, Page 23-12). Replace springs that are discolored from heat
(light gold or blue tinted).
4. Test the brush springs for proper tension.
4.1. Place a C-shaped steel plate on a scale.
4.2. Place the end of the C-shaped plate so that it is between the spring and the brush as shown (Figure
23-13, Page 23-11).
4.3. Gently pull the scale to obtain the spring tension reading. See following CAUTION.
CAUTION
• When checking brush spring tension, do not over-extend the spring. Using excessive force will
damage the spring.
4.4. Replace springs which require a force of less than 35 oz. (990 grams) (Figure 23-13, Page 23-11). See
following NOTE.
NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the terminals
and brushes will be properly positioned in the rigging. Refer to Motor Assembly on page 23-13 for brush
installation.
When replacing brushes, replace all four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
Brush Inspection
3. Inspect the brushes (13) for damage or excessive wear (Figure 23-15, Page 23-12). Replace brushes if required.
See preceding NOTE.
4. Use dial calipers or a micrometer to measure the brush length. The minimum-allowable brush length is 0.62
inches (16 mm). Replace the set of brushes as required. See preceding NOTE.
Terminal Insulator Inspection
2. Remove the terminal insulators by performing steps 1 through 12 of Motor Disassembly on page 23-5.
3. Inspect the insulators (4 and 6) for cracks or other damage (Figure 23-15, Page 23-12). Replace insulators
as required.

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Component Testing and Inspection 23
Bearing Inspection
NOTE: Replacement of the end cap bearing is highly-recommended if the end cap is removed from the motor. The
following procedure is provided as a guideline for determining general bearing failure.
2. Remove the bearing by performing steps 1 through 14 of Motor Disassembly on page 23-5.
3. Use a clean cloth to wipe the carbon dust off of the bearing. Inspect the bearing by spinning it by hand and
checking for both axial (A) and radial (B) play (Figure 23-14, Page 23-11).
4. Replace the bearing if it is noisy, does not spin smoothly, or has excessive play. Check the bearing and replace if
rusted, worn, cracked, or if there is an abnormal color change in the metal of the bearing.
A B
756 736
Figure 23-13 Brush Spring Tension Test Figure 23-14 Bearing Inspection
Speed Sensor Magnet Inspection
Inspect the speed sensor magnet (24) for rust, wear, and cracks (Figure 23-15, Page 23-12). Replace the magnet
if necessary.

10
3 7
11 23
6 24
5
14
4
25
16
13
12
9
8
16
2
15
20 19 1
22
21
30
18
17
Items 19, 20, 21, and 22: Used only on EJ4–4001 motor
757
Figure 23-15 Motor

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Reconditioning the Motor 23
RECONDITIONING THE MOTOR
Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures
is absolutely essential for successful motor reconditioning.
MOTOR SPECIFICATIONS
Any rework must be performed by a qualified technician. Motor service specifications are listed in the following table.
ITEM SERVICE LIMIT

Commutator diameter (minimum) 2.80 in. (71.10 mm)
Commutator concentric with armature shaft within 0.003 in. (0.08 mm)
Bar to bar runout should not exceed 0.005 in. (0.013 mm)
Undercut of segment insulator after machining commutator 0.040 in. (1.0 mm)
Armature resistance at 75 °F (24 °C) 0.012 ohms between bar 1 and bar 15
Field coil resistance at 75 °F (24 °C) 1.75 ohms
MOTOR ASSEMBLY
1. Replace the bearing.

1.1. Use an arbor press to install a new bearing into the end cap. To help avoid damaging the bearing, apply
pressure only to the outer race when installing the bearing.
1.2. Install the retaining ring to secure the bearing (Figure 23-11, Page 23-8).
2. Install the brushes and brush rigging. See following NOTE.
NOTE: When installing new brushes, remove and replace brushes one at a time. This method ensures the terminals
and brushes will be properly positioned in the rigging.
When replacing brushes, replace all four brushes. Never replace only two.
Install the brushes in the same rigging 180° apart from each other.
2.1. Insert the brushes into the brush rigging as shown (Figure 23-16, Page 23-14).
2.2. Insert the two terminal posts through insulators (4) in the end cap (11) wall at the A1 and A2 positions
(Figure 23-15, Page 23-12).
2.3. Place external insulators (5) and washers (6) on each terminal post, and secure terminal with nuts (7).
Tighten nuts (7) to 100 in-lb (11.3 N·m). Ensure that the terminal posts do not rotate when tightening
the nuts (Figure 23-15, Page 23-12).
2.4. Secure the brush rigging to the end cap with two screws. Tighten the screws to 25 in-lb (2.8 N·m) (Figure
23-10, Page 23-8).
2.5. One at a time, push the brushes back until they are completely retracted into their mounting slots and the
spring pressure holds them in the retracted position as shown (Figure 23-17, Page 23-14).

23 Motor Assembly MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
758 759
Figure 23-16 Brush Rigging Figure 23-17 Retracted Brushes
760 761
Figure 23-18 Armature Installation Figure 23-19 Brush Setting
3. With the brushes retracted, use an arbor press to press the armature shaft into the end cap bearing (Figure
23-18, Page 23-14). See following CAUTION.
CAUTION
• Make sure the brushes are held back. Do not allow the brushes to support the weight of the
commutator. The brushes can be easily damaged by this weight.
4. Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown
(Figure 23-19, Page 23-14).
5. Align the match marks on the end cap and the motor frame (1) and secure with two bolts (16) (Figure 23-15,
Page 23-12). Tighten bolts to 130 in-lb (14.7 N·m).
6. Install the speed sensor magnet (24) with screw (23). Tighten to 65 in-lb (7.3 N·m).
7. Install the speed sensor (10) with screws (25). Tighten to 20 in-lb (2.2 N·m).
8. Make sure the armature turns freely. If it does not turn freely, disassemble the motor to find the problem.

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Installation 23
MOTOR INSTALLATION
1. Clean the transaxle input shaft.

1.1. Spray the input shaft thoroughly with CRC® Brakleen™ or equivalent brake cleaner degreaser.
1.2. Wipe input shaft with a clean cloth.
1.3. Inspect the grooves of the input shaft and remove any remaining debris.
1.4. Repeat steps 1.1 through 1.3 until input shaft is clean.
2. Lubricate the transaxle input shaft.
2.1. Squeeze approximately 1/2 inch (1.3 cm) of moly-teflon lubricant (CC P/N 102243403) from tube onto a
putty knife as shown (Figure 23-20, Page 23-15).
2.2. Rotate wheels to rotate input shaft.
2.3. Apply motor coupling grease evenly to the rotating input shaft starting at approximately 1/8 inch (3.1
mm) from the end of the shaft and working back toward the transaxle (away from the end of the shaft)
(Figure 23-21, Page 23-15).
2.4. The grease should be evenly distributed in the grooves to a width of approximately 3/8 inch (9.5 mm).
2.5. Use a flat screwdriver to clean the grease out of one of the grooves and allow air to escape when the
motor is pushed onto the input shaft.
mm 1 2
inch 1/2 1
mm 1 2
inch 1/2
1/8 INCH
3/8 INCH (9.5 MM) (3.1 MM)
741 742
Figure 23-20 Grease on Putty Knife Figure 23-21 Application of grease to Input Shaft Grooves
2.6. Check the chamfer (1) and end (2) of the input shaft to ensure these areas are completely clean of grease
as shown (Figure 23-22, Page 23-16).
3. Install the molded bumper.
3.1. With the flat side toward the bottom of the coupling, install the molded bumper (30) into the motor coupling
NOTE: The motor coupling and the new molded bumper must be free of grease and debris.
3.2. Ensure that the installed bumper is seated at the bottom of the coupling.
4. Install motor on transaxle.
4.1. Slide the motor coupling onto the transaxle input shaft. See following NOTE.
NOTE: The coupling will push any excess grease on the input shaft along the shaft toward the transaxle.

