1996 club car golf cart manual

Replace balancer guide pin if necessary. With an outside micrometer, measure the outside diameter of the balancer guide pin surface. If the outside diameter is smaller than 1. Page Crankshaft Inspection, Continued: 8. Turn the crankshaft 1 slowly and measure total indicated run-out at the location shown 2 Fig- ure If total run-out exceeds 0. Place the crankcase cover 1 on a bench with its outside up gasket surface against the bench Fig- ure With the crankweb supported as shown, slide the link rod onto the PTO side of the crankshaft, and install the key.

Press the spur gear and helical gear onto the crankshaft Figures and , Page Page 3. Align the timing marks 3 Figure Page Service Specifications Connect impulse line of fuel pump to engine. Install air intake hose See Fuel System - Section Connect wire to the oil sending unit on the crankcase cover.

Position the carburetor with the drain screw 11 over a catch basin Figure Turn the carburetor bowl drain screw counterclockwise two or three turns and drain all of the fuel from the bowl into the catch basin Figure Tighten the drain screw to in. Select the proper size main jet. Check the size designation marking on the jet to insure that it is the cor- rect part.

Install the new main jet and tighten it to in. Be sure the key switch is OFF before disconnecting the accelerator rod. Remove the accelerator rod by disconnecting the ball joint 1 from the ball stud 2 on the accelerator pedal Figure and from the bell crank at the electrical box See Figure , Page Page Accelerator Rod Installation and Adjustment 1. Before installing the accelerator rod, adjust accelerator pedal position See Section 6. Install the ball joint on the ball stud at the accelerator pedal Figure , Page If the seat is in place on the rear body, remove it.

Page 9. Again check rod adjustment for proper switch activation. Install the electrical box cover. While holding the arm and shaft in the fully counterclockwise position, tighten the governor arm lever nut to 36 in. Check governed speed adjustment as instructed on Page Page Choke And Intake System 3. Connect a tachometer Club Car Part No. With the tachometer connected, check high speed RPM. Page Fuel Filters 2. To prevent draining of gasoline, plug the fuel lines 18 and 19 Figure , Page Page Fuel Pump 5.

Remove four screws 24 and lock washers 25 from front of the fuel pump Figure Install the fuel gasket 35 and diaphragm 34 on the back cover 36 Figure Install the valve assembly in the pumping chamber Figure If the vehicle is to be placed in extended off-season storage, prepare the vehicle as follows: 1.

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. The fuel lines should be kept clean. Page VICE position. Start the engine and check for exhaust leaks and proper engine operation. Page Troubleshooting Maintaining proper adjustment of the engine and governor, as well as the torque converter, is essential to the troubleshooting process.

Remove the thrust washer 11 from the moveable face 14 Figure Remove the clutch buttons Figure , Page : 4. Inspect the bore of the moveable face assembly 14 Figure , Page for scarring or wear. The moveable face assembly must be replaced if the bore is worn to a diameter of.

Install a wave washer on each mounting pin. Make sure that the concave side of the washer faces the side of the primary weight with the small guide pin protruding from it Figure Insert a puller plug Club Car Part No.

Retain the key 4 Fig- ure , Page See Figure Remove the spring 6 Figure , Page Page Figure , Page Place the clutch assembly in a press and position the cam press tool Club Car Part No.

To install the driven clutch, reverse the removal procedure. Before tightening the center bolt to 14 ft. The transmission is mounted directly to the transaxle. The engine, drive clutch, belt, and driven clutch rotate in one direction only, and the transmission is used to reverse vehicle direction.

Page Transmission removed also to allow the lubricant to drain faster. Torque plug to ft. Fill with 20 oz. Disconnect accelerator cable by removing the retaining E-ring 3 and then slipping the cable off the short end of the governor arm. Remove governor cable from transmission by removing the cotter pin 6 and clevis pin 8 from the long end of the governor arm 2 Figure Remove four retaining bolts 52 from the cover of the transmission.