23 Motor Installation MOTOR (MODELS EJ4-4001 AND EJ8-4001A)
When the motor is pushed onto the input shaft, the motor housing will not bottom out against the transaxle
housing (Figure 23-15, Page 23-12). There will be approximately 1/16 inch (1.6 mm) gap between the motor
adapter ring and transaxle housing as shown (Figure 23-23, Page 23-16).
1/16 INCH (1.6 MM)
743 744
Figure 23-22 Clean Chamfer and Input Shaft End Figure 23-23 Gap at Motor and Transaxle
4.2. Loosely install the four bolts (EJ4–4001 motor) (Figure 23-24, Page 23-17), or three bolts (EJ8–4001A
motor) (Figure 23-25, Page 23-17), and lock washers that secure the motor to the transaxle. Do not tighten.
4.3. Begin finger-tightening the bolts (1 and 2) in the sequence indicated. Continue tightening by hand until the
motor is seated in the transaxle housing. See following CAUTION and NOTE.
CAUTION
• Make sure the motor is properly seated in the transaxle housing.
NOTE: Failure to install and tighten the motor mounting bolts in the proper sequence and to the proper tightness may
result in motor noise during operation.
4.4. Tighten the right bolt (1) to 65 in-lb (7.3 N·m).

4.5. Tighten the left bolt (2) to 65 in-lb (7.3 N·m).
4.6. Tighten the center bolt (3) to 65 in-lb (7.3 N·m).
4.7. EJ4–4001 motor only: Tighten the bolt (4) inserted through the L-bracket to 155 in-lb (17.5 N·m) (Figure
23-24, Page 23-17).
4.8. Install the motor wires, making sure they are connected to the correct motor terminals and that the terminal
orientation is correct. See Wiring Diagram – Electric Vehicle, Section 18, Page 18-2. Hold the bottom
nut of stud with wrench and tighten the terminal retaining nuts. For 5/16 inch (8mm) diameter studs, tighten
the nuts to 100 in-lb (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten the nuts to 45 in-lb (5.0 N·m).
4.9. Secure the white, orange, green, and blue wires with a wire tie so that none of the motor wires will scrub the
motor or transaxle when the vehicle is in operation.

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) Motor Installation 23
4.10.Connect the three-pin speed sensor wire to the vehicle wire harness.
5. If using a chain hoist, lower the vehicle and guide the leaf springs into the shackles. If using a floor jack, raise the
transaxle until the leaf springs can be guided into the shackles.
6. Insert the mounting bolts through the spring shackles and the bushings in the leaf spring eyes and install lock
nuts. Tighten the bolts to 23 ft-lb (31 N·m). See Leaf Spring Installation, Section 9, Page 9-4.
7. Install the shock absorbers. Tighten nut until rubber bushing expands to the diameter of the cup washer.
8. If removed, install wheels and finger tighten the lug nuts.
9. Lift vehicle and remove jack stands. Lower vehicle to the floor and tighten lug nuts, using a crisscross pattern, to
55 ft-lb (74.6 N·m).
12. Inspect the vehicle for proper operation. See following WARNING.
WARNING
is in REVERSE.
position.
2 3 2 3
1 1
746 1313
Figure 23-24 EJ4–4001 Motor Mounting Bolts and Figure 23-25 EJ8–4001A Motor Mounting Bolts and
Tightening Sequence Tightening Sequence

SECTION 24 – TRANSAXLE (TYPE G) 24
DANGER
WARNING
LUBRICATION
There are two plugs located on the lower half of the transaxle housing. The upper plug (21) (as viewed when the
vehicle is on a level surface) is used as a lubricant level indicator (Figure 24-5, Page 24-3). When the vehicle
is parked on a level surface, the lubricant level should be even with the bottom of the hole. The lower plug (22) is
for draining the lubricant. When draining the lubricant, the upper plug should be removed so the lubricant will drain
faster. Be sure the drain plug is installed before filling. See following NOTE.
NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations.
AXLE BEARING AND SHAFT
AXLE SHAFT
Axle Shaft and Oil Seal Removal
2. Place chocks at the front wheels. Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain
hoist or floor jack. Place jack stands under the axle tubes to support the vehicle. See WARNING “Lift only one
end...” in General Warnings on page 1-1.
3. Remove the rear wheel and brake drum. See Section 8 – Wheels and Tires. See Section 6 – Wheel Brake
Assemblies.
4. Use 90° internal snap ring pliers to remove the internal retaining ring (6) from the axle tube (Figure 24-5, Page
24-3). See also Figure 24-1, Page 24-2.
5. Remove the axle, retaining ring, and bearing assembly by pulling the axle straight out of the housing.
6. If necessary, remove the axle oil seal and adapter ring.
6.1. Use a bearing puller (CC P/N 1016417) to remove the axle seal and adapter ring from the axle tube (Figure
24-2, Page 24-2). See following CAUTION and NOTE.

24 Axle Bearing and Shaft TRANSAXLE (TYPE G)
CAUTION
• Do not scar or damage the inside surfaces of the tube when removing the oil seal and adapter ring. A
damaged tube might have to be replaced.
NOTE: Do not discard the adapter ring. If the adapter ring is lost or damaged, the axle tube will have to be replaced.
Varying rear axle configurations have been installed on vehicles. If replacing axle tubes, take note of individual
axle tube lengths to ensure proper fit.
6.2. Use a press to separate the axle oil seal (15) from the adapter ring (39) (Figure 24-3, Page 24-2). Retain
the adapter ring and discard the oil seal.
7. Inspect the axle shaft assembly to be sure the bearing and collar have not slipped and are still seated against
the shoulder on the axle shaft.
8. Inspect bearing (5) (Figure 24-5, Page 24-3). If the bearing in a Type G transaxle is worn or damaged, the
entire axle shaft assembly (1 or 2) must be replaced.
1
0
762 763
Figure 24-1 Remove Internal Retaining Ring Figure 24-2 Axle Seal and Adapter Ring Removal
39
15
A. Adapter Ring Lip
764 765
Figure 24-3 Axle Seal and Adapter Ring Figure 24-4 Axle Seal and Adapter Ring Installation

TRANSAXLE (TYPE G) Axle Bearing and Shaft 24
37
38
12
11
10
8
3
1
4
20
5 16
24
6
36
14
16 17
39 19
15 16
18 21
23
22
25
32
36
26 13
33
35 15
39
30
31
13
28 8
30 2
27
29
36 3
27
766
Figure 24-5 Transaxle – Type G

24 Axle Bearing and Shaft TRANSAXLE (TYPE G)
Axle Shaft and Oil Seal Installation

1. If previously removed, install a new oil seal.
1.1. Clean seal seat in the adapter ring (39) (Figure 24-3, Page 24-2).
1.2. Place a new seal (15) in the adapter ring with the seal lip facing toward the adapter ring lip (Figure 24-3,
Page 24-2). Use an axle seal tool (CC P/N 1014162) and mallet to tap it in until it seats firmly in position
(Figure 24-3, Page 24-2). A hydraulic press may also be used with the axle seal tool.
1.3. Clean adapter ring seat(s) in the axle tube (14 or 35) (Figure 24-5, Page 24-3).
1.4. Apply Loctite® 603 to the outer diameter of the adapter ring.
1.5. Place the oil seal and adapter ring assembly into the axle tube with the seal lip facing away from the
bearing (Figure 24-4, Page 24-2). Use an axle seal tool (CC P/N 1014162) and mallet to tap it in until it
seats firmly in position. See following CAUTION.
CAUTION
installing the axle shaft to prevent oil from coming in contact with brakes.
2. Install the rear axle into the transaxle. See following NOTE.
2.1. Insert the shaft, splined end first, through the seal and into the axle tube. Be careful not to damage the seal
on the inside of the axle tube hub. Advance the shaft through to the bearing on the shaft, then rotate it to
align the shaft splines with the splined bore of the differential side gear (27) (Figure 24-5, Page 24-3).
Continue advancing the shaft until the bearing on the axle is firmly seated within the axle tube hub seat.
2.2. Use a pair of snap ring pliers to install the retaining ring (6) inside 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
24-5, Page 24-3).
NOTE: If the retaining ring (6), axle bearing (5), or sleeve (4) must be replaced, the entire axle shaft assembly (1
or 2) must be replaced (Figure 24-5, Page 24-3).
2.3. Place a 1/4 to 3/8-inch (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four to five
locations around the retaining ring to ensure it is properly seated. See following WARNING.
WARNING
• Be sure the retaining ring is properly seated in its groove. If the ring is not properly installed, the axle
of vehicle control could result, causing severe personal injury or death.
3. If a new oil seal was installed, allow 24 hours before operating the vehicle to allow the Loctite 603 to fully cure.
AXLE BEARING
Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly
(1 or 2) must be replaced (Figure 24-5, Page 24-3).

TRANSAXLE (TYPE G) Transaxle 24
TRANSAXLE
TRANSAXLE REMOVAL
2. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. See WARNING “Lift only one
end...” in General Warnings on page 1-1.
3. Place a floor jack under the transaxle and raise the rear of the vehicle. Position jack stands under the aluminum
frame rails forward of the spring mount. Lower the vehicle to let the jack stands support the vehicle (Figure 24-6,
Page 24-5). See WARNING “Lift only one end of the vehicle...” in General Warnings on page 1-1.
4. 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.
5. Remove the bow-tie pins (1), brake cable clevis pins (2), and cable retaining E-clips (3). Disconnect the brake
cables (4) (Figure 24-7, Page 24-5).
1
3
5
2600-30000-10369 1400-18100-10243
Figure 24-6 Vehicle Supported on Jack Stands Figure 24-7 Brake Cable
6. Disconnect the shock absorbers from their lower mounts (Figure 24-8, Page 24-6).
7. Disconnect the four motor wires. Use two wrenches to prevent the post from turning.
8. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so
they are clear of springs (Figure 24-9, Page 24-6).
9. If a chain hoist was used to raise the vehicle, lift the vehicle high enough to permit easy access and clearance
for removal of the motor. If a floor jack was used to raise the vehicle, lower the transaxle enough to permit
easy access and clearance for removal of the motor.
10. Remove the three motor mounting bolts (1) (Figure 24-11, Page 24-6) and the motor positioning bolt (EJ4–4001
motor only) (Figure 24-12, Page 24-7), securing the motor to the transaxle. See following CAUTION.

24 Transaxle TRANSAXLE (TYPE G)
CAUTION
• Do not position fingers under motor when sliding motor off of the input shaft. Fingers may get
pinched when motor disengages.
1330 768
Figure 24-8 Disconnect Shocks Figure 24-9 Shackles
11. Carefully remove the motor from the transaxle. Slide the motor away from the transaxle until the motor spline
becomes disengaged from the input shaft, then lift motor out. See preceding WARNING.
12. If a floor jack was used, pull floor jack from beneath the transaxle and allow the springs to rest on the floor.
13. Remove the U-bolts attaching the transaxle to the leaf springs (Figure 24-10, Page 24-6).
14. Carefully lift each end of the transaxle off its positioning pin (on the leaf spring) and slide the transaxle to the rear
and out of the vehicle.
15. Drain the lubricant from the transaxle and remove the axle shafts. See Axle Shaft and Oil Seal Removal on
page 24-1.See following NOTE.
NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations.
16. Remove the brake assemblies if required. See Brake Cluster Removal on page 6-9.
3 4
2700-18500-10353 770
Figure 24-10 Leaf Springs Figure 24-11 Motor Mounting Bolts

TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly 24
25
24
745
Figure 24-12 Motor Positioning Bolt – EJ4–4001 Motor
Only
TRANSAXLE DISASSEMBLY, INSPECTION, AND ASSEMBLY
TRANSAXLE DISASSEMBLY AND INSPECTION
1. To detach axle tubes (14 and 35) from the transaxle housing, remove the bolts (8) (Figure 24-5, Page 24-3).
2. Remove 11 bolts (24) that hold housing together.
3. Pull the halves of the housing (11 and 20) apart. If necessary, tap lightly on the spline of the input pinion (17).
CAUTION
• To prevent damage to the housing mating seal surfaces, use caution when separating halves.
4. Remove input pinion gear (17) by pulling gear out while rocking intermediate gear assembly (19). Lift intermediate
gear assembly and differential gear case unit out simultaneously (Figure 24-5, Page 24-3). See following
CAUTION.
CAUTION
• Do not damage gears. Use extreme care when handling them.
5. Use a bearing puller or arbor press to remove bearings (16) from the input pinion gear. If the oil seal (10) is
damaged, replace it (Figure 24-5, Page 24-3). See also Figure 24-13, Page 24-8. See following CAUTION.

24 Transaxle Disassembly, Inspection, and Assembly TRANSAXLE (TYPE G)
CAUTION
• Do not reuse bearings after removing them. Replace bearings with new ones.
6. To disassemble the intermediate gear assembly, press off together the bearing (16) and the gear (19) (Figure
24-5, Page 24-3). See also Figure 24-13, Page 24-8.
7. Press the bearing (18) off the intermediate gear assembly (Figure 24-5, Page 24-3).
1. Press Ram 2. Arbor
771
Figure 24-13 Intermediate Gear Assembly
8. Disassemble the differential gear case:
8.1. Remove the hex bolts (33) and the ring gear (32) from the differential case (Figure 24-5, Page 24-3).
8.2. Remove the ring gear.
8.3. Separate the differential gear case housing. If necessary, install two of the hex bolts (removed previously in
step 8.1.) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap
the bolt heads (Figure 24-14, Page 24-8). Remove the two bolts.
772
Figure 24-14 Separate Housing
8.4. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figure 24-5,
Page 24-3). See also Figure 24-15, Page 24-9.
8.5. Remove the idler gears (1 and 2) and thrust plates (3 and 4) (Figure 24-16, Page 24-9).

TRANSAXLE (TYPE G) Transaxle Disassembly, Inspection, and Assembly 24
5
7
2
4
3
1
6
8
26
773 774
Figure 24-15 Differential Pin Figure 24-16 Left Differential
8.6. Remove the differential gears (5 and 6) and thrust plates (7 and 8).
8.7. Inspect the bearings (13) of the differential case (26) and replace them if they are damaged (Figure 24-5,
Page 24-3). To remove them, press them off. See following CAUTION.
CAUTION
• Do not reuse bearings after removing them. Replace bearings with new ones.
9. Inspect parts for wear or damage. Any worn or damaged parts should be replaced. See following NOTE.
NOTE: Damaged or worn gears should be replaced as sets.
TRANSAXLE ASSEMBLY
CAUTION
• Do not press against the bearing outer race.
• The housing and all parts must be wiped clean and dry before reassembly.
1. If bearings (13) were removed during disassembly, install new bearings using an arbor press (Figure 24-5,
Page 24-3).
2. Assemble the differential gear case.
2.1. Install the pin (31) (Figure 24-5, Page 24-3). Apply a small amount of oil to all thrust plates and to both
ends of the pin.
2.2. Install the hex bolts (33) and output gear (32). Tighten bolts to 58 ft-lb (78.6 N·m).
3. Press a new bearing (18) onto the intermediate gear assembly (Figure 24-5, Page 24-3).
4. Press new bearing (16) onto input pinion gear (17).
5. Apply grease to the lip of the new oil seal (10) and install the seal using a transaxle pinion seal tool (CC P/N
1014161). The lip of the oil seal should face the inside of the transaxle housing. Make sure the seal is firmly
seated.
6. Install the differential assembly (4), the intermediate gear assembly (3), and the input pinion gear (2)
simultaneously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for
smooth gear operation (Figure 24-11, Page 24-6).
7. Install dowel pin(s) (25) (if originally installed) in the transaxle housing (20) (Figure 24-5, Page 24-3).