Make sure the mounting screw 35 from the reverse side is removed and remove the cover Figure Remove governor arm shaft 18 by rotating back and forth. Oil seal 24 , upper retaining ring 16 and middle retaining rings 16 will be removed with shaft Figure Discard thrust washers 39 Figure Remove the two synchro springs 45 from both sides of the clutch hub assembly Figure Slide the sleeve 48 off the clutch hub 46 Figure Remove the synchro inserts 47 Figure Input Shaft Disassembly 1.

Page Transmission Housing Disassembly, Continued: 2. Inspect the shifter shaft If there is oil around the opening, the O-ring 23 should be replaced. If there is no oil, disregard steps 4, 5, and 6 below Figure , Page To remove the outer race, apply a few drops of a loosening agent between the outer race and bearing seat.

Use a slide hammer to remove the outer race and discard Figure Oil seal press jig Club Car Part No. Internal governor arm alignment tool Club Car Part No. Put a light coating of clean transmission oil on the outside edge of the seal to assist installation.

Press oil seal 31 into the output shaft bore using transmission oil seal tool Club Car Part No. Page Cover Assembly, Continued: 3. If input shaft needle bearing 60 was removed, press in a new bearing Figure , Page Slide the thrust washer 43 onto the end of the output shaft with the inner spline.

Place the gear assembly 49 wider gear , new thrust washer 39 , Belleville spring washer 73 and the ball bearing 38 onto the end of the output shaft. To install the oil seal 24 , a governor shaft cap jig Club Car Part No. Place the governor shaft cap jig on the governor arm shaft. Slide the new oil seal 24 over the tool until the oil seal contacts the transmission housing. Place the internal governor arm 7 around the internal governor arm alignment tool. Install the two screws 6 with a drop of thread locking adhesive.

Torque screws to 26 in. Remove the internal governor arm alignment tool Figure Page Assembly of the Transmission, Continued: 3. Using a depth gauge, measure the distance from the gasket surface of the housing to the side of gear 62 on the input shaft Figure Use the table to determine which thrust washer to use. Less than. Install driven clutch and key on transmission input shaft See Torque Converter - Section Remove the ball joint socket 2 from the forward and reverse shifter assembly ball stud 3.

Remove the ball joint socket 2 from the shifter arm ball stud 19 on the transmission Figure See Figure , Page Install the ball joint socket 2 on the forward and reverse shifter assembly ball stud 3 Figure , Page It consists of two mono-leaf springs controlled by two shock absorbers mounted between the springs and the vehicle frame.

The engine is mounted on an inner-frame that moves with the rear suspension. A snubber, mounted on the front of the inner-frame and contained by brackets on the vehicle frame, controls inner-frame motion. To remove a shock absorber, remove the nut 5 , cup washer and rubber bushing Item 7 from the shock absorber stem Figure Remove the nut 14 and washer 15 from the lower mounting stud Figure Position jackstands under the frame cross-member between the spring mount and the side stringer, just forward of each rear wheel.

To install the springs, reverse the removal procedure. Place the jack under the transaxle and raise the vehicle enough to remove the jackstands. Lower the vehicle. Page The on-board receptacle fuse link provides additional protection for the vehicle charging circuit. If it is blown, the cause should be determined before the fuse is replaced.

Vehicle will not run - Batteries 1 Battery connections. Test Procedure 1 no solenoid click. Key Switch 1 Loose wires. Test Procedure 2 2 Failed switch. Vehicle runs slow, continued: Batteries 1 Loose terminals or corrosion. Page Circuit Testing The numbers on the probe symbols indicate test proce- dure numbers. If the reading is incorrect at either lever position, check the wires and terminals.

The Forward and Reverse Anti-arcing Limit Switch is located on the forward and reverse switch and is acti- vated by a cam on the forward and reverse switch rotor. Connect the green wire to the normally closed NC terminal and the black wire to the common COM terminal of the limit switch. The normally open NO terminal should have no wire attached to it. Pull center dash out approximately one inch from the frame and then bend the top right corner of the dash panel inward while pulling the top of the panel out and down.

S AND To ensure proper wiper switch adjustment, all of these items must be properly adjusted. If any one of them requires adjustment, all of them must be checked, and also adjusted if necessary, in the order listed in the WARNING at the top of page If the ball stud 5 was removed, insert it through the bell crank with the ball facing away from the wiper switch housing and install the lock nut 7.

While holding the ball stud with a wrench, tighten the lock nut to ft. Install the accelerator rod onto the ball stud. Connect the 18 gauge green wire from the limit switch to the rear small post on the solenoid Figure , Page Connect the 18 gauge black wire to black lead from charger receptacle Figure , Page Remove the screws 11 and nuts 12 that mount the forward and reverse switch to the body Figure Pull the forward and reverse switch away from the body and out of the battery compartment for ease of service.

The earlier version used a multi-step wiper switch potentiometer in the speed control circuit, whereas the current version, beginning with serial number A, uses a continuously variable potentiometer. Both versions feature a 48 volt electrical system, including an on-board computer that controls the battery charger, monitors vehicle energy usage, and provides test data to the optional Communication Display Module. OBC data can also be useful in performing electrical system diagnostics.

The key switch is an ON-OFF type, the function of which is to disable, or open, the control circuit when the vehicle is not in use. Page Troubleshooting Guide The on-board fuse link provides additional protection to the vehicle charging circuit. The fuse is rated for use only with a Club Car PowerDrive charger. If it is blown, the cause should be determined before it is replaced. Vehicle runs slowly. Wiring 1 Improperly wired.

Figure or , Page or Batteries 1 Loose terminals or corrosion. Test Procedure 1, and Batteries, Section 22 2 Improperly wired. Page Circuit Testing The numbers on the probe symbols indicate test procedure numbers. Remove Diode terminal end from the small post on solenoid with 18 gauge yellow wire attached.

Make sure that the diode direction is correct Figure , Page , or Figure , Page Remove 6 gauge white wire from A2 motor terminal and secure it so that it will not make contact with any live components or connections.

Reconnect batteries Figure , Page 2. Check for proper wiring Figure or and tight connections. Func3 - Total accumulated energy units removed. Contact your Club Car representative for more comprehensive information.

Testing the Limit Switches 1. Page The Reverse Buzzer 1. Using the wire crimper, crimp the butt connector to permanently attach it to the wire from the harness. Place the red probe of the multi-meter on the positive post of battery No.

The multimeter should show battery voltage. Install the solenoid to the mounting plate and torque to 66 in. The solenoid does not have to be oriented in any particular manner. Install wires on the solenoid as shown in the wiring diagram Figure , Page , or Figure , Page Page On-Board Computer 2. Discharge the controller See instructions in Warning Box on Page Remove the 18 gauge red and yellow wires on the solenoid.

Page D. Remove the 10 gauge red wire 4 from the positive post of battery No. Disconnect batteries Figure , Page Remove the potentiometer housing and pivot rod support from the I-Beam. Installing the Continuously Variable Potentiometer Figure 1. Page Battery Warning Light 5. Connect the 18 gauge black 2 , white 3 , and blue 4 wires to the multi-step potentiometer.

See Figure , Page for proper wir- ing connections. Connect the accelerator rod 1 to the potentiometer. When the vehicle is in use with the key switch ON, the zero speed detect function will resist vehicle rolling. When the key switch is turned to the ON position and the two second 20 seconds on some early models time delay transistor in the speed controller is on, the circuit is complete and the main solenoid coil is activated, closing the solenoid power contacts.

Page wire or blue wire, depending on the position of the rocker switch. When operating the vehicle in forward, the white wire supplies voltage from the rocker switch No. When operating the vehicle in reverse, the blue wire supplies voltage from the rocker switch No.

Page Controller Activating Circuit, Continued: With the key switch in the ON position, the forward and reverse rocker switch in forward or reverse, and the accelerator pedal depressed, voltage is supplied to the Z8 position in the controller. This activates the con- troller which completes the circuit, supplying voltage to the motor. Although the motor operates on 48 volt input at both low and high speeds, the controller regulates ground speed of the vehicle by shortening or lengthening the pulses to the motor.

Page Speed Control Circuit, Continued: The potentiometer detects accelerator pedal position and sends a corresponding voltage signal to the con- troller. As the accelerator pedal is depressed, voltage from the potentiometer changes, causing the controller to send longer pulses to the motor and thereby increasing vehicle speed.