24 Transaxle Installation TRANSAXLE (TYPE G)
8. Install left half of transaxle housing:

8.1. Place a 1/8-inch (3 mm) bead of Three Bond liquid gasket on mating surface of housing.
8.2. Install left half of transaxle housing (20) (Figure 24-5, Page 24-3).
8.3. Install bolts (24) in the case housing and tighten to 19 ft-lb (25.7 N·m). Type G transaxles have no shims
or gasket.
8.4. Install axle tube (14 and 35) with bolts (8) (Figure 24-5, Page 24-3). Tighten the bolts to 37 ft-lb (50.2 N·m).
9. Install the brake assemblies as instructed. See Brake Cluster Installation on page 6-9.
10. Apply a small amount of grease to the lip of the oil seal (15) (Figure 24-5, Page 24-3). See following CAUTION.
CAUTION
installing the axle shaft to prevent oil from coming in contact with brakes.
11. Install the rear axle onto the transaxle.

11.1. Insert the splined end of the axle shaft into the axle tube. Be careful not to damage the seal on the inside of
the axle tube hub. Advance the shaft through to the bearing on the shaft, and rotate it to align the shaft
splines with the splined bore of the differential gear. Continue advancing the shaft until the bearing on the
axle is firmly seated within the axle tube hub seat.
11.2. Using 90° internal snap ring pliers (0.090 tip) (CC 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 24-5, Page 24-3).
11.3. Place a 1/4 to 3/8-inch (6 to 10 mm) diameter rod against the retaining ring and tap lightly at four or five
locations to ensure it is properly seated. See following WARNING.
WARNING
• Be sure retaining ring is properly seated in its groove. If ring is not properly installed, the axle
of vehicle control could result in severe personal injury or death.
12. Make sure the drain plug (22) is installed in the transaxle and tightened to 23 ft-lb (31 N·m). Fill the transaxle,
through the level indicator hole, with 22 ounces of SAE 30 API Class SE, SF, or SG oil (a higher grade may also
be used). Install and tighten the level indicator plug (21) to 23 ft-lb (31 N·m).
TRANSAXLE INSTALLATION
1. If using a chain hoist, raise the vehicle and place transaxle in position on the jack stands. If using a floor jack,
lower the jack stands to their lowest settings and place the transaxle in position on the jack stands.
2. Align the center hole in the saddle of the transaxle with the pilot bolt in the leaf spring assembly.
3. Install the two U-bolts, jounce bumper mount (if required), and spacers, lock washers, and nuts. Tighten the nuts
to 25 ft-lb (34 N·m). Tighten the U-bolt nuts so an equal amount of thread is visible on each leg of the bolt.
4. Install the motor. See Motor Installation, Section 23, Page 23-15..
5. If using a chain hoist, lower the vehicle while guiding the leaf springs into the rear spring shackles. If using a
floor jack, raise the differential while guiding the leaf springs into the rear spring shackles. Then raise the jack
stands to support the transaxle.

TRANSAXLE (TYPE G) Transaxle Installation 24
6. Connect the motor wires, making sure they are connected to the correct motor terminals and that the terminal
orientation is correct. Hold the bottom nut of stud with wrench and tighten the terminal retaining nuts. For 5/16
inch (8mm) diameter studs, tighten the nuts to 100 in-lb (11 N·m). For 1/4 inch (6.3mm) diameter studs, tighten
the nuts to 45 in-lb (5.0 N·m). See following NOTE.
NOTE: If the motor wires were not tagged when disconnected, refer to the wiring diagram for proper connection. See
Wiring Diagram – Electric Vehicle, Section 18, Page 18-2.
7. Insert bolts through the spring shackles and bushings in the leaf spring eyes. Secure bolts with lock nuts.
Tighten to 15 ft-lb (20.3 N·m).
8. Connect the brake cables using new bow tie pins (1) (Figure 24-7, Page 24-5).
9. Install the shock absorbers. Tighten shock absorber retaining nuts until the rubber bushings expand to the
same size as the cup washers.
10. Install the rear wheels and finger-tighten the lug nuts.
11. Lift the vehicle and remove the jack stands.
12. Lower vehicle and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).
14. Inspect the vehicle to check for proper operation. See following WARNING.
WARNING
is in REVERSE.
position.

SECTION 25 – IQ DISPLAY MODULE PROGRAMMER (IQDM-P):
IQ SYSTEM 25
DANGER
WARNING
NOTE: For information pertaining to the introductory display, menu navigation, and monitor, faults and function menus,
See Section 19 – IQ Display Module (IQDM) and IQDM-P Diagnostics: IQ System.
The information presented in this section addresses the series 2 versions of the IQDM-P and IQDM handsets.
PLUGGING THE HANDSET INTO THE VEHICLE
1. Connect one end of the cable to the jack located on the bottom of the handset.
2. Connect the cable adaptor to the IQDP-P cable.
3. Find the IQDM jack on the vehicle (Figure 25-1, Page 25-1).
4. Remove the dust cap from the IQDM jack.
5. Align the keyed portion of the plug with the IQDM jack and connect the plug to the jack.
Seat shown may not match all models.
1319
Figure 25-1 IQDM Port

IQ DISPLAY MODULE PROGRAMMER
25 Program Menu (IQDM-P): IQ SYSTEM
PROGRAM MENU
The program menu can be accessed by pressing the right arrow on the navigation button when the square beside
program is blinking (Figure 25-2, Page 25-2). When the program menu is active, use the up or down arrows on the
navigation button to go to the desired item in the program menu. Again, press the right arrow to select the menu item.
Use the change value button to change the values of the selected item as necessary.
The following parameters can be programmed with the handset from the program menu:
1 3
1 2 3
775 776
Figure 25-2 Access Program Menu Figure 25-3 Change Speed Setting