When the batteries are at or near full charge, the dynamic braking solenoid will shut off when the motor is generating energy, sending the current to the resistor coil. This indicates that the batteries did not receive a full charge. The light will go out when AC power is restored or the DC cord is unplugged.

When motor braking is activated, the power circuit will direct motor generated current to either the batteries or the energy displacement module, depending on the battery pack state of charge See Figure If the batteries have discharged to the point that they can accept a regenerative charge from the motor, the dynamic braking solenoid will remain closed there will be con- tinuity across the large posts and the current will continue from the dynamic braking solenoid to the controller through another 6 gauge white wire, and then on to the batteries through a 6 gauge black The batteries and the battery charger will be dis- cussed in separate sections in this manual Batteries - Section 22, and Battery Charger - Section Battery Pack Voltage 2.

Individual Battery Voltage 3. Battery Pack with Low Voltage 4. Voltage at Z1 Position in Z Plug 5. Z1 Red Wire Continuity 6. Motor Sensor 3-Wire Plug Connection Leave the batteries connected and leave the Z plug connected to the controller.

Disconnect the Z plug from the controller. Leave the batteries connected. Place the black - probe of a multimeter, set to Volts DC, on the negative - post of battery No. Disconnect the bat- teries. Leave the Z plug connected to the controller. Disconnect the bat- teries and disconnect the Z plug from the controller. Remove the three mounting screws from the forward and reverse switch case and remove the case from the rear body. Disconnect the 18 gauge black wire from the center terminal on the forward and reverse switch.

The fuse on the red wire is now located approximately six inches 15 cm from the main solenoid and is in a yellow rubber housing. Turn the key switch to ON and place the forward and reverse rocker switch in reverse; Page The energy displacement module is mounted on the vehicle frame, directly behind the batteries.

Raise the rear of the vehicle. Page 3-wire plug Figure , Page Inspect the wires in the 3-wire connector from the potentiometer. Disconnect the plug and inspect for broken wires at the pin terminals. Inspect the pins to make sure that they are secure in the plug. With the accelerator pedal in the UP position, the voltage reading should be zero. Slowly depress the accelerator pedal. Disconnect the 3-wire plug at the motor speed sensor. It is not necessary to connect the green wire from the CTM to another wire.

Disconnect the bat- teries and disconnect the Z plug from to the controller. Page 7. Pull gently on the two halves of the plug connection to ensure that they are fastened securely. Check wire positions in the 3-wire plug and make sure that wires of the same color mate when the plug is connected. Club Car Service Manual A Club Car service manual is a great source of information for operating, servicing and fixing your golf cart. To purchase your Club Car golf cart repair manual you will need to know: 1.

Gas or Electric 2. The year the golf cart was made You will find the year of your golf cart by checking the serial number. Where to Purchase You can purchase a Club Car manual from a couple of different on line websites.

Golf Car Catalog at and 2. Golf Cart Trader at 3. Amazon has a limited selection 4. About the Author: Chris Anderson. Chris Anderson has been in the golf cart and electric cart community for over 10 years and has worked with many retail and business to business companies in the industry.

He is also an avid photographer and windsurfer. Related Posts. November 10th, 0 Comments. This indicates an abnormal charge cycle. The light will go out when AC power is restored. An experienced operator should accompany each first-time driver on a test drive before allowing him her to operate the vehicle alone.

Only licensed drivers should be allowed to drive this vehicle. Read and understand all instructions prior to driving the vehicle. Enter the vehicle. Study and understand controls. Be sure everyone is seated and holding onto seat handles or handrails.

Read safety warnings located above pedals. Make sure wheels are turned in desired direction. Slowly depress accelerator pedal. The park brake will release automatically and the vehicle will start to move. As the accelerator pedal is depressed, speed will increase until full speed is reached. With the accelerator pedal partially depressed, the engine governor will cause the engine to control downhill speed.

See Performance Inspection, Page 6. To stop the vehicle, release the accelerator pedal and depress the brake pedal with your right foot until the vehicle comes to a complete stop. After stopping the vehicle, firmly depress the park brake pedal until it locks. This will prevent the vehicle from rolling.