IQ DISPLAY MODULE PROGRAMMER (IQDM-P):
IQ SYSTEM Program Menu 25
SPEED SETTING
The vehicle’s top speed can be changed by selecting values 1 through 3 (Figure 25-3, Page 25-2). If a value of 4 is
displayed for the speed setting, a special access code has been entered to place the vehicle in “private speed mode.”
A speed setting of 4 cannot be selected with the speed setting menu item. For additional information on speed setting
4, refer to Code A, Code B, and Code C. See Code A, Code B, and Code C on page 25-3.
SPEED SETTING DESCRIPTION VEHICLE SPEED
1 Commercial speed 8.0 mph (12.9 km/h)
2 Slow golf speed 13.2 mph (21.3 km/h)
3 Normal golf speed 14.8 mph (23.8 km/h)
4 Private speed mode 19.6 mph (31.5 km/h)
FAST ACCEL
Fast accel (fast acceleration) is an option that can be enabled or disabled. With fast accel turned on, the vehicle will
accelerate at a noticeably faster rate. With this feature turned off, the vehicle speed will gradually increase, even if the
accelerator is quickly pressed to the floor. Turn the feature on or off by pressing + or – on the change value button.
PEDAL UP MODE
Three options exist for pedal up mode (motor braking). When the accelerator pedal is released, motor braking will
slow the vehicle to a speed of approximately 11 mph (17.7 km/h) when pedal up motor braking is enabled (option 1 or
2). If pedal up motor braking is disabled (option 0), the vehicle will coast to a stop when the pedal is released. See
following NOTE.
Change the settings of the Pedal Up Mode by pressing + or – on the change value button.
NOTE: Pedal up mode does not affect top vehicle speed. If the accelerator pedal is released when the vehicle is
going down an incline, the motor braking function will activate, slowing the vehicle to the speed setting defined
in the Program menu. See Speed Setting on page 25-3.
PEDAL UP MODE SETTING MODE OPERATION DESCRIPTION
0 Off Pedal up motor braking is disabled
1 Mild pedal up Mild pedal up motor braking
2 Aggressive pedal up Aggressive pedal up motor braking
SPEED CAL
The speed cal (speed calibration) menu item allows the user to fine tune the vehicle speed. This feature cannot be used
to increase the vehicle speed. The range for speed calibration is 0 to 10. Each time the number is increased, the top
speed will be decreased by 0.12 mph (0.2 km/h). The top vehicle speed will be determined by the speed setting menu
item and the speed calibration setting. For example, if the speed setting is set for a value of 3 (14.8 mph (23.8 km/h)),
and the speed calibration is set for 5, the total top speed of the vehicle should be approximately 14.2 mph (22.9 km/h).
CODE A, CODE B, AND CODE C
The code entries are used to place the vehicle in “private speed mode”, speed setting code 4. Each vehicle has a
unique code for placing the vehicle in this mode. A vehicle programmed for “private speed mode”, speed setting 4,
does not conform to ANSI Z130.1 – American National Standard for Golf Cars – Safety and Performance Specifications
because it is capable of speeds in excess of 15 mph (24.1 km/h). For more information on this feature, contact your
local Club Car distributor or dealer.

IQ DISPLAY MODULE PROGRAMMER
25 Program Menu (IQDM-P): IQ SYSTEM
SLOW PEDAL UP
slow pedal up is an option that toggles either on or off. With the slow pedal up parameter turned off, downhill speed
with the pedal up will be maintained at 11.3 mph (18.2 kph). Turned on, this parameter maintains pedal up, downhill
speed at 10.4 mph (16.8 kph).
KSI SRO ENABLE
The ksi sro enable (key switch static return to off) option toggles either on or off. With this menu item enabled, the
vehicle will not operate if the key switch is on after the car is charged or the run/tow switch is cycled. The vehicle will be
disabled when the controller is powered up with the key switch on and after any of the following events have occured:
1. the run/tow switch had been placed in the tow position, 2. the DC plug of the charger had been plugged into the
vehicle, 3. the battery set had been disconnected or 4. if the vehicle had gone into sleep mode and the accelerator
was pressed while the key switch was switched on. The KEY SWITCH SRO fault detect that is controlled by the
ksi sro enable parameter is disabled (off) by default.
M2 MAX SPEED
The m2 max speed option allows for adjustability of the SPEED 2 speed setting. From the factory, the vehicle can
be set to one of four standard SPEED 2 speed settings. The four speed settings are 11.4, 12.4, 13.2 and 14.0 mph
(18.4, 20.0, 21.3 and 22.6 km/h, respectively). The default SPEED 2 speed setting is 13.2 mph (21.3 km/h). The top
speed of the vehicle can be set between 11.2 to 14.8 mph in 0.2 mph (18.1 to 23.9 km/h in 0.3 km/h) increments.
(The IQDM displays mph as “%”).

INDEX
A discharge test, interpreting test

results ............................................... 21-6, 21-11
accelerator hydrometer test......................................21-3, 21-8
cable hydrometer test, interpreting results ........... 21-
installation ................................................... 14-10 4, 21-9
removal ....................................................... 14-10 on-charge voltage test ............................21-3, 21-8
pedal (electric) voltage test...................................................18-11
height adjustment........................................... 5-18 voltage test (under load) ............................... 18-17
installation ..................................................... 5-10 troubleshooting examples ........................ 21-6, 21-11
removal ........................................................... 5-7 vibration damage............................................. 21-17
pedal (gas) battery
height adjustment........................................... 5-13 hydrometer test ................................................. 11-9
installation ....................................................... 5-6 installation ...................................................... 12-36
removal ........................................................... 5-5 storage ........................................................... 12-37
pedal limit switch testing .............................................................. 11-9
testing ..........................................................11-14 testing under load...................................11-11, 11-30
rod voltage test ...................................................... 11-11
installation and adjustment ............................. 14-7 battery charger
removal ......................................................... 14-6 16 hour shut-off ............................................... 21-21
accelerator pedal limit switch AC service, incoming ....................................... 21-22
installation ...................................................... 12-17 numbering vehicles and chargers ..................... 21-22
removal .......................................................... 12-17 testing ......................................................21-3, 21-7
air box on-charge voltage test ............................21-3, 21-8
installation ...................................................... 14-12 battery warning light
removal .......................................................... 14-12 installation ...................................................... 20-14
air filter............................................................... 14-15 removal .......................................................... 20-14
replacement.................................................... 14-15 testing ............................................................ 18-34
armature bearing, axle
see starter/generator ......................................... 12-1 see transaxle, type g, axle bearing ..................... 24-4
armature, motor bearing, motor
see motor, armature .......................................... 23-8 see motor, bearing............................................23-11
axle belt, drive
bearing see drive belt .................................................... 17-3
installation ..................................................... 16-5 body, front
removal ......................................................... 16-4 installation .......................................................... 4-6
shaft removal .............................................................. 4-6
installation ..................................................... 16-6 see also repair, front and rear body ...................... 4-6
oil seal .......................................................... 16-3 body, rear
removal ......................................................... 16-3 installation ........................................................ 4-10
removal .............................................................. 4-8
brake, park
B see park brake .................................................... 5-4
brakes
batteries............................................................... 21-1 adjustment .......................................................... 6-8
care................................................................ 21-13 cable
charging ......................................................... 21-19 installation ..................................................... 6-10
deep discharge ............................................... 21-21 removal ......................................................... 6-10
electrolyte cleaning assembly............................................... 6-4
adding water (mineral content)...................... 21-14 cluster
level ............................................................ 21-16 installation ....................................................... 6-9
excessive early discharging ............................. 21-22 removal .......................................................... 6-9
fleet rotation.................................................... 21-22 pedal
hydrometer calibration ...............................21-4, 21-8 height adjustment (electric)............................. 5-15
maintenance, preventive .................................. 21-14 height adjustment (gas) .................................. 5-10
see also batteries, electrolyte........................ 21-14 installation ....................................................... 5-1
replacement.................................................... 21-12 removal ........................................................... 5-1
see also battery charger .................................... 21-1 shoe
self-discharge ................................................. 21-16 installation ....................................................... 6-6
storage ........................................................... 21-22 removal ........................................................... 6-1
testing ......................................................21-3, 21-7 braking, motor
discharge test ...................................... 21-5, 21-10
2009-2011 DS Golf Car Maintenance and Service Manual Page i-1

INDEX
see regenerative braking ................................... 18-5 testing ............................................................ 18-13

braking, regenerative drive belt
see regenerative braking ................................... 18-5 inspection ......................................................... 17-2
breather valve (reed valve) .................................... 13-3 installation ........................................................ 17-3
removal ............................................................ 17-3
drive clutch
C assembly ........................................................ 17-10
cleaning and inspection .............................17-5, 17-9
carburetor ............................................................ 14-1 disassembly...................................................... 17-7
closed throttle or idle adjustment ...................... 14-10 installation .......................................................17-11
jet, main............................................................ 14-3 removal ............................................................ 17-4
elevation/size chart ........................................ 14-3 drive motor
CAUTION see motor ......................................................... 23-4
definition of ......................................................... 1-1 drive unit
CE Mark see unitized transaxle ........................................ 16-7
ferrite beads.................................................... 20-16 driven clutch
charger receptacle assembly ........................................................ 17-13
inspection ....................................................... 20-12 disassembly.................................................... 17-12
installation ...................................................... 20-12 inspection ....................................................... 17-13
removal .......................................................... 20-12 installation ...................................................... 17-16
testing ............................................................ 18-30 removal .......................................................... 17-12
choke
choke and air intake system ............................. 14-12
choke button
installation ...................................................... 14-12 E
removal .......................................................... 14-12 electric motor
cleaning see motor ......................................................... 23-4
brake assembly................................................... 6-4 electrical system
seat .................................................................... 4-1 engine ignition circuit
vehicle body........................................................ 4-1 see also ignition coil and ignition
clutch (torque converter) troubleshoot- testing ........................................................11-21
ing ..................................................................... 17-1 IQ system ......................................................... 18-1
clutch, drive pedal-start gasoline vehicle................................ 11-8
see drive clutch ................................................. 17-4 testing circuits ..................................................18-11
clutch, driven engine
see driven clutch ............................................. 17-12 assembly .......................................................... 13-9
column, steering removal ............................................................ 13-3
see steering column ............................................ 7-2 rotation ............................................................. 13-1
communication display module (CDM) RPM adjustment...............................................14-11
function codes................................................. 18-35
retrieving data from ......................................... 18-36
troubleshooting ............................................... 18-37
commutator
F
see starter/generator ......................................... 12-1 ferrite beads ....................................................... 20-16
connector, 16-pin floor mat
see test procedures ......................................... 18-19 installation ........................................................ 4-11
crankcase cover removal ............................................................ 4-11
installation ........................................................ 13-6 flywheel
removal ............................................................ 13-4 removal ............................................................ 13-7
cylinder head........................................................ 13-3 forward/reverse
cable
adjustment................................................... 16-21
D installation ................................................... 16-20
removal ....................................................... 16-20
DANGER handle (lever).................................................... 16-1
definition of ......................................................... 1-1 Forward/Reverse switch
diagram, wiring installation ........................................................ 20-3
pedal-start gasoline vehicle................................ 11-6 removal ............................................................ 20-3
differential testing ............................................................ 18-32
see unitized transaxle ........................................ 16-7 front body
diode, solenoid see body, front .................................................... 4-6
Page i-2 2009-2011 DS Golf Car Maintenance and Service Manual

INDEX
fuel filter
installation ...................................................... 14-16
I
removal .......................................................... 14-16 ignition
fuel gauge/hour meter ......................................... 12-24 testing spark ....................................................11-19
fuel gauge circuit ignition coil
testing ..........................................................11-32 installation .............................................. 12-28, 13-9
fuel level sending unit ...................................... 12-25 removal .................................................. 12-27, 13-7
fuel level sending unit testing ............................11-30 testing .............................................................11-21
hour meter circuit inspection
testing ..........................................................11-33 drive clutch ....................................................... 17-5
installation ...................................................... 12-25 drive clutch parts............................................ 17-9
operation ........................................................ 12-24 driven clutch ................................................... 17-13
removal .......................................................... 12-24 front wheel free play .......................................... 7-25
fuel level sending unit ......................................... 12-25 fuel pump........................................................ 14-19
fuel level sending unit testing................................11-30 motor
fuel lines ............................................................ 14-24 armature ground test ...................................... 23-9
fuel pump ........................................................... 14-18 armature inspection........................................ 23-8
assembly ........................................................ 14-19 bearing.........................................................23-11
cleaning and inspection ................................... 14-19 brush .......................................................... 23-10
disassembly.................................................... 14-18 brush spring ................................................ 23-10
installation ...................................................... 14-20 field windings............................................... 23-10
removal .......................................................... 14-18 speed sensor magnet....................................23-11
fuel shut-off valve ............................................... 14-25 shock absorber ................................................... 9-1
fuel tank ............................................................. 14-21 spark plug......................................................... 13-2
disposal .......................................................... 14-22 starter/generator
installation ...................................................... 14-23 armature ....................................................... 12-7
removal .......................................................... 14-21 bearing.......................................................... 12-5
storage ........................................................... 14-22 brush spring .................................................. 12-3
fuse brushes ......................................................... 12-3
installation ...................................................... 12-16 commutator ................................................... 12-7
removal .......................................................... 12-16 field coils ....................................................... 12-9
testing ............................................................. 11-11 transaxle, type g................................................ 24-7
fuse, sense lead ................................................. 18-30 intake duct
installation ...................................................... 14-13
removal .......................................................... 14-12
IQ Display Module (IQDM)
G IQ system
governor diagnostics .................................................... 19-1
governor system................................................ 16-2 IQ Display Module Programming (IQDM-P)
governor cable IQ system ......................................................... 25-1
installation and adjustment................................. 14-9 diagnostics .................................................... 19-1
removal ............................................................ 14-8 IQDM
ground cable IQ system
testing .............................................................11-12 diagnostics .................................................... 19-1
Faults Menu .................................................. 19-7
Functions Menu ........................................... 19-13
Get Settings From Controller ........................ 19-13
H handset ......................................................... 19-1
headlight bulb Handset Cord .............................................. 19-19
installation ...................................................... 12-31 Handset Cord Adaptor.................................. 19-19
removal .......................................................... 12-30 Information .................................................. 19-16
headlight switch Introductory Display ....................................... 19-2
installation ...................................................... 12-33 IQDM Ports ................................................. 19-20
removal .......................................................... 12-32 Menu Navigation............................................ 19-2
headlights Monitor Menu ................................................ 19-4
see also lighting circuit......................................11-35 Programmer Setup....................................... 19-17
testing .............................................................11-35 Reset All Settings......................................... 19-15
high pedal detect .................................................. 18-5 System Faults................................................ 19-7
hydrometer test .................................................... 11-9 Test Procedures........................................... 19-19
Troubleshooting ........................................... 19-18

INDEX
Write Settings to Controller ........................... 19-14 batteries ......................................................... 21-14