Remove the key when the vehicle is not in use. All vehicles are equipped with both front and rear tow bar attaching points. A light duty tow bar is avail- able for break-down towing and single vehicle towing.

A heavy duty tow bar and an on-board tow bar are available for multi-vehicle towing. Observe all of the above warnings when towing. To prepare your vehicle for extended off season storage: 1. Store vehicle in a cool place. This will prevent self discharge of the battery. If the battery appears to be weak, have it charged using an automotive type 12 volt battery charger rated 10 amps or less.

Drain carburetor and seal the fuel tank. Disconnect the fuel line from the fuel pump and run the engine until fuel remaining in the carburetor and fuel lines is used up and the engine stalls. Loosen do not remove the carburetor drain screw and drain fuel remaining in bowl into a small container, then pour the fuel from the container into vehicle fuel tank.

Reconnect fuel line to fuel pump. Disconnect fuel vent line from fuel tank vent nipple. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap. Increase tire pressure to 20 psi. Thoroughly clean front body, rear body, seats, engine compartment, and underside of vehicle. Do not latch the park brake. Block tires to prevent the vehicle from rolling. Restore fuel system to operation. Remove plug from the fuel tank vent nipple and reconnect fuel vent line to tank.

Crank the engine until fuel is pumped into the carburetor and fuel lines and the engine starts. Readjust tire pressure to psi. Perform the Pre-Operation Checklist See pages 6 and 7. Wash off any corrosion around the terminals with a solution of baking soda and water, then rinse NOTE: Do not allow this solution to enter the batteries. Store in a cool, dry place. This will prevent self discharge of the batteries. Adjust tire pressure to 20 psi.

Thoroughly clean front body, rear body, seats, battery compartment, and underside of vehicle. To Return the Stored Vehicle to Service: 1.

Regular and consistent vehicle maintenance can prevent the vehicle down-time and expensive repairs that 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. Regular Interval Service Recommended Lubricant.

Quarterly by Owner or 1. Front suspension 5 fittings Chassis Lube. Annually by Trained 5. SAE 30 WT. Inspect front wheel bearings Chassis Lube Repack as necessary. First Change Hours - 8. Change engine oil and oil filter. Forward and reverse switch contacts and Charger Receptacle WD Annually by Trained 6.

Even though the oil warning light on the dash should warn you if your oil is getting low, engine oil level should be checked monthly See Figure Remove oil level dipstick from the oil filler tube and wipe oil from it with a clean cloth or paper towel. Check oil by inserting the dipstick fully into oil filler tube and immediately removing it again. Reinsert dipstick into oil filler tube.

Lift and remove seat bottom. The fuel tank is located on passenger side of vehicle. Remove fuel cap and fill the fuel tank with fresh unleaded gasoline only.

Replace fuel cap on tank, being sure cap is tightened securely. Replace seat bottom. The battery in the DS Gasoline Vehicle is a 12 volt, low maintenance battery that requires infrequent watering Figure Rinse solution off the battery. Be sure terminals are tight. Be sure battery hold-down bracket is properly tightened. Torque to in.

A loose hold-down bracket may allow the battery to become damaged from vibration or jarring. A hold-down bracket that is too tight may buckle or crack the battery case.

If battery appears weak, have it charged by a trained mechanic. The battery should never be left dis- charged any longer than absolutely necessary do not leave discharged overnight. Both the 6 and 8 volt batteries are deep cycle batteries, specially built for electric vehicle application.

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 bat- teries, restrict vehicle with new batteries to 36 holes of use between charges in the first two months of operation. Batteries should be fully charged before first use of new vehicle, and before releasing vehi- cle for use each day. Battery Care: To keep batteries in good working condition, follow this maintenance program on a regular basis: 1.

The batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water. The water level in the batteries should be checked weekly See Figure 22, Page 25, for proper level. Add water only after charging unless the water 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 water level.

For best battery life, add only distilled water. The hold-down straps 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. Torque hold-down retaining nuts to in. The terminal connections should be clean and tight, and any worn insulation or frayed wires should be replaced.