IQDM-P motor ...........................................................18-1, 23-1
IQ system armature
Code A, Code B, and Code C ......................... 25-3 ground test .................................................... 23-9
Fast Accel ..................................................... 25-3 inspection...................................................... 23-8
handset ......................................................... 25-1 assembly ........................................................ 23-13
KSI SRO Enable ............................................ 25-4 bearing
M2 Max Speed .............................................. 25-4 inspection.....................................................23-11
Pedal Up Mode .............................................. 25-3 braking
Program Menu............................................... 25-2 pedal down motor braking .............................. 18-1
Slow Pedal Up ............................................... 25-4 pedal up motor braking................................... 18-5
Speed Cal ..................................................... 25-3 brush
Speed Setting ................................................ 25-3 inspection.................................................... 23-10
brush spring
inspection.................................................... 23-10
K disassembly...................................................... 23-5
features ............................................................ 18-1
key switch field winding inspection .................................... 23-10
engine kill circuit identification...................................................... 23-1
testing ..........................................................11-27 installation ...................................................... 23-15
installation .............................................. 12-15, 20-2 motor braking.................................................... 18-1
removal .................................................. 12-13, 20-1 protection circuit ................................................ 18-5
starter circuit testing (pedal-start) ......................11-13 reconditioning ................................................. 23-13
testing ............................................................ 18-18 removal ............................................................ 23-4
kill circuit, engine service specifications....................................... 23-13
testing .................................................. 11-19, 11-28 speed sensor
kill limit switch testing ......................................................... 18-31
installation ...................................................... 12-18 speed sensor magnet
removal .......................................................... 12-18 inspection.....................................................23-11
kill limit switch, engine testing ............................................................ 18-15
testing .............................................................11-27 see test procedures, motor ............................. 23-2
walk away braking ............................................. 18-1
motor braking
L see regenerative braking ................................... 18-5
motor controller output regulator (MCOR)
leaf spring installation ........................................................ 20-6
see suspension, front and suspension, removal ............................................................ 20-5
rear................................................................... 9-3 testing .................................................. 18-14, 18-18
light switch muffler
testing .............................................................11-33 installation ........................................................ 15-1
limit switch removal ............................................................ 15-1
accelerator pedal see also exhaust system.................................... 15-1
installation ................................................... 12-17
removal ....................................................... 12-17
kill limit
installation ................................................... 12-18 N
removal ....................................................... 12-18 neutral lockout...................................................... 16-1
low oil warning light cam
installation ...................................................... 12-23 installation ................................................... 12-21
removal .......................................................... 12-23 removal ....................................................... 12-20
testing .............................................................11-29 limit switch
lubrication installation ................................................... 12-19
front suspension................................................ 7-16 removal ....................................................... 12-19
transaxle, type g................................................ 24-1 testing ..........................................................11-15
neutral lockout cam
testing .............................................................11-30
M
magnet, motor speed sensor
see motor, speed sensor magnet.......................23-11 O
maintenance oil level sensor

INDEX
installation ........................................................ 13-5 serial number, vehicle ............................................. 3-1

removal ............................................................ 13-5 service tools
testing .............................................................11-29 torque converter kit............................................ 17-1
onboard computer (OBC) ...................................... 18-5 unitized transaxle .............................................. 16-3
installation ........................................................ 20-9 shock absorber
rebooting ........................................................ 18-34 see suspension, front and suspension,
removal ............................................................ 20-8 rear................................................................... 9-1
retrieving data from ......................................... 18-36 shock absorber, front
testing ........................................18-12, 18-29–18-30 installation ........................................................ 7-24
removal ............................................................ 7-24
solenoid
P installation .............................................. 12-16, 20-8
removal .................................................. 12-15, 20-7
park brake testing .................................................. 11-14, 18-32
adjustment (electric) .......................................... 5-17 solenoid activating coil
adjustment (gas) ............................................... 5-12 testing ............................................................ 18-13
installation .......................................................... 5-4 spark plug ............................................................ 13-1
removal .............................................................. 5-4 cleaning, inspection and repair ........................... 13-2
pedal group adjustment gap adjustment ................................................. 13-2
electric.............................................................. 5-15 installation ........................................................ 13-3
gasoline............................................................ 5-10 removal ............................................................ 13-2
testing .............................................................. 13-2
specifications
R torque............................................................. 13-10
vehicle................................................................ 2-1
rack and pinion speed controller
assembly .......................................................... 7-10 cloning.................................................. 19-13–19-14
disassembly........................................................ 7-8 connector, 16-pin
installation ........................................................ 7-13 see test procedures...................................... 18-19
removal .............................................................. 7-7 installation .......................................................20-11
rear suspension removal .......................................................... 20-10
see suspension, rear ........................................... 9-1 starter/generator
receptacle armature
see charger receptacle .................................... 20-12 ground test .................................................... 12-8
regenerative braking ............................................. 18-5 inspection...................................................... 12-7
repair servicing........................................................ 12-5
front and rear body assembly ..................................................12-4, 12-9
gouges, punctures, tears .................................. 4-3 bearing
minor impact damage/deformations................... 4-2 cleaning ........................................................ 12-5
minor scratches and surface inspection...................................................... 12-5
blemishes ...................................................... 4-2 removal ......................................................... 12-6
stress lines or streaks....................................... 4-2 belt tension adjustment .................................... 12-12
tire...................................................................... 8-2 brush spring
reverse buzzer inspection...................................................... 12-3
installation .............................................. 12-21, 20-7 replacement .................................................. 12-3
limit switch brushes ............................................................ 12-2
installation ................................................... 12-22 inspection...................................................... 12-3
removal ....................................................... 12-22 replacement .................................................. 12-3
testing ..........................................................11-28 commutator....................................................... 12-5
removal .................................................. 12-21, 20-7 armature replacement .................................... 12-7
testing .................................................. 11-29, 18-33 cleaning ........................................................ 12-7
RPM adjustment ..................................................14-11 inspection...................................................... 12-7
RPM limiter disassembly..............................................12-2, 12-5
testing .............................................................11-20 field coil
inspection...................................................... 12-9
removal ......................................................... 12-6
S installation ...................................................... 12-10
removal ............................................................ 12-1
safety..................................................................... 1-1 rework .............................................................. 12-9
schematic diagram testing .................................................. 11-16–11-17
pedal-start gasoline vehicle................................ 11-6

INDEX
steering OBC gray wire and fuse................................... 18-30

adjustment .......................................................... 7-5 OBC, rebooting ............................................... 18-34
rack and pinion onboard computer SCR ................................... 18-29
assembly....................................................... 7-10 onboard computer solenoid lockout
disassembly .................................................... 7-8 circuit............................................................ 18-12
installation ..................................................... 7-13 reverse buzzer ................................................ 18-33
removal ........................................................... 7-7 solenoid.......................................................... 18-32
steering column solenoid activating coil..................................... 18-13
assembly ............................................................ 7-4 solenoid diode................................................. 18-13
disassembly........................................................ 7-4 speed sensor, motor ........................................ 18-31
installation .......................................................... 7-4 Tow/Run switch ............................................... 18-16
removal .............................................................. 7-2 test procedures, index of
steering wheel pedal-start gasoline vehicle................................ 11-8
installation .......................................................... 7-2 test procedures, IQDM and IQDM-P
removal .............................................................. 7-1 handset ............................................................ 19-19
storage test procedures, motor
electric vehicle .................................................... 3-2 1 internal short circuits....................................... 23-2
gasoline vehicle .................................................. 3-5 2 armature circuit open ...................................... 23-2
stress lines 3 field circuit open ............................................. 23-3
see repair, front and rear body.............................. 4-2 armature ground test ......................................... 23-9
suspension, front test procedures, pedal-start gasoline vehicle
camber adjustment............................................ 7-16 accelerator pedal limit switch.............................11-14
components ...................................................... 7-18 battery .............................................................. 11-9
delta a-plate, installation ................................. 7-24 battery load test ...............................................11-30
delta a-plate, removal..................................... 7-24 disconnected kill wire........................................11-19
kingpin and steering spindle, engine kill wire .................................................11-28
installation ...........................................7-20, 7-23 fuel gauge........................................................11-32
kingpin and steering spindle, fuel level sending unit .......................................11-30
removal ...............................................7-18, 7-21 fuse ................................................................. 11-11
leaf spring, installation .................................... 7-18 ground cables ..................................................11-12
leaf spring, removal........................................ 7-18 headlight socket
shock absorber, installation............................. 7-24 voltage at .....................................................11-35
shock absorber, removal................................. 7-24 hour meter .......................................................11-33
wheel bearings and hub, inspection................. 7-25 ignition coil.......................................................11-21
wheel bearings and hub, installation ................ 7-25 ignition spark....................................................11-19
wheel bearings and hub, removal.................... 7-25 key switch
lubrication ......................................................... 7-16 starter circuit (pedal-start) ..............................11-13
toe-in adjustment............................................... 7-17 key switch (engine kill circuit) ............................11-27
wheel alignment ................................................ 7-16 kill limit switch ..................................................11-27
suspension, rear light switch .......................................................11-33
leaf spring low oil warning light ..........................................11-29
installation ....................................................... 9-4 neutral lockout cam ..........................................11-30
removal ........................................................... 9-3 neutral lockout limit switch ................................11-15
shock absorber oil level sensor .................................................11-29
inspection and removal..................................... 9-1 reverse buzzer .................................................11-29
installation ....................................................... 9-1 reverse buzzer limit switch ................................11-28
RPM limiter ......................................................11-20
solenoid...........................................................11-14
T starter/generator.................................... 11-16–11-17
voltage limiter...................................................11-34
test procedures voltage regulator ..............................................11-18
16-pin connector ............................................. 18-19 wire continuity ..................................................11-17
batteries/voltage check .....................................18-11 testing
battery pack voltage (under load) ..................... 18-17 armature ground test (starter/genera-
battery warning light ........................................ 18-34 tor) ................................................................. 12-8
charger receptacle........................................... 18-30 spark plug......................................................... 13-2
Forward/Reverse rocker switch ........................ 18-32 tie rod and drag link
key switch....................................................... 18-18 installation ................................................7-14–7-15
MCOR ............................................................ 18-14 removal ....................................................7-14–7-15
MCOR limit switch ........................................... 18-18 tire
motor, A1 and A2 voltage................................. 18-15

INDEX
installation .......................................................... 8-3 definition of ......................................................... 1-1

removal .............................................................. 8-2 water level
repair.................................................................. 8-2 see batteries, electrolyte level .......................... 21-16
tools wheel
see service tools ............................................... 16-3 installation .......................................................... 8-1
torque converter removal .............................................................. 8-1
troubleshooting ................................................. 17-1 see also tire ........................................................ 8-1
Tow/Run switch .................................................... 18-5 wire continuity
installation ........................................................ 20-4 testing .............................................................11-17
removal ............................................................ 20-4 wiring diagram...................................................... 18-2
testing ............................................................ 18-16 pedal-start gasoline vehicle................................ 11-6
transaxle, type g
assembly .......................................................... 24-9
axle bearing ...................................................... 24-4
axle shaft
installation ..................................................... 24-4
removal ......................................................... 24-1
disassembly...................................................... 24-7
inspection ......................................................... 24-7
installation ...................................................... 24-10
lubrication ......................................................... 24-1
oil seal
installation ..................................................... 24-4
removal ......................................................... 24-1
removal ............................................................ 24-5
troubleshooting..................................................... 18-2
battery troubleshooting examples .............. 21-6,
21-11
communication display module
(CDM)........................................................... 18-37
IQDM and IQDM-P handset ............................. 19-18
torque converter ................................................ 17-1
troubleshooting guide 1...................................... 18-6
troubleshooting guide 2...................................... 18-9
troubleshooting guide
pedal-start gasoline vehicle................................ 11-1
U
unitized transaxle
installation ...................................................... 16-15
lubrication ......................................................... 16-3
removal ............................................................ 16-7
service.............................................................. 16-2
V
voltage limiter
testing .............................................................11-34
voltage regulator
installation ...................................................... 12-13
removal .......................................................... 12-12
testing .............................................................11-18
W
walk away braking ................................................ 18-1
WARNING

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2009-2011 DS Golf Car

Maintenance and Service

Gasoline and Electric Vehicles

Manual Number 103472703

Copyright © 2009, 2010, 2012 Club Car, LLC

2009-2011 DS Golf Car Maintenance and Service Manual Page i

SECTION 1 – SAFETY ...................................................................................................................................... 1-1

General Warnings.......................................................................................................................................... 1-1

SECTION 2 – VEHICLE SPECIFICATIONS ........................................................................................................ 2-1

SECTION 3 – GENERAL INFORMATION ........................................................................................................... 3-1

Serial Number Identification............................................................................................................................ 3-1

SECTION 4 – BODY AND TRIM......................................................................................................................... 4-1

Cleaning the Vehicle ...................................................................................................................................... 4-1

SECTION 5 – ACCELERATOR AND BRAKE PEDAL GROUP ............................................................................ 5-1

Brake Pedal and Park Brake .......................................................................................................................... 5-1

2009-2011 DS Golf Car Maintenance and Service Manual Page iii

SECTION 6 – WHEEL BRAKE ASSEMBLIES .................................................................................................... 6-1

General Information ....................................................................................................................................... 6-1

SECTION 7 – STEERING AND FRONT SUSPENSION ....................................................................................... 7-1

General Information ....................................................................................................................................... 7-1

SECTION 8 – WHEELS AND TIRES .................................................................................................................. 8-1

General Information ....................................................................................................................................... 8-1

Page iv 2009-2011 DS Golf Car Maintenance and Service Manual

SECTION 9 – REAR SUSPENSION ................................................................................................................... 9-1

General Information ....................................................................................................................................... 9-1

SECTION 10 – PERIODIC MAINTENANCE ...................................................................................................... 10-1

General Information ..................................................................................................................................... 10-1

SECTION 11 – TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE290 PEDAL-START GAS

General Information ......................................................................................................................................11-1

SECTION 12 – ELECTRICAL COMPONENTS: FE290 PEDAL-START GAS VEHICLE ...................................... 12-1

Starter/Generator (Model 114–01–4005B) ..................................................................................................... 12-1

2009-2011 DS Golf Car Maintenance and Service Manual Page v

Page vi 2009-2011 DS Golf Car Maintenance and Service Manual

SECTION 13 – ENGINE ................................................................................................................................... 13-1

General Information ..................................................................................................................................... 13-1

SECTION 14 – FUEL SYSTEM ........................................................................................................................ 14-1

General Information ..................................................................................................................................... 14-1

2009-2011 DS Golf Car Maintenance and Service Manual Page vii

SECTION 15 – EXHAUST SYSTEM: GASOLINE VEHICLES ............................................................................ 15-1

Muffler ........................................................................................................................................................ 15-1

SECTION 16 – UNITIZED TRANSAXLE ........................................................................................................... 16-1

General Information ..................................................................................................................................... 16-1

SECTION 17 – TORQUE CONVERTER: GASOLINE VEHICLE......................................................................... 17-1

General Information ..................................................................................................................................... 17-1

SECTION 18 – IQ SYSTEM TROUBLESHOOTING........................................................................................... 18-1

General Information ..................................................................................................................................... 18-1

Page viii 2009-2011 DS Golf Car Maintenance and Service Manual

Plugging the Handset into the Vehicle ........................................................................................................... 19-1

2009-2011 DS Golf Car Maintenance and Service Manual Page ix

SECTION 20 – ELECTRICAL COMPONENTS.................................................................................................. 20-1

Key Switch .................................................................................................................................................. 20-1

SECTION 21 – BATTERIES ............................................................................................................................. 21-1

General Information ..................................................................................................................................... 21-1

Page x 2009-2011 DS Golf Car Maintenance and Service Manual

SECTION 22 – BATTERY CHARGER .............................................................................................................. 22-1

SECTION 23 – MOTOR (MODELS EJ4-4001 AND EJ8-4001A)......................................................................... 23-1

General Information ..................................................................................................................................... 23-1

SECTION 24 – TRANSAXLE (TYPE G) ............................................................................................................ 24-1

Lubrication .................................................................................................................................................. 24-